Pas Reform Home of Hatchery Innovation

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1 NatureForm Uvesa USA NatureForm Hatchery Technologies A force Spain Uvesa chooses innovative for hatchery excellence in the USA > p. 2 total hatchery solutions for major new Greenfield hatchery Pas Reform Times > p. 9 Pas Reform Hatchery Technologies Pas Reform Home of Hatchery Innovation Babolna Tetra So Salvador Betagro Hungary Setting the pace for change! Babolna Tetra builds Alimentos Thailand Betagro commissions SmartPro single stage incubation one of Europes most advanced Brazil So Salvador Alimentos for increased capacity > p. 39 hatcheries with SmartPro shifts to single stage > p. 21 incubation with SmartPro > p. 7 Pas Reform: celebrating innovation, partnership and expansion in a global poultry industry As we go to press with this, the latest edition of Pas Reform development of new incubation tools, such as Circadian Times, our company is celebrating 95 years of innovation, Incubation. For hatcheries, food safety also means that partnership and expansion: an unparalleled journey that has hygiene is becoming increasingly important. Our response, placed Smart single stage incubation technologies at the which delivers easy to clean equipment and innovative heart of hatchery operations for customers in more than solutions, among them antibacterial additives in plastics, most of all, the support of our loyal customers. Every year, 100 countries worldwide. is proving to be highly effective for our customers. our SmartPro hatchery technologies become available in more countries. Our global distribution network continues Looking back over those decades, we have learned a great Another key issue for the industry globally is sustainability: to show strong growth and we remain absolutely deal to support growth in a global poultry industry that how to provide animal protein for a growing world committed to seeing still further expansion, looking forward faces many challenges: challenges that are rapidly being population while at the same time using less water, feed and to working together with partners and colleagues on every overcome by better, more efficient solutions. energy and reducing CO2 emissions, for example. This has continent: to deliver excellence as standard throughout the created an increased focus on Feed Conversion Ratios and poultry production chain. We have learned that collaboration between customers, hatchability in our industry. To meet these needs, Pas suppliers and scientists working together has the power to Reforms attention is unwavering in delivering better It is my great pleasure to invite you to explore this dramatically improve results in the many, different processes uniformity, both in the processes we employ and ultimately extraordinary edition of Pas Reform Times, where I trust you that take place in the poultry production chain. In this, in the day old chicks produced by our advanced incubation will find innovation, inspiration and new partners to expand Pas Reform Academy is becoming an increasingly significant technologies. We know that the short hatch window our your business, wherever you are. source of knowledge for the good of the industry every year. customers can achieve with SmartPro gives their birds the best start in life, to grow in a uniform way - and with the Pas Reform Hatchery Technologies Food safety has emerged as a major issue for the industry best chance of reaching their full genetic potential. worldwide, bringing with it the need to produce robust day Bart Aangenendt old chicks with less medication. Meeting this need has been The journey we are taking would not have been possible CEO an important focus for Pas Reform, giving rise to the without the support and dedication of all our partners but

2 Pas Reform Times Celebrating innovation, partnership and expansion 1 Pas Reform expands into USA 2 Circadian incubation for broiler quality and robustness 4 CIC Feeds, Sri Lanka 6 SPK Udarnik, Russia 6 Pas Reform appoints new regional sales director 6 So Salvador Alimentos, Brazil 7 Occhiodoro, Italy 8 Herbro, Hungary 8 Uvesa, Spain 9 Integrating innovation: Hatchery Automation Systems 10 Pas Reform appoints new sales director 10 SmartCount 11 Do we understand hatch of fertile correctly? 12 New Pas Reform collaboration provides deep data mining to optimize hatchery performance 12 Algerian hatchery sector welcomes Pas Reform 13 Learning from the shape and texture of hatching eggs 14 Pas Reform Pas Reform appoints new manager research and development 14 Aviagen, The Netherlands 15 Ariztia, Chile 15 The true value of preventive hatchery maintenance 16 expands into USA Kazakhstan signs up for Smart hatchery expansion 17 Hyfresh, Malaysia 17 Holmes Foods, USA 18 Pas Reforms new Logistics and Training center: open for business! 18 Preventing cross-contamination in the hatchery 19 SmartTray - Smart thinking from Pas Reform 20 Bbolna TETRA 21 Pas Reform has made another landmark move in its plans for international expansion, with the formation of a new The power of data to unlock performance 22 Marking a Lifetime Achievement 22 company, based in the USA, to serve the North American poultry industry. Ross Breeders, Zambia 24 AS Putra, Indonesia 24 Pas Reform has joined forces with NatureForm, a leading Willmar/AG Forte, 25 supplier of single stage technologies for the poultry, game and vaccine development markets. The newly formed Correctly interpreting dead in shell 26 company, NatureForm Hatchery Technologies, will deliver fully integrated solutions for North American hatcheries New appointment to drive Supply Chain developments 26 seeking expansion, as the US poultry industry prepares to deliver 15 per cent growth* over the next seven years. Incupasaje, Ecuador 27 Amrit Group, India 27 NatureForm Hatchery Technologies product range includes Hama Plus 28 Pas Reforms SmartPro hatchery technologies, NatureForms Duck King, Thailand 28 Phoenix range of incubators and a full complement of hatchery automation and hatchery climate control systems. Frango Natto, Brazil 29 Building the future of Hatchery Technologies 30 In addition to equipment supply and technical support services, the new partnership will have the full backing of Poltavskaya, Ukraine 32 Pas Reform Academy, for incubation research, hatchery Hy-Line, Italy 32 Grading eggs for improved uniformity 33 Pollo Bakity, Mexico 34 Where to put the paper? 34 Pas Reform appoints new representative in the Philippines 34 Krasnodonskaya, Ukraine 35 Hukuru, Zimbabwe 35 Luckily it rained 36 St Petersburg SRI, Russia 36 Combining expertise to reduce farm mortality 37 NatureForm met colleagues Aviagen, Russia 37 from across the poultry sector Pronavicola, Colombia 38 when the new company was Pas Reform delivers growth for Sarawaks poultry unveiled at this years IPPE Show integrations 38 in Atlanta. Betagro, Thailand 39 SuperChicks, Zimbabwe 39 2

3 management training and customer-level consultancy. Bart Aangenendt, CEO Pas For further, detailed information The new company will be headquartered in Jacksonville Reform Hatchery Technologies about NatureForm Hatchery (Florida, USA) with production facilities, logistics, sales and and Steve Warren, President Technologies, please request your after-sales service coverage for customers across North NatureForm Hatchery own free, full-colour, fully America. Technologies illustrated brochure by emailing [email protected] or download The two companies are complementary in many aspects, the brochure in pdf format directly says Pas Reform CEO Bart Aangenendt, which will be a from Pas Reform online at strong foundation for the new venture: NatureForm and Pas Reform have enjoyed a mutually successful association for several years. As companies and as people we share a dynamic and progressive vision for the future of the hatchery sector globally. We believe that this new company has unparalleled expertise in single stage hatchery practice and is unique in being able to deliver truly integrated solutions for the hatchery business in North America. NatureForm Hatchery Technologies signals a key moment in Pas Reforms plans for international expansion, and we are NatureForm fully committed in this collaborative venture and in the future of the poultry industry in the USA. Hatchery Technologies A force for hatchery excellence in the USA * Source: USDA In partnership with Pas Reform 1 pas0328-b_corporate brochure_10.indd 1 20-12-13 14:39 3

4 Circadian incubation for broiler quality and robustness By Dr Marleen Boerjan, director R&D, Pas Reform Academy, General aspects of embryonic development and imprinting development, but egg content also reflects maternal stress, The Netherlands, Lenise Incio de Souza, Pas Reform do which is transferred to chicks (Rettenbacher, 2013). Brasil, Rio Claro, Fernanda Flores, Universidade Estadual de The female gamete, oocyte, floats on top of the yolk and is Experiments in quail showed that chicks produced from Campinas, SP fertilized within 15 -18 mins. of its arrival in the upper part of mothers exposed to heat stress perform better under heat the oviduct. The single-cell embryo cleaves several times to stress conditions compared to standard normal conditions Modern poultry integrations require broilers that grow form a cluster of undifferentiated embryonic cells. As the (Groothuis et al. 2013). We do not know whether broiler uniformly and efficiently. Efficient birds use only small embryo grows, the number of cells increases and when the breeders, comparable to quail mothers, transfer amounts of nutrients to maintain their basic physiological egg arrives in the shell gland, the first important steps of environmental experiences to the chicks. But if so, it could systems and are robust and resistent to stressful conditions development are initiated. During shell formation, both the explain the heterogeneity of results in experiments using in the farm. Batches of robust chicks need less medication head-to-tail axis and the dorsal-ventral axis of the future hatching eggs from flocks managed differently. and have the potential for optimum growth. chick are determined and differentiated. When a cell is Recently Pas Reform has introduced Circadian Incubation differentiated, it is assigned a specific fate: some cells will When the premature egg arrives in the shell gland (uterus), as a natural and progressive development of single stage grow to muscle tissue, while others become part of the the egg rotates along its long axis to form a smooth egg incubation. Circadian incubation is based on observations skeleton, for example. The differentiation of cells is the result shell. However, as a consequence of the rotation a that embryonic training, or the imprinting of body of differential gene expression, whereby muscle cells express differential gene expression is activated in the embryo that functions, stimulates robustness on the farm. This genes for contractive proteins, while bone cells produce becomes visible in the formation of the head-to-tail axis imprinting is achieved by exposing the embryo to proteins that can bind calcium. In conclusion differential (Gilbert, 2006). The activation of differential gene expression environmental triggers, like short periods of high or low gene expression is the fundament of embryonic is the result of an environmental factor: gravity as a result of temperatures, during critical periods in embryonic development. It is now generally accepted that minute egg rotation. development. variations in the environment of cells induce variations in Mounting evidence, accumulated from scientific gene expression, also called epigenetic adaptation. In birds In conclusion, the condition of the mother hen influences the experiments and trials in the field, shows that short periods and therefore in our domesticated poultry breeds, we must first stages of embryonic differentiation during eggshell of thermal conditioning reduce the basic metabolism of discriminate between the maternal factors and the formation, while her physical and nutritional condition is embryos and broilers during the growing phase in the farm. incubation dependent factors which imprint the developing reflected in the composition of the egg and in the Although we see clear interference with breeder embryo. performance of the chick. management or egg quality, we conclude that there are Embryos derived from the same parents have basically many reasons to implement Circadian incubation in inherited similar genetic potential, yet develop to different Environmental programming of embryonic development: hatchery practice, that improve performance throughout the phenotypes because the embryos were exposed to different influence of incubation conditions poultry production chain overall. environmental inducing or imprinting factors. Epigenetic adaptation studies how changes in gene expression patterns Today, the basic assumption in the single stage incubation mediated by the environment can cause phenotype program is based on the idea that the embryo should variations. An example of epigenetic adaption in poultry develop under constant conditions without any fluctuation production is thermal conditioning (Circadian incubation) in either climate parameter. However from scientific during sensitive phases of embryonic development. research, it becomes clear that the so-called thermal conditioning of the embryo during specific phases of Maternal programming of embryonic development: incubation induces long-term adaptations, such that post- influence of the breeder hatch thermoregulation and performance is positively influenced (Piestun et al.,2008; Shinder et al., 2009; Much more information is now available regarding maternal Tzschentke and Halle, 2009). In layers, temperature influence on chick quality and performance. The freshly laid manipulation during late embryogenesis has been shown to egg contains not only the nutrients needed for optimum influence postnatal temperature preference until day 8 of age (Walstra et al., 2010). Pas Reform Academy provides practical training for customers at its new state-of-the-art facility in Doetinchem, The Netherlands 4

5 Summary 1 In birds, embryonic development starts during egg formation. 2 The development of the day old chick is the result of differential gene expression, induced both by internal factors and by factors from the environment. 3 Breeder management influences chick quality through factors transferred by the hen to the egg and by embryo quality. 4 Epigenetic adaptation studies how changes in gene expression patterns mediated by the environment can cause variations in phenotypes. An example of epigenetic adaption in poultry production is thermal conditioning (Circadian incubation ) during sensitive phases With thermal-conditioning, the embryo receives hot or cold Circadian incubation means that the embryos receive of embryonic development. stimulation at specific time-points during embryonic short, daily periods of heat or cold stimuli of 1 to 2 C during 5 Circadian incubation is implemented as a development. Thermal conditioning is only beneficial when the second or third week of incubation. Circadian progressive development of single stage is it applied in a clear, controlled manner for specific critical incubation provides the hatchery manager with an extra incubation for the production of high quality, time points and duration (Tzschentke, 2008). In turkey tool to produce high numbers of robust day old chicks, which robust day old chicks. embryos, the number of muscle cells is increased by thermal can cope with different environmental conditions and fully 6 The influence of the parent flock on the effect conditioning during the early phases of muscle cell benefit from their genetic potential. Circadian incubation of Circadian incubation on chick quality differentiation (Maltby et al, 2004). In broilers, the metabolic has been applied on a commercial scale in several broiler requires evaluation. rate of embryos and chicks is lowered after the application of hatcheries in Europe and Brazil. In all these commercial 7 To support the effective, optimized use of thermal conditioning (12 h/day at 39.5 C/day) for embryos hatcheries, the setters and hatchers were equipped with Circadian incubation, the single-stage 14-18 days of age, when the hypothalamus-hypophyse- accurate climate controllers and sufficient cooling capacity. incubator should provide highly accurate control thyroid axis is developing (Piestun et al., 2009, 2013). Thermal over time and climate, to promote tight conditioning during the final phases of embryonic chick Short-term thermoconditioning has been shown to improve temperature uniformity. development induces a shift of the neurons in the brain hatching results in the majority of incubation trials, increasing involved in thermoregulation and metabolism (Tzschentke, final body weight by 1-2 % and delivering 1 to 2 points better References are available upon request. 2007). feed conversion rates. Results were predictable and good in most cases, with the recommendation that hatchery Conclusions managers finetune incubation programs carefully to achieve optimum timing and duration of temperature stimulation In recent years, a growing body of research has shown that during thermal conditioning. In addition, results can be the thermal conditioning of bird embryos improves influenced by breeder flock management. As discussed hatchability and feed conversion rates. Thermal conditioning above, this may be related to the transfer of environmental in the practice of a commercial hatchery is defined as experience from the breeder hen to her chicks. Circadian incubation. Figure 1: Temperature profile of cold stimuli in a commercial setter (76.800 eggs) during five successive Figure 2: Temperature profile of hot stimuli in a commercial setter (76.800 eggs) during five successive days starting at day 14 of embryonic development days starting at day 14 of embryonic development Temp. 1 Temp. 2 Temp. 3 Temp. 4 Temp. 1 Temp. 2 Temp. 3 Temp. 4 99,50 102,00 99,00 101,00 98,50 100,00 98,00 99,00 97,50 98,00 97,00 97,00 96,50 96,00 96,00 95,00 95,50 94,00 13.19:58 14.01:51 14.07:43 14.13:36 14.23:00 15.04:52 15.10:54 15.16:46 15.23:28 16.05:20 16.11:12 16.17:04 16.22:56 17.04:48 17.10:40 17.16:32 17.22:24 18.04:17 18.10:08 13.22:52 14.04:45 14.10:37 14.16:29 14.22:21 15.04:13 15.10:05 15.15:57 15.21:49 16.03:41 16.09:33 16.15:24 16.21:16 17.03:09 17.09:15 17.15:07 17.20:59 18.02:51 18.08:43 5

6 CIC Feeds targets efficient growth with SmartPro Russias SPK Udarnik on track for increased incubation production with Smart Sri Lankas CIC Feeds (Pvt) Ltd. has selected the latest The company has chosen 12 SmartSetPro setters and SmartSetPro setters and SmartHatchPro hatchers, 12 SmartHatchPro hatchers, in combination with together with a full suite of ventilation, climate control and Pas Reforms SmartTray 162 setter tray with space saving hatchery automation systems from Pas Reform, to fasttrack honeycomb design, for improved cost per hatch. The new plans for further expansion. hatchery is nearing completion and will be fully operational As an integrated poultry company the operations of CIC in the third quarter of this year. Feeds Group include the manufacturing of compound feeds, breeder farms, hatchery, broiler farms and processing plant. The Groups General Manager Mr. Ajith Weerasinghe and his Mr. Grigoriy Chistyakov, General Director of Udarnik team have set high standards for the new hatchery, which is With plans to expand its breeder business, the company will expected to be one of the best in Sri Lanka. Overall hatch Russias SPK Udarnik has completed the major refurbish- increase production with a further 400,000 day-old chicks quality, performance and the savings we can realise, both in ment and expansion of its hatchery complex in the Vyborgskiy per week, to meet rising demand both in its own broiler improved feed conversion in the broiler chicks and in the district of Leningradskaya region, with the installation of farms and for supply to customers. reduced electrical energy consumption of Pas Reforms Smart hatchery technologies from Pas Reform to produce Mr Lal Silva, Managing Director of CIC Feeds Group, said: SmartPro incubators, will make our new hatchery one of nine million day old chicks per year. For solid, sustained growth, we have looked at the latest the most efficient and profitable in Sri Lanka. With more than four decades experience of egg production, Modular, single-stage technologies to deliver robust, SPK Udarniks hatchery expansion includes five SmartSet uniform day-old-chicks that support our plans throughout setters, six SmartHatch hatchers and a full complement of the integration, as well as increasing efficiencies in our hatchery automation, climate control and ventilation systems. hatchery operations. The reconstruction in parallel of 12 broiler houses, a In choosing Pas Reform, we have an incubation partner that slaughter capacity of 3,000 broilers/hour, waste utilization understands our challenges and opportunities for the future, factory, feed mill and hen egg production farm has enabled with SmartPro hatchery technologies that meet all of our the company to meet increased local demand for its poultry criteria for quality, increased production and energy savings. meat products. Partnering with Pas Reform for this major project came after As an integrated operation, says Mr Silva, it has become a rigorous comparison of hatchery equipment imperative to exploit the full genetic potential of modern manufacturers. This was a major project to meet growing chicken breeds, which is made possible by modular, single demand from local customers who enjoy visiting our stores, stage incubation practices. says Grigoriy Chistyakov, general director of Udarnik, It is good for the region and with government support, Mr. Lal Silva, Managing Director CIC Feeds Group we were able to undertake this work as quickly as possible, so that we are now in a position to look to the future with confidence! Pas reform appoints new for client relations, account executive and four years in a undertaking a Ph.D in Poultry delighted to welcome Asad to regional sales director management and the ongoing sales management role for Al Production, at the King Saud our team, says Mr. Kampscher, development of Pas Reforms Wadi Poultry (Saudi Arabia), also University in Saudi Arabia. We wish him great success in In line with continuing growing profile as a premier on the equipment side. This strong combination of developing relationships and international expansion and supplier of hatchery No stranger to sales and industry and marketing retention with existing growing demand for its technologies and automated marketing in the poultry experience, a scientific customers - and further growth hatchery technologies, Pas hatchery solutions. equipment sector, Asads background and his familiarity for Pas Reform, particularly in Reform has appointed Mr Asad Mr. Yaseens previous experience academic background has also with the Middle East have, says the area of hatchery automation Yaseen to the new role of includes six years with centered on poultry, with an the Companys Sales Director where demand is growing regional sales director. Agricultural Development M.Sc. in Poultry Production from Michael Kampscher, been rapidly in the region. Based in Riyadh, Saudi Arabia, Company (Saudi Arabia), as a Jordan University of Science and compelling in appointing Asad Mr. Yaseen will be responsible poultry equipment sales Technology and he is currently to this pivotal new role. We are 6

7 Brazils So Salvador Alimentos shifts to single stage incubation with SmartPro from Pas Reform Five years since the launch of its multi-stage hatchery, We had been following the progress of Pas Reform do Brasil, and Pas Reforms new partnership, continues Claudionor So Salvador Alimentos is expanding the operations of its and over the past five years, we have seen what they can do, Thomazini. hatchery with SmartPro from Pas Reform do Brasil. delivering single stage incubation projects on time, and with a dedication to their customers that we have not seen before Thomas Calil from Pas Reform do Brasil, comments, When When the company, a family-owned corporation from in this country. So Salvador Alimentos first built its new hatchery, Pas Itabera in the Gois state of Brazil, built its hatchery in 2008, Reform do Brasil was just taking off in Brazil. Our success in single stage hatchery operations were not well established Speaking with current customers of Pas Reform was, says expanding our customer base and indeed, the success of in Brazil and So Salvador Alimentos elected the traditional director Mr. Rimarck Vieira de Carvalho, a compelling factor our customers here over the last five years - has definitely route, building a multi stage hatchery which at the time was in So Salvador Alimentos ultimate decision. We were contributed to So Salvador Alimentos decision to join the one of the most modern in the country. However with a struck by the way service was always mentioned as an Pas Reform family. Our focus on service and the technical period of rapid growth necessitating the further expansion important aspect of collaborations with Pas Reform. support available from Pas Reform Aacademy has played a of hatching operations, the Company looked again at single pivitol role in their decision to start their collaboration with stage as an option for its future plans. After undertaking some trials with a single stage system and us, and we look forward to working with them for many a thorough analysis of results and the options available, So years to come. After thorough consultation with industry leaders and Salvador Alimentos decided that the combination of different groups that were already using single stage SmartPro single stage equipment and technical support incubation, we started looking at the single stage SmartPro from Pas Reform Academy offered the best solution for its system from Pas Reform do Brasil for our expansion, future plans, according to Roberto Jardim Filho, Technical comments Claudionor Thomazini, hatchery manager. Director of So Salvador Alimentos. So Salvador Alimentos expansion project has now been realised with 16 SmartPro 6setters, 2 SmartPro 3setters and 18 SmartHatchPro hatchers. With an HVAC system from NatureForm Hatchery Technologies already in place, our decision to work with SmartPro incubation only seems even more logical since the announcement of NatureForm Asad Yaseen can be contacted directly on +966533500150 or by email, to [email protected] 7

8 Hungarys Herbro triples capacity with SmartPro hatchery expansion Italys Occhiodoro Hatchery makes Smart investment Mr Pl Kiszel, owner of Herbro Ltd., his son Gbor Kiszel, production director and Michal Kampscher, sales director Pas Reform Hatchery Technologies Italys Occhiodoro Hatchery is further consolidating its The hatcherys recent investment includes SmartSet Herbro Ltd., part of the Hercsihs Ltd integration in Hungary, position as a supplier of premium eggs, layers and high Setters with Pas Reforms unique SmartTray 150 setter tray is to more than triple its annual production of day old chicks quality day old chicks, with a renewed investment in Smart incorporating Microban antimicrobial technology; a with SmartPro single stage incubation technologies from hatchery technologies from Pas Reform. dynamic, web-based SmartCenter hatchery information Pas Reform. The hatchery modernisation and extension system, and the upgrade of the existing hatchers with programme, which also includes hatchery automation for Established by founder Guiseppe Occhiodoro in the 60s, the CO2-level controllers, also integrated to deliver real-time candling and transfer, chick counting and boxing, full HVAC family owned and run business first adopted Pas Reform data through SmartCenter. (climate control) with energy-saving heat recovery system incubation technologies more than 50 years ago. Today, the and washing machines, will bring total production to more company produces around 5 million varied breed d.o.c. a year, In an operation that today covers c. 35 hectares, Occhiodoro than 34 million day old chicks each year. including Red Shaver, Naked Neck Red and Grey, Grey Kabir, is fully engaged in every aspect of poultry farming, from egg Red Kabir, White HI-Y and Red Color Pac, for the domestic production and breeding, to the production of organic feed, The Company, founded in 2008 to ensure the continous market. with strict policies to safeguard bio-security throughout the production of quality day-old-chicks for Hercsihs companys operations. integrated operations, is expanding capacity from 11 mio. day old chicks each year, in response to an expanding share Keeping it in the family: L-R: Anna Occhiodoro, wife of founder, with We are finding already that automated incubation of the domestic market and new opportunities for growth. daughters Paola, owner and commercial manager, and Luisa, office programmes and the careful monitoring of CO2 levels in our manager. Back: Paolas husband and hatchery manager, Achille setters is producing significant benefits in terms of chick Based close to Hercsihs Ltds headquarters in Hernd, the Cristiani, and their son Matteo. quality, says hatchery manager Achille Cristiani. new Herbro hatchery is an investment for the combined integration, which currently processes 14 million chickens SmartCenter makes it very simple to create ideal annually through a network of owned- and contracted conditions for every breed-type, while at the same time farms throughout Hungary. Sister-company Bro-Ker-Bt simplifying and improving hatchery and incubation Ltd.s yearly production is 18 million Ross, Cobb and Sasso management processes, thanks to the remote monitoring breed hatching eggs, with parent stock farms located close and intervention that is possible using SmartCenter via a to the hatchery, near jhartyn. Associated production in Smartphone or iPad, from any location. collaboration with a German company brings annual production up to more than 20 million broilers a year, with Occhiodoro Hatchery plans to further increase production additional hatchery operations. with additional SmartSet and SmartHatch incubators in the future. 8

9 Spains Uvesa adopts Smart innovations for green field hatchery Mr. Ral Gmez Arranz, General Director of Grupo Uvesa Grupo Uvesa, one of Spains leading broiler integrations, is to As a leading producer of poultry products in Western Europe, showcases all our specialisms, incubation, climate control build its new green field broiler hatchery with the most the Spanish poultry sector has grown considerably in recent and hatchery automation, in a truly future-focused new advanced SmartPro single stage incubation, climate control years. With a substantial share of this growing market, hatchery environment. and hatchery automation systems from Pas Reform. UVESAs general director, Mr. Ral Gmez Arranz, says that investment in a new hatchery is a logical move for the Erwin Prinzen, Pas Reform sales director, concludes: Western The new hatchery, which will be located at Tudela in the Company which is committed to deploying the latest, most Europe is a region of great importance to Pas Reforms Navarra region of Spain, 300 km to the west of Barcelona, advanced incubation technologies in its operations. He says: strategic growth plans. Over the last few years, we have built will incorporate 25 SmartSetProsetters using Pas Reforms In our search for the most innovative solutions for a new several new green field projects in the region, among them space saving honeycomb 162 SmartTrays, for the highest green project, we have visited hatcheries in several Western new hatcheries for ISA in the Netherlands and Tetra, in number of hatching eggs per m2 and incorporating European countries over the last five years - and seen the Hungary. Microban antibacterial technology, and 24 SmartHatchPro level of equipment and results that are being delivered by hatchers. In addition, Pas Reform is designing and installing a Pas Reforms hatchery technologies. This new project for Uvesa is a further and unique bespoke HVAC (climate control) system, including a opportunity to demonstrate our capabilities as a total hatchery-specific heat recovery system, to maximise We were impressed by Pas Reforms technological hatchery solutions provider, with the full integration of efficiencies and reduce costs while maintaining biosecurity advancements and while we did look initially at working incubators, climate control and hatchery automation throughout the facility and creating an optimised with separate suppliers for incubation and hatchery systems. We are delighted to have been commissioned and environment for producing high quality day old chicks. automation systems, we found that Pas Reform was very look forward to placing Uvesas state-of-the-art new able to combine both and truly deliver a complete hatchery hatchery as an important reference site for Pas Reform in Comprehensive automation in the new hatchery will include solution for Uvesa. Western Europe. SmartTransfer for the simultaneous transfer of up to 34 settertrays and a complete candling and transfer line, with We see many advantages to working with a single supplier automatic unloading, stacking and de-stacking; an for all systems, comments Rodrigo Garcia, UVESAs hatchery automatic separator will deliver hatched chicks, without manager, Aside from streamlining development by working remnants of shell, to the next stage of processing. A double with just one engineering team for this project, we will see SmartCount counting and boxing system, incorporating Pas advantages once the hatchery is in operation, by being able Reforms innovative new Vision Technology, will count and to integrate incubation data with climate control data and box chicks after inline sexing and high pressure washing hatchery automation data through the new machines will ensure the thorough cleaning of all trays, SmartCenterPro system. baskets and boxes between hatch cycles. Running behind every aspect of hatchery operations, Pas The combination of optimizing incubation profiles to Reforms advanced SmartCenterPro Hatchery Information achieve the shortest hatch windows, while integrating these System will integrate the control of incubation, HVAC hatch window measurements with the uniformity frequency (climate control) and automation systems to a single user distribution of day old chicks from the SmartCount interface, recording all key data and generating batch reports technology will open new horizons for the hatchery in the to assist the hatchery manager in the full optimization of years to come. hatchery performance. Jaume Santaularia, Pas Reforms representative in Spain, adds: We have been gaining market share over the last five years in Spain with installations at Crusvi, Aviagen, Avilesa and Avigan Teralta. This new green field hatchery with Uvesa is an important development to our positioning in the Spanish market - and moreover an exciting one, as it Mr Jaume Santaulria, Erwin Prinzen, sales director Pas Reforms Representative Pas Reform in Spain 9

10 Integrating innovation: Hatchery Over the past 95 years, Pas Reform has remained true to founder Gerrit Pas vision for innovation and forward thinking. By continually developing and evolving hatchery technologies, the Company has become a driving force for Tray transfer from farm trolley to meeting the new challenges that face the global poultry Egg handling setter trolley industry in the 21st Century. The companys Smart single stage incubation technologies have been adopted by modern hatcheries in more than 100 countries for their impact on uniformity, chick quality and overall performance. But today, Pas Reforms capabilities extend much further, with the application of hatchery automation and climate control systems: complete, turnkey solutions that have a positive impact throughout the poultry value chain. Hatchery Automation Systems From the gentle, accurate handling of eggs and chicks for (Un)loading of setter trolley improved hatchability and uniformity, to supporting exemplary hatchery hygiene with equipment that is built to last and easy to clean, Pas Reforms HAS systems deliver improved efficiency and reliability while requiring minimal maintenance. Full integration with automated data management software further optimizes hatchability and Egg setting with process planning. point down correction and 4 class grading With HAS now integral to the Companys capabilities as a total solutions provider for the hatchery sector, Pas Reform occupies a unique position in the poultry industry globally. Supported by Pas Reform Academy and the advanced logistics delivered by LAN Handling Systems, a Pas Reform company, the companys expansion will continue to fuel Semi-automatic innovation and partnership for growth, setting new transfer from setter standards for uniformity and excellence in the poultry tray to hatcher basket industry globally. (Un)loading of setter trolley Transfer from setter tray to Candling & transfer hatcher basketbasket Candling and take-out with inline semi- automatic transfer Candling and take-out for separate transfer In-line stacking and de-stacking Manual transfer of stacks of Candling, take-out and transfer baskets from / to dolley to hatcher basket With an accuracy of two chicks per thousand, SmartCount can Pas Reforms visionary see, analyse, vaccinate and SmartCount chick counting correctly distribute up to 60,000 system has become a flagship chicks per hour into chick boxes, for Pas Reforms innovative HAS while still maintaining low solutions: an advanced chick conveyor speeds to promote a counting and quality analysis stress-free process for the chicks. system that uses Vision Technology to process chicks in stress-free conditions. 10

11 Automation Systems Counting, dosing and spraying by means of Vision technology Carrousel for sexing and / or vaccination Chick handling Separation of day old chicks and egg shells In-line sexing Manual separation of day old chicks and egg shells Direct stacking and de-stacking from dolley Vacuum waste collection High pressure trolley washing High pressure washing of baskets and / or boxes Washing and waste handling High pressure tray washing Elshuis Hatchery in The part of their journey much more greenfield hatchery develop- combine both and truly deliver Netherlands has been among quickly and without stress. ment in the Navarra region. a complete hatchery solution for the first European hatcheries to General director Mr. Ral Gmez Uvesa. adopt the Companys innovative Spains Grupo Uvesa, one of the Arranz, says: SmartCount system. Owner countrys leading broiler In our search for the most Hugo Elshuis says, Less haste, integrations, was among the innovative solutions, we did look more speed it is a principle latest to adopt HAS systems, initially at working with that SmartCount seems to including SmartCount and a separate suppliers for incubation embody, yet at every point the fully integrated SmartCenterPro and hatchery automation chicks are managed accurately hatchery information system, to systems, but found that and gently, completing this optimize performance at its new Pas Reform was very able to 11

12 Do we understand hatch of fertile correctly? By Gerd de Lange, Senior Poultry Specialist, Pas Reform The question is, on which calculation method is the generally Eggs set Clears 1st class 2nd class Total Academy accepted standard for good hatchery performance of 95 % chicks chicks chicks hatch of fertile based? When, incorrectly, clears determined 100 9 86 1 87 Hatchability is commonly used to evaluate hatchery (and by standard candling procedures are the basis for the Infertile Early dead Mid dead breeder flock) performance. Simply said, percentage calculation, it is easier to achieve this standard. However, 5 4 1 hatchability = (number of chicks/number of hatching eggs) mostly some of the clears are fertilized eggs that contain a * 100. However, different interpretations of both the number dead embryo. A better definition for the result of this of chicks and number of hatching eggs, can cause confusion calculation is hatch of transfer. Advice in hatchery performance accounting. Consider the following example: Hatch of transfer also depends on accuracy of candling. Interpret hatchability data only when the method of Imagine in the above example, with precise candling, one calculation is known. A batch of 100 hatching eggs produces 87 day-old-chicks (see additional clear, a mid term mortality, was revealed. Hatch Base hatchability calculations on saleable chicks rather table). Hatchability of eggs set is (87/100) * 100 = 87.0 %. of transfer then increases one percent to (86/(100-10) than total chicks hatched. However if one of these 87 chicks is of second class quality, it * 100 = 95.5 %, although this does not actually mean that Use hatch of fertile to better understand true hatchery is logical to base percentage hatchability on saleable chicks hatchery performance is better! performance. only: (86/100) * 100 = 86.0 % Perform a hatching egg break out on a representative To achieve 95 % hatch of (true) fertile, 90 saleable chicks number of clears, preferably obtained during 10-day Evaluating true hatchery performance by calculating should hatch from the 100 eggs set - and with five infertile candling, to estimate true fertility. hatchability of fertile eggs (hatch of fertile) is widely eggs, only five hatching eggs may be lost due to early, mid or Use hatch of transfer if there is no procedure to estimate accepted. This makes sense, because no skill, expertise or late embryonic mortality. true fertility. technology can hatch chicks from infertile eggs. Continue to seek improvement even when hatch of Hatch of transfer = (saleable chicks/number of transferred eggs) x 100 transfer is over 95 %, if early mortality is high. Returning to the example: eggs are candled before transfer Hatch of fertile = (saleable chicks/number of true fertile eggs) x 100 and nine clears recognized and removed. It is not uncommon to calculate hatch of fertile based on the number Calculating hatch of fertile in daily hatchery practice is of transferred eggs: (86/(100-9)) * 100 = 94.5 %. challenging, and complicated by the need for correct procedures to accurately estimate true fertility. Just candling It is unlikely that all nine clears are actually infertile and is not enough. Early dead embryos during the first days of performing an egg break-out on the clear eggs will establish incubation are incorrectly counted as infertile eggs and true fertility. Suppose of those nine eggs, five are infertile candling equipments ability to recognize true infertile eggs and four show embryos that died during the first week of depends on accurately calibrating sensors and software. incubation. This brings real fertility to 95.0 %. By this method, the correctly calculated hatch of fertile is not 94.5 It is labour intensive to break out a representative number of %, but (86/(100-5)) * 100 = 90.5 %: a very significant hatching egg clears, ideally obtained during a 10 day difference of 4 % - simply as a result of defining fertile eggs candling procedure. However this does provide the most differently. accurate representation of true fertility and patterns of embryo mortality. L-R: Kristof Mertens, Managing New Pas Reform evaluate and enhance hatchery Director Porphyrio, and Bart collaboration provides deep performance. Kemps, Product Manager data mining to optimize Following trials undertaken last Porphyrio hatchery performance year, this new collaboration means that Pas Reform will be Pas Reform has signed an the only manufacturer of agreement with Leuven incubation equipment to offer University spin-off Porphyrio, this level of detailed hatchery a leader in the field of animal data analysis to customers science and data mining, to worldwide. provide customers with deep Using Pas Reforms advanced data analysis services to hatchery management 12

13 Algerian hatchery sector welcomes Pas Reform Pas Reform continues its international expansion, with news Eurl Ouarou Avicol: Mr. Youcef Ouarou is replacing existing Sarl Cherrati Engrais de Volailles: Hatchery owner and CEO of a series of new contracts in Algeria. machines and expanding the capacity of his broiler chick Mr. Hacene Cherrati will invest in the further expansion of hatchery, with SmartSetPro setters and SmartHatchPro his broiler hatchery with six new SmartSetPro 2 setters and Typically a relatively fragmented market, with many small hatchers. With a commitment to investing in the latest two SmartHatchPro hatchers, for a weekly production producers and hatcheries, the tendency in this the largest technologies, both in terms of machine engineering and capacity of 65,000 day old chicks per week (3.4 million day country in Africa has, says Pas Reforms local representative technical service and back up, Mr Ouarou selected Smart old broilers per year). Bob de Rycke, been to consolidate, while at the same incubation technologies after visiting Eurotier in Hanover developing GP hatcheries to fuel growth. Notably, he says, (Germany) last year, and comparing all the world leading Ouchelouz Sarl: Situated in Timgad, Batna, in the east of the Arbor Acres commitment to this dynamic and emerging incubation solutions. The new installation will provide a country, Mr Tarek Ouchen is investing in a new Smart single region signaled an increase in the development of GP capacity of 7 million hatching eggs per year. stage hatchery, with an initial capacity of 100,000 day old facilities, when they partnered with Groupe Kerbouche two chicks per week. Mr Ouchen recently met with Pas Reform at years ago, to develop a state-of-the-art Smart installation Sarl Nutrimag: owned by the Douadi family, this growing the SIPSA exhibition in Algiers, to discuss the final stages of for the production of female parent stock. young company, situated in the West of Algeria, close to the installation process, and make plans for familiarising Oran, specializes in animal feed and now plans to further hatchery personnel with the new incubation systems Pas Reforms new contracts include: expand operations with the development of a new broiler through a programme of training with Pas Reforms Lounigrain Import-Export: Mr. Khaled Lounis, CEO, was hatchery. Mr. Bnaceur Douadi selected Pas Reforms Smart incubation specialists and technical training programmes. instrumental in placing the first SmartSetPro setters and hatchery technologies after visiting the company and its SmartHatchPro hatchers, to evaluate the machines in team in Zeddam, Netherlands where he was invited to Since joining Pas Reforms international team in 2010, Bob de terms of chick quality, hatchability and ease of operation. Mr. discuss the new project with Pas Reforms technical team, Rycke has been responsible for market development in Lounis has, he says, been impressed with hatch results in including machine engineering, HVAC specialists and Belgium, France and francophone Africa, as well as for the terms of hatch of fertile percentages and resulting day old commercial and technical staff. Our aim is for nothing short distribution of Smart incubation, hatchery automation and pullet quality. of excellence in our day old chicks, he says, and we believe climate control systems. that Pas Reforms Smart technologies represent the future Eurl El Rabie Engraissement de Volailles: headed and lead by of incubation. The Nutrimag installation is for a a complete Pas Reform has seriously invested in this new market, to Mr. Saleh Rabie, and a company well established in East incubation system, including SmartSetPro setters and make a strong and enduring commitment to the future of Algeria for the production of Lohmann layers in the market. SmarthatchPro hatchers, a complete HVAC system and the hatchery sector here. Mr. Rabie and his brothers have, they say, chosen Pas Reform hatchery automation, to ultimately produce and process technologies for their new broiler project, because they 200,000 day old chicks per week / 10 million d.o.c. per year. These new contracts and installations represent a very recognize the need for greater day old chick uniformity to exciting time for us a true accomplishment, and we very maintain a market-leading position. Smart single stage much look forward to extending the same, continuing high technologies will expand current weekly production capacity levels of service and support for our customers in North from 88,000 day old female pullets per week, to a weekly Africa in the future. capacity of around 130,000. information software, Pas The insights revealed by Reform Academy says: Pas capabilities of Pas Reform Reform Academy initially Porphyrios analysis enable Reforms commitment to Academy with the ground- organizes and consolidates the hatchery managers to innovation is focused on breaking new techniques complex datasets derived from implement changes and rapidly delivering excellence in hatchery available through Porphyrio, we every recorded hatching cycle to improve day-to-day operational performance. are now in a unique position to formulate hatchery-specific decision-making in hatchery- With the availability of deliver highly advanced queries. This information is then critical processes, such as the increasingly advanced hatchery statistical analysis that unlocks supplied to Porphyrio for optimization of incubation for technologies throughout the insights for a profound impact detailed analysis, to unlock key different egg types. incubation process, hatchery on hatchery performance. insights for the refinement of Commenting on the new data plays an important role in customers incubation programs. collaboration, Dr Marleen that strategy. But data as such is Boerjan, director R&D, Pas just numbers. By combining the 13

14 Learning from the shape and texture of hatching eggs By Dr Marleen Boerjan, director R&D, Pas Reform Academy Calcium carbonate crystals are deposited at a constant rate 3 White, pigment-less shells often are the result of viral of about 0.33 g/h. To facilitate smooth, regular shell infections, like Infectious Bronchitis (IB), Egg Drop syndrome Eggshell is a well-organized structure, arranged in a matrix formation, the egg rotates in the shell gland. Any or Avian Influenza. IB eggs are not only white, but also have of organic matter (proteins) and a palisade layer of disturbance of this rotation, for example when the female abnormal shapes and albumen quality is often affected, crystalline calcium carbonate columns. Between these encounters an aggressive male during mating, produces with thick albumen becoming thin and watery. columns, funnel-shaped openings, pores, are formed, which abnormally formed shell. The shape and texture of the shells facilitate the exchange of gas, including water vapor, during is therefore a good reflection of the health and well being of Advice the development of the embryo. The outer surface of the the breeder flock. shell is covered by a waxy cuticle that protects the eggs from Score the general appearance of eggshells: good, medium, dehydration and invasion by micro-organisms. This understanding is valuable to hatchery managers, not poor, from each batch of hatching eggs that arrives at the only to help evaluate the quality of the eggs delivered to the hatchery. hatchery, but also to have valid input into discussions with Perform a detailed analysis of 450 eggs, if general breeder farm managers about ways in which to improve appearance scoring is poor. hatching egg quality. It is important to remember the Contact the breeder farm manager or supplier if 3% or influence of flock age on egg (shell) quality. Older flocks lay more of eggs are classified as poor. larger eggs with thinner shells - and the number of Use this simple classification as a guide for discussions misshapen shells increases. with suppliers about egg quality. Poor hatching egg shell quality often results in increased weight loss and decreased hatchabilities, with an increased risk of cracks during handling leading to dehydration and contamination. Broadly, there are three major classes of shell abnormality: 1 Rough, sand paper-like shells point to a delayed oviposition. Environmental farm factors, e.g. too high a temperature or a cold draught, can cause retention of the From arrival in the shell gland, it takes approximately 20 egg in the oviduct while additional calcium deposition hours for the eggs shell to form completely. Albumen and occurs. This can lead to brittle, pink colored shells. shell membranes have developed while the yolk, with its embryo (blastoderm) on top, travelled through the magnum 2 Misshapen eggs are usually the result of a disturbance of and isthmus, in the upper part of the hens oviduct. The shell the deposition of calcium carbonate in the shell gland by gland is the part of the oviduct that secretes a highly (viral) disease or stress. Irregular ovulation in young flocks, concentrated solution of different minerals: calcium chloride, as well as stress or disease in the hen, can influence shell sodium bicarbonate, sodium chloride, potassium chloride quality and result in misshapen eggs, such as the flat and proteins. Shell formation begins with the precipitation sided example shown in the photo below. of calcium carbonate crystals and glycoproteins on the outer Another type of misshapen eggs are so called body shell membrane. checks: eggs that have broken and repaired in the shell gland. Externally, this is visible by a thickened ring around the egg. Conditions in the farm-house, for example fighting between birds, cold draughts or high temperatures, can influence the external appearance of the shells in a batch of eggs. Pas Reform appoints new Based at the companys Zeddam where he was Manager the introduction of new Manager Research and headquarters in The Standardization and Vice products and processes. Development Netherlands, Mr. Tinnevelt President Order Engineering. Working in close collaboration brings more than 25 years of In his new role, Edwin will with Pas Reform Academy and Leading Dutch hatchery experience in manufacturing, manage Pas Reforms full team its director Dr Marleen Boerjan, technology supplier Pas Reform design and engineering to the of hardware, software, electrical director R&D, Pas Reform has expanded its Research & post, with specialisms in and mechanical engineers. He Academy, Edwin will drive the Development team with the software systems engineering, will also have responsibility for long-term translation of market appointment of Mr. Edwin mechatronic project engineering implementing technical policies needs and developments into Tinnevelt to the position of R&D and project management. and developments, supporting concrete product innovations. Manager. Prior to joining Pas Reform, production and procurement for With technical responsibility for Edwin worked with VMI Holland, customer-level projects, and for Pas Reforms entire product 14

15 Aviagen boosts R&D investment with SmartPro hatchery at Ariztia chooses Spelderholt SmartPro for new GP hatchery in Chile Aviagen has made significant investments at its Spelderholt The Spelderholt facilities offer a unique opportunity to research and development facility based in Lelystad, the investigate the production, environmental and welfare Netherlands. The latest of these is a newly equipped impact of slower-growing alternative products in addition hatchery to add to the existing Broiler and PS houses. to the more traditional and well known brands. This recent addition now makes Spelderholt a self-contained, fully-comprehensive research facility covering all aspects of As a company, we invest heavily in research and are always breeder, incubation and commercial broiler performance. looking to find ways in which we can improve our R & D Previously owned and run by Livestock Research Wageningen offering. The set-up of Spelderholt allows us to replicate UR, the Spelderholt facilities opened in 2003 but closed in conditions and monitor performance across the entire early 2012. Aviagen then took on the buildings on a long poultry production chain. The addition of these facilities to term lease, boosting its global R & D capabilities. our current resources is therefore a real boost not only to Aviagen but also to our customers. For the new hatchery, Aviagen worked closely with Pas L-R: Mr Don Manuel Ariztia, President of Agricola Ariztia and Reform to design a suitable hatchery to set and hatch the Just prior to completion of the hatchery works there was Mr Fernando Varas, Pas Reforms representative in Chili eggs produced in the breeder trials houses every week, as a great opportunity for students at the Aviagen EMEA well as to provide suitable facilities to run trials of egg Hatchery School, which also took place in the Netherlands, Chiles Agricola Ariztia, one of the countrys largest poultry storage, egg hygiene and incubation conditions. The new to get a first-hand look at the facility and see some of the producers, has commissioned Pas Reform Hatchery hatchery boasts SmartSetPro setters and SmartHatchPro key developments in incubation technology as well as Technologies for the supply and installation of a new Grand hatchers. The facility will allow weekly single stage setting of getting advice on best practise within a hatchery Parent hatchery in Lagunillas (near Casablanca). Pas Reform eggs for trials from on-site production facilities. environment. will supply SmartSetPro setters and SmartHatchPro Other additions to the new Spelderholt hatchery include egg hatchers as well as the complete HVAC system for the new disinfection facilities, two separately controlled storage hatchery, which is due to be operational in August 2013. rooms for hatching eggs, an egg quality and breakout room, transfer facilities and take off, dispatch and cleaning room. The new hatchery will take full advantage of some of the Full shower in and out facilities have also been installed for latest innovations from Pas Reform, by incorporating new the new hatchery, meeting required biosecurity standards. SmartSetPro Setters with Microban setter trays, new Jim McAdam, UK Breeding Programme Director said: SmarthatchPro hatchers with Pas Reforms patented 5-blade Vortex ventilation principle, and the integration of HVAC control in the SmartCenter operating software, for detailed analysis and remote diagnostics throughout the new installation. range, he will also be performance and return on very pleased that Edwin has enhancement that Pas Reform responsible for continuously investment. Access to the latest joined us at this critical time. customers expect. improving the quality and scientific studies and proven With his broad range of efficiency of processes within knowledge-base make this a technical, product development the companys Research and very exciting role that works at and managerial experience, he Development teams. the forefront of emerging will contribute significantly to Commenting on his hatchery technologies. the further definition of Pas appointment, Edwin says: As a Pas Reforms CEO, Bart Reforms market presence, by sector experiencing high levels Aangenendt, welcomed Edwin working with our scientists, of pro duct development and saying: The company is evolving engineers and product receptive to new technologies, to support continuing developers to drive the stream the focus is on enhanced international growth and I am of innovation and product 15

16 The true value of preventive hatchery maintenance A well-organized preventive maintenance program typically includes: regular checks to ensure that all hatchery equipment is functioning correctly carrying out relevant services and maintenance to extend the lifetime of essential parts, and replacing parts before they reach the end of their technically recommended lifetime. When problems are detected during regular checks, there is still ample time to plan for the replacement of relevant parts before they actually break down, which is fundamental to preventing disruption to the smooth-running of the hatchery. Accurately recording maintenance activities generates an essential maintenance history for the hatchery, which will be invaluable in the event of changes to personnel. By analyzing maintenance data over a longer time period, the frequency of preventive maintenance as well as specific instructions for maintenance activities can be adjusted. With such a systematic approach to preventive maintenance, hatchery equipment can be expected to deliver top performance, achieve a maximum lifetime of use and contribute to hatchery reliability and profitability. Advice List all hatchery equipment that requires preventive maintenance. Define who is responsible for the preventive maintenance of each item of hatchery equipment. Schedule the frequency of regular service/maintenance By Erik Meijer, Manager Parts & Maintenance Programmes, The hatcherys technical engineer may not be available checks for each item of hatchery equipment. Pas Reform Hatchery Technologies when the breakdown or malfunction occurs, or not know Describe what should be done at which interval. Make a exactly how to repair or solve an urgent problem distinction between activities that should be carried out Modern hatcheries are capital intensive, production Relevant spare-parts may not be in stock and it may take daily, weekly, before each incubation cycle and less orientated businesses that depend on minimal downtime to several days for urgently ordered spare parts to be received. frequently, for example every six months. realise optimised profitability. A well-organized preventive During the period of equipment break-down, followed by Record all preventive maintenance activities, including any maintenance program is therefore a critical focus for these time to make the required repair, costs are being incurred, and all corrective actions performed and/or which parts businesses which, by anticipating and preparing for potential for example because hatchery staff are idle for some hours are repaired or replaced. machinery or equipment failures, are far more efficient, until they can re-commence their normal work activities. Review maintenance records on a regular basis, to fine- smooth-running and ultimately better placed to realise Depending on the duration of the break-down or tune the optimal frequency of the hatcherys preventive maximum returns on investment. equipment malfunction, such an event will almost maintenance program. certainly have a negative effect on hatchery results. Operational or equipment break-downs and malfunctions can cause severe disruption to the business, potentially with serious A skilled and dedicated technical staff and the ready onsite and costly implications for hatchability and chick quality. availability of a full range of spare parts are key ingredients for a successful preventive maintenance program. Waiting until equipment breaks down is the opposite of a proactive, well-organized preventive maintenance program. With these factors in place, the hatchery can expect to It is important to avoid equipment break-downs and achieve relatively uninterrupted operation, not only of malfunctions because: incubation equipment, but also of supporting and auxiliary functions, such as climate control systems, hatchery They almost always come unexpectedly and at automation, stand-by generator, alarm and waste systems, inappropriate moments, such as half way through an trucks and the many other services and systems that incubation cycle, in the middle of the night or during a together support the comprehensive modern hatchery in its festive holiday. day-to-day operations. 16 Mr Ranulfo Ortiz, Representative Mexico Mr Luis Dulanto Martnez, Representative Peru Mr Jose Izaguirre, Representative Venezuela

17 Mrs. Aigul Nurmagambetova, Manager of the poultry division, Crown Central Asia Malaysias Hyfresh Group sees results with SmartPro Kazakhstan signs Hyfresh Group is a fully integrated poultry business, with feedmill, breeder farm and broiler farms in several Malaysian States. The company supplies chicken to the three broiler processing plants in Sri Sulong, also up for Smart headquarter for the Group, in Pedas Halal Park and in Singapore too. The processed product is supplied to its own Hyfresh retail shops plus other customers. hatchery expansion Dato Sri Pua Tian Siong, Group Managing Director said The integrated model is borne out of necessity. Well-managed, it is a competitive model that delivers a fair return. Together with his younger brother Mr.Pua Tian Haw, Executive Director, Hyfresh Group has plotted a path for further successful growth. We will grow with the market and by 2016, Hyfresh Group will need another 24 sets of Pas Reform has recently concluded several contracts for the For Sarybylak Company in the Almatinskaya region, incubators to meet the growing demand for our day-old delivery of Smart and SmartPro, including: purchasing new Pas Reform equipment means stronger chicks said Mr.Pua Tian Haw. performance on the market. Sary Bulak Ltd. has Hyfresh Group has based its planning, investment and Priirtyshskaya Broilernaya Ptitsefabrika LLP (PBPF) has commissioned Pas Reform to equip its new broiler hatchery growth on a fundamental belief in quality. Starting in the recently refurbished its hatchery in Eastern Kazakhstan in Chapaevo, Republic of Kazakhstan, with eight SmartSet hatchery, this standard ensures that crucial stocks of robust Oblast, with Smart incubation from Pas Reform. The 77 setters and eight SmartHatch hatchers, hatchery day-old chicks are supplied to the groups own broiler farms commission includes SmartSet setters, SmartHatch automation and climate control systems. The hatchery is a as well as to customers farms. hatchers, a pressure controlled ventilation system and part of an integration that produces 10,000 metric tonnes of hatchery automation systems. PBPF is a subdivision of AFK broiler meat per year. SmartPro single stage incubation from Pas Reform is Ardager LLP. serving the integration well. The first six sets of SmartPro These projects will better meet Kazakhstans demand for incubators at Kuantan Hatchery have been operational for Vostok Broiler (formerly Semey Kus) has also opted for poultry meat, at the same time significantly reducing the more than six months, and the impact of high quality day- Smart incubation, with the scheduled delivery of 10 countrys dependence on poultry imports. Domestic poultry old chicks is being seen in highly uniform broilers for SmartSet 38400 setters and six SmartHatch hatchers for production benefits from growing industrial capacity and processing that also give a great FCR. a reconstructed facility that is being redirected from egg strong domestic demand, and now accounts for half of all Hatchery Manager Mr. Azam has, he says, been a happy man production to the production of 20,000t of broiler meat per poultry consumed in Kazakhstan. since the installation of Pas Reforms SmartPro incubation year. technologies; he says: We are seeing a higher percentage hatchability with single stage over the old multi stage Kysylzhar Kus in Pavlodarskaya region is also moving into machines and because hatch quality is so uniformly good, meat production, with a phased transition that will initially they complete the job much earlier. produce 4,000t of meat per year, doubling to 8,000t. The installation includes four SmartSetPro setters with a Dr Khaw Eng San, the Groups Poultry Integration Planner, capacity of 57,600 eggs each and three SmartHatchPro concurs: Hyfresh Group selected Pas Reform based on its hatchers, to combat the high cost of energy in the northern people, its advanced SmartPro incubation system, the cost region of Kazakhstan and meet the demands of local of ownership and overall value of investment. Based now consumers. also on results, I would say it was a good choice. Mr Jamil Al-Khawaja, Representative Jordan Mr Hany Hassan, Representative Egypt Mr Hisham Hassan, Representative Egypt 17

18 Holmes Foods chooses Phoenix from NatureForm Hatchery Technologies for renovation project in the USA Holmes Foods has placed a new order with Natureform Mr Weber says news of Natureforms new partnership with Hatchery Technologies as it continues the renovation of its Pas Reform was a pleasant surprise. Pas Reform Hatchery Gonzales-based hatchery in Texas, USA. Technologies has the longest experience in single stage incubation in the poultry industry - and they offer the The company first installed Phoenix machines in 2010, when support and expertise of Pas Reform Academy. This it placed six single stage Phoenix P18 incubators in test combination of a committed R&D department with new alongside six single stage incubators from a previous machine developments and a hands on approach to training supplier. demonstrates a wealth of knowledge and great confidence in the US industry. Holmes Breeder Hatchery Manager Joe Weber says, The Phoenix single stage machines have outperformed our In the second phase of the renovation project, Holmes Foods previous incubators in terms of hatchability and post hatch is adding nine more P18 incubators and plans to replace the performance. When compared with our existing multistage entire hatchery with Phoenix single stage incubation from operations, the improvements are even more significant. NatureForm Hatchery Technologies. As each Phoenix single stage incubator occupies the same The formation of Natureform Hatchery Technologies has footprint as the companys existing multi-stage machines, been so well received by the industry, says Steve Warren, the Holmes Foods will be able to renovate and expand its companys President, The integration of our founding hatchery operations on the same premises, reducing the companies has created a business capable of delivering total expected return on investment time to less than three years. solutions for projects of any size and we truly appreciate the continued confidence that Holmes Foods has placed in NatureForm Hatchery Technologies. They are fantastic people to work with and we are delighted to be supporting the renovation of their Gonzales hatchery. Pas Reforms new Logistics Zeddam headquarters, in The The new Center, which has been and Training center: Netherlands. designed to provide light, airy open for business! workspaces throughout, also The days proceedings included a includes a training floor, with Hundreds of invited guests, tour of the new facility, which practical study spaces to including customers, suppliers incorporates the most advanced accommodate the increasing and colleagues, accepted Pas computer-controlled logistics number of international poultry Reforms invitation to the official capabilities for the fastest, most specialists visiting Pas Reform inauguration of the Companys accurate delivery of Pas Reforms Academy to further develop new purpose-built Logistics & Smart incubation, hatchery their hatchery management Training Center, located at automation and climate control skills. Doetinchem, near the Companys systems to customers worldwide. 18

19 Preventing cross-contamination in the hatchery By Gerd de Lange, Senior Poultry Specialist, Pas Reform area where processing takes place, on their way to the directly into exhaust plenums that can easily be cleaned and Academy transfer room. And importantly, hatchery staff, including the disinfected. The use of air ducts should be restricted for technician responsible for maintenance, do not walk from clean, unused air only. Due to its central position between breeder farms and the chick processing room to the setter room on a hatch day. poultry production houses for meat and eggs, optimised Differently coloured hatchery clothing and shoes, as well as In the hatcher, condensation on the cooling surface is normal hatchery hygiene plays a crucial role in preventing the spread tools like floor rubbers, greatly help to enforce hygiene- and the majority of fluff will be caught by this moisture if of pathogens in the poultry value chain. responsible behaviour by hatchery personnel. the surface is large enough. The integration of cooling pipes inside the wall panels creates a large surface area that Optimised hygiene in the hatchery is dependent on three key Exploders, often caused by Pseudomonas spp, are an significantly minimizes the risk of cross contamination, while areas: important source of cross-contamination between batches at the same time greatly reducing cleaning time and 1 preventing pathogens from entering the hatchery, ie. within the same setter. To reduce this risk, batches with an promoting excellent disinfection results. maintaining bio-security; increased incidence of exploders should be transferred to the 2 avoiding cross-contamination or the transfer of pathogens hatcher last. Advice within the hatchery; 3 inhibiting further pathogenic development in the Strictly applying the One batch per hatcher rule, enabled by Organize regular hygiene-awareness training for hatchery hatchery ie. cleaning and disinfection. limiting the capacity of the hatchers, greatly prevents the staff; people are often the weakest link in the hygienic risk of cross contamination, for example from older to chain. This article focuses on the prevention of cross-contamination younger batches. In a well designed hatchery the number of Apply the rule clean should never meet dirty strictly, for from relatively dirty rooms in the hatchery, such as the chick hatchers per hatcher room is based on the daily production eggs, people, air and items such as trolleys and trays. processing room, to what should be the cleanest room, the of chicks. This prevents recontamination after cleaning and Maintain setter room in overpressure in relation to setter room. disinfection, so minimizing the risk of contaminating hatcher rooms to avoid the entrance of fluff. tomorrows hatch. Transfer batches with an increased risk of exploders to the To prevent cross-contamination, it is important to clearly hatcher last. demarcate the different hygienic zones in the hatchery: egg Chick down, also a potential contaminant, is easily airborne. Plan daily chick production based on the number of arrival area; setter room; candling/transfer room; hatcher Its movement must therefore be controlled to prevent cross- hatchers per hatcher room. room; chick handling and despatch room. In a well designed contamination. The setter room, to be maintained as the hatchery, the practical implementation of the clean should cleanest room in the hatchery, should be kept overpressure never meet dirty rule is easily achievable. For example, eggs in relation to the hatcher rooms. The accumulation of down being transferred to the hatcher do not cross the path of in air ducts should be avoided, because this forms breeding chicks just being pulled. After being washed and disinfected, grounds for moulds like Aspergillus spp. Air leaving the hatcher baskets do not pass through the chick room or any hatcher - and ideally also the setter should be brought 19

20 SmartTray- Smart thinking from Pas Reform Nine good reasons to choose SmartTray over traditional setter trays Pas Reforms SmartTray setter trays offer unrivalled performance in the modern hatchery. Best And the good news is you can enjoy these advantages even if youre not running Smart incubation systems! Check out the benefits of using SmartTray below and contact us today for your free, no obligation quotation. buy 1 Supports hatching eggs at two levels 2 Open, spacious grid 3 Microban antibacterial technology One size fits all! Innovative design provides maximum Open, spacious grid promotes the free movement of air for The only setter tray to incorporate Microban continuous protection for hatching eggs of all sizes with support points more uniform heat and humidity distribution. antibacterial technology. at two levels and no hairline cracks! 4 Superior Construction 5 Stable and self-centering 6 Safe, secure stacking Superior construction: highly impact and temperature Stable and self-centering: securely positions each egg for Blind-find bottom design for fast, safe, secure stacking. resistant. Ideal for automated hatcheries! on-target in-ovo vaccination. 7 HACCP compliant 8 Ergonomic design 9 Space saving honeycomb design Smooth finish for easy, thorough, fully HACCP compliant Lightweight, ergonomic design for ease and comfort in Space saving honeycomb design: range of capacities now cleaning. handling. includes SmartTray 162, for the highest number of hatching eggs per m2 Contact [email protected] for your free SmartTray quotation or visit: SmartTray 150 SmartTray 162 SmartTray 126 SmartTray 126 capacity 150 hen eggs capacity 162 hen eggs capacity 126 duck eggs capacity 126 turkey eggs 20

21 Eco-friendly Smart hatchery sets the pace for Bbolna TETRA expansion Bbolna TETRA Kft., one of the worlds leading layer-hybrid Bbolna TETRA Kft. is market leader in Hungary and breeding companies, has developed one of Europes most distributes its TETRA grandparent- and parent breeders to advanced hybrid hatcheries at Uraijfalu, in Hungarys Vas chick hatcheries producing commercial egg layers for egg county, with SmartPro single stage hatchery technologies producers in more than 40 countries around the world. from Pas Reform. Committed to the highest levels of efficiency and environmental awareness, the Companys hatchery With an annual capacity of 35 million eggs, Bbolna Tetras expansion in Uraiijfalu is the result of increased sales new hatchery has been developed with all the very latest worldwide, following the successful genetic development of innovations in single stage incubation, hatchery automation three new Hybrids, the Tetra HB Color, Tetra Blanka and Tetra and environmental control from Pas Reform. Opened in SL Long Life. March 2014 the new site includes 12 SmartSetPro 6 setters, Mr. Zoltn Budai, director of Bbolna TETRA Kft., says of the 12 SmartSetPro 2 setters, 22 SmartHatchPro hatchers and project: Our company is delivering significant growth for an onsite Watter disinfection production system. sales of our breeder layer lines and with Pas Reforms innovative hatchery technologies to support that growth, we For all egg- and chick handling, Pas Reforms latest have created a strong, stable platform for achieving automation systems are being employed to deliver ambitious targets both now and in the future. pointsetting, egg grading, sexing and vaccination, chick counting, vacuum waste system, washing, stacking and de-stacking. The hatchery uses various renewable energy sources to deliver environmental and energy-efficient benefits in its operation, including Pas Reforms innovative heat transfer system, which uses the heat produced by the developing embryos during incubation to preheat fresh air intake within the hatcherys ventilation and climate control systems. Mr Lszl Korsi, Representative Michal Kampscher, sales Hungary director Pas Reform 21

22 Improving hatchability and chick quality The power of data to unlock performance By Dr Marleen Boerjan, director R&D, Pas Reform Academy, In collaboration with Porphyrio, Pas Reform Academy can now an overview of the number of observations per flock. Figure K. Mertens and B. Kemps (Porphyrio, Leuven) perform such advanced statistical analyses for customers 1b shows in which setter the eggs from the different flocks worldwide, to unlock the information held in the available data were placed. Additionally, figure 1c displays the storage Introduction as a real asset to day-to-day operations in the modern hatchery. duration of eggs from the different flocks. Finally, figure 1d shows the age range of the different flocks during the period A great deal of data is collected in hatcheries all over the Data quality evaluation of data collection. For example, in the case of flock 61 (fig. 1a), world, as batches of eggs, originating from many different there are 227 observations; the eggs were set in setter sources, are set. Hatcheries hold information about the An important first step in data analysis is to gain insight into numbers 1 to 24 (fig 1b)(excluding Setter 8), they were stored history of the eggs: which flock they originate from, flock the available data. Figure 1 shows the experimental structure from 1 to 8 days (fig. 1c) and flock age ranged from 40 to 70 age, the number of egg storage days and many other factors, of the dataset gathered in Latin America. Figure 1a provides weeks during the period of data collection (fig. 1d). as well as hatchability percentages, fertility percentages, and very often the results of detailed break out analyses. Figure 1. Overview of the data distribution for the different flocks. This data is extremely valuable, as it can be used not only to gain insights into the incubation process, but also to improve a. Number of observations per flock 400 hatchery performance. However, in day-to-day hatchery practice, the expertise and/or time available to extract 200 practical information out of such complex datasets is often Counts missing. 0 55 60 65 70 75 80 During the season 2011/2012, Pas Reform gathered data from Flock number 6,800 batches of eggs set in Latin America. To fully exploit b. Distribution of the eggs per flock over the setters this data we initiated a collaboration with Porphyrio. The 50 Setter number expertise of Porphyrio was used to convert the available raw data into reliable information. 0 The report of this study, summarized in this article, 55 60 65 70 75 80 demonstrates the value of a profound statistical analysis of Flock number observational datasets gathered in hatcheries. After a c. Distribution of eggs over days of storage detailed evaluation of the quality of the dataset, analysis can 20 provide fact-based information for improved hatchery management and decision-making. 10 Counts First, the importance of data quality evaluation was 0 discussed in terms of the great care that should be taken 55 60 65 70 75 80 Flock number when interpreting complex data, to avoid reaching the wrong conclusions and consequently making incorrect d. Range of available ages for each flock management decisions. Secondly, those parameters that 100 have an important influence on hatchability rate were 50 Age (wks) investigated. Finally, the performance of the SmartSetPro setter (Pas Reform) was compared to that of a conventional 0 incubation system. 55 60 65 70 75 80 Flock number Dr Marleen Boerjan, Marking a Lifetime outstanding performance and director R&D, Pas Reform Achievement loyalty to Pas Reform. Sergio has Academy set a powerful example while Pas Reform recently celebrated building our business in Italy, Mr Sergio Morellis 40th said CEO Bart Aangenendt, and Anniversary as Pas Reforms it is with gratitude and respect, representative in Italy. that we acknowledge the hard work and skill he has committed Before friends and colleagues to Pas Reform and our from around the world, Mr. customers for more than four Morelli was honoured for his decades. 22

23 From Figure 1, it can be seen that many combinations of A statistical logistic model selection procedure was applied Analysis revealed that the SmartSetPro setters perform parameters are not present, e.g. for some flocks, observations to determine the most informative statistical model for a significantly better in terms of hatchability rate compared for a limited range of flock age were available and the eggs given number of parameters. For a straightforward with conventional setters. A difference of hatchability of 2 % were not placed in all setters. This is a common observation interpretation, only the parameters that have the largest was observed (76.8 % for conventional vs 78.6 % for for data collected at a hatchery. For such an observational impact on hatchability rate are included. This allows rapid SmartSetPro Setters). dataset, it is difficult to extract causal relations. assimilation into the management decision-making process. We illustrate this with an example. Figure 2 shows the It was concluded that variables FlockAge and EggStorage It was also observed that comparing hatchability rate observed hatchability rates for two different flocks without have the largest influence on hatchability rate. Compared to between different SetterType without correcting for FlockAge taking relevant information such as age of the flock and FlockAge and EggStorage, the other variables and their will produce incorrect conclusions. Since the distribution of storage duration into account. The conclusion from this data interactive effects have a less pronounced effect. FlockAge of eggs set in different SetterType was very is that flock 57 performs significantly worse than flock 82 different, the actual effect of SetterType was masked by the (fig. 2). As can be seen from Figure 1d, observations for flock Performance analysis FlockAge effect. 57 originate from old hens, while the observations for flock 82 originate from young hens. However for old hens, the An analysis was performed to compare the performance of Conclusion hatchability rate decreases significantly as can be seen in the SmartSetPro setter with a conventional incubation figure 3. system. A powerful way to investigate the effect of To conclude, Pas Reform sees great potential in the new SetterType (conventional vs SmartSetPro setter) is to use collaboration between its Academy and Porphyrio, for the To conclude: comparing hatchability rates between flocks the information from batches of eggs for which one part was opportunity to obtain and provide deeper insights into the without taking this relevant information into account will incubated in a conventional setter and the other part of the dynamics of modern incubation for the benefit of clients lead to the wrong conclusions. The hatchability rates batch in a SmartSetPro setter. Eggs from one batch worldwide. Such collaboration enables the profound and well- observed in Figure 2 result, among other factors, from originate from the same flock, with the same flock age and substantiated analysis of numerous large and complex differences between the flocks and differences in the age of storage duration. Therefore, any variability due to Flock, hatchery data sets. This report shows that such levels of the flocks during data collection. Based on the available data, FlockAge and EggStorage is excluded. analysis can support day-to-day operational decision-making it is impossible to separate these effects. Therefore in this in hatchery-critical processes, such as the optimization of example, a conclusion about the origin of the observed Based on these observations, the average hatchability rate incubation time and the performance of individual incubators. differences in hatchability rate cannot be made. for the SmartSetPro setters and conventional setters was On a more strategic level, reliable data analysis forms the 78.6 and 76.6 % respectively. A student t-test was performed basis for decision-making in poultry integration, for example Results Which parameters influence hatchability rate? to analyze whether the effect of SetterType on hatchability regarding investment proposals. This sort of analysis has the rate is significant. The calculated t-statistic corresponds to a potential to become a powerful management tool for From figure 1, it could be seen that the experimental design p-value of 0.013, leading to the following conclusion: hatcheries and integrations focused on performance, results is incomplete, i.e. many combinations of parameters are not At a significance level of 0.05, it can be stated that the new and growth. present. To minimize the problem of correlated parameters, a SmartSetPro setters perform significantly better in terms of subset is created for which the experimental design is as hatchability rate compared with conventional setters. Figure 4. Distribution of the number of observations per flockage for complete as possible. The observations from flocks 66 to 74 each setter type are the most complete with respect to setter (fig. 1b), storage Comparing average hatchability data per machine type could duration (fig. 1c) and age of the flocks (fig. 1d) and are used to easily lead to the formation of incorrect conclusions. Figure 4 Conventional setters SmartSetPro setters create the subset on which the final analysis was performed. shows the distribution of the number of observations per n=1252 n=642 70 This subset consists of approximately 3500 observations. FlockAge for the different SetterType. This indicates that the batches of eggs incubated in the SmartSetPro setters 60 Next, an initial selection of the most important parameters originate from older flocks than those set in the conventional with respect to hatchability rate was made based on existing setter. As shown in Figure 3, hatchability rate decreases 50 literature (Yassin et al., 2008) to include the following during considerably with FlockAge. Therefore to make a fair this investigation; comparison, flock age should be considered and kept equal. 40 Age of the flock (FlockAge) Summary Number of observations 30 Storage duration (EggStorage) Flock Statistical analyses were performed on a relational dataset 20 SmartSetPro setter vs conventional setter (SetterType) gathered in Latin America. It was concluded that the age of Season flock and the duration of storage have the largest influence 10 on hatchability rate. Other variables and their interactive effects have a less pronounced effect. 0 30 40 50 70 60 Breeder age (wks) Figure 2. Boxplot of the hatchability rates for flock 57 and 82 Figure 3. Boxplot of the hatchability rates at different flockage. 90 90 85 80 80 75 70 70 60 Hatchability rate (%) 65 Hatchability (%) 50 60 40 55 57 82 Flock 30 40 50 60 70 Flock Age (wks) Celebrating a lifetimes achievement: Mr Sergio Morelli was presented with a sculpture symbolising the strength and energy of cooperation by Bart Aangenendt, CEO, and Bouke Hamminga, Director International Sales and Business Development. 23

24 The skys the limit for quality partnership in Zambia Seen from the air! Ross Zambias flagship new Chainda Hatchery is the result of a recent collaboration between Ross, Pas Reform Hatchery Technologies and its local representative, Pas Reform Southern Africa Region: a state-of-the art new facility, ready to deliver 350,000 day old chicks per week in support of Zambias growing poultry sector. Future-focused AS Putra expands into hatchery operations with SmartPro Ross Breeders Javas AS Putra is to add broiler breeding and hatchery operations to its established poultry business on West Java, with a significant investment in SmartPro modular single stage hatchery technologies from Pas Reform. Zambia expands Research to find a preferred incubation solution was, says company director Aif Sidhik, very extensive and a quite a challenge. After more than 15 years in the broiler producing business, he says, we believe that the process does not with Pas Reform start on the farm, but rather when embryo development begins - in the incubator. Ultimately this was why we selected Pas Reforms SmartPro incubation system for our new hatchery. We see a great synergy between our beliefs and observations in practice and Pas Reforms focus and results in achieving Ross Breeders Africa is expanding its Zambian operations Additional breeder houses will be constructed when the greater chick uniformity, as a precursor to greater efficiency with SmartPro incubation technologies and air handling hatchery is completed in October this year, to triple Ross throughout the broiler production process. systems from Pas Reform. The project includes a new broiler Breeders Zambias production capacity with the complete hatchery, additional breeder houses, a new grandparent relocation of the current Grand Parent Project to the new The new hatchery will include SmartSetPro setters, farm, staff housing and ancillary buildings. site at Mazabuka. This will allow full veterinary equipped with Pas Reforms innovative Energy Saving compartmentalization of the facility, which will open new Module (ESM), to reduce the use of electricity while export markets as well as securing the veterinary status of providing active control over ventilation in the setter; the the flocks. A greenfield project, the new breeder facility will SmartCenter hatchery information system and comprise a dedicated new grandparent hatchery, separate SmartHatchPro hatchers, equipped with SmartWatch, an and bio-secure breeder facilities and staff housing. innovation that monitors and adjusts the hatching process GP farm and parent breeder houses are due for completion automatically from the day of transfer through to the last by the end of 2014. chick hatched. Mr Colin Lindsay, managing director of Ross Breeders First established in 1986 as an egg producer for the local Zambia, commented on the developments: This investment market, AS Putra began broiler production to serve its local is a reflection of Ross Breeders Zambias continuing market in 1997. Today, the company raises 1.5 million commitment to the Region as an expanding economy. chickens each week, for distribution throughout Java Island The broiler hatchery, situated at the Companys main and Southern Sumatra, with day old chicks sourced from breeding farm close to Lusaka, will hatch 1 million day old The new facility will create 200 new jobs in the poultry various producers. The new hatchery operation is targeting broiler chicks per week in a state-of-the-art new building, sector, as a hub for the export of parent stock all over 30 per cent of d.o.c. supply for the companys broiler designed to hatch six times per week rather than the southern and central Africa, as well as providing the local operations over the next three years. conventional four. This system enables Ross Breeders Zambia industry with Ross 308 broilers and parents. to fully realise the genetic performance of the Ross 308 while also giving customers more choice on which day of the We chose Pas Reform because sound engineering and week to place broilers. technological advances in the SmartPro incubators will see us producing the best quality chicks for a long time to come. We are thrilled to be one of the first customers for the SmartHatchPros Vortex-based airflow system. This is a very exciting project for Zambia and the region. Pas Reform Southern Africa L-R: Jankees Sligcher, Adriaen Sligcher 24

25 Outstanding results for Willmar / AG Forte with Phoenix incubation from NatureForm Hatchery Technologies Willmar Poultry Company/ AG Forte is reporting outstanding The collaboration that they now bring to the market with first hatch results following the recent installation of 12 new Pas Reform adds new knowledge and commitment to our US Phoenix single stage turkey incubators from NatureForm turkey industry. We have been watching Pas Reform and we Hatchery Technologies at its hatchery in Aurora, Missouri. are impressed by their R&D facilities and capabilities. The partnership of these two companies represents a dynamic First hatch results are close to breaking all previous hatch new force for the US poultry industry generally, and for the records, with almost 91 per cent hatch from eggs set. Flock turkey sector in particular. vs. flock against results recorded with previous equipment is up across the board, with increases ranging from 1 9.6 per Steve Warren, President of NatureForm Hatchery cent. Technologies, adds: NatureForm has traditionally been very strong in the turkey market, with dedicated machines We have been working with Natureform Hatchery designed specifically to support the turkey incubation Technologies for over two decades and have always process, which is more challenging than that of broilers and appreciated their dedication. We consistently have layers. outstanding service from them and excellent performance from their equipment, says Richard VanderSpek, President & Our new partnership with Pas Reform extends and deepens COO at Willmar Poultry Company/AG Forte. this knowledge - and we look forward to sharing our combined research and capabilities, through specialised incubation training courses with the turkey sector worldwide. 25

26 Correctly interpreting dead in shell By Gerd de Lange, Senior Poultry Specialist, Pas Reform Determining the true level of DIS can be problematic, as From this example, it can be concluded that DIS-figures Academy counting them accurately is not practically achievable. This is should be interpreted with great care to avoid hasty or in contrast to clears, which are either counted electronically incorrect conclusions. A high percentage of clears is usually regarded as a breeder by the automatic candling equipment, or by simply counting, farm or egg handling problem, whereas a high rate of late for example, the number of 30-egg flats with clears when Advice embryonic mortality is more likely to be seen as a hatchery using a simple candling table or hand candling lamp. failure. While suboptimal incubation conditions may indeed Determine, record and monitor DIS-levels on a regular be responsible, other non-hatchery factors should not be It is therefore not uncommon for DIS to be calculated based basis in at least six baskets per batch. overlooked. on the number of eggs set, minus clears removed during Recognise that a calculated DIS-level (eggs set clears candling, minus hatched chicks. While this method is easy chicks) may not represent the actual percentage of late Determining, recording and monitoring levels of late and fast, it still may not accurately provide the actual levels mortality. embryonic mortality is good practice - and can be valuable of DIS or late embryonic mortality, as defined above. Perform a break-out of all unhatched eggs (after candling) to optimizing hatchery results. Consider the following simplified example, derived from from at least six baskets per batch to determine the actual actual practice: percentage of late mortality. It is not uncommon for the term Dead in Shell, or DIS, to be Pay attention to special observations while performing an used instead of late embryonic mortality. Logically one From a batch of 100 set hatching eggs, 15 clears are removed egg break-out, such as the wetness of embryos, would expect DIS to represent late embryonic mortality. But during candling. The remaining eggs are transferred to the malpositions/malformations, rots and cracks and delayed the question remains: on which day during incubation does hatcher, to produce 74 first class chicks and one culled chick chicks (live pips), as these provide relevant information mid-mortality stop and late mortality begin? on hatch day. The hatchery manager calculates 100 15 for the optimization of hatchery management and the (74+1) = 10 DIS, or 10 per cent of eggs set. For DIS as defined finetuning of incubation parameters. To avoid confusion around this definition, especially when above (ie. mortality after 17 days) this is far too high and Take corrective actions if DIS-levels exceed your hatchery sharing data with other hatcheries or consultants, it is could indicate considerable challenges in the hatchery. specific flock-age dependent standards. recommended that DIS, as well as late mortality, are defined However, performing a break-out on the 10 unhatched eggs as follows: All embryos that died after the start of yolk sac still remaining in the hatcher basket after chick take-off retraction into the abdominal cavity, therefore all embryonic finds: five clears (including one infertile egg and others with mortality after approximately day 17. According to this mortality up to the dark eye stage); one mid-mortality and definition, DIS includes all embryos that died after four late mortality embryos, in which retraction of the yolk transferring the eggs from setter to hatcher. It is worth has actually started. So in reality, DIS is in fact much lower, at noting that live pips are not included in this definition, and just 4 per cent. raised numbers of these point either to pulling the chicks too early, or to too broad a hatch window. New appointment to drive procurement professional, The true power of Pas Reforms markets, as the Dutch company Supply Chain developments Jacques holds a B.Ec. in Logistics Supply Chain lies in its gears up for increasing demands for Pas Reform and Economics from HEAO- flexibility, he says, and the on its supply chain globally. Arnhem, and has worked in added value that comes from a Pas Reform achieved its highest Pas Reform has set the tone for senior purchasing, procurement coordinated, highly motivated ever supply of units in a single further expansion and supply and supply chain management international team on all sides month last year, he says, which chain development with the roles for more than a decade. of the supply chain. really tested and proved - appointment of Jacques le In his new role with Pas Reform, Director of Operations Wouter communications, flexibility and Comte to the new role of Jacques is responsible for Heideman says Jacques dependability within our supply Procurement and Supply Chain strategic procurement and the appointment is central to Pas chain. Manager. day-to-day management of an Reforms strategy for further With Value Engineering at the An experienced, international international team. expansion in new and current core of its strategy, Pas Reform 26

27 SmartPro delivering daily for Ecuadors Incupasaje Cia. Ltda. Amrit Group brings Incupasaje Cia. Ltda., one of Ecuadors leading producers of day old chicks, is planning the second phase of its hatchery expansion with Pas Reform, following a successful first phase development last year. single stage innovation The installation of a complete SmartPro single stage incubation system at the companys hatchery in Pasaje, Ecuador in 2013 has, says company President Jimmy Rios, to the fore in India delivered very good results in terms of uniformity and a reduced hatch window, with the hatchery now outperforming its multi-stage predecessor on a daily basis. Pas Reform supplied SmartSetPro setters and SmartHatchPro hatchers, to deliver advanced, next- generation single stage incubation capabilities, together In the year that Indias Amrit Group celebrates its 20th Mr. Harish Bagla, Group Managing Director, says, Amrit with a complete HVAC system including air handling units, anniversary, the company is on track to launch a landmark Group has demonstrated strong growth over two decades pressure controls, air ducting and chillers, to create a fully new hatchery complex at its new 1.15 million egg/week for its focus on quality and its dedication to the continuing managed and conditioned environment throughout the hatchery facility in Panagargh, India. expansion in four key areas; feeds, poultry, dairy and frozen entire facility. Incupasaje also invested in hatchery food. And we at Amrit Group are unwavering in our automation from the Dutch company, with a complete chick Amrit Group signed a contract with Pas Reform at VIV Asia in commitment to provide premium quality for our customers. take off system incorporating in line sexing and vaccination March last year for the supply and installation of a fully carousels, as well as washing machines and a waste equipped SmartPro single stage hatchery at its new poultry This strategy is centred on the delivery of products with high handling system. processing complex in Panagargh. The new development nutritional value, setting new standards in India for also includes feed mills, broiler, breeder and layer poultry excellence and hygiene. Our new SmartPro hatchery fully The Pasaje development came following a recommendation farms, which are being built concurrently. supports these aims and we look forward to seeing it fully from the hatcherys genetics supplier, explains Mr Rios: We operational so that we can quickly realise the benefits of were advised to look at Pas Reforms machines, climate Due for completion towards the end of this year, the new SmartPro incubation throughout the integration. control and hatchery automation systems and in particular Amrit Hatcheries Pvt. Ltd. Facility has been conceived and to evaluate machine quality and after sales technical developed to incorporate the most advanced, innovative support. materials and technologies: a flagship operation for a company that has demonstrated strong, sustained growth Now in operation since the second half of 2013, we have by leading the way in innovation in India since 1994. been getting very good results and can comment positively and confidently on Pas Reforms after sales support first- With a full suite of hatchery technologies from Pas Reform, hand, which has included numerous visits from Pas Reforms the hatchery will incorporate the most advanced SmartPro incubation specialists to help us realise optimum modular, single stage incubation technologies, with 24 performance from our new single stage incubation SmartSetPro setters, each with a capacity of 115,200 operation. hatching eggs and a corresponding suite of 24 SmartHatchPro hatchers, each holding 19,200 hatching eggs, to deliver a weekly setting regime of 921,600 hatching eggs. The new hatchery also includes climate control and los mejores pollitos BB hatchery automation systems from Pas Reform. will also introduce a new maintaining this robust Mr Natarajan Venkitakrishnan, barcode system and an performance with increased Country Manager India international code of practice demand. this year. Jacques le Comte will be based Jacques role is to coordinate, at Pas Reform headquarters in manage and optimize Zeddam, The Netherlands. contributions to these goals from the entire supply chain. Jacques can be contacted His substantial OEM experience directly on +316 22 542 848, and collaborative, highly or by email to: motivational approach will be [email protected] important drivers for 27

28 Duck King on a Smart track for continued growth in Thailand Polands Hama Thailands Duck King is on track to achieve capacity production by 2016, in line with a brand development programme to highlight the Companys reputation for quality and professionalism as Thailands top broiler duck producer. Plus to double Since expanding hatchery operations with a new Smart single stage duckling hatchery in the final quarter of 2012, the company has more than doubled capacity to deliver a total of 180,000 ducklings every week, with plans to further increase that number by 2016. capacity with Duck Kings managing director, Mr Naris Poonyalikit, says the new hatchery has improved duckling quality, reducing first week mortality to less than two per cent, with ducks reaching a final weight of 3-3.2kg by 45 days of age. The company plans to build a new parent stock farm to take full SmartPro advantage of its expanding hatchery capacity and to accommodate growth, which has been maintained at a steady rate of 15 per cent each year. Duck King distributes whole ducks and cut ups under the Siam Makro brand ARO, with whole duck products being produced for restaurant chains in the country. With product also distributed regionally through a collaboration with Hama Plus S.A., Polands largest producer of day-old-chicks In 2014, the Stary Widzim hatcheries are being refurnished Betagro, the Company is cementing growth with and a fully owned subsidiary of Denmarks DanHatch A/S, is with Pas Reforms most advanced SmartPro single stage customised lines for food service outlets and developing advancing its plans to double capacity with SmartPro incubation technologies and fully automated egg setting new duck menus for retail customers, as well as developing single-stage incubation technologies from Pas Reform. lines, as the hatchery extends capacity to deliver 95 million ready to cook meals and ready to eat products for retail day old chicks annually by June of this year and putting the distribution throughout Thailand. The company aims to continue its dynamic growth on the company on track to achieve production levels of 115 million Polish and European markets by constantly increasing its day old chicks each year by 2016. range of high quality products, an important strand in By deploying the very latest hatchery technologies for its parent company DanHatch A/Ss expansion, particularly in forward-looking plans, Hama Plus S.A. has grown quickly to the north-east and southern regions of Europe. become one of the largest producers of day-old broiler chicks: a strong partner not only for individual producers in With such ambitious growth as a key pillar of Hama Plus Poland, but also for large integrated poultry companies S.A.s development strategy, work began in 2012, when the developing in across Europe. company launched its first hatching egg farms at its Stary Widzim site, to provide the highest quality eggs for its hatchery operations, with 20 million eggs produced annually. Since then, further expansion has brought production to 50 million hatching eggs each year . L-R: Mr Maciej Kolanczyk, Senior Hatchery Specialist, Pas Reform Academy and Mr Marek Pospiech, Representative Poland 28

29 Pas Reform do Brasils expansion continues with green field project for Frango Natto Poultry integration Frango Natto, from Northeast Brazil, is Family-owned Frango Natto has served the Northeast region building a new state of the art green field hatchery near the of Brazil for the last 15 years and currently exports to the city of Balsas in Maranho State, with advanced SmartPro Middle East and Asia. Owner Markos Notaro comments: incubation technologies from Pas Reform. This is a logical step that will complete our poultry integration. With an annual capacity of 40 million day old chicks per year, the new facility will be the largest single stage facility in the With the Companys heritage stemming originally from region, supporting Frango Nattos expanding operations in feedmill operations, we understand the importance of feed the north while also representing a substantial boost for the conversion ratios in the integration. We have watched Pas poultry sector in this part of the country. Reforms expansion in Brasil and also in the rest of Latin America in recent years, and on speaking with other users of Pas Reform do Brasil will supply 24 SmartSetPro 6 setters, the Companys Smart hatchery technologies, all have 24 SmartHatchPro hatchers and a complete hatchery HVAC highlighted improvements in feed conversion ratios when system to provide total environmental control throughout moving to single stage incubation with Pas Reform. the new hatchery. In addition, all design drawings for the green field project have been supplied by Pas Reform do Pas Reform do Brasils Thomas Calil has been pivotal to Brasil. Construction will begin in June 2014 for the hatchery developing the partnership with Frango Natto. He concludes: to be fully operational by the end of the year. This is an ambitious project for a customer that is focused on market leadership through quality at every level of its integrated operations. The combination of advanced, results-orientated Smart hatchery technologies, as well as sophisticated hatchery automation and climate control systems and Pas Reform do Brasils unwavering commitment to service has enabled us to become a dominant player in the Brazilian market in just five years and we look forward to continuing our expansion with projects of this calibre. Mr Thomas Calil, Director Bouke Hamminga, director Pas Reform do Brasil international sales & business development, Pas Reform 29

30 Building the future of 30

31 Hatchery Technologies 31

32 Hy-Line Italy selects Smart for further hatchery expansion Hy-Line Italy, the largest supplier of day old layer pullets for the Italian market, is fuelling the further expansion of its hatchery operations with SmartPro single stage incubation technologies from Pas Reform. Ukraines PAO Poltavskaya The company, formerly owned by the Costa family and now part of Hy-Lines hatchery operations in Europe, selected SmartPro after a careful evaluation of the incubation extends operations with solutions currently on the market. Pas Reform has supplied SmartSet incubators as well as a complete HVAC system for the hatchery expansion project, which has been in operation since the start of 2014. Smart incubation The new hatchery incorporates all of Pas Reforms most advanced technology innovations, with SmartSet setters, Microban antibacterial technology in the setter trays and a new SmartCentre hatchery information system with operating software for detailed analysis and remote One of Ukraines largest producers of table eggs, PAO Having already seen the incubation results, the quality of the diagnostics throughout the expanded installation. Poltavskaya PF, has commissioned a new 20 mln. egg per chicks and the performance of the commercial layers, year Smart hatchery from Pas Reform, with further plans for Mr Plakhtoya says that PAO Poltavskaya welcomes the Mr. Claudio Ambrogio, GM at Hy-Line Italy comments: expansion to 30 million eggs. ongoing, comprehensive support of Pas Reform in bringing Hy-line Italy has worked with Pas Reform for 35 years now, the new hatchery up to peak performance. Our aim is to and with results that have always been among the top in As part of the Inter-Agrosystems Group of companies, the increase capacity; to strengthen our existing facilities and the industry, we have seen the benefits of Pas Reforms new Poltavskaya hatchery is located in v. Machukhi, capabilities. Our trusted partnership with Pas Reform is a technologies in terms of dependability and performance. Poltavskaya region, joining a large integration that includes significant contributor to achieving these goals. PS farms, eight commercial layer farms, six feed mills, This expansion is a logical next step for us, as a result of slaughter houses and a brand new factory for feed additives, Leading the project management team, Pas Reforms increased demand for our pullets in the Italian market and as well as logistics and final product sales. Representative in Ukraine Mr Boris Marchenko has worked based on our experience with our existing incubators, the Pas Reforms project management team has provided closely with Poltavskaya throughout the planning, decision to continue working with Pas Reform for this detailed planning and technical support, together with the negotiations and delivery of the new hatchery. He concludes: present expansion was not difficult. delivery, supervision and commissioning of 12 SmartSet Poltavskaya PF, which also exports 300 mln eggs per year, setters, 18 SmartHatch hatchers and a SmartCenter has an exclusive agreement with Lohmann Tierzuht Gmbh., In looking for a state of the art incubation system that hatchery information system. he installation also includes producing 18 mln. hatching eggs for its own farms as well as would be suited to our conditions, we found Pas Reforms full hatchery automation, vacuum waste and hatchery for customers hatcheries in Ukraine. support and technicians to be extremely well-informed in climate control systems, with detailed planning for The company is making a substantial commitment to future their use and understanding of the latest technologies. incubation schemes, technological routes, drainage, growth and the quality of supply for its growing markets Moreover, they are well positioned to give us incubation ventilation, automation and other hatchery utilities. and Pas Reform is committed to Poltavskayas success. support from their operational base in Italy. This decision was not made lightly, says Poltavskaya PF According to Sergio Moreli, Pas Reforms representative in director, Mr. S.I. Plakhotya, We evaluated all the alternatives Italy for 40 years, confirmation of this new project for Hy- for both our current and future requirements, to establish Line is a good demonstration of customer satisfaction in the the options for delivering and safeguarding our future plans country, both with the companys Smart incubators and for the business. the levels of operational and technical support that they We chose Smart incubation systems from Pas Reform for receive. Hy-Line Italy and the Hy-Line group are well known many reasons, but especially for a narrow hatch window, and in Europe, he says, and continuing to deliver projects for this the ability to increase hatchery capacity from 20 to 30 mln. important customer provides an excellent reference site in hatching eggs per year with minimum investment. the European market. Mr Boris Marchenko, Representative Ukraine 32

33 Grading eggs for improved uniformity By Gerd de Lange, Senior Poultry Specialist, Pas Reform However it is not uncommon to see substantial egg weight Advice Academy variation in batches of eggs originating from the same breeder flock and grading eggs into two or three different Make egg weight uniformity a major focus of breeder The modern poultry industry requires uniformity, which weight categories seems a logical solution. There are farm management. dictates that broiler farms deliver batches of broilers for however various aspects to consider: Decide if grading eggs prior to setting delivers the processing with the smallest possible variation around necessary benefits by considering all the above mentioned target weight. Research has shown that one gram of 1 An egg in a certain weight category from a younger flock points. difference in the weight of the day-old-chick eventually leads is not the same as an egg with a similar weight from an Aim to place day-old chicks from one breeder flock only to between 2-13 gram difference in broiler weight at six to older flock (see table 1; Vieira et al, 2005). For example, per broiler house. If this really is not possible, minimize eight weeks of age (Wilson, 1991). It is therefore fully eggs of 54 and 58 grams of different flock ages are in the breeder flock age difference to less than 10 weeks. understandable that broiler farmers look for batches of same weight category, but differ significantly in yolk Avoid collecting eggs from a breeder flock for one specific uniform day-old-chicks from the hatchery. percentage. The same applies to eggs of 73 and 69 gram. setting over periods any longer than 5 7 days. Yolk percentage depends more on flock age and less on The major factor determining chick weight is the weight of the weight category of the eggs. breeder age egg weight yolk albumen shell the hatching egg. Under optimal egg storage and incubation (weeks) (g) (%) (%) (%) conditions, chick weight is 6769 per cent of egg weight at 2 Collecting eggs of similar weight categories from different 27 54d 26.9b 61.3a 11.8ab setting. It is therefore safe to assume that the more uniform breeder flocks to supply a specific broiler house may result 40 light 58c 31.4ab 56.7c 11.9a the egg weight, the more uniform the chick weight. Breeder in more uniform body weights in a batch of day-old-chicks, eggs uniformity determines uniformity in the hatching eggs but less uniformity in maternal aspects, eg. immunity, 40 heavy 73a 29.7ab 58.8b 11.5b produced; the more uniform the breeder flock, the more nutrition and stress factors. Also in this scenario, tracing eggs uniform the egg weights. first week mortality problems in the broiler farm back to a 59 69b 34.1a 54.5c 11.4c specific breeder flock is impossible. Means followed by the same letter within a column are not different 3 Depending on flock size, grading eggs into different according to Tukeys test Source: Vieira et al, 2005 weight categories within one specific breeder flock means that eggs need to be collected over a longer period of time and therefore need to be stored for longer, to have sufficient eggs per weight category to produce a batch of day-old-chicks for one specific broiler house. Storage beyond 57 days reduces hatchability, chick quality and post hatch performance, while setting eggs of short and long storage periods together widens the hatch window, which negatively affects uniformity in the resulting batch of day old chicks. Grading eggs and incubating these separately while mixing the chicks again during placement does not make much sense. 4 Grading eggs could also aim to simply reject eggs that are out of the hatchery-specific acceptable range. 5 Individual weighing of eggs, needed for accurate grading, delivers detailed information about weight uniformity and is a useful evaluation tool for breeder farm management. Gerd de Lange, Senior Poultry Specialist, Pas Reform Academy 33

34 Mexicos Pollo Bakity makes its mark with SmartPro and HAS from Pas Reform Where to put Mexicos Bahena-family owned Pollo Bakity has commissioned Pas Reform to deliver its new state-of-the-art hatchery in Uruapan with SmartPro modular, single stage incubation systems that will, when all phases of the new project are complete, deliver well over 600,000 day-old- the paper? chicks each week. The hatchery, which is a completely new green field operation, is a turnkey project with layouts and planning also supplied by Pas Reforms engineering team. As a multi- phase project, the hatchery will begin operations in its first phase with six SmartSetPro setters, each with a capacity of 115,200 hatching eggs and six SmartHatchPro hatchers, each holding up to 19,200 eggs. By Martin Tiny Barten, senior hatchery specialist, The house was well-equipped with feeding pans and Pas Reform Academy drinking nipple lines and, placing my hand on the concrete The new Uruapan hatchery is fully climate-controlled, with below the thin layer of wood shavings, I was satisfied that Siemens controlled air handling units to manage air Most of the time, my visits are limited just to the hatchery the house was properly warmed. conditioning in the setter rooms, hatcher bays and chick and certainly there is usually plenty to discuss with the holding rooms, pressure controls for exhaust plenums and hatchery manager and his staff. During a visit to a recently Much to my surprise however, I saw big rolls of chick paper Pas Reforms SmartCenter hatchery information system to installed hatchery however, my only critical observation was being rolled out underneath the feeders, but not under the provide total operational control of the different hatchery related to pulling time. I noticed that the empty shells left in drinking lines as one would expect. When I asked one of the functions from a single work station. the hatcher basket after the chicks had been taken out were workers why, he explained that this was to stimulate the quite heavily stained with meconium and most of the chicks chicks to start feeding as quickly as possible: the sound of Hatchery automation is also being supplied by Pas Reform, showed mild dehydration of their legs. the first chicks walking and picking on the paper attracted including an egg classification line and 50,000 egg-per-hour the others to come and feed too. Embrex-integrated candling transfer system, to Since pulling time was relatively fixed as a result of labour automatically detect infertile eggs and early, mid- and late and transport planning, we agreed to set the eggs several I advised that stimulating water intake was more urgent, embryonic mortality, eliminating clears from the setter hours later, for the hatchery manager to follow-up on the especially when the chicks were already showing signs of trays before vaccination. effect of this change. But as the chicks already showed signs slight dehydration. Placing paper under the drinking lines of dehydration, I asked about brooding conditions in the and making some feed available there too has the added The hatchery, owned by Uruapans Bahena family, has been broiler farms and whether he knew how quickly and easily advantage of getting the chicks to drink and feed as quickly planned with expansion in mind, with full online the chicks had access to drinking water. He admitted that he as possible, so getting the best of both worlds. connectivity through SmartCenter to enable Pas Reform to did not know, so we decided to follow the chicktruck to one provide technical support whenever it is required. While of the broiler houses to observe unloading and this type of online backup will never replace on site chick-placement. technical service visits, comments Ranulfo Ortiz of Pas Reform Mexico, it is an excellent source of reassurance and After driving for almost two hours, we watched as the chicks backup that receives positive feedback from our clients. were taken out of the well-designed chick truck. They were in good condition and the receiving team worked efficiently Carlos Bahena concludes: Our new Pollo Bakity hatchery to drive the dolleys with chick boxes into the broiler house will be one of if not the most advanced in Mexico, and we and, after changing into farm clothes, we followed them will make full use of the access we have to Pas Reform inside. Academy and its hatchery management training programmes, to fully optimise our single-stage capabilities in this new operation as quickly as possible. Pas Reform appoints new As a registered Philippine positioned MFC as a benchmark automation equipment, we are Bas Kanters concludes: MFC representative in the Corporation, MFC is primarily for quality in the supply of delighted to represent Pas shares very similar values with Philippines engaged in the supply of high agricultural products and Reform. Pas Reform, with a focused quality poultry equipment. services in the region. This cooperation is a milestone dedication to valued customers Pas Reform is continuing its Strongly focused on building Speaking of the new for our Organization, completely and to the markets we serve to international expansion with partnerships with industry cooperation between the two supporting MFCs mission to deliver business growth. the appointment of Mr Victor C. leaders, MFCs dedicated companies, Mr Velonza says: collaborate with industry Pas Reform welcomes Maagir Velonza, president of Maagir approach to providing As a recognized leader and leaders for the delivery of the Farm Corporation into our Farm Corporation (MFC), as the knowledge-based support for innovator in single-stage highest quality products, growing global family. We look companys representative in the customers has, says Pas Reforms incubation technologies, services and innovations for our forward to working in Philippines. sales director Bas Kanters, hatchery climate control and markets. partnership for many years to 34

35 Krasnodonskaya Hukuru selects commissions Smart SmartPro for expansion in turnkey project in Russia Zimbabwe Hukuru and its sister company Charles Stewart Day Old Chicks produce Ross genetics for the broiler market in with integrated in-ovo vaccination system and washing Zimbabwe with a current capacity of 140,000 day old chicks machines, as well as comprehensive climate control and per week. ventilation systems throughout the new facility. After an in-depth evaluation of the options available for such With plans to increase production, the Company is a project, Krasnodonskoe chose Pas Reform for its market- embarking on a three-phase expansion programme that leading position in single-stage incubation, combined with will enable the production of 450,000 day old chicks in its the companys competence, experience and understanding final phase. of the complete poultry value chain. Hukuru selected SmartPro setters and hatchers, says We wanted a fully integrated approach to the development Gordon Brown, co-owner and director, not only for their of our new hatchery, says general director of OAO excellent quality, but also for their flexibility in expansion. Krasnodonskaya, Ruslan Gashuk, and found that Pas We are very impressed with the ability to convert the Mr Ruslan Gashuk, general director OAO Krasnodonskaya Reforms capability and resources extended not only to SmartSetPro 4 setters into SmartSetPro 6 setters. This delivering a complete technical solution in their setters, degree of flexibility fell very much in line with Hukurus OAO Krasnodonskaya Poultry Farm has signed an exclusive hatchers and ventilation systems, but also that they could expansion plans and was a lynchpin in the finalisation of agreement with Dutch hatchery technology company Pas provide experienced project management to fully support the contract. Reform for the design and installation of a new 27 mln. eggs the development of this major project. per year turn-key Smart hatchery project in Volgogradskaya Hukuru has, says David Bookless, also a co-owner and region, in the South of Russia. Pas Reforms project team has designed the entire hatchery director of the Company, also been impressed by Pas Krasnodonskaya, the largest producer of poultry and pork in layout, including detailed plans for hot and cold water Reforms hatchery consultants.: In 20 years of working with the Volgograd region since 1996, operates on a closed cycle plumbing and drainage, and the facilitys complete other incubation companies, none has ever sent out an system and before construction of the new project ventilation systems. expert of the quality of Martin Barten to audit my hatchery. incubated 11 million eggs per year. At the time of writing, work has started on the groundworks In recent years KHK OAO Krasnodonskoes modernization for Hukurus extended hatchery building, with plans to The new hatchery will deliver additional hatching egg program has covered the feed mill and slaughterhouse, as have completed the first phase of expansion by August of capacity in a fully integrated turn-key project that well as the modernization and construction of broiler sites. 2014. incorporates SmartSet and SmartHatch single-stage With the new hatchery facility in place, the company will incubation systems and a full suite of hatchery automation produce 36,000 tons of poultry per year. equipment, including automatic egg positioning and setting, stackers and destackers, automatic egg candling and transfer come, as together we work to L-R: Dr. Yani Adviento, Director provide the highest quality Operations & Marketing, products, unparalleled service, Victor C. Velonza, CEO, integrity and commitment to Ms. Lyn Redelosa, Accounts our customers in South East Executive and Dr. Ivan Lazaro, Asia. Technical & Marketing Executive Contact details: Phone +63 235 459 88 Fax +63 235 459 88 Email [email protected] 35

36 St Petersburg SRI to develop world- ranking influenza vaccine incubation facility Luckily it rained St. Petersburg Scientific Research Institute of Vaccines and By Martin Tiny Barten, senior hatchery specialist, Finally we discovered the cause on the hatchery roof. Sera in Russia is to renovate its primary stage vaccine Pas Reform Academy Previously, with high under-pressure inside the fluff tunnel incubation centre with advanced single-stage hatchery air handling unit and chiller, both - also situated on the roof - technologies from NatureForm Hatchery Technologies. Despite excellent hatchability overall, one of our South East were gathering exhaust fluff. Covering the fluff tunnel Asian customers had, over several weeks, observed weak, exhaust pipes with a dust bag had rectified this but in so The Institute, which produces human influenza vaccines for listless and even dead chicks at the moment of pulling. They doing, created another problem! Normally, the extraction the Russian market, has commissioned the renovation of its contacted our local agent and I altered my travel plans, so fans just had to work a little harder to overcome the extra entire primary incubation centre with the Companys P18 that I could visit the hatchery to investigate. resistance created by these bags. However on this morning, primary phase incubators. With an annual primary Arriving at the hatchery just prior to transfer, I noticed heavy rain had effectively turned the dust bags into almost incubation capacity of around 28 million embryos per year, immediately that extraction fans in the fluff tunnels behind airtight, wet cloth. the new facility will rank among the largest and most the hatchers were running at full speed. Due to massive advanced systems in the world. under-pressure, opening the fluff tunnel doors was hard, With heavy downpours a common occurrence and these which could lead to poor air circulation in the hatcher. I dust bags in place, the hatchers could not breathe freely, In total, 12 P18 primary stage incubators, each with a explained to the hatchery manager that fluff tunnel control which had lead eventually to the reported problems. capacity of 77,760 eggs, will provide a total incubation should maintain light under-pressure of 3-5 Pascal, allowing capacity of 933,120 chicken eggs at any one time, incubating the hatcher to breathe freely, while also allowing small With normalised under-pressure, the dust bags served no chicken embryos to day nine, at which point they will be amounts of fluff in hatcher air exhaust to settle on the floor, purpose and could be removed - and with the hatchery inoculated with human influenza virus for vaccine rather than blowing onto the roof. We restored the original committing to keeping all doors closed, normal levels of production. settings. hatchability were quickly resumed. Lucky it rained! Steve Warren, CEO of NatureForm Hatchery Technologies Yet to my surprise the next morning, we found two of the from Jacksonville Florida comments, We have been working four control boxes indicating zero pressure, while the on this project with various vaccine production specialists exhaust fans were still running at maximum speed. On for more than a year, to design and lay out a facility that entering the chick processing room, the reason for this delivers the highest levels of bio-security. became clear. Workers folding chick boxes had improved their working environment by opening the doors to two of NatureForm Hatchery Technologies has created bespoke the fluff tunnels, to create airflow. Naturally this made it programmes for its single stage primary incubators, to impossible to achieve the required under-pressure, and I guarantee the fastest, most uniform growth of the embryos asked the hatchery manager to enforce the golden rule: over the requisite nine day incubation period. Mr Warren keep all doors closed! explains, Using embryos that are well developed and uniform in size at this stage greatly enhances the vaccine Two hours before pulling time later that week and again, the yield post-inoculation. fans were running full speed this time with the doors wide open! Despite closing the doors of the fluff tunnels, they The renovation project is due to begin in the second quarter blew open as soon as I released them! Inside the hatchers, of the year and will be completed in time to support COc-concentration was rising above set point with dampers production for the 2014 flu season. fully open. Martin Tiny Barten, Senior Pas Reform Academy provides Hatchery Specialist, Pas Reform hatchery management training Academy for customers around the World, to accelerate the delivery of optimized results using single stage incubation technologies 36

37 Combining expertise to reduce Partnering for expansion: Aviagen farm mortality and Pas Reform Russia By Martin Tiny Barten, senior hatchery specialist, Meeting with the resident consultant, the hatchery manager Pas Reform Academy and the broiler farm manager together, we discussed at length possible reasons for increased farm mortality. It As a travelling consultant it is not uncommon to visit transpired that mortality was not only high during the first customers who also receive recommendations from other week, but remained high every week until slaughter. This advisors. This can be useful, especially when the consultancy made it even more unlikely that the hatchery was the source covers different fields of expertise. It is less productive of the problem. however, when recommendations are contradictory or provide conflicting advice. The customer is left confused and without Eventually, as we continued to explore factors that could be Aviagen LLC in Yasnogrosk, Russia, has now reached a supply clear direction for how to proceed. A cooperative approach, contributing to the situation, the consultant mentioned that volume of 6.8 million PS females plus relevant males at its whereby individual consultants each contribute from their there had been a problem with Aspergillus in the broiler Smart-enabled breeder hatchery, establishing a firm own expertise to a total solution, is always more fruitful. houses. The more we talked, it became clear that Aspergillus reputation in the Russian Federation for supplying Ross 308, infected floor litter in the broiler houses was the most likely Ross PM3 and AA broiler breeder parent stock since the In one case that I recall, broiler farm mortality was too high. reason for ongoing mortality: a result of poor conditions for hatchery went online four years ago. The resident consultant linked this to incubation the storage of the wood shavings. By combining our temperature being too high, combined with pulling the individual expertise, we had found the cause of the problem Hatchery director Anna Matveeva, who was pivotal to chicks too late. On his advice, temperature was dropped and could now take action to remedy high mortality on the Aviagens decision to work with Pas Reform in Russia, says of during the final days of both setting and hatching. Yet farm. developments: With two new GP farms also established mortality remained high and in fact began to rise. locally in the last two years, the new hatchery has delivered Several weeks after my visit, the hatchery manager reported very good chick quality and excellent liveability. Before implementing a second drop in temperature, the to me that chick quality had returned to normal levels and hatchery manager invited me to review the situation. On farm mortality during the first 10 days was below 1%. The From the start we had very good support from Pas Reforms attending a hatch, we found per hatcher basket four or five supplier was treating the wood shavings before project management team, both during construction and in living chicks still partially inside the eggs and many chicks with transportation to the farms and storage conditions had delivering technical services. The quality of product thick bellies and poorly closed navels. Measuring shell improved. performance now gives us confidence in the potential for temperatures in several setters confirmed that incubation further growth, which the hatchery is very capable of temperature was already too low. I urged the hatchery manager delivering. to return to the original settings, because with poor chick quality continuing, mortality would certainly remain high. Pas Reform Russia L-R: Wim Schaafsma, Anna Kolygina 37

38 Pioneering Pronavicola first to sign for SmartPro in Colombia Pas Reform delivers growth for Sarawaks poultry integrations Pronavicola, one of Colombias leading companies in the poultry sector, is embarking on a multi-phase hatchery With a focus on international expansion, leading Dutch Dr Tan Ee Seng concludes: Over the years, Pas Reform has expansion project for its broiler operation in Buga (Valle del hatchery technology company Pas Reform continues to remained entirely committed to its customers throughout Cauca) with a complete SmartPro single stage incubation achieve its strategic aims by committing to the delivery of Asia, delivering true partnership in its solutions for projects system, the first in Colombia, from Pas Reform. sustained and consistent growth for its customers of all sizes. worldwide. Phase one of Pronavicolas expansion includes the Pas Reforms Smart single stage incubation has proven its installation of 3 SmartSetPro setters, each with a capacity In Kuching, the state capital of Sarawak on the island of value in terms of performance and results for these forward- of 115,200 eggs and 6 SmartHatchPro hatchers, each Borneo in Malaysia, the company now accounts for more looking companies. The Dutch company has also taken holding 19,200 eggs. than 80 per cent of hatching eggs produced in a strong and practical steps to support the local poultry sector, opening growing poultry sector. an office in Malaysia in 2008 and appointing an experienced The project will also include a full HVAC system from Pas As a major growth centre for business, Kuching serves the local team, including agent Mr.Kenny Tan and more recently Reform, to deliver heating, cooling and air conditioning whole Sarawak population of around 2.5 million people. Five a dedicated engineer for the region, Mr Yew Wei. capacity capable of meeting the future needs of the major poultry integrations are based here, each producing hatcherys multi-phase expansion. In addition, with eggs between 150,000-300,000 hatching eggs to meet demand Dr Seng concludes: Pas Reforms presence in this region is being delivered to Pronavicolas Buga hatchery on setter for an estimated total of 1 million hatching eggs per week. fully supported by regular customer consultation visits by trays as standard, installing a classification line for the the companys hatchery specialists and access to Pas Reform hatching eggs not only overcomes setter tray Pas Reform Hatchery Technologies now supports four of Academy training for hatchery staff. Taken together, all these incompatibility, but also allows the setting of all the eggs these poultry integrations with its Smart modular, single factors have served to build confidence - and to build greatly into four weight ranges to help reduce the hatch window stage hatchery technologies; Sing Heng Huat Farming Sdn valued partnerships with our Malaysian customers. for improved day old chick uniformity. Bhd, QL Livestock Farming Sdn Bhd, Heng Feng Industries Sdn Bhd and the latest addition, Yeung Lok Breeding Farm Sdn Pronavicola is well established in the Colombian poultry Bhd, which is still under construction. At almost 850,000 industry and the company took care to critically review all hatching eggs per week, the combined setting capacity of its available options before selecting SmartPro. The these four companies represents more than 80 per cent of company visited a number of existing SmartPro hatchery total production. operations outside of Colombia, to meet customers already using Pas Reforms most advanced single stage incubation Pas Reforms Sales Director in Malaysia, Dr Tan Ee Seng, is a technologies. veteran of the poultry sector and has worked closely with companies throughout the region since 1990. He says that Mr Raymundo Gonzalez, Pronavicolas production director integrators here were quick to realize the importance of explains: These site visits created an excellent opportunity single stage technologies to their plans for future growth. for us not only to see SmartPro in action, but also to hear Against a backdrop of rising feed prices, customers using from hatchery owners and managers who, without Pas Reform single stage incubators are realizing about 80g Mr Yew Wei. exception, were very positive about their relationships with of feed saving in a 2 Kg broiler. One customer who produces the company. All talked about being part of a Pas Reform 100,000 broilers/week using Smart incubation reports family, clearly valueing the support of Pas Reform Academy saving more than 100g feed easily on a 2.5 Kg broiler. At an and the quality of technical backup that they routinely average 1.70 FCR, this compares very favourably with results received from the Pas Reform team. previously delivered using multistage incubation, where the best average recorded FCR was 1.74. L-R: - Dr Tan Ee Seng, Sales Director Pas Reform Henry Arts, Marketing Director Pas Reform Bas Kanters, Sales Director Pas Reform Suzan Hansen, Office Manager Pas Reform 38

39 Mr Jakkrin Taepaisitpong, senior vice president poultry integration, Betagro Group SmartPro and the personal SmartPro delivers touch for Betagro top results for SuperChicks in expansion Zimbabwe SuperChicks started out in Zimbabwes poultry sector with adapted ostrich incubators - and under these circumstances did relatively well. However, according to Brenton Catterall, the Companys co-owner, they were never going to achieve the kind of results that could really make their operation Leading Thai broiler company Betagro is increasing hatching Betagro likes the advanced technology that runs and efficient and ultimately profitable. capacity with an investment in SmartPro single stage supports SmartPro incubation, with a particular focus on SuperChicks relies on hatching eggs from South Africa and incubation technologies from Pas Reform, to deliver greater improved chick quality and hatchability results, a reduced need to ensure that they get maximum hatchability from efficiencies and reduced rejection rates as the company hatch window and improved standards of hygiene and these relatively expensive imported eggs. To achieve this, targets ambitious growth to 2017. biosecurity, which are important features in Betagros SuperChicks wanted to invest in the highest quality exports for European and Japanese customers. equipment. The new facility at Betagros Lopburi site, north of Bangkok in one of Thailands major poultry producing areas, has been These factors, together with the availability of a trusted local The company selected Pas Reform to supply incubators and built as an extension to the companys existing hatchery, to agent, ready access to technical and service support and climate control to update its hatchery and was the first in allow for the full utilisation of the chick processing area to spare parts and Pas Reforms ability to deliver in line with the country to take delivery of Pas Reforms innovative new accommodate increased capacity. The company currently required timescales, were central to Betagros decision in honeycomb design 162 SmartTrays. produces around 40 per cent of its total weekly demand, up commissioning the project, which is already realising Since its very first hatch in the new hatchery last December, to 1.8 million broiler chicks per week, between its Lopburi and improved performance. SuperChicks has achieved top results from their Pak Chong sites. SmartSetPro setters and SmartHatchPro hatchers. In addition to SmartPro setters and SmartPro hatchers, Results have been excellent, says Brenton Catterall, and Pas Reform has supplied ventilation systems, chiller and heat we are now confident in being able to continuously deliver recovery units, as well as providing intensive hatchery 140,000 day old chicks to the Zimbabwean broiler market management training at its Zeddam headquarters in The every week. Netherlands and a comprehensive onsite training programme for Thai hatchery staff, during the installation and commissioning of the new facility. L-R: Henk Markhorst, Sales Director Pas Reform Mr Kenny Tan, Representative Malaysia Mr Somnuk Hophaisarn, Representative Thailand 39

40 Pas Reform setting standards for uniformity worldwide The Netherlands Bulgaria Jordan Philippines Sri Lanka United Kingdom / Ireland Pas Reform BV Ecomat Ltd. Mr. Jamil Al-Khawaja Maagir Farm Corporation Nature Hobbyist Mr. Peter Furlong Head Office Krum Kyulavkov Str. 11, at. 4 P.O. 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