Dr. Craig Rowles - Back to the Future: Producing Food in a Changing Consumer Environment
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Back to the Future: Producing Food in a Changing Consumer Environment - Dr. Craig Rowles, Chief Operating Officer, Biova LLC, from the 2016 Boehringer Ingelheim Vetmedica, Inc. Swine Health Seminar, February 26, New Orleans, LA, USA. More presentations at http://www.swinecast.com/2016-boehringer-ingelheim-aasv
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Dr. Craig Rowles - Back to the Future: Producing Food in a Changing Consumer Environment
- 1. Back to the Future: Producing food in a changing consumer environment February 26, 2016 Craig Rowles DVM CEO Iowa Cage Free
- 2. The egg industry has changed a lot!
- 3. • Overview of the Industry • Animal welfare/Housing issues • Egg Safety Rule • Audits • Keys to success – Pullet development Todays topic’s
- 5. U.S. Egg Industry 1960’s and 1970’s 1980’s and 1990’s
- 6. U.S. Egg Industry State 1995 2015 (Million Layers) (Million Layers) Iowa 14,709 58,100 Ohio 21,754 29,733 Indiana 19,528 26,629 Pennsylvania 19,390 24,089 California (70’s – 45 million layers) 24,794 15,234 Texas 13,403 14,760 Minnesota 10,145 10,583 Nebraska 8,700 9,342 Michigan 9,907 12,688 Florida 8,381 8,191 Total 150,711 209,349 (70% of Industry)
- 7. U.S. Egg Industry Mid 1970’s – 10,000 egg farmers in U.S. (est.) 1987 – 2,500 egg farmers 2015 – 175 commercial egg companies represent 99% of all eggs produced in the U.S. 60 companies with more than one million layers These companies represent approximately 255 million layers or 89% of egg production 17 companies with more than 5 million layers
- 8. U.S. Egg Industry Prior to AI - 305 million layers in U.S. Average size farm around 1.5 million layers Some farms with more than 6 million layers 91.3% of eggs still produced in cages 4.5% traditional cage-free 4.2% organic
- 9. U.S. Egg Industry How are consumers… consuming eggs in the U.S.
- 10. U.S. Egg Industry Of the 229 million cases of shell eggs produced: (Approximately 6.8 Billion Dozens – 82 Billion Eggs) 122.1 million cases went to retail (53.3%) 73.3.0 million cases were further processed (32%) 22.9 million cases went for foodservice (10%) 10.7 million cases were exported (4.7%)
- 11. U.S. Egg Industry Per Capita Consumption – 316 million Americans 2000 – 251.7 2005 – 255.4 2010 – 247.9 2015 – 261 (estimate)
- 13. 2002 Has it been enough? 2015
- 15. States with Laws Passed 65 Million Layers Interstate Commerce Nightmare
- 16. Conventional Caged Egg Production
- 17. Modern Production Facility Aerial photo looking west 6.4 Million Hens
- 23. Enriched Colony Egg Production
- 34. • Cap Ex. Per Bird – Old high rise buildings - $16 – Belted Battery Cages - $23 – Cage Free - $42 • Labor per dozen: – Caged $.02 – Big Dutchman Aviary $.05 – Vencomatic $.07 • Total Costs per dozen for cage free versus cage is 35% higher! Costs…………….
- 35. • Salmonella Enteritidis prevention program • Pullets– must be procured from SE monitored breed flocks • Environmental testing – Chick paper on arrival – 14-16 weeks of age environmental test – 40-45 week environmental test – 4-6 weeks post molt • Biosecurity Practices – Visitors, cross contamination, wild birds, rodents, animals – Rodent, fly, other pest control programs • Cleaning and disinfection – Remove manure, dry clean the house, spray disinfectants • Refrigeration – hold and transport eggs at 45 degrees Egg Safety Rule
- 37. • Written SE prevention Plan • Documentation that pullets were raised under “monitored” conditions • Document compliance with – Biosecurity, rodent and pest control, cleaning and disinfection, and refrigeration • Environmental and egg sampling procedures • Test results • Diversion of eggs • Records of review, modification, and corrective actions Required Records
- 38. • American Humane Certification • United Egg Producers • American Bakery Institute • Specific customer audits Audits
- 39. • Growing system must be appropriate for the layer system • Vaccinations must be timely and appropriately administered – 8 vaccination steps • Management and nutrition must be monitored – 14 management checkpoints – 5 diets – Water and feed consumption monitored daily Keys to success - Pullet Development
- 41. Spray vaccines at the hatchery
- 43. Spray vaccines on the farm
- 44. Number of birds weighed 99 Mean body weight 1.783Lb Mean + 10% 1.961Lb Mean – 10% 1.605Lb Number of birds outside 1.961 and 1.605 lb 9 Uniformity = ([99-9]/99) x 100 = 91% CV = (.11/1.783) x 100 = 6.1% Pullet Growth
Editor's Notes
- This facility, located in the Midwest, housing 5.1 million hens, consists of: 28 layer barns for the hens, 1 state of the art feed formulation mill Soil conditioner holding facilities, water towers and distribution facilities 1 processing and breaking plant with modern waste treatment facilities. Plus, offsite, the necessary baby pullet raising facilities As a producer, food quality is our #1 concern. These facilities are constructed to deliver: optimum quantity/quality of space for the hens, feed, water, air, temperature, light etc. to the hens, A great deal of science has been applied to see that the hens are properly housed and animal certified cared for. UEP (United Egg Producers) and VPC (Verified Process Control) have commissioned independent board of scientific academic advisors to specify what’s optimal/best for the animals. VPC has USDA certification approval for those practices. We have an investment in excess of $18/hen in facilites alone!
- Our hens lay eggs that roll out onto a belt that moves the eggs from the hens to the collection belts.
- The belt pulls them to the front of the house (Center Fresh), where they go on a cross belt to a processing and breaking facility. 75 ½ billion eggs/year produced yearly in the US… approximately 60% are shell eggs for cartooning/table consumption At the processing facility the eggs are: Graded Washed Candled Sorted And either cartoned OR Broken Shipped NEVER being touched by a human hand!
- The other 40% are broken into a liquid product Here operators are checking computerized candling machines to further ensure food safety After washing, candling, the eggs are passed through a wall into a more biosecure USDA inspected further processing room for breaking, cooling and holding for shipment. Our breaker operation processes 3.7 MILLION eggs per day on the average.
- This equals – A FEW FUN FACTS! 463,000 eggs/hour through 3 separate egg breaking machines that is: 155,000 eggs/hour per machine or 2,600 eggs/minute per machine or even further 44 eggs/second! Our machines mechanically: pick up the egg cut it with a knife pull open the shell drop the whites and yolks out discard the shell to further processing All at a rate of 450 cases/hour per machine!. I hope that gave you a feel for what modern facilities are like today.
- pics of hens free roaming, using perches, using nests, using decks to hop around and exercise + scratching on floor and under nest/deck system. Note belts beneath decks to remove byproduct daily.