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Feeding Challenges in an Integrated
System
September17,2018
Feedmill Tons/week manufactured
Okeene, OK 1,700
Holyoke, CO 3,500
Perryton, TX 5,400
Optima, OK 9,000
Hugoton, KS 9,000
Iowa Falls, IA 9,000
Leoti, KS 11,200
Toll mill #1 2,400
Toll mill #2 1,600
Total 52,800
Live Production
• 338,000 sows
• 78 commercial sow farms
• Located in 5 states (OK, KS, CO, TX, IA)
• ~1.20 million nursery spaces
• 153 sites
• ~1,300 rooms
• ~3.15 million finishing and GDU spaces
• 541 sites
• ~3,400 barns
• ~2,500 employees in live production and
support systems
Capturing Value
• Exploiting vertical integration
• Controlling cost
• Generate revenue
• As a result we look at
profitability on a fixed asset
basis rather than on a per pig
basis.
• Shackle space basis
• Model information all the way
through packing plant margins.
Goals and Objectives of a Production
Nutritionist
1. ALL PIGS HAVE FEED
2. ALL PIGS HAVE THE RIGHT FEED
3. DEFINE WHAT THE RIGHT FEED IS
Site and Barn Level Constraints
• Bin Sizes
• Single vs. tandem bin
• Feed line configurations
• Level of specificity related
to accounting
• Pig Flow/Fill times
• Barn/room sizes
Growth through greenfield construction vs acquisition
Feed Mill, Transportation, and
Compliance Constraints
• Grinding Capacity and grinding system
• Mixer Size (batch sizes)
• Pellet Mill Throughput
• Finished Feed Bin Capacity
• Truck Compartment Size
• Flushing/Sequencing Procedures
• Biosecurity Guidelines
• Medication Feeding Directions (feeding Periods)
• VFD Validation and Compliance
• Medication Withdrawal Times
Feed Mill Constraints
Hugoton
6 ton mixer
2 pellet lines
½ day finish feed
capacity
Iowa Falls
8 ton mixer
3 pellet lines
2 day finish feed
bin capacity
BatchingMixingPelleting
Pellet
Cooling
Finished
Feed
Ingredient
Receiving
Ingredient
Storage
Grinding
System
Flow Chart
Emergency Outage = 2 hours lost, 165
tons lost potential
Feed Ordering
• Complex process
• Ensuring Feed budgets are followed properly
• Optimizing Transportation efficiency
• Optimizing Feed Mill production
System Controls
• Feed Ordering System
• Designed to monitor Group
level feed budgets and usage
• Identifies over feeding of a
specific diet
• Automatically populated with
valid VFDs
• Establishes a relationship of
farm, medication regimen, feed
type, feed budget, and feed
form.
Implementation and Modification of
Feeding Programs
• Simple vs. Complex
• Effective Communication (following the Org chart)
Senior Production
Manager
Regional OPS
Manager
GF Nurs Sow
Regional OPS
Manager
GF Nurs Sow
Regional OPS
Manager
GF Nurs Sow
Implementation Example
• Sow Gestation Feeding Program
• 2 feeding levels based on Body Condition
• 3.5 lb base feeding rate per day for sows in ideal or heavy
condition
• 6.0 lb allocation for sows visually assessed as thin
• Body condition assessed bi-weekly throughout gestation.
No Good Deed Goes Unpunished!
Summary thoughts
• Leveraging vertical integration redefines the measure
of profitability
• Although the goals of a production nutritionist may
sound simple the complexity within a connected food
system make it challenging.
• Implementation and execution of a program are
tougher than development of said program.
• In large companies simplicity and good communication
are paramount in implementation and execution of
processes and programs.
Opportunity for future improvement
• Centralization of information
• Individual silos of data that do not communicate effectively or
promptly
• Reduce process delays due to information transfer
• Reduce demand on clerical staff
• Accelerate reporting capabilities
• Technologies to reduce population variation or
improve population predictions
• Technologies that can offset labor
Josh Flohr - Addressing Feeding Challenges
My background
• Flohr, J. R., M. D. Tokach, S. S. Dritz, J. M. DeRouchey, R. D. Goodband, J. L. Nelssen, and J. R. Bergstrom.
2014. An evaluation of the effects of added vitamin D3 in maternal diets on sow and pig performance. J. Anim.
Sci. 92: 594-603.
• Flohr, J. R., M. D. Tokach, S. S. Dritz, J. M. DeRouchey, R. D. Goodband, J. L. Nelssen, S. C. Henry, L. M.
Tokach, M. L. Potter, J. P. Goff, N. J. Koszewski, R. L. Horst, E. L. Hansen, and E. D. Fruge. 2014. Effects of
supplemental vitamin D3 on serum 25-hydroxycholecalciferol and growth of preweaning and nursery pigs.
• Flohr, J. R., J. C. Woodworth, J. R. Bergstrom, M. D. Tokach, S. S. Dritz, R. D. Goodband, J. M. DeRouchey.
2016. Evaluating the impact of maternal vitamin D supplementation: I. Sow performance, serum vitamin
metabolites, and neonatal muscle characteristics.
• Flohr, J. R., J. C. Woodworth, J. R. Bergstrom, M. D. Tokach, S. S. Dritz, R. D. Goodband, J. M. DeRouchey.
2016. Evaluating the impact of maternal vitamin D supplementation on sow performance: II. Subsequent
growth performance and carcass characteristics of growing pigs.
• Flohr, J. R., J. M. DeRouchey, J. C. Woodworth, M. D. Tokach, R. D. Goodband, S. S. Dritz. A survey of
current feeding regimens for vitamins and trace minerals in the US swine industry.
Things to Consider When performing nutrient
related diagnostics (tissue, serum, feed samples)
• Sample from both general population and challenge population
• Does the clinical pathology fit the clinical symptoms
• Try to understand the metabolic marker being analyzed
• If results are accompanied by reference ranges, understand the
source of the reference range
• Understand analytical procedures
• Identify the expected analytical error associated with testing
• Communicate with the proper nutritionist
Thank you

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Josh Flohr - Addressing Feeding Challenges

  • 1. Feeding Challenges in an Integrated System September17,2018
  • 2. Feedmill Tons/week manufactured Okeene, OK 1,700 Holyoke, CO 3,500 Perryton, TX 5,400 Optima, OK 9,000 Hugoton, KS 9,000 Iowa Falls, IA 9,000 Leoti, KS 11,200 Toll mill #1 2,400 Toll mill #2 1,600 Total 52,800 Live Production • 338,000 sows • 78 commercial sow farms • Located in 5 states (OK, KS, CO, TX, IA) • ~1.20 million nursery spaces • 153 sites • ~1,300 rooms • ~3.15 million finishing and GDU spaces • 541 sites • ~3,400 barns • ~2,500 employees in live production and support systems
  • 3. Capturing Value • Exploiting vertical integration • Controlling cost • Generate revenue • As a result we look at profitability on a fixed asset basis rather than on a per pig basis. • Shackle space basis • Model information all the way through packing plant margins.
  • 4. Goals and Objectives of a Production Nutritionist 1. ALL PIGS HAVE FEED 2. ALL PIGS HAVE THE RIGHT FEED 3. DEFINE WHAT THE RIGHT FEED IS
  • 5. Site and Barn Level Constraints • Bin Sizes • Single vs. tandem bin • Feed line configurations • Level of specificity related to accounting • Pig Flow/Fill times • Barn/room sizes Growth through greenfield construction vs acquisition
  • 6. Feed Mill, Transportation, and Compliance Constraints • Grinding Capacity and grinding system • Mixer Size (batch sizes) • Pellet Mill Throughput • Finished Feed Bin Capacity • Truck Compartment Size • Flushing/Sequencing Procedures • Biosecurity Guidelines • Medication Feeding Directions (feeding Periods) • VFD Validation and Compliance • Medication Withdrawal Times
  • 7. Feed Mill Constraints Hugoton 6 ton mixer 2 pellet lines ½ day finish feed capacity Iowa Falls 8 ton mixer 3 pellet lines 2 day finish feed bin capacity BatchingMixingPelleting Pellet Cooling Finished Feed Ingredient Receiving Ingredient Storage Grinding System Flow Chart Emergency Outage = 2 hours lost, 165 tons lost potential
  • 8. Feed Ordering • Complex process • Ensuring Feed budgets are followed properly • Optimizing Transportation efficiency • Optimizing Feed Mill production
  • 9. System Controls • Feed Ordering System • Designed to monitor Group level feed budgets and usage • Identifies over feeding of a specific diet • Automatically populated with valid VFDs • Establishes a relationship of farm, medication regimen, feed type, feed budget, and feed form.
  • 10. Implementation and Modification of Feeding Programs • Simple vs. Complex • Effective Communication (following the Org chart) Senior Production Manager Regional OPS Manager GF Nurs Sow Regional OPS Manager GF Nurs Sow Regional OPS Manager GF Nurs Sow
  • 11. Implementation Example • Sow Gestation Feeding Program • 2 feeding levels based on Body Condition • 3.5 lb base feeding rate per day for sows in ideal or heavy condition • 6.0 lb allocation for sows visually assessed as thin • Body condition assessed bi-weekly throughout gestation. No Good Deed Goes Unpunished!
  • 12. Summary thoughts • Leveraging vertical integration redefines the measure of profitability • Although the goals of a production nutritionist may sound simple the complexity within a connected food system make it challenging. • Implementation and execution of a program are tougher than development of said program. • In large companies simplicity and good communication are paramount in implementation and execution of processes and programs.
  • 13. Opportunity for future improvement • Centralization of information • Individual silos of data that do not communicate effectively or promptly • Reduce process delays due to information transfer • Reduce demand on clerical staff • Accelerate reporting capabilities • Technologies to reduce population variation or improve population predictions • Technologies that can offset labor
  • 15. My background • Flohr, J. R., M. D. Tokach, S. S. Dritz, J. M. DeRouchey, R. D. Goodband, J. L. Nelssen, and J. R. Bergstrom. 2014. An evaluation of the effects of added vitamin D3 in maternal diets on sow and pig performance. J. Anim. Sci. 92: 594-603. • Flohr, J. R., M. D. Tokach, S. S. Dritz, J. M. DeRouchey, R. D. Goodband, J. L. Nelssen, S. C. Henry, L. M. Tokach, M. L. Potter, J. P. Goff, N. J. Koszewski, R. L. Horst, E. L. Hansen, and E. D. Fruge. 2014. Effects of supplemental vitamin D3 on serum 25-hydroxycholecalciferol and growth of preweaning and nursery pigs. • Flohr, J. R., J. C. Woodworth, J. R. Bergstrom, M. D. Tokach, S. S. Dritz, R. D. Goodband, J. M. DeRouchey. 2016. Evaluating the impact of maternal vitamin D supplementation: I. Sow performance, serum vitamin metabolites, and neonatal muscle characteristics. • Flohr, J. R., J. C. Woodworth, J. R. Bergstrom, M. D. Tokach, S. S. Dritz, R. D. Goodband, J. M. DeRouchey. 2016. Evaluating the impact of maternal vitamin D supplementation on sow performance: II. Subsequent growth performance and carcass characteristics of growing pigs. • Flohr, J. R., J. M. DeRouchey, J. C. Woodworth, M. D. Tokach, R. D. Goodband, S. S. Dritz. A survey of current feeding regimens for vitamins and trace minerals in the US swine industry.
  • 16. Things to Consider When performing nutrient related diagnostics (tissue, serum, feed samples) • Sample from both general population and challenge population • Does the clinical pathology fit the clinical symptoms • Try to understand the metabolic marker being analyzed • If results are accompanied by reference ranges, understand the source of the reference range • Understand analytical procedures • Identify the expected analytical error associated with testing • Communicate with the proper nutritionist