J. Allen Byrd PhD, DVM USDA-ARS

Southern Plains Agricultural Research Center Food and Feed Safety Research Unit, College

Station, TX USA

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Production Cost

Selling Price

Consumer Demands

Animal Welfare

Environmental Regulations

Food Safety

21st Century Decision Tree

Food Animal

Agriculture

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Production segments involved in production of broilers

Broiler breeders Hatchery Grow-out farm Feed mill Animal health

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Broiler Breeders

Male (roosters) and female (hens) that are of reproductive age 18 weeks or older)

Lay fertile eggs that develop to produce broilers

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Hatchery The hatchery is responsible for the

incubation and hatching of the chicks from fertile eggs obtained from the breeders.

The hatchery consists of incubation

equipment responsible for maintaining ideal environmental conditions for embryo development. Setter/incubator hatcher

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Setter/Incubator Fertile eggs are incubated in the setter for 18

days. The setter provides ideal temperature and

humidity conditions for embryo development. The eggs are stored on trays that are secured to

incubator racks. The setter also rotates eggs to ensure proper

orientation of the developing embryo in the egg.

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Hatcher After 18 days in the setter, eggs are transferred from

trays to hatching baskets and are moved to the hatcher.

The hatcher provides ideal temperature and humidity for late-stage embryo development and hatching. Unlike the setter, the hatcher does not rotate eggs.

The chicks hatch after 3 days in the hatcher, resulting in a total incubation period of 21 days.

While in the egg, chicks use their beak to break out of the shell, a process referred to as pipping.

Chicks are damp when the exit the shell, or hatch, and the warm temperature in the hatcher plays an important role in drying the chick and maintaining their body temperature

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Hatchery Certain vaccinations may be

administered “in ovo”, injected through the shell.

Once hatched, chicks are removed from the hatching baskets and egg shell debris is discarded.

Chicks are inspected and are serviced (vaccinated, loaded into boxes, etc.) prior to delivery to a grow-out farm.

Chicks are counted into trays that are used for delivery to grow-out farms. 9

Vaccination Most vaccinated in ovo (in the egg), at hatch

the chicks are transferred to processing room where they are vaccinated in the neck with Marek’s

Vaccinated for Newcastle disease and Infectious Bronchitis by cabinet, eyedrop, beak-o-vac methods

Beak trimming of roaster and breeders Sexing of birds not praticle for broilers

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Chick Transportation

The chick trays are loaded into an

environmentally controlled delivery vehicle and are transported to the farm where they will be raised to market weight.

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Grow-Out Farm

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Grow-out farms Grow-out houses are specialized

buildings that allow age-appropriate automated control of temperature, humidity, food delivery, water delivery, and lighting for the broilers.

The grow-out house provides birds the freedom to move throughout the house as they want.

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Biosecurity

Location: Isolate farms from other poultry and livestock. Single-age sites are preferable to limit recycling of pathogens and live vaccine strains. • Farm design: A barrier (fence) is necessary to prevent unauthorized access. Design housing to minimize traffic flow and to facilitate cleaning and disinfection. Construct housing to be bird and rodent proof. • Operational procedures: Prevent the introduction and spread of disease with procedures that control the movement of people, feed, equipment and animals on the farm. Routine procedures may have to be modified in the event of a change in disease status

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Curtain-SidedHouses

These houses contain a curtain that runs along both sides of the house that can be raised or lowered depending upon external temperatures to maintain desired environmental conditions in the house.

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Tunnel-Ventilated Houses

These houses contain solid walls on all sides of the house.

One end of the house contains large exhaust fans while the other end of the house contains large cool cell.

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Tunnel-Ventilated Houses Tunnel ventilation is used in warm to hot weather

or where large birds are grown. Cooling is achieved through high-velocity airflow. Use bird behavior to assess if environmental

conditions are correct. Care should be taken with young chicks which are

prone to wind chill. Consider installation of migration fences.

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Ventilation Ammonia Can be detected by smell at 20 ppm or above

>10 ppm will damage lung surface >20 ppm will increase susceptibility to respiratory diseases >50 ppm will reduce growth rate

Carbon Dioxide >3500 ppm causes ascites and is fatal at high levels

Carbon Monoxide 100 ppm reduces oxygen binding and is fatal at high

levels

Dust Damage to respiratory tract lining and increased susceptibility to disease

Humidity Effects vary with temperature. At >29°C (84°F) and >70% relative humidity, growth will be affected

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Automated Feed Lines Grow-out houses contain 3 automated feed lines

that are height adjusted daily to reduce feed wastage. Feeders should be adjusted so that the rim of the feeder pan is level with the birds back.

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Automated Water Lines Grow-out houses also contain water lines that

provide unrestricted access to fresh, clean water. Test the water supply regularly for bacteriological

and mineral contaminants and take any necessary corrective action.

Water treatments of organic or nonorganic acids, probiotic bacterial, cleaners, disinfectants, chlorination, etc.

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Lighting

Light is an important management technique in broiler production. There are at least 4 important aspects: • Wavelength (color). • Intensity. • Photoperiod length. • Photoperiod distribution (intermittent programs).

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Lighting Live weight at

slaughter

Age (days) Intensity (lux) (foot candles)

Day length (hours)

Less than 2.5 kg (5.5 lb)

0–7 8–3 days before

slaughter*

30–40 (3–4) 5–10 (0.5–1.0)

23 light/1 dark 20 light/4 dark**

More than 2.5 kg (5.5 lb)

0-7 8-3 days before

slaughter*

30–40 (3–4) 5–10 (0.5–1.0)

23 light/1 dark 18 light/6 dark

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Litter Local economics and raw material availability will dictate the

choice of litter material used. Litter should provide: • Good moisture absorption. • Biodegradability. • Bird comfort. • Low dust level. • Freedom from contaminants. • Consistent availability from a biosecure source. Evenly distribute soft wood shaving material to a depth of 8–10

cm (3–4 in). Where floor temperatures are adequate (28–30°C/82–86°F) the litter depth can be reduced where litter disposal is an issue.

Wet litter results in: Mold problems Coccidiosis which decreases feed conversion Air movement and proper ventilation maintain 20-30%

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Litter • Brooder portion is cleaned once per year, remaining portion of the

house is cleaned once every 2-5 years. After previous flock has been removed , litter is tilled with a machine which removes the large caked portions of the litter and leaves the fine particles. Usually 5-6 flocks per year. ALL IN ALL OUT

• Rodent control, insect treatment

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Litter Material Characteristics

New white wood shavings

Good absorption and breakdown

Possible contamination by toxic insecticides and other chemical compounds (giving a musty taint)

Chopped straw Wheat straw is preferred

Possible contamination by agrochemicals, fungi and mycotoxins. Slow to break down Best used 50/50 with white wood shavings

Sawdust

Not suitable; Needs good management

Dusty, and may be ingested Chemically treated straw pellets

Chaff and hulls

Not very absorbent Best mixed with other materials May be ingested

Shredded paper Can be difficult to manage in humid conditions

Glossy paper is not suitable

Sand Can be used in arid areas on concrete floors

If too deep bird movement may be impeded 26

Examples of Chemical or Biological Litter Treatments

Ferrous Sulfate Aluminum Sulfate Phosphoric Acid Sodium Bisulfate Acetic acid Probiotics Antibiotics

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Grow-Out Farm Placement

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Space requirements for chickens Bird live weight

kg (lb)

Square feet per bird

Hatch to approx 2 weeks 0.25

1.4 (3.0) 0.50

1.8 (4.0) 0.70

2.3 (5.0) 0.85

2.7 (6.0) 0.90

3.2 (7.0) 1.00

3.6 (8.0) 1.15

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Chick Brooding First two weeks Half house brooding with 1000 chicks per stove Stove heaters placed 18-24 inches above litter Lit 24 h prior to placement; degrees 90-95o F At end of 1st week reduce temperature 5 degrees per

week until reach 70. Measured 4-6 feet high and should be 80-85 degree

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Feed Mill

The feed mill is responsible for preparing finished feed. Different feed rations are used for newly hatched chicks (starter), birds in the development phase (developer) and mature birds (grower).

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Form of Feed by Age AGE of Broiler Feed Form and Size

0-10 days sieved crumbs or mini-pellets

11–24 days 2–3.5 mm (0.08–0.125 in) diameter pellets or coarse grinded mash

25 days to processing 3.5 mm (0.125 in) diameter pellets or coarse grinded mash

http://www.extension.org/pages/65751/pellets 32

Animal Health

Many commercial broiler producing companies employ veterinarians to develop, maintain, and implement an animal health plan.

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Culling and Dead Bird Disposal

Birds should be culled daily to remove cripples, poor-doers, and runts.

Dead birds picked up twice daily and during a disease outbreak 3 to 5 times daily.

All culls and mortality should be recorded daily. Dead birds are either buried, composed, or

incinerated.

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Feed withdrawal Feed should be removed 4 to 6 hours

before the truck arrives or 8-12 hours before processing.

Water should be removed 30 minutes before truck arrives

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Feed Withdrawal Use a Withdrawal feed (i.e. without coccidiostat)

to avoid residues in meat. Allow 3 days on full light (23 hours light and 1 hour

dark) to avoid problems during catching. Appropriate feed removal from the birds will ensure

that the digestivesystems are empty before processing commences, limiting fecal contamination during transport.

Remove whole wheat from the ration 2 days before slaughter.

Delay the removal of drinkers for as long as possible.

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Catching Most catching of chicken are performed by

hand and placed into large poultry Coops for transportation to the Processing plant.

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Production Cost

Selling Price

Consumer Demands

Animal Welfare

Environmental Regulations

Food Safety

21st Century Decision Tree

Food Animal

Agriculture

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Conclusions This is a represented example of how

poultry companies may raise commercial poultry and does not reflect an individual company.

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A Final Word

The complete intervention program begins prior to hatch and ends with proper cooking and handling of the product by the consumer.

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