Jamesway Single Stage verses Multi Stage Incubation Why Single

Jamesway Single Stage
verses
Multi Stage Incubation
Why Single Stage?
by:
JERRY GARRISON
Consultant - Technical Advisor
Jamesway Incubator Company
Let Me First State
Has Two Excellent Incubation
Systems
“Single Stage and Multi Stage”
Either of Which Can and Will
Yield Superior Results
Jamesway Multi Stage
Incubation System
Jamesway Multi Stage Incubator
Two Door Hatcher
PX Hatcher
This
ThisConcept
ConceptSince
Since
Early
Early1960’s
1960’s--Lot
Lotof
of
Internal
InternalModifications
Modifications
All
AllHatchers
HatchersSingle
SingleStage
Stage
Jamesway ACI Single Stage
Incubation System
ACI
ACILarge
LargeIncubator
Incubator
ACI
ACIMedium
MediumHatcher
Hatcher
ACI
ACI==Activated
ActivatedConcept
ConceptIncubation
Incubation
This
ThisConcept
ConceptSince
Since
Late
Late1980’s
1980’s
This
ThisRevised
Revised
Single
SingleStage
Stage
Concept
Concept
(Technology)
(Technology)
Introduced
Introducedin
in
October
October2003
2003
Platinum
Platinumincubator
incubator
Platinum
PlatinumHatcher
Hatcher
Considering the Number One Goal of Any
Successful Hatchery
--------Being-------Good Quality Chicks Produced at the Least
Cost
Is This Still Achievable With the
Challenges in Today’s Modern
Poultry Industry?
“YES”
However???
We Much Pay Particular
Attention!!!!
Attention To:
All of the Aspects Involved in
Proper Incubation As
Associated With Chick Quality
“Starting With The Basics”
Are All Hatcheries Expected to Perform
the Same?
In Reality Can All Hatcheries Perform
the Same?
What Is Hatchery Performance Based
On?
How Is Your Hatchery Performing?
“One Important Fact I Observe”
All Hatcheries I Visit Are Not the
Same (Equal)
There Are Many Things to Consider
But
Simply Only Two Basic Categories
“Standard”
OR
“Non – Standard”
What Makes a Standard Hatchery?
Simply Must Have All of the Basics!
• Good Stable Reliable Electricity
• Good Quality Water That Meets the Correct Criteria
• Good Clean and Dry Compressed Air That Meets the
Correct Criteria
• Good Ventilation That Properly Supports the
Machines and Embryos
• Good Egg Pack That Meets the Correct Criteria
• Along With Good Management and Maintenance
Non - Standard Hatcheries
------Requires-----Non - Standard Practices
Manipulation
Compromise
------Most Often Causing-----Misunderstanding
Confusion
Inferior Results
The High Yield Advanced Genetics of Today’s Breeds At
Best Presents More Challenges Than Ever In Regard to
the Basics and Details of Proper Incubation.
The Advanced Genetics With Less Consideration To
Hatching and Emphasis Primarily on Growth and White
Meat Yield Requires More Attention Than Ever Before.
However very good and comparable results in regard to
hatching and chick quality are being consistently
achieved with these breeds
(Even In Some Very
Old Facilities).
To Put This Into
Perspective…
•
•
•
•
What You Do?
What You Have?
What You Do With What You Have?
What You Should Do?
Determines Your Success or Failure!!!
In Order to Accomplish Our Goal at
the Hatchery of Good Quality
Chicks at Least Cost
----------------------------Must Start With the Basics
-----------------------------Without the Basics We Are Defeated
or To Say the Least Handicapped
From the Start
Four Basic Inputs That Must Be Provided to the
Machines
(Influences Outside the Machines)
•
•
•
•
Proper Electricity
Proper Water (Quality,Volume and
Pressure)
Proper Compressed Air
Ventilation
Also Proper Egg Pack - Very Important Input
Proper Design and Layout is a Must
Don’t Expect Your
Hatchery’s
Performance, Efficiency And
Output To Be Optimum or
Even Standard If You Choose
To Neglect The Very Basics
It Is Your Responsibility To Supply The
Basics That Allows The Machines To
Perform And The Embryos To Develop
As They Should!!!
Important Facts That Must Be
Properly Considered In
Regard to Incubation
No Incubation Equipment Has the Ability To:
• Fertilize Eggs
• Sanitize Eggs
• Size Eggs
• Properly Handle and Store Eggs
• Can Not Manage Itself
• Can Not Create the Correct Profile
• Can Not Manufacture It’s Basic Needs
Proper Electricity
Proper and stable electricity must be
supplied due to the controls being
microprocessors and the components
being solid state. Improper electricity is
a major contributor to improper
calibration and malfunctions of controls
plus the longevity and consistency of
the control system will be
negatively affected
Proper Water
Proper water must be supplied in regard to quality,
volume, flow and pressure due to its influence and
performance of the machines
Incorrect water in both Multi and Single Stage is
detrimental to the developing embryos
The Jamesway Multi Stage Incubation System is by
definition air- cooled the spray also contributes
In reality 70% of the cooling is from the air intake and
30% from the proper spray in Multi Stage
In Single Stage Incubation 70% of the cooling is
water and 30% from air
Proper Compressed Air
Proper compressed air must be supplied in regard to cleanliness
and dryness due to each incubator rack turn with its
individual air cylinder. Oil and water from the air compressor
must be properly handled and eliminated to prevent
premature air cylinder failure.
------------------------------------------------------Proper air pressure @ 65 PSI minimum at the buggies for Multi
Stage and 100 PSI for the Single Stage large machines must
supplied to allow for proper turning. Improper lines can also
create problems.
Proper Ventilation
The sole purpose and definition of proper ventilation is to
“replace stale air with fresh air”
Needed by the developing embryos in their varying stages
of embryonic development
Multi Stage Incubation Works on Average
(temperature, humidity and damper operating range, O2 – CO2 balance)
Non-specific to any particular stage of embryonic
development but maintains proper average for all.
Single Stage Incubation is Specific to the
Stage of Embryonic Development
Proper Ventilation
Proper Ventilation is a Very Important Basic Input in Both
the Multi Stage and Single Stage Incubation
“Must be properly sized, designed, controlled, installed and maintained”
Allowing for Correct Embryonic Development as well as
Proper Machine Performance and Efficiency
“The Egg Pack”
A Basic Input Into the Incubator
•
•
•
•
•
•
Egg Pack Uniformity
Egg Handling on the Farm
Farm Egg Storage
Hatching Egg Transportation
Hatchery Egg Storage
Egg Storage to the Incubator
EGG PACK UNIFORMITY
Non Uniformity Now Seems To Be More Commonly
Accepted As Normal in Today’s Industry
• SIZE - Influences Airflow and Varying Embryonic Heat
Based on Chick and Fertility
• Uniformity
• SHAPE - Same plus Impaired Chick Quality
• SHELL QUALITY - Influences Moisture Lost and More
Susceptible to Contamination
• CLEANLINESS - Garbage in = Garbage Out
Flock Age Egg Size Differences
“Influence Airflow and Fertility”
26
26Wk..
Wk..
45
45Wk..
Wk..
32
32Wk..
Wk..
52
52Wk..
Wk..
39
39Wk..
Wk..
58
58wk..
wk..
Egg Pack Uniformity Input
Affects Chick Size Output
In Today’s Industry a Proper Understanding
and Application of the Basics Must Be
Considered and Applied in Regard to
Embryology and the Incubation Equipment
in Use
- Considering The Four Basic Requirements for
Incubation (Inside the Machines)
a. Heat
b. Humidity
c. Airflow
d. Turning
A. Three Controlled Factors in an
Incubation System
a. Temperature
b. Humidity
c. Damper
B. One Established Factor
a. Airflow
C. One Programmed Factor
a. Turning
In General the Four Basic
Requirements
To Achieve Correct Incubation
•Heat - Determines Air Temperature that dictates speed of Embryonic
Development
•Humidity - Controls moisture lost and afford some of the cooling
•Air Flow - generated by the fans creating the correct air movement
through the egg pack (To obtain, maintain and distribute the correct
air temperature to achieve and control constant embryo temperature.
•Turning - Keep embryo in the correct position in the early stages of
Embryonic Development to avoid sticking to the sides as it develops).
ALSO very important…
•Damper - Controls O2 and CO2
Simply:
Operate and Maintain Your Equipment as per
Manufacturer Recommendations (Specifications)
Procedure, Principles and Concept Understanding
for Every Cause There is an Effect.
TEAMWORK-COMMUNICATION
In the Hatchery as well as Total Feedmill -BreederHatchery-Broiler-Processing
Two Types of Incubation
Systems in
Today’s Modern Industry
Multi Stage Incubation and Single Stage Incubation
The Industry is Definitely Trending Toward Single Stage
Because There is an Observed
and Obvious Difference
“Again”
The #1 Objective, Purpose and/or Goal of Any
Successful Hatchery
--------------------------------------------Produce Good Quality Chicks at Least Cost
• In Reality Good Quality Chicks Can be Produced
in Either Multi Stage or Single Stage Incubation
“But”
• What If Good Quality Could Be Excellent Quality?
Multi Stage Single Stage
Quality !!!
Quality!!!
Embryos Incubated 6 Days
Single Stage
@ 6 Days
Multi Stage
@ 6 Days
Embryos Incubated 8 Days
Single Stage
@ 8 Days
Multi Stage
@ 8 Days
What Does Excellent Quality
Verses Good Quality Actually
Interpret Into?
•
•
•
•
•
•
•
Less Cull Chicks at the Hatchery
Improved Quality Generally Yields Improved Hatch
More Viable, Hydrated and Healthy Chicks
Reduced 1st Week Mortality
Improved Growth Rate in Broiler
Improved Feed Conversion
More Meat at Less Cost = BIG $$$$$$$
If You Start With Quality There Will
Be Quality Birds Throughout Grow
Out
Quality Chicks Results in
Quality Meat Processed
Single Stage vs. Multi Stage Differences
What Accounts for Improved Quality?
•
•
•
•
•
•
•
•
Recognition of Challenges of Today’s Embryos
Understanding the Concept Differences
Providing the Machines Their Needs
Applying the Proper Management Strategy
Supplying the Proper Basic Inputs
Knowing Your Egg Pack
Creating the Correct Parameters for the Egg Pack
Following the Procedural Recommendation
Today’s Modern Embryos
• With the Challenges of Today’s Industry and the
Embryo From the Genetically High Yield Breeds
• Single Stage Incubation is Fast Becoming the
System of Chose Over Multi Stage Incubation
• Due Primarily to the Single Stage System Can Be
Profiled
• Meet the Specific Needs of the Developing Embryos
• Multi Stage Incubation Operates on Averages
Single Stage vs. Multi Stage
One of the Major differences to be considered in regard to
Single Stage vs. Multi Stage Incubation
1. Multi Stage Incubation Success is dependant on what you do
and how you do it.
Multi Stage Incubation System require more intense scheduling of
set time, transfer, cleaning and etc. Maintenance is more intense
due to continual going in and out of machines performing the
needed functions involved.
2. Single Stage Incubation Success is dependant on what it does.
Single Stage Incubation System require you follow simple
guidelines and procedures and let the machine do its thing. Once
the incubation starts and you shut the door you are finished until
transfer.
Multi Stage vs. Single Stage
Multi Stage Incubation Success Depends On:
• What You Do?
• What You Have?
• What You Do With What You Have?
• What You Should Do?
--------------------VERSES-----------------------Single Stage Incubation Success Depends On:
• What Parameters (Profile) You Program
• What It Done With What It Has?
The Profile is the
Key to Single
Stage Incubation
The Single Stage Profile
Understanding Parameters
Three Objectives to Consider
• Temperature - Specific = Controls Speed of
Embryo Development
• Humidity - Non Specific When Damper
Closed and Specific When Damper Opens =
Controls Moisture Lost
• Damper - Specific = Controls O2 and CO2
Note: Damper Can Be Programmed For
Either CO2 or Percentage
Air Temperature Zones vs Stages of
Development
Degree F
Correct Zone of Hatching Potential Deg. F Air
Temperature
101
100.4
99.5
99
98.6
97.7
97
96.8
95
Start
Mid
End
Incubation
Hatcher
Stages of Embryonic Development
End Hatch
Our Customers See Results!
The following data is based on an actual Jamesway Customer
Hatchery with:
•24 P120 Platinum Incubators and 12 P40 Hatchers,
•16 Super J Space Saver Incubators and 16 PX Hatchers
With a weekly egg capacity of:
•Platinum SS = 967, 680 eggs
•Multi Stage = 483, 840 eggs
Reported Chick cost = $ 0.26 USD
Data compilation date: March 1-June 30/09
Our customers saw great improvements in
hatch and grow out rates!...
Actual 1999
Multi Stage Incubators
Actual 2009 P120
Platinum Single Stage
Incubators
Hatchery Results from Jamesway Customer
Note: Same Identical Flocks Set for both Platinum and Multi Stage
for below data.
900,000
800,000
700,000
600,000
Number Set
500,000
Total Number Hatch
400,000
300,000
200,000
100,000
90
89
88
87
86
85
84
83
82
81
80
Platinum
Multi Stage
Total % Hatch
0
Platinum
Multi Stage
Platinum % Hatch:86.60%
Multi Stage % Hatch:84.01 %
Platinum Set: 831,096
Platinum Hatch: 719,732
Multi Stage Set: 770,588
Multi Stage Hatch: 647,369
Platinum Advantage
2.59%
Hatchery Results from Jamesway
Customer
Note: Same Identical Flocks Set for both Platinum and Multi Stage for
below data.
4,800
1,900
4,600
1,800
4,400
Platinum
Multi Stage
1,700
Platinum
4,200
Multi Stage
4,000
3,800
1,600
3,600
1,500
3,400
3,200
1,400
2nd Grade Chicks
Number Culls
Platinum # Culls: 1,624
Multi Stage # Culls: 1, 679
Platinum 2nd Grade Chicks: 4,008
Multi Stage 2nd Grade Chicks: 4,350
1st Grade Chicks
Platinum = 85.92%
Platinum Advantage = 2.69%
Multi Stage = 83.23%
Hatchery Results from Jamesway
Customer
Note: Same Identical Flocks Set for both Platinum and Multi Stage for
below data.
50
49.5
49
48.5
48
47.5
47
46.5
46
45.5
45
44.5
44
43.5
43
42.5
42
41.5
41
40.5
40
Platinum
Multi Stage
Chick Weight (grams)
Platinum Advantage = +1.21 grams
Platinum Chick Weight: 44.84 grams
Multi Stage Chick Weight: 43.63 grams
Hatchery Results from Jamesway
Customer
Note: Same Identical Flocks Set for both Platinum and Multi Stage for
below data.
98
96
94
Platinum
Multi Stage
92
90
88
86
84
Hatch of Fertile (%)
Platinum Hatch of Fertile: 93.78%
Multi Stage Hatch of Fertile: 90.98%
Platinum Advantage = 2.80%
Hatchery Results from Jamesway
Customer
Note: Same Identical Flocks Set for both Platinum and Multi Stage for
below data.
1.7
1.2
Platinum
Multi Stage
0.7
0.2
-0.3
First Week Field Mortality
Platinum 1st Week Field Mortality: .77%
Multi Stage 1st Week Field Mortality: .945 %
Platinum Advantage = .175%
Grow Out Results from Jamesway Customer
4,600,000
100
4,400,000
98
4,200,000
96
4,000,000
Platinum
Multi Stage
Total Birds Placed
Total Birds Processed
94
3,800,000
92
3,600,000
90
3,400,000
88
% Livability
3,200,000
Platinum
Multi Stage
Platinum Total Birds Placed: 4,193,180
Multi Stage Total Birds Placed: 3,962,541
Platinum Livability: 95.79%
Multi Stage: 94.20%
Platinum Total Birds Processed: 4,016,518
Multi Stage Total Birds Processed: 3,732,787
Platinum Advantage = 1.59%
Grow Out Results from
Jamesway Customer
60
50
40
Platinum
30
Multi Stage
20
10
-1
Age of Bird @ Processing
Average Weight @ Processing
Average Daily Gain
Platinum: Age @ Processing: 45.8
Weight @ Processing: 6.05
Avg. Daily Gain:59.9 grams
Multi Stage: Age @ Processing:45.4
Weight @ Processing: 5.92
Avg. Daily Gain:59.1 grams
Platinum Advantage = .8 grams/day
Grow Out Results from
Jamesway Customer
2
2
Platinum
2
Multi Stage
2
2
2
Feed Conversion per US Ton
Platinum Feed Conversion: 1.894
Multi Stage Feed Conversion: 1.951
FEED COSTS @ $314.28/US ton
Platinum Advantage = .057
Grow Out Results
from Jamesway Customer
30,000,000
28,000,000
26,000,000
Platinum
Multi Stage
24,000,000
22,000,000
20,000,000
18,000,000
16,000,000
Total Meat Processed (LBS)
Platinum Meat Processed:24,317,151 lbs
Multi Stage Meat Processed: 22,106,851 lbs
Platinum Advantage = 2,210, 300 lbs
The Proof is in the Platinum
2, 210, 300 additional lbs. (4.76%) of Meat from the Platinum
2, 210, 300 additional lbs. of meat from the Platinum x .89= $1, 967, 167.00
More money for the customer!
Example of Company Profile with Platinum:
Company makes 10% profit on processed meat @ 89 cents USD/lb
89 cents USD x 10% = 8.9 cents USD profit/lb
2, 210, 300 lbs. of additional meat processed x .089= $196, 716.70 profit for 4 months
$196, 716.70 x 3= $590, 150.10 yearly, attributed to Platinum!
(plus much more savings energy, feed, hatchery and etc.!)
*Results were obtained from an actual Jamesway Customer. Results may vary.
Electricity Consumption Results
from Jamesway Customer
Electricity Consumption
Actual Numbers as Provided by Customer in April 2009
Jamesway Platinum Single Stage
Jamesway Multi Stage
66, 000 K/Hrs. per Month (60% Total)
44, 000 K/Hrs. per Month (40% Total)
12-P120 @ 483,840/wk Set Capacity
10-Super J @ 302,400/wk Set Capacity
1, 935,360 Monthly Set Capacity
1, 209,600 Monthly Set Capacity
66,000 K/Hr @ 1,935,360 eggs
=.0341 K/Hr per egg
44,000 K/Hr @ 1,209,600 eggs
=.0364 K/Hr per egg
Cost per Egg USD=.0071 cents
Cost per Egg USD=.0076 cents
*Results were obtained from an actual Jamesway Customer. Results may vary.
Understanding Today’s Incubation
•The Challenges of Today High Yield Advanced Genetic Embryos
•Differences When Comparing Two Systems: Multi Stage Averages vs. Single Stage Specifics
•Causes of Concerns Affecting Incubation and Results
a. Improper Procedures,
b. Improper Water,
c. Improper Ventilation,
d. Maintenance Issues and
e. Improper Egg Pack
•Importance of Properly Supplying the Basic Inputs
a. Proper Electricity,
b. Proper Water,
c. Proper Compressed Air,
d. Proper Ventilation and
e. Proper Egg Pack
•The Basic Requirements for Incubation Today is the Same.
a. Heat,
b. Humidity,
c. Airflow and
d. Turning
•Importance of Proper Maintenance
•Monitoring Identifies Concerns but Does Not Correct
•Proper Hatchery Management is a Must
What Incubation System is Still the
Best and Who Has It?
The Mother Hen!
On behalf of Jamesway…
Thank you!
From the Egg…
To the Chick…