{"id":52730,"date":"2020-08-21T14:08:58","date_gmt":"2020-08-21T12:08:58","guid":{"rendered":"https:\/\/lohmann-breeders.com\/waste-management-at-ibertec-seizing-opportunities\/"},"modified":"2020-08-21T14:08:58","modified_gmt":"2020-08-21T12:08:58","slug":"waste-management-at-ibertec-seizing-opportunities","status":"publish","type":"post","link":"https:\/\/lohmann-breeders.com\/zh-hans\/waste-management-at-ibertec-seizing-opportunities\/","title":{"rendered":"WASTE MANAGEMENT AT IBERTEC: SEIZING OPPORTUNITIES"},"content":{"rendered":"
The management of waste from any livestock operation, and especially hatchery waste, has undoubtedly caused a crisis situation and brought warnings of collapse. This has forced the hatchery sector\r\nitself to work diligently to discover the industrial processes that have enabled a large part of this waste\r\nto be included in the by-product category, with its associated value. This is how the hatchery sector\r\nhas transformed a cost and a problem into an income and a business opportunity, and we at IBERTEC\r\nhave done the same in Spain, at a hatchery producing 15 million LOHMANN<\/strong> chicks a year.

<\/blockquote>\r\n\r\n\r\n\r\n

Quantifying waste generation<\/h2>\r\nFirst, we are going to review the quantities\r\nof waste generated in a hatchery. When\r\nwe load our incubators with 100 eggs at\r\n58 g each, we get:

\r\n 40 female chicks at 38 g each.<\/strong>
\r\n 10 clear eggs at 51 g each.<\/strong>
\r\n 10 unhatched eggs at 46 g each.<\/strong>
\r\n 41 males at 39 g each.<\/strong>

\r\nWe can express these quantities per female\r\nchick, or per 100,000 female chicks, produced. This is the number that we usually hatch\r\nin our hatchery per hatch day, so for each\r\n145 g of hatching egg per female chick, or\r\n14.5 t per 100,000 female chicks, we get:
\r\n38 g of female chick or 3.8 t per\r\n100,000 females

\r\n 78 g, or 7.8 t<\/strong>, of waste split between:
\r\n 13 g or 1.3 t<\/strong> clear eggs.
\r\n 13 g or 1.3 t <\/strong>egg shells.
\r\n 12 g or 1.2 t<\/strong> unhatched eggs.
\r\n 40 g or 4.0 t<\/strong> male chicks.

\r\n Water vapour: we must remember that\r\nthe hatching process dries the hatching\r\negg to its optimum level to produce a\r\nfully-developed day-old chick.
\r\n Heat: this is generated in the last few\r\ndays of the process and we recover it\r\nfor use in our daily hatching operations.

\r\nAs we can see in Figure 1 above, the weight\r\nof waste produced is double the weight of\r\nthe day-old female chick, so a more detailed analysis of the management of each\r\ntype of waste is required, starting with the\r\nmale chicks whose weight exceeds 50% of\r\nthe total waste produced. This management exercise will obviously require this\r\nwaste to be recovered and categorised as\r\na by-product.
\r\n\r\n

Male chick processing and recovery<\/h2>\r\nThis process has been fully integrated into\r\nour operations for more than 15 years, producing a commodity to feed birds of prey,\r\nhawks, animals etc., in an animal-welfare\r\nfriendly manner.
\r\n\r\nMale chicks are euthanised with CO2\r\nafter hatching and immediately deep-frozen at -30 \u00b0C with optimal air circulation, to\r\narrest any internal microbial growth completely. The males should be completely\r\nfrozen after 24 hours, and they are then\r\nstored at -20 \u00b0C for a few weeks, before sale\r\nand distribution worldwide.\r\nThis is a good example of how to make\r\na crisis into a business opportunity: if we\r\nhad not done this, we would never have\r\ngained access to markets such as the United Arab Emirates.
\r\n\r\n

Clear egg and egg shell processing<\/h2>\r\nand recovery\r\nManagement of the contents of clear\r\neggs was a problem 8\u20139 years ago so, in\r\ncollaboration with technology centres and\r\negg-drying equipment suppliers, we decided to create a prototype to handle this\r\ntype of waste, which we have finally managed to recover and include in various pig,\r\npet and poultry feed ranges.\r\nClear eggs are separated by automatic\r\ncandling at 18 days\u2019 incubation, when the\r\neggs are transferred from the incubators\r\nto the hatchers. These clear eggs, which\r\nare rejected from the hatching process,\r\nare separated into shell and contents by\r\na centrifuge, and are automatically channelled through a system of tubes to two\r\nseparate silos in our egg-drying plant.\r\nThe liquid part of the egg is then subjected to a double process:\r\n1. Coagulation: the egg is heated to 80 \u00b0C\r\nfor 20 minutes, to create a semi-solid

\r\n\r\n
\"\"<\/div>\r\n\r\n\r\n\"\"
\r\n\r\nTable 1. Summary of the quantities of waste generated in a hatchery.<\/strong>
\r\n\r\n\r\ntexture which can be handled easier in\r\nlater phases.\r\n2. Drying: the coagulated egg runs\r\nthrough a drier at a temperature of 245\r\n\u00b0C for 90 minutes.

\r\n\r\n\r\n\r\n
Approximately 11 g of dried product is\r\nobtained per clear egg as a result of the\r\ndrying process, reducing the initial volume\r\nof waste to a fifth.\r\nThe resulting product is an excellent raw\r\nmaterial for livestock feed in general, with\r\nthe following guaranteed nutritional value:<\/blockquote>\r\n\r\n\r\n Moisture: <12%.\r\n Crude fat: >34%.\r\n Crude protein: >44%.

\r\n \r\nMicrobiological quality is also optimal,\r\nwith no Salmonella or Clostridium, and\r\nwith enterobacteria below 10 CFU.\r\nThe shell from clear and hatched eggs\r\ncan also be placed directly in this same\r\ndryer and subjected to a temperature of\r\n45 \u00b0C for 15 minutes to reduce its initial\r\nweight by 30%.

\r\n\r\n

The balance of recovery cost and\r\ndisposal cost <\/h2>\r\nWaste management is now another cost\r\non the balance sheet for our operation, and\r\nwe can adopt two strategies to manage it:
\r\n\r\n Accept recycling costs of \u20ac240\/t for\r\nhatching waste (category 2 animal\r\nby-products not destined for human consumption according to\r\nEuropean legislation) and \u20ac108\/t for\r\nthe remaining waste (category 3).\r\nLogically, these costs depend on the\r\ndistance to the disposal plant, the\r\nvolume of waste produced at each\r\nhatch, etc. This waste management\r\ncosts \u20ac1,000\/100,000 female chicks, or\r\n\u20ac0.01\/female produced.

\r\n\r\n Recovering waste, avoiding recycling\r\ncosts and creating other income\r\nstreams for our balance sheet. We will\r\nnow analyse the treatment of each\r\nkind of waste, from the accounting\r\nperspective:
\r\n\r\n Male chicks. We have developed a\r\nnew sideline to the hatchery business\r\nwhich is complemented by a whole\r\nrange of products, as well as the male\r\nchicks. The financial end result, after\r\ncosts and depreciation, is a \u20ac480

\r\n\r\n\"\"
\r\n\r\nFigure 1. Production of waste per female chick produced (in grams)<\/strong>\r\n\r\n\r\n\"\"
\r\n\r\n\r\nFigure 2. Distribution of waste produced (%)<\/strong>
\r\nmargin per 100,000 female chicks\r\nproduced.
\r\nClear eggs. Most of these are used in\r\nthe manufacture of feed for our own\r\nparent stock and point-of-lay birds for\r\nsale, generating savings of \u20ac23\u201330\/t in\r\nfeed, mostly early stage or high nutrient concentration rations. The financial\r\nend result of this operation is neutral,\r\nbut we avoid the recycling costs.
\r\n\r\nShells from clear and hatched eggs.\r\nWe have developed the technology to\r\nmanage these internally but, given the\r\nlow value of the final product, it makes\r\nmore sense to contract the services of\r\nan authorised company, at a cost of\r\n\u20ac140\/100,000 female chicks.

\r\n\r\nUnhatched eggs. This is the only waste\r\ntype that we cannot handle in our facilities, so we have to accept the cost of\r\ndisposal, at \u20ac276\/100,000 female chicks.\r\nHeat Recovery. At this point in our\r\nsection on recycling and recovery, we\r\nmust not forget the outputs generated\r\nduring hatching. Current technology\r\nallows us to recover part of the heat\r\nproduced during the process, to\r\nheat the water for the initial stages\r\nof incubation and to make use of\r\nthe cool temperatures during the

\r\n\r\n\"\"
\r\n\r\nFigure 3. Air circulation inside the deep-freezing tunnel.<\/strong>\r\n\r\n\"\"
\r\n\r\nPhoto 1. Egg-drying equipment.<\/strong>
\r\n\r\nnight to save on consumption by the\r\ncoolers. This initiative allows us to\r\nsave 20\u201325% of our gas and electricity\r\nuse, which translates into a saving of\r\n\u20ac364\/100,000 female chicks.

\r\n\r\nUsing this second strategy, we handle and\r\nrecover 84\u201385% of our waste internally, with\r\na margin of \u20ac428\/100,000 females, which is\r\na huge competitive advantage over the alternative of recycling through a third party\r\nat \u20ac0.014\/female chick produced.\r\nWe must implement these initiatives\r\nin our operations, not only because they\r\nsignificantly reduce the volume of waste\r\n(five-fold in some cases) and produce a\r\npositive financial balance in our profit and\r\nloss account, they also generate qualitative improvements that are sometimes undervalued or overlooked.
\r\n\r\nStaff awareness of the need to comply\r\nwith the animal welfare policy.
\r\nReinforcing and improving our biosecurity programmes.
\r\nBringing our agro-industrial operations\r\nin line with any other economic activity, obliging our plant and operations\r\nto be clean, respectful and compatible\r\nwith the environment.

\r\n\r\nTo sum up, the way that problems or crises\r\nare managed in situations such as this generates competitive situations and opportunities. These may be of a purely financial\r\nnature, or they might improve our animal\r\nwelfare and biosecurity conditions, and\r\nthe suitability of our operations for any\r\nlocation.
\r\n\r\nPascual Alonso, Ibertec<\/strong>\r\n\r\n\"\"
\r\n\r\nTable 2. Comparison of standard recycling costs and internal recovery by Ibertec.<\/strong>\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n","protected":false},"excerpt":{"rendered":"The management of waste from any livestock operation, a […]","protected":false},"author":15,"featured_media":52269,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"ngg_post_thumbnail":0,"footnotes":""},"categories":[2335],"tags":[],"class_list":["post-52730","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-poultry-news-zh-hans","issue-2-2017-zh-hans","yeararchive-2017-zh-hans"],"acf":[],"yoast_head":"WASTE MANAGEMENT AT IBERTEC: SEIZING OPPORTUNITIES - Lohmann Breeders<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/lohmann-breeders.com\/zh-hans\/waste-management-at-ibertec-seizing-opportunities\/\" \/>\n<meta property=\"og:locale\" content=\"zh_CN\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"WASTE MANAGEMENT AT IBERTEC: SEIZING OPPORTUNITIES - 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