Egg Production FacilityEgg Production Facility

Clay CraneClay Crane

Why Egg Production?Why Egg Production?

Kansas is an agriculture state, we’ve Kansas is an agriculture state, we’ve covered the flour productioncovered the flour production

Great economic impact on the communityGreat economic impact on the community

Actually been through a facilityActually been through a facility

Surprising how highly atomized the Surprising how highly atomized the industry has becomeindustry has become

Czech quality…..disturbing?Czech quality…..disturbing?

Changing IndustryChanging Industry

Prior to WWII most egg Prior to WWII most egg producing facilities were producing facilities were ‘free run’ with flock sizes ‘free run’ with flock sizes less than 400 hens.less than 400 hens.

Now the birds are kept in Now the birds are kept in cages which has allowed cages which has allowed for more atomization and for more atomization and larger flock sizes. Some larger flock sizes. Some facilities now can house facilities now can house as many as 2.5 million as many as 2.5 million hens. Genetics play a hens. Genetics play a very large role now as very large role now as hens can be designed to hens can be designed to be layers with little meat be layers with little meat and a high resistance to and a high resistance to disease.disease.

Pullets (chicks)Pullets (chicks)

Kept in separate houses from the layersKept in separate houses from the layers

Extremely tight bio-security to prevent disease Extremely tight bio-security to prevent disease contaminationcontamination

Very rigid with vaccinationsVery rigid with vaccinations

Manipulating the amount of light received allows Manipulating the amount of light received allows the maturing of the bird’s frame, however delays the maturing of the bird’s frame, however delays sexual maturitysexual maturity

After 17 weeks they are moved to the laying After 17 weeks they are moved to the laying houses, 18houses, 18thth week the pullets become layers week the pullets become layers

LayersLayers

Diet changes- more calcium to promote sexual maturity Diet changes- more calcium to promote sexual maturity and ensure good shell qualityand ensure good shell quality

NO hormones are used in the U.S.NO hormones are used in the U.S.

Start increasing light 15 minutes/day (17hrs max)Start increasing light 15 minutes/day (17hrs max) Tricks them into thinking it’s spring timeTricks them into thinking it’s spring time

Start laying eggs after 20-30 weeksStart laying eggs after 20-30 weeksOverall a facility will have about 80-90% productivity Overall a facility will have about 80-90% productivity across the boardacross the boardMost facilities do molt to keep costs down, but I don’t Most facilities do molt to keep costs down, but I don’t have details on that…..have details on that…..After 110 weeks the hens are sold for processingAfter 110 weeks the hens are sold for processing

In the Laying HouseIn the Laying House

Everything is computer controlled from a Everything is computer controlled from a ‘command center’‘command center’ Light, temperature, humidity, air circulation, Light, temperature, humidity, air circulation,

belt speeds, feed augers belt speeds, feed augers

Several back up generators to ensure the Several back up generators to ensure the fans and the motors don’t stopfans and the motors don’t stop

There appear to be endless columns of There appear to be endless columns of chickens as far as the eye can seechickens as far as the eye can see

There’s 6 hens/cageThere’s 6 hens/cageWater and food are Water and food are easily availableeasily availableThe cage floor has a The cage floor has a 10 deg. slant10 deg. slantThe small conveyers The small conveyers flow to a main flow to a main conveyer that runs conveyer that runs perpendicular to all perpendicular to all houseshouses

Egg PreparationEgg Preparation

1. Pre-wash1. Pre-wash Loosens any materials on the eggLoosens any materials on the egg

2. Two washers spraying hot water at 2. Two washers spraying hot water at high pressure while brushes go over eggshigh pressure while brushes go over eggs3. Eggs dried under blowers3. Eggs dried under blowers4. Mineral oil applied4. Mineral oil applied Must be done because the washing removes Must be done because the washing removes

the natural cuticle that prevents bacteria from the natural cuticle that prevents bacteria from entering the eggentering the egg

Egg Processing cont’dEgg Processing cont’d

5. Dirt detector5. Dirt detector A set of cameras calibrated to a certain shade of color A set of cameras calibrated to a certain shade of color

(white)(white) Anything else and the egg is redirected on a conveyer Anything else and the egg is redirected on a conveyer

back to the washersback to the washers

6. Crack detector6. Crack detector Sonar devise measuring sound vibrationsSonar devise measuring sound vibrations Cracks give off a funny vibrationCracks give off a funny vibration If cracked, the eggs go to a “breaking plant” where If cracked, the eggs go to a “breaking plant” where

they will be pasteurized and dried and sold as they will be pasteurized and dried and sold as ingredients to bakeries and suchingredients to bakeries and such

Egg Processing cont’dEgg Processing cont’d

7. Weighing 7. Weighing The moment the egg is weighed, the machine knows The moment the egg is weighed, the machine knows

exactly where the egg is and what packer it should go exactly where the egg is and what packer it should go to to

8. Packers8. Packers 12 packers in total, most of which are for large eggs12 packers in total, most of which are for large eggs The machine drops the proper egg into the proper The machine drops the proper egg into the proper

packerpacker Then placed in carton, date stamped and packed into Then placed in carton, date stamped and packed into

boxesboxes

EfficiencyEfficiency

Have their own mill to Have their own mill to make proper mixmake proper mix

Wastes and recycledWastes and recycled Sold to farmers as Sold to farmers as

fertilizerfertilizer

SourcesSources

www.aeb.org/eii/production.htmlwww.aeb.org/eii/production.html

http:ag.ansc.prudue.edu/poultry/publication/http:ag.ansc.prudue.edu/poultry/publication/commegg/inex.htmcommegg/inex.htm

Ryan A. Meunier and Dr. Mickey A. LatourRyan A. Meunier and Dr. Mickey A. Latour

Todd Walters, Complex manager, Cal-Maine Todd Walters, Complex manager, Cal-Maine Foods, INC.Foods, INC.