Archive for March, 2019

US food giant Tyson Foods invests in SmartPro™ hatchery technology

Wednesday, March 13th, 2019

US food giant Tyson Foods invests in SmartPro™ hatchery technology

US-based Tyson Foods Inc. has chosen Pas Reform and NatureForm, the world’s only single-source supplier of integrated hatchery solutions, to equip the hatchery of its new chicken production complex at Humboldt in Gibson County, western Tennessee.

The facility will include a feed mill, hatchery, processing plant and related operations to produce pre-packaged trays of fresh chicken for retail grocery stores nationwide. It is expected to process 1.25 million birds per week when it opens in 2020.

Tyson Foods is one of the world’s largest food companies and a recognised leader in protein-based foods, with its headquarters in Springdale, Arkansas. Founded in 1935 by John W. Tyson, it has grown under three generations of family leadership. In 2017 the company had sales of USD 38.3 billion.

The Humboldt project received the go-ahead in January 2018. In the preceding months the engineering teams of Tyson and Pas Reform/NatureForm worked together to specify the project’s scope, calculate technical specifications and model optimal processes for the hatchery.

The hatchery will make full use of Pas Reform’s and NatureForm’s single-source capabilities. The project includes 36 SmartSetPro™-6 setters, 6 SmartSetPro™-3 setters and 39 SmartHatchPro™ hatchers, to bring total weekly capacity up to 1.7 million eggs.

Installation will also include a complete heating, ventilation and air conditioning (HVAC) installation, with seven air-handling units, three chillers and a heat recovery system.

On the hatchery automation front, the project consists of a farm-to-setter-trolley transfer system, a fully automated candling and transfer unit with in-ovo vaccination, stackers, de-stackers, separators, washing and waste handling systems, and innovative, animal-friendly SmartCount™ chick counting and dosing systems.

Pas Reform’s advanced, web-based SmartCenterPro™ hatchery information software will enable Tyson Foods to control setter, hatcher, climate control and hatchery automation operations from a single computer, as well as providing remote access capabilities to manage and respond to system alerts and provide technical and troubleshooting support.

Tyson Foods has also adopted a SmartCare™ Lifetime Services contract, which covers every level of hatchery operations, to deliver an assurance of efficient, uninterrupted performance over the next five years.

In addition to the Humboldt Project, Tyson has ordered 4 SmartStart™ hatchers to be installed this spring. Tyson will be the first major poultry producer in the US to install this type of hatchers, which have the capability of providing day old chicks with moisture enhanced feed, eliminating the need for open water sources in the hatcher.

Steve Warren, President of NatureForm Hatchery Technologies, comments: “This is another milestone for Pas Reform and NatureForm. Since the start of our collaboration in 2014 we have been in frequent contact with Tyson staff, visiting their hatchery operations with our incubation specialists and inviting them to our Pas Reform Academy. This was a great way for us to get in-depth knowledge of the Tyson group. And of course Tyson staff also got to learn about our equipment and our company philosophy.”

Bouke Hamminga, Pas Reform’s Director for International Sales and Business Development says: “Since Tyson is one of the three largest poultry companies in the world, the impact of this agreement will be viewed very positively both in the USA and worldwide.

“We feel that this project helps us to get a major foothold on the US market and internationally as well. We have always viewed our collaboration with NatureForm as a strategic way of gaining substantial market share in the US market and we are doing just that.”

Photo caption: L-R: Michael Freer, Complex Engineer, Tyson Foods; Mike Tubb, Managing Director Engineering, Tyson Foods; David Corvin, Live Production Manager, Tyson Foods; Jan-Peter Eil, Project Manager, Pas Reform Hatchery Technologies; Jack Hubbel, VP Sales, NatureForm Hatchery Technologies; Bouke Hamminga, Director International Sales & Business Development, Pas Reform Hatchery Technologies; Tom McCue, Complex Manager Tyson Foods; Shelby Watkins, Director of Breeder & Hatchery Ops, Tyson Foods; Barry Vincent, Breeder Hatchery Tech Support, Tyson Foods

SmartPro™ NF is chosen by Wayne Farms for US hatchery renovation project

Wednesday, March 13th, 2019

SmartPro™ NF is chosen by Wayne Farms for US hatchery renovation project

Wayne Farms LLC, one of the top-six poultry producers in the United States, has chosen SmartPro™ NF incubators from NatureForm and Pas Reform for its hatchery upgrade project in Decatur, Alabama.

With its headquarters in Oakwood, Georgia, Wayne Farms is also amongst the world’s 10 largest producers. Established in 1965, the company has evolved significantly from its origins as a spin off from the Continental Grain Company. Today it employs 9,000 staff and has a production capacity of close to 8 million broilers a week and annual sales of poultry products worth USD 2.6 billion.

The Decatur project is the first in a planned company-wide overhaul of its 10 hatcheries to install equipment, which is expected to take five years to complete. Renovation at Decatur will include 24 SmartPro™ NF 18-54 setters and 12 SmarthatchPro™ NF 6 hatchers, to bring total weekly capacity up to 962,280 hatching eggs. The installation will also include Pas Reform’s SmartCenterPro™ hatchery management system, which will seamlessly connect incubation, climate control and hatchery automation systems and capture data from every layer of hatchery operations.

Wayne Farms has a customer-driven strategic focus on RWA (raised without antibiotics) production and the latest GAP2 animal welfare standards. This has triggered a complete shift towards single stage incubation, which results in a much shorter hatch window and lower first-week mortalities. Innovative, post-hatch feeding practices are also under consideration for the hatchery upgrades.

Wayne Farms believes in upholding a set of rigorous standards to deliver exceptional products for some of the largest branded food companies across America, assuring strict product quality and food safety from the farm to the kitchen. This is largely a product of  vertically integrated process, which gives control over every step of the process and provides a level of traceability and accountability unparalleled by the majority of food production.

Wayne Farms’ decision to invest in the SmartPro™ NF product line at Decatur followed a rigorous, year-long comparative testing versus multistage incubators. Superior hatchability versus these multistage incubators showed overall improved results which justified the renovation investment.

Steve Warren, President at NatureForm Hatchery Technologies, comments: “We are very glad to have such an important company as Wayne Farms starting to transform its hatcheries from multistage to single-stage incubation with us. Our team of combined Dutch and American specialists has been instrumental in working together with the client.”

“We are now looking towards further strategic collaboration with Wayne Farms in post-hatch feeding and a further overhaul of some of its other hatchery operations.”

The entire Decatur project will be delivered and installed in phases over the winter months of 2018 and into the first few months of 2019 and will produce its first day old chicks in December 2018.

NatureForm appoints Rory Harman as new Regional Sales Manager for North America

Wednesday, March 13th, 2019

NatureForm appoints Rory Harman as new Regional Sales Manager for North America

NatureForm Hatchery Technologies has appointed hatchery specialist Rory Harman as Regional Sales Manager North America, based at the company’s Jacksonville HQ in Florida.

Rory joins NatureForm with over 35 years’ experience in the US hatchery industry. Starting his career in hatchery maintenance and management in Georgia with Gold Kist Inc. in 1983, he spent 15 years as a technical advisor and consultant, specialising in hatchery automation design, with companies including Texas-based Pilgrim’s Pride Corp. He has been an area sales manager since 2012.

Commenting on his appointment, Rory said: “It was the positive feedback I heard from existing NatureForm/Pas Reform customers on their equipment, service, and support that convinced me to join NatureForm. The total hatchery solutions and innovations offered by Pas Reform will definitely lead the industry for years to come.

NatureForm President Steve Warren said on Rory’s appointment: “From the start-up position just five years ago, Pas Reform and NatureForm have evolved into major players in North America’s hatchery industry. Rory’s appointment is a logical and important next step. We wish him every success in his new role and look forward to continuing expansion in this dynamic market.”

Rory Harman can be contacted directly on 770 608 4489, or by email at rharman@natureform.com

SmartPro™ NF is chosen by Wayne Farms for US hatchery renovation project

Wednesday, March 13th, 2019

SmartPro™ NF is chosen by Wayne Farms for US hatchery renovation project

Wayne Farms LLC, one of the top-six poultry producers in the United States, has chosen SmartPro™ NF incubators from NatureForm and Pas Reform for its hatchery upgrade project in Decatur, Alabama.

With its headquarters in Oakwood, Georgia, Wayne Farms is also amongst the world’s 10 largest producers. Established in 1965, the company has evolved significantly from its origins as a spin off from the Continental Grain Company. Today it employs 9,000 staff and has a production capacity of close to 15 million broilers a week and annual sales of poultry products worth USD 2.2 billion.

Wayne Farms has a strategic focus on RWA (raised without antibiotics) production and the latest GAP2 animal welfare standards. This has triggered a complete shift towards single stage incubation, which results in a much shorter hatch window and lower first-week mortalities. Innovative, post-hatch feeding practices are also under consideration for the hatchery upgrades.

Wayne Farms’ decision to invest in the SmartPro™ NF product line at Decatur followed rigorous, year-long comparative testing across the entire range of competitor single stage incubation systems. At the end of these side-by-side comparisons, SmartPro™ NF ultimately emerged victorious. Overall improved field results versus the existing multi stage equipment justified the renovation investment.

Photo: L-R: Randy Caudill, North Alabama Live Production Manager, Wayne Farms; Kevin Martin, North Alabama Area Hatchery Manager, Wayne Farms