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The country, that is the biggest hatchery for the sector, hosts the 24th World’s Poultry Congress

World's Poultry Congress Especial Edition

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Premix and Nucleos Pre-Starter Feed

Brazil is in the spotlight of the poul-try world. Not only because it is hosting the XXIV World’s Poultry Congress, but also because it is one of the world’s biggest meat producers, including chi-cken. Today, Brazil is the biggest expor-ter in the world of poultry and the third biggest producer. In this special supple-ment, you will find unprecedented data from the FAO about poultry farming in the world and exclusive articles prepared by specialists on Brazilian and world poultry. For example, the FAO evaluates that poultry farming, historically one of the most dynamic meat sectors, has seen its growth affected by high costs of inputs, the resurgence of Bird Flu out-breaks in Asia and trade disputes. “As a

result, world production does not grow 2% and should be around 103.5 million tons,” reveals the analysis.

Francisco Turra, president of Ubabef, and James Sumner, president of USAPE-EC, also provide comments and projec-tions about Brazilian and world poultry farming. Sumner, in a more comprehen-sive analysis, suggests that Brazil and the United States could unite to standardize their productions of chicken meat since the two countries, together, control 2/3 of the global meat market. Learn more about Brazilian poultry farming, its po-tential and its projections starting on page 4.

Pleasant reading!

eDITORIAL

Brazil: the chicken boss

Acknowledgements

We would like to thank all those who collaborated with this edition, such as Francisco Turra and James Sumner, as well as all the companies that sent material to our products section and made the project for this special edition of the AviSite Magazine possible.

PublisherPaulo [email protected]

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Diagramming and artMundo Agro e WL [email protected]

InternetJessica Sousa Rafael Ribeiro Vinicius [email protected]

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Circulation and subscriptionÉrika Guimarães (19) [email protected]

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Summary

24th World’s Poultry Congress Special Edition | 3

Francisco TurraGlobal demand for food and the challenges of Brazilian poultry production

16

Global Products SolutionsA selection of products, equipments and solutions for the poultry sector

22

VetancoTools to reduce the negative effects of this practice

17

PfizerIn ovo technology driving hatchery modernization

18

James SumnerUnited States and Brazil are in a virtual tie for the quantity of exports

Technical-business reports

04

FAO’s forecasts for 2012 For the organization, low profitability limits poultry production growth

08

4 | 24th World’s Poultry Congress Special Edition

International Opinion

With poultry meat ex-pected to dominate growth in the global

protein sector for the foreseeable future, the United States and Bra-zil are in the enviable position to take advantage of this trend of ri-sing poultry consumption. The two countries are the number one and three producers of poul-try in the world, with China san-dwiched in between. Moreover, the United States and Brazil ac-count for two-thirds of global poultry trade, and are in a virtu-al tie for the quantity of exports.

The question is this: with so much at stake for the industries in both countries, can we work together for our mutual benefit?

I think we can; and I think we must. In fact, the USA Poultry & Egg Export Council (USAPEEC) and UBABEF, the Brazilian Poul-try Producers and Exporters As-sociation, have joined together on several occasions already. When Ukraine filed an anti-dum-ping suit against both U.S. and Brazilian chicken, USAPEEC and UBABEF worked together in de-fending our interests and were ultimately successful in winning the case.

Also, our two organizations recently organized a joint trade mission to India in hopes of con-vincing the Indian industry and government that it’s in their long-term best interests to end

their protectionist stance with regard to poultry imports and to begin adhering to international trade rules. USAPEEC also sup-ports Brazil’s decision to call for the World Trade Organization to adjudicate South Africa’s anti--dumping case against Brazilian poultry, and we have asked our government to adjoin the case on our industry’s behalf.

Both the U.S. and Brazilian industries see the benefit of working together on issues of common interest. USAPEEC and UBABEF are founding members of the International Poultry Council, an organization com-prised of industry associations from 28 nations around the world that meets twice each year to discuss issues that affect all of our industries. The motto of the IPC is “Working Together Works.”

Still and yet, the United States and Brazil are strong competitors in the global arena of poultry tra-de and will remain so, even with the “cross-pollination” of com-pany ownership that has occur-red over the past few years. Trade is a world of ever-changing dyna-mics, and demand trends tend to shift over time. Our organiza-tions recognize that both our in-dustries must adapt in order to survive and prosper.

While Brazil will certainly re-main competitive as a producer and exporter of poultry because

To work together

By James H. Sumner President of USA Poultry & Egg Export Council (USAPEEC)

United States and Brazil are strong

competitors in the global arena of

poultry trade and will remain so

United States and Brazil are the number one and three producers of poultry in the world, with China sandwiched in between. Moreover, the two countries account for two-thirds of global poultry trade, and are in a virtual tie for the quantity of exports

Jim Sumner has served as President of the USA Poultry & Egg Export

Council since February 1990


of its reputation around the world as an exporter of quality products, it faces some challen-ges nonetheless. Brazil’s eco-nomy is expected to remain strong, and the cost of labor in the poultry sector is rising. In fact, the cost of Brazilian labor is rising at a faster rate than in the United States.

Also, Brazil’s robust economic engine is powering a rising stan-dard of living and, as a result, dramatic increases in demand for its poultry meat by domestic con-sumers. While strong domestic sales may be good news for the Brazilian industry, it will almost certainly affect exports by incre-asing prices.

Brazil is not alone in its gro-wing middle class. This pheno-menon is happening globally, es-pecially in the developing world, and will fuel demand for protein for many years to come. Demand is in fact growing at a faster rate than production. While this bo-des well for well for the world’s more efficient poultry producers, it may also impact the alignment of which country serves which markets.

Some economists predict that in the coming years the United States and Brazil could face stiff competition from Argentina, Thailand, Ukraine, and even Rus-sia. With feed costs lower than both the United States and Brazil, Argentina is developing rapidly as a poultry producer and is a worthy competitor in some ex-port markets.

Although economists differ on the probable outcomes, Thai-land recently regained access to the European Union for its raw poultry after a long absence be-cause of avian influenza issues. To their credit, when the EU ban on raw product took effect, the

Thai quickly re-tooled its indus-try into a dynamo for producing cooked product and became one of Europe’s largest suppliers of further processed items.

While some observers say that the rescinded ban on raw poultry will help Thailand return to prominence as a major expor-ter of raw product to the EU, others counter that it makes little economic sense for Thailand to abandon its lucrative further pro-cessed business in Europe to resu-me shipping large quantities of lower-value raw product. With

the volatility of grain markets ex-pected to continue over the long term, corn-dependent Thailand may well stick with its current export model.

Also, it appears to be likely that Japan may reopen its market to raw Thai product, a move that would also affect Brazil and the EU, both of which have enjoyed Thailand’s absence.

Although it has long been an importer of chicken, largely from the U.S., Ukraine’s poultry pro-duction is rapidly expanding while its imports have declined. With production is well on its

way toward exceeding imports, Ukraine could soon become a net exporter to Europe as well. The industry, led by Myronivsky Hli-boproduct( MHP), has made sig-nificant strides in developing one of the world’s most modern and high-tech processing operations and stand poised to gain appro-val to begin shipping product to the European Union.

With Russia set to enter the WTO in the summer, the govern-ment has not only brought its re-gulatory system in line with in-ternational norms, but it has also poured billions upon billions of rubles into a massive campaign to bring its crumbling meat and poultry industry into the 21st century. Russian poultry produc-tion has been increasing by dou-ble digits annually for the last se-veral years and the government has a stated goal of soon beco-ming a net exporter, also targe-ting Europe.

As for important export ma-rkets for the United States and Brazil, China is at the top of the list – at least for now. China’s po-pulation is massive, is growing rapidly, is becoming increasingly upwardly mobile, and its middle class is expanding exponentially. China is also the world’s second--leading producer of poultry, and has the world’s second-leading total poultry consumption.

Even so, China is heavily grain-dependent and its lack of arable land and looming water is-sues will prevent its poultry in-dustry from significant expan-sion. Moreover, China’s per capita domestic consumption ho-vers at about 10 kilograms, which means that even a gain of a single percentage point in consumption would translate into thousands of tons of poultry that must come from imports.

Brazil is not alone in its growing

middle class. This phenomenon is

happening globally,

especially in the developing world


International Opinion

The biggest plum on the bush, however, is India. India’s popula-tion and its demand for poultry are growing so rapidly that it is expected to surpass China as a market of importance. Per capita consumption is very low, about 2.3 kilograms, but is ticking upward with the emergence of a middle class that is hungry for meat protein but does not consu-me red meat. India’s domestic in-dustry primarily produces live birds for the ubiquitous wet ma-rkets and seems uninterested in producing for the exploding number of quick-serve restau-rants (QSR).

The QSR companies are plea-ding for a stable supply of pro-duct and are pushing for the In-

dian government to open its borders to imports so that their expansion can continue. This is why USAPEEC and UBABEF made their joint trade mission to India and plan to continue to collabo-rate to open the market.

As for the next few years, glo-bal poultry production is expec-ted to continue to expand at an annual rate of 3 to 4 percent, fas-ter than production of red meat, with exports increasing at a simi-lar pace. The U.S. and Brazilian poultry industries are well-posi-tioned to continue their expan-sion of global trade.

Yes, we are strong competi-tors, but we have a single goal: a chicken in every pot on every ta-ble in the world.

As for the next few years, global

poultry production is expected to continue to

expand at an annual rate of 3

to 4 percent


Projection

8 Produção Animal | Avicultura

In its first study on produc-tion tendencies for 2012, the United Nations Food and

Agriculture Organization (FAO) says the poultry sector, histori-cally one of the most dynamic in the meat segment, has been having its growth affected by the high costs of inputs due to the reappearance of outbreaks of Bird Flu in Asia and by trade disputes. As a result, world pro-duction does not reach a 2-per-cent growth and should be around 103.5 million tons.

At first glance, most of the projected increase tends to be concentrated in Asia, especially China, India, Japan, South Ko-

rea and Turkey. However, the growing numbers of Bird Flu – in February, seven Asian coun-tries (a record number) reported cases of the disease – have risen doubts about the perspectives for significant increases in the region.

In Bangladesh, nearly six thousand granges have been closed since the beginning of the year not only because of the bird flu, but also because of the high costs of rations. And in Africa, propagation of the disea-se by Egypt should affect the development of the poultry sec-tor in the current fiscal year.

The drop in broiler chick

housing in the beginning of 2012 indicates declining pro-duction in the USA, while Euro-pean production is enjoying a slight increase – two opposing behaviors, but which point to production stability in develo-ped countries.

This suggests greater expan-sion in emerging countries. And the most prominent is Russia, which has launched ten new in-vestment projects in 2012 and should grow at least 6% to 3 million tons of poultry meat. In Brazil, production should incre-ase 3% and approach the 12 million ton mark (the FAO esti-mated 11.641 million tons for

FAO’s forecasts for 2012 alert

Source: FAO Elaboration and analysis: AviSite

For the organization, low profitability limits poultry production producer, consumer, importer and


World production

does not reach a 2-percent growth and should be

around 103.5 million tons

last year). This, in spite of the drop in prices at the beginning of the year that generated se-rious concern in the production sector.

Mexico also deserves FAO re-ference with a 2% increase in production and 2.9 million tons, due to the vertical integra-tion of its production system and the high prices for other meats.

Moving on to Africa, the FAO observes that although some lo-cal governments – such as Na-mibia – are investing heavily in poultry production, factors such as the high cost of inputs and competition of imports hamper

the increase in produced volu-me. Ghana, Angola, Benin, and Congo are cited specifically.

Also in Africa, and conclu-ding its comments on the ten-dencies of global poultry pro-duction in 2012, the FAO observes that as a result of the adoption of anti-dumping mea-sures on poultry imports from the USA and Brazil, the perspec-tives for South African produc-tion are increasing.

The table below gathers the 10 main producer countries ci-ted by FAO, while also pointing out production tendencies among emerging and already developed countries.

to the high costs of inputsgrowth. Get to know the FAO’s classifications for the biggest exporter countries of poultry meat.


Projection


The 10 biggest consumers in the world: humble growth in 2012

World consumption of poultry in 2012 will grow no more than 2% - a humble amount, but explicable due to the current economic situa-tion.

Nevertheless, it underscores the fact that among the ten biggest consumers, only one sho-ws a tendency for a reduction in consumption compared to 2011 – the USA. However, what is going to determine this possible regression here is not economic difficulty but rather a reduction in production, which should result in lower vo-lume in the triennial period of 2010-2012.

Another thing that draws attention is the possibility of Japan seeing an expansion in con-sumption equal to “zero”, mainly due to the negative growth of the Japanese population. Regardless, maintenance of the consumption levels will not come about by lower production, but rather by a reduction in imports, which has been affecting the exports of Japan’s main sup-plier: Brazil.

Observe that the ranking of the 10 biggest consumers refers only to the total consumed and not to consumption per capita. Thus, for example, although Japan (eighth biggest consu-mer in the world of poultry) exceeds the volume consumed in South Africa (ninth biggest consu-mer), its consumption per capita corresponds to just half that of South Africa. Likewise, India (seventh biggest consumer in the world) has one of the smallest consumptions per capita in the world at around 3 kg per year.

Maintenance of consumption levels

will not occur through smaller production but rather a reduction in

imports


Projection

The 10 biggest producers in the world Four biggest are responsible for 60% of the total

Whereas in relation to chicken, specifi-cally, annual Chinese production corresponds to little more than 80% of American produc-tion, when considering all poultry produced by the two countries this percentage increases in nearly 95% (projection for 2012). This oc-curs because poultry production in the USA is essentially represented by two types of birds – chickens and turkeys – much more restricted than the Chinese, which is represented by chicken, duck, geese, pheasant, quail - just to name the main species.

FAO’s 2012 data also point out that also as a result of greater diversity, poultry produc-tion in the European Union is ranked third in the world. Therefore, in this case, it exceeds production in Brazil which, with chicken meat, is the world’s biggest producer.

It is also well-known that the numbers re-lated to Brazilian production are underestima-ted. Thus, accepted as correct projections rela-ted exclusively to chicken meat presented, externally, by the US Department of Agricul-ture (USDA, which estimates Brazilian pro-duction in 2012 at 13.250 million tons) and, internally, by the Federation of Industry of the State of São Paulo (13.483 million tons) or by the Ministry of Agriculture (13.028 million tons), Brazil is still, indisputably, the third bi-ggest producer in the world, not only of chi-cken, but of poultry.

Brazil is still, indisputably, the third

biggest producer in the world, not only

of chicken, but of poultry


Among the 10 biggest importers in the world: Angola and Canada are the only countries not served by Brazil

As already occurred in 2011, in 2012 China continues as the biggest importer of poultry in the world, absorbing nearly one-fifth of world imports. These numbers are accurate, but they include the imports made by Hong Kong, which re-exports most of the poultry it imports to con-tinental China.

With that considered, China loses its leader position, dropping to fifth (direct imports of just over 500 thousand tons). On the other hand, Hong Kong – just a special Chinese terri-tory and not a country – takes over the leading

position originally occupied by China, with es-timated imports of 1.8 million tons.

It is worth pointing out that among the 10 biggest importers of poultry in the world, eight are the main importers of Brazilian chicken. The exceptions are Angola and Canada, which are served by the USA.

China continues as the biggest

importer of poultry in the world,

absorbing nearly one-fifth of world

imports. These numbers are

accurate, but they include the

imports made by Hong Kong


Projection

The 10 biggest exporters in the world: Brazil is still the leader

While the imports of poultry tend to pre-sent an expansion of 5% in 2012, exports should increase no more than 3%, as projec-ted by FAO, pointing to the shaky global economy as the reason behind such a humble projection.

In this scenario, the indication that China will tend to increase its exports by 15% is surprising. If true, that corresponds to nearly 60% of the additional volume projected for 2012. However, one should go easy: most of these exports refer to re-exportation from

Hong Kong (a special Chinese territory) to China itself. With this considered, the ex-ports specifically made by China stemming from internal production should present an annual growth of around 5%.

Brazil, as can be observed, continues (for the ninth year running) as leader in world exports of poultry. Regardless, the number adopted by the FAO for 2011 is surprising since it indicates that Brazil already exceeded 4 million tons last year. And this is truly seen since, besides the 3.943 million tons of chi-cken, the Brazilian poultry industry exported another 141 thousand tons of turkey. What is curious, in this case, is that when adding both exports, we arrive – in 2011 – at a total volume of 4.084 million tons of poultry. And that is exactly the volume projected by the FAO for 2012.

Brazil, as can be observed, continues (for the ninth year

running) as leader in world exports

of poultry


Challenges and Demand

Analyses on the future of the international meat market, whether from the standpoint

of production, consumption or price behavior, have been on the rise in re-cent months.

According to one of these studies, done by the Organization for Econo-mic Co-operation and Development (OECD-FAO), global consumption of chicken meat should grow by 22.3% by 2020, reaching 122.5 million tons. Other segments will have less subs-tantial growth, such as beef, growing by 13.7%, and pork, up 16.2%.

Outlooks for increased interna-tional meat consumption are encou-raging for a country like Brazil, which has promoted a true revolution in poultry production in the last 60 ye-ars. That is, from the installation of the integrated production model to technical and scientific development, with advancements in the areas of ge-netics, nutrition (based on a balanced and efficient diet) and sanitation ma-nagement, which have resulted in a bird that requires around 1/3 of the time and 1/3 of the total food that a bird produced in the 1950s would have needed, for example.

All of this has allowed Brazil to re-ach the second decade of this century as the third largest producer of chi-cken. In 2011 alone, 13.058 million tons were produced, a volume close to what China produced in the same period, which was 13.2 million tons. Today’s largest producer is the USA, with 16.7 million tons.

Also thanks to this efficiency,

Brazilian chicken production has es-tablished itself as a global leader in exports, shipping 3.9 million tons in 2011, one million tons more than the USA, the world’s second largest exporter; together, these two coun-tries account for 73% of all poultry meat traded internationally. There are over 150 countries that consume Brazilian poultry, creating revenues of US$ 8.2 billion.

International trade figures un-derscore the dynamic nature of this activity and highlight other points. For example, they emphasize the so-lid image that Brazil has built abroad, after opening its doors to internatio-nal visits and inspections that veri-fied the high levels of health and quality in our product.

They furthermore showed that Brazil plays a leading role when it co-mes to international trends for sus-tainable consumption. Brazilian poultry production is widely recog-nized for its respect for environmen-tal conservation. All agricultural in-dustry exporters are located in regions outside of the Amazon Bio-me. Moreover, data from the United Kingdom’s Department for Environ-ment, Food and Rural Affairs (DE-FRA) show that Brazilian chicken meat production uses 25% less ener-gy and emits 17% less greenhouse gasses than British production. When looking at CO2 emissions alo-ne, the comparative percentage jumps to 45%.

Management of environmental resources used by companies is ano-

ther edge in sustainable poultry pro-duction in Brazil. One example is the use of waste in other production pro-cesses, such as fat that is transformed for biodiesel production. There is also composting, reduced use of pa-ckaging, use of natural lighting to re-duce energy consumption, off-set-ting degradation by planting trees, and countless other initiatives.

If on the one hand our poultry production produces high-quality and healthy meat, within a sustaina-ble profile, amidst an inevitable rise in global demand for food, on the other we see unlikely barriers being maintained in markets that are de-manding more and more food, with growing populations and per capita incomes.

Unjustified actions against Brazi-lian chicken, such as the antidum-ping measures in South Africa, a Rus-sian embargo and Indian import tariffs (surpassing 100%) are some examples of this. In the specific case of South Africa, consumers have felt the immediate effects, with domestic prices on products subject to the me-asure at 18% higher.

This will be the major challenge and the mission of the Brazilian poultry production export chain in the coming years: tearing down bar-riers, showing potential markets that our goal is to foster domestic con-sumption, contributing to local de-velopment and helping food security for the population. We live in a plu-ral world where there is no more room for protectionism.

Global demand for food and the challenges of Brazilian poultry production

By Francisco TurraFormer Minister of Agriculture, Livestock and Supply and Executive President of the Brazilian Poultry Association (União Brasileira de Avicultura)

Outlooks for increased international meat consumption are encouraging for a country like Brazil


Blend of organic acids

improves water palatability, and hence stimulates a higher water intake during

the feed withdrawal

period

Technical-business report

PREHARVEST FEED WITHDRAWAL

By MSc. Tiago UrbanoVetanco do Brasil

Tools to reduce the negative effects of this practice

The preharvest feed withdra-wal is a standard manage-ment practice in poultry

production. It aims to reduce car-cass contamination by digestive tract content and feces in the pro-cessing plant. The feed withdra-wal period includes the time that birds are kept without feed in the house, the live hauling time, the time in plant holding area, and the time in the plant until the bir-ds reach the stunning process. In addition to the long period wi-thout feed, birds are also stressed with the handling and transpor-tation. According to the welfare recommendations of the Brazilian

Association of Poultry Production and Poultry Exporters (UBABEF), the preharvest feed withdrawal should not exceed 12 hours.

From an economic perspecti-

ve, what is the real shrink that the preharvest feed withdrawal causes and in which part of this process does the biggest shrink occur? Additionally are there any tools or practices that could help in redu-cing these losses?

To answer these questions the technical support team of Vetan-co do Brasil has been working in partnership with several poultry companies. More than a dozen field trials were conducted under different weather conditions and feed withdrawal and hauling time periods. In all of the trials a pro-duct based on a blend of organic acids was added to the drinking water of broilers during the feed withdrawal at the farm. A sum-mary of the results of these expe-riments is presented below.

The data shown above indica-te that the use of organic acids re-duced around 25 g the broiler live weight losses during the feed wi-thdrawal period at the farm. It was followed by an additional re-duction of around 14 g in the wei-ght losses during transportation. Therefore, birds receiving the blend of organic acids showed a

reduction of 39 g in the total wei-ght losses compared to those birds that consumed pure water during the feed withdrawal period. That represents a 35.75% reduction in total weight losses in broilers that received the organic acids blend.

These good results could be explained by the fact that this blend of organic acids improves water palatability, and hence sti-mulates a higher water intake du-ring the feed withdrawal period. Due to the higher level of hydra-tion of the broilers, there is a ten-dency to lose less body weight, to decrease mortality during trans-portation, and to reduce carcass condemnations in the processing plant.

In conclusion, organic acids are proven to be excellent tools to use during the preharvest feed wi-thdrawal period. In order to ob-tain optimum results, the organic acids should be administered in enough concentration to have bactericidal effects; with the care for not depressing water intake.

*The full version of the article and its references can be found at www.vetanco.com.br

Loss of weight during

feed withdrawal at the farm (g)

Loss of weight during

transportation (g)

Totalweight loss (g)

*Totalweight loss (%)

Control 85.66 33.56 119.22 4.14

Organic Acids

60.55 19.65 80.20 2.66

*Total weight loss related to the bird´s weight at the beginning of the feed withdrawal



Twenty five years ago the only way to vaccinate broilers against Marek’s Disease (MD) was to

give day-of-hatch chicks a subcuta-neous injection by hand. It was labour--intensive, stressful for the chicks and delayed their transfer into the growing environment.

On average, one person can inject about 2,000 chicks per hour, so a hatchery producing 250,000 chicks per day needed a team of at least 12 peo-ple, and enough room for them to work in. The solution to this bottleneck in the system was the introduction of the first commercial in ovo vaccination device in 1992 by Embrex (now part of Pfizer Animal Health Global Poultry). This new technology not only revolu-tionised hatchery vaccination but also had a fundamental impact on the way hatcheries operate.

General automation The poultry industry was growing

and hatch per day figures were increa-sing, so vaccination crews were no longer a practical solution. Many peo-ple believe that it was the introduction of in ovo vaccination technology which led to the general automation of ha-tcheries and to many other changes, such as an improvement in hygiene and the use of early vaccination against other diseases.

The USA was the birthplace of in ovo technology and has remained its most enthusiastic supporter ever since. The technology fits perfectly with the business profile of large integrated companies which dominate the market

there. Over 90% of all US hatche-ries now use in ovo devices, and more than 15 billion eggs are vaccinated glo-bally every year.

The stimulus for the develop-ment of commer-cial in ovo vacci-nation devices came originally from research conducted by the USDA in the Avian Disease and Oncology Laboratory in East Lansing, Michigan. It showed that embryos could be vacci-nated and generate a protective immu-ne response against MD if they were injected just before hatch, between day 18 and 19. The finding triggered the Embrex company to develop an auto-mated device that could deliver a vacci-ne into the eggs, quickly, accurately and safely for the embryo.

Trigger immune response One of the key requirements of in

ovo vaccination is the ability to deliver the same amount of vaccine consisten-tly to the right site within the egg, every single time. The vaccine must go into the amniotic fluid or subcutaneou-sly into the embryo, if it is to trigger the best immune response. Vaccine delive-red into the amniotic fluid at day 18/19 is quickly distributed to the upper respiratory tract, gut and bursa – all key sites for the development of immunity against diseases.

World Poultry, Vol. 28, No. 3, 2012. 03 Apr 2012

In ovo vaccination has widely been accepted as an effective means of obtaining early immunity in day-old chicks. Particularly in the US the majority of professional large scale hatcheries have adopted this technology. Outside the US, in ovo is also finding its way into smaller sized hatcheries. Basic requirements in the hatchery are essential to let this technology be effective however.

In ovo technology driving hatchery modernisation

By Dr Tarsicio Villalobos , Director of Technical Support, Pfizer Animal Health Global Poultry, Durham, NC USA

Checking air intake filter and sampling are

necessary to examine whether hatcheries will

meet with the demands for in ovo technology


But how do you deliver a dose of vaccine to a tray with up to 165 eggs, in the correct site and all at the same time? Eggs are different shapes and sizes, so the injection locator needs to be able to adjust both laterally and vertically to ensure that the shell of each one is punctured in the correct site. Embrex solved the problem by designing a system of floating tooling heads with an expandable tubing matrix which, for a fraction of a se-cond, receives a burst of air to fix each individual tooling in the correct posi-tion and ensure the right needle trajec-tory on its egg. So each egg is taken care of individually.

Maternal antibodies Along with the benefits of a more

automated hatchery, the introduction of in ovo devices also heralded a more effective way of delivering vaccines to broilers. At 18/19 days, some but not all of the maternal antibodies in the yolk have been absorbed by the em-bryo; full maternally-derived immunity does not develop until few days post--hatch.

If a live vaccine is given to the embryo during this ‘window’, then the virus can replicate without too much interference from maternal antibodies and thus trigger a good immune res-ponse; at the same time the embryo has enough maternally-derived immu-nity to protect it from developing disease as a result of being vaccinated. The result is a chick which has the earliest possible immune response and thus protection against disease when it moves into the growing environment.

Along the East coast of the US, where a very virulent form of MD virus circulates, chicks are subject to a very early disease challenge. By injecting in ovo, the vaccine has been replicating for 2-3 days before hatch, so when the chicks move to the farm, they are able to cope better with the disease challen-ge than if they were vaccinated at day of hatch.

Comparable test results The same applies to Gumboro

vaccine, especially where variant Gum-boro virus is present, as it tends to infect chicks at a very early age. Howe-ver, although the potential benefits of earlier vaccination may be obvious on paper, they are not so easy to demons-trate in practice. It is actually quite difficult to show the benefits to an individual producer, because to do that you have to conduct a “pair type” study where all the possible sources of variation are equalised between the in ovo vaccinated and the conventional vaccinated groups.

Such a trial requires that eggs come from the same broiler breeders’ flocks, be stored in the same room for the same amount of time and incuba-ted in exactly identical ways – even down to the proportion of eggs allo-cated on different levels within the incubator. At the transfer time, eggs have to be separated into two diffe-rent hatchers to avoid mixing them up when the chicks hatch.

Birds then need to be raised in identical conditions, in two separated houses that share the same ventilation, feeder and drinking systems, with exactly the same initial stocking density. You need to make sure everything is identical, except the vaccination system, and not many producers are willing to do that.

Pfizer Animal Health Global Poultry has data from three such studies howe-ver, conducted in 1993, 2000 and 2005 (HTable 1H). They generally show im-provements in the percent of hatch, mortality, body weight and feed con-version with in ovo vaccination. As might be expected, the exact figures vary between the three different stu-dies. The feed conversion is between one and two points better with in ovo vaccination. In the US, a one point saving represents about $100,000 for a unit processing 50 million birds a year.

Key questions Although in ovo vaccination has

potential benefits for many hatcheries, it is not suitable for every facility. There are a number of key questions which hatchery managers need to answer in order to determine if in ovo is the right solution for them. Is an approved in ovo vaccine available to match the local disease challenge? Not all in ovo vacci-nes are available in all countries. Off-la-bel delivery of other vaccines could cause serious problems. In the US the number of in ovo vaccines available to producers has more than doubled,

Table 1. Performance parameters for in ovo vaccinated birds vs subcutaneous vaccinated birds in three separate, controlled trials. 1993P(1)

1993(1) 2000(2) 2005(3)

Difference in hatchability

+0.04% +0.88% -0.06%

Difference in mortality

0.00% +0.19% -0.21%

Difference in body weight

+09.10 g +50.00 g +16.00 g

Difference in feed conversion

-0.019 -0.020 +0.012

The egg room of a hatchery should not be

misused like for the storage of other materials


from four to nine, over the last 10 years or so and more are in the pipeline. As the use of in ovo devices increases in other markets, the number of vaccines is likely to follow suit.

How many eggs are processed each month and how many times a week are they transferred out? To justify the use of a full-size Embrex Inovoject, hatcheries need to be pro-cessing on average more than 2 million eggs/month. The recent addition of a smaller, semi-automated model to the Embrex product portfolio (model Ino-voject m), means that many hatcheries with smaller throughput (<2 million eggs/month) or less floor space can also now adopt in ovo technology. Hatcheries that require processing between 12,000 and 20,000 eggs per hour might consider the smaller machi-ne.

How many different flat configura-tions are used in the hatchery? Each Inovoject machine is tailor made speci-fically to work with a particular setter tray. A wide range of different configu-rations are available, but if the hatchery uses several different flats, it may not be able to vaccinate 100% of all birds in ovo.

Infrastructure suitable If these initial questions produce

positive answers, then the next step is to check that the hatchery infrastructu-re is suitable. To determine this, Pfizer Global Poultry conducts two surveys.

A site survey is conducted to make sure that the buildings, space distribu-

tion, storage facilities, utilities (water/electricity), ventilation, air compressor capability, etc are suitable for installing and operating an in ovo device. An environmental assessment is conduc-ted to check the level of contamina-tion. Samples are taken from around the hatchery and analysed for the prevalence of fungi and bacteria, but specially for Aspergillus molds. Because in ovo vaccination requires the egg shell to be punctured, hatchery hygiene is a prime consideration. The need for low contamination risk with in ovo has been a driving force behind the impro-ved hatchery hygiene that has been seen in US hatcheries in recent years.

Staff training The survey results determine what

work, if any, needs to be done before an in ovo device can be installed and operated successfully. Once all the installation criteria have been met, it is essential that staff are properly trained and onsite support provided.

Pfizer Global Poultry staff stay with the hatchery for the first two weeks, making sure the operators are fully trained and that the device is working properly and optimally. In addition, they leave a stock of common spare parts in the hatchery, so if something happens, parts can be replaced and the device can be working again with

minimal down time. Pfizer also opera-tes a rapid call-out support system, and makes regular, scheduled maintenance visits, at least once every nine weeks, to all of its devices in the field.

Making the most of in ovo Some advice for those hatchery

managers who already have an in ovo vaccination device in operation is use-ful.

At first, one needs to be sure that the vaccine preparation is aseptic. If vaccine is not well mixed and asepti-cally prepared, then you can jeopardise its efficacy and even potentially kill birds. Each Embrex Inovoject device incorporates a dual needle system to reduce contamination from the egg surface: the outer needle punches a hole in the egg shell and the inner needle penetrates in to the hole to the correct depth to deliver the vaccine. The system is automatically sanitised between injections by having a disin-fectant solution washed between the two needles.

Auto-sanitisation is critical to the success of the device because we know that every surface will have a certain amount of bacteria and fungi. Howe-ver, it is important to make sure the hatchery is clean and sources of conta-mination such as the ventilation system are addressed.

Future developments Initial adoption of in ovo vaccina-

tion was highest in those markets where MD is an issue and in those markets that have a more consolidated industry and higher labour costs. It accounts for over 90% of production in the US and the majority of produc-tion in Brazil and Argentina. The deve-lopment and launch of new in ovo vaccines, higher labour costs, and the need to adopt more efficient hatchery technology by an increasingly consoli-dated industry, means that in ovo vaccination is likely to expand into many other regions around the world.


With high-tech in ovo technology, vaccine is applied to hatching eggs in the final stage of incubation

In ovo vaccination takes place before egg transfer to the hatcher. The aim is to obtain day-old chicks with early immunity


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Agroceres Multimix Nutrição Animal envisions itself as leading the ma-rket in technical services and custo-mer satisfaction standards. Since its very beginning, almost 40 years ago, it is supporting farmers in the swine, poultry, beef and milk pro-duction with top level nutrition products and services.

Avestart is designed for easy picking of food for chicks. It is produced with unique micro-pellet technology developed and tested by Agroceres Multimix Nutrição Animal. Better weight gain and better overall performance were confirmed in both experimental and commercial farms of broilers fed Avestart.Avestart is a pre-starter feed with highly digestible ingredients for broiler chickens. Avestart was designed to meet the nutritional requirements of chicks during the first days of life, optimizing growth that reflect positively on performance results.

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AB Vista is an integrated international supplier of new generation micro-in-gredients for animal feeds, providing solutions for agribusiness. UK basis is supported by offices around the globe. ABV´s the feed ingredients division of AB Agri, which is the agricultural arm of Associated British Foods.

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Maximizing Pre-Starter NutritionIn poultry production, productivity is crucial for company’s longevity. Improving pre-starter nutrition becomes the key for optimizing productivity and profitability.In this phase, birds are developing their digestive anatomy and physiology. While formulating we must consider: nutritional requirements due to specific pedigrees, ingredients’ quality and its digestibility.After hatching, chicks prefer granulated feed instead of powder feed. Granulated feed has advantages when compared to powder feed: the shape avoids ingredients selection and improves digestive system.Therefore, investments in pre-starter diet bring better zootechnical and economic results.

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FloraMax-B11 is an all natural product that is known for establish a highly protective microflora in the gastrointestinal tract of poultry. FloraMax-B11 provides an alternative to antibiotics used to gro-wth promotion and a natural solution for maintai-ning healthier birds in addition to performance benefits. It is a probiotic developed by Arkansas University after years of research and contains 11 standardized strains of bacterias that promote a protective microbiota in the gastrointestinal tract of birds and proven action against pathogenic bacte-rias. FloraMax-B11 enhances zootechnical gains of poultry for commercial production purpose.

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Founded in 2008, Yes is a Brazilian company innovating in the market for animal nutrition additives, relying on the latest technology to develop its products and bring specialized solu-tions to its clients. It has a full line of additives for poultry, swine, cattle, pets, aquatics and horses.

One of the products from the additives line is YES MOS, a dietary supplement composed of a yeast and chelated mineral cell wall, with a total absen-ce of antibiotics. It has the power to agglutinate 90% of Salmonella and 100% of E. coli, inactiva-ting these bacteria. YES MOS also serves as a substrate for beneficial bacteria present in the intestinal environment, to the balance of intestinal microbiota, helping improve immunity, promoting better zootechnical indexes and reducing mortali-ty. Supplements for all animal species.The entire YES product line can be found at: www.yes.ind.br. SEE FOR YOURSELF!

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SmartPro™To support the use of Circadian Incuba-tion™, the incubator must deliver precise climate control. To achieve truly homoge-neous temperature distribution, the chal-lenge is to exchange energy, CO2/O2 and moisture – without affecting temperature uniformity around the eggs.To maximize temperature homogeneity for Circadian Incubation™, Pas Reform has developed SmartPro™, a new incubator design concept that combines modular design, a new Vortex™-based airflow principle and Adaptive Metabolic Feedback™.

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Pas Reform is an international com-pany, which has specialised in the development of innovative hatchery technologies for the poultry sector since 1919. The company has earned its position as one of the world’s leading hatchery equipment manu-facturers, through decades of resear-ch into the biological and physiologi-cal aspects of embryo development, combined with a thorough unders-tanding of all aspects of the poultry production chain – and a dedicated focus on the future.


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Phytate is compromising your feed performancePhytate anti-nutrient effects could be costing you $6 per tonne in lost performance.

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