Egg Production Facility

1. Egg Production Facility Clay Crane

2. Why Egg Production? • Kansas is an agriculture state, we’ve covered the flour production • Great economic impact on the community • Actually been through a facility • Surprising how highly atomized the industry has become • Czech quality…..disturbing?

3. Prior to WWII most egg producing facilities were ‘free run’ with flock sizes less than 400 hens. Now the birds are kept in cages which has allowed for more atomization and larger flock sizes. Some facilities now can house as many as 2.5 million hens. Genetics play a very large role now as hens can be designed to be layers with little meat and a high resistance to disease. Changing Industry

4. Pullets (chicks) • Kept in separate houses from the layers • Extremely tight bio-security to prevent disease contamination • Very rigid with vaccinations • Manipulating the amount of light received allows the maturing of the bird’s frame, however delays sexual maturity • After 17 weeks they are moved to the laying houses, 18th week the pullets become layers

5. Layers • Diet changes- more calcium to promote sexual maturity and ensure good shell quality • NO hormones are used in the U.S. • Start increasing light 15 minutes/day (17hrs max) • Tricks them into thinking it’s spring time • Start laying eggs after 20-30 weeks • Overall a facility will have about 80-90% productivity across the board • Most facilities do molt to keep costs down, but I don’t have details on that….. • After 110 weeks the hens are sold for processing

6. In the Laying House • Everything is computer controlled from a ‘command center’ • Light, temperature, humidity, air circulation, belt speeds, feed augers • Several back up generators to ensure the fans and the motors don’t stop • There appear to be endless columns of chickens as far as the eye can see

7. There’s 6 hens/cage Water and food are easily available The cage floor has a 10 deg. slant The small conveyers flow to a main conveyer that runs perpendicular to all houses

10. Egg Preparation • 1. Pre-wash • Loosens any materials on the egg • 2. Two washers spraying hot water at high pressure while brushes go over eggs • 3. Eggs dried under blowers • 4. Mineral oil applied • Must be done because the washing removes the natural cuticle that prevents bacteria from entering the egg

11. Egg Processing cont’d • 5. Dirt detector • A set of cameras calibrated to a certain shade of color (white) • Anything else and the egg is redirected on a conveyer back to the washers • 6. Crack detector • Sonar devise measuring sound vibrations • Cracks give off a funny vibration • If cracked, the eggs go to a “breaking plant” where they will be pasteurized and dried and sold as ingredients to bakeries and such

12. Egg Processing cont’d • 7. Weighing • The moment the egg is weighed, the machine knows exactly where the egg is and what packer it should go to • 8. Packers • 12 packers in total, most of which are for large eggs • The machine drops the proper egg into the proper packer • Then placed in carton, date stamped and packed into boxes

14. Efficiency • Have their own mill to make proper mix • Wastes and recycled • Sold to farmers as fertilizer

15. Sources www.aeb.org/eii/production.html http:ag.ansc.prudue.edu/poultry/publication/commegg/inex.htm Ryan A. Meunier and Dr. Mickey A. Latour Todd Walters, Complex manager, Cal-Maine Foods, INC.