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Commercial Egg Production and Processing
| By Pinoy Farmer | April 28, 2008 |  |
The poultry industry is vertically integrated, which means the industry has a tremendous amount of control of their products. It is distinctly different from many other animal industries. In that egg producers own and manage nearly every aspect of their business (e.g., rearing of birds, feeding, housing, husbandry, and marketing of their product) and are capable of meticulously monitoring the entire process. Poultry producers usually do not own the primary breeding stock (i.e., the parent lines supplying their operation), these birds are purchased from primary breeders.
Raising Layers (Leghorns)
The purpose of this section is to provide a general overview of a typical layer cycle in terms of chick placement, vaccination schedules, lighting, heating/cooling, feeding, molting, and removal of layers. Keep in mind, there are a number of ways to rear laying hens. It would be very unlikely that any two companies rear layers exactly the same way. However, all companies use a slight variation of the typical rearing program detailed in this section. Management differences for rearing layers may be accounted for by economics (breed selected, vaccination package and decision when to molt), producer preference (breed and strain selected), and/or geography (breed selected and vaccination package).
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Hatching and Placement
Egg producers purchase their layer stock (i.e., day old leghorn chick) from an egg-type hatchery. Hatcheries deliver chicks to the producer within one to two days of hatching. At arrival, chicks are either placed in typical layer pens or reared in a pullet house. At the hatchery, chicks are vaccinated according to the producer’s specifications. For details regarding a typical vaccination schedule see Table 1.
Lighting and Temperature
Lighting and temperature conditions for a typical layer production period are shown in Tables 2, and 3 respectively. For those chicks reared in layer cages, a biodegradable mat is generally placed in the pen. The mat allows chicks to better locate feed while also providing time for the chicks to slowly adjust to the wire mesh floor. Within a week, the biodegradable mat is removed or degrades into the litter pit. A single layer cage may occupy as many as fifty chicks, but as they mature, cage density is lessened. Chicks placed in pullet houses are reared on a floor covered with absorbent materials, such as pine shavings. During the first week, pullet chicks are usually beak trimmed. Pullets started on the floor remain there for approximately 10 to 15 weeks and then move to a layer facility. In either case, from chick placement through approximately 16 weeks of life, the pullets are fed according to body weight gain and/or age.
The goal is to raise a strong and healthy bird that can support egg production. As noted in Table 2, daily light exposure (photoperiod) begins to increase at Week 16. This increase in light exposure triggers hens to begin laying eggs. If the laying hen has not reached proper body weight (usually 3 lbs.) by Week 18, egg production will cease very quickly, following the onset of the laying period. Hence, it is important for the young laying hen (pullet) to attain the proper body weight that will support egg production. In tandem with light manipulation, the diet is also altered in order to support egg production.
Feeding
It is assumed that layers, unlike birds raised specifically for meat, regulate their feed intake. Layers are generally reared on full feed (ad libitum). The feed is offered to birds via the chain system. The chain system transports feed into the metal feeder at precise times during the day. In general, 2 inches of feeder space is allotted per pullet and 2.5 inches or more for each adult laying hen (Animal Care Series, California Poultry Workshop, 1998). Table 4 illustrates the dietary protein and energy recommendations based on age in of typical layer. Young birds are fed a high protein diet (20 percent) during the first few weeks of life. This level continuously decreases until it reaches approximately 12 to 15 percent protein during egg production. In addition to monitoring dietary protein, producers must closely examine other ingredients. During the laying phase, lysine, methionine, calcium, and phosphorus are precisely monitored to support maximum egg production.
Egg Production
As shown in Table 2 and Table 4, producers begin to photostimulate and manipulate the diet around 18 weeks of age in order to support egg production. Minor nutrients have also been manipulated such that calcium levels in the diet are approximately five to seven times greater than phosphorus levels. When a flock (group of hens) first enters egg production, the rate of egg lay will be around 10 to 20 percent. This means that 10 to 20 percent of the hens are laying eggs at 18 to 22 weeks of age. The flock quickly reaches peak egg production (90 plus percent) around 30 to 32 weeks of age. Post-peak egg production (after 30 to 32 weeks of age) continually decreases to approximately fifty percent around 60 to 70 weeks of age. At this point an economic decision must be made by the producer; fifty percent production is near the “break-even” point for egg producers (e.g., feed cost = market price of eggs). When the flock reaches 50 percent production, producers commonly decide to molt the flock in order to achieve a higher level of egg production.
As a rule of thumb, it takes approximately 10 weeks from the beginning of a molting program to be back at 50 percent production following the molt. Post-molt egg production will increase such that peak egg production reaches about 80 percent. Peak production following a molt is short-lived and the flock generally returns to 50 percent production by 100 to 110 weeks of age. Many producers (one-third to one-half) will induce a second molt, this is the same process that occurred at 60 to 70 weeks of age. The second molt is commonly dictated by the current egg prices and the availability of replacement pullets. As previously stated, once flock egg production falls below fifty percent, an economic decision is made whether to molt the birds or the hens to a spent-hen processing facility. The majority of hens are between 100 and 130 weeks of age when they reach the end of their egg production cycle. The time span between 100 and 130 weeks of age can be accounted for by management decisions. Thus hens may be molted a second time and then sent to a spent hen facility (120 to 130 weeks of age) or sent directly to a spent hen facility following the first molt (100 to 110 weeks of age). After the flock vacates the layer house, the house is stripped of all organic matter and sanitized before another flock enters the house.
Egg Collection
In layer facilities, there are two primary methods of egg collection, a) in-line facilities, and b) off-line facilities. In either case, hens lay eggs onto an angled wire floor which rolls the egg toward the front of the cage (floor angle is generally eight to ten degrees) onto a nylon belt. The belt transports eggs out of the house either to the egg processing facility or to a storage cooler. Since the processing facility and cooler remove eggs from the house, based on hourly demand, eggs may reside on the belt for as long as 12 to 14 hours, but most are collected within a few hours post-lay.
The first type of layer facility is the in-line facility. In this facility, eggs move directly from the layer house to the egg processing facility. Once the eggs enter the egg processing center, within minutes to 12 to 14 hours post-lay, they are washed (detergent solution near 100°F, pH 11.0 that removes soil), visual inspected (checked for eggshell problems, cracks, and blood spots), and then graded for packaging. Following packaging, eggs are moved to a cooler room (40-45°F), where they await shipment to retail outlets. Egg producers commonly deliver eggs to retail outlets within one week of lay.
The second type of layer facility is the off-line facility. This facility functions nearly identical to the in-line facility except that the eggs are transported out of the house directly to an egg cooling room. In this method, the eggs remain in the cool room for approximately two to three days, and then they are transported to an egg processing facility via a refrigerated truck. These eggs are treated identically as those from the in-line operations.
Table 1. A typical vaccination schedule for leghorns
| Week of Vaccination | Type of Vaccination |
| Day old | Marek’s |
| 15 days (1/2 dose) | Infectious Bursal |
| 20 days (1/2 dose) | Infectious Bursal |
| 25 days | Bronchitis, New Castle, Infectious Bursal (Typical Brand name Combo Vec. 30) |
| 30 days | Bronchitis, New Castle, Infectious Bursal (Typical Brand name Combo Vec. 30) |
| 49 days | Bronchitis, New Castle, Infectious Bursal (Typical Brand name Combo Vec. 30) |
| 10 Weeks | Fowl Pox and Laryngotracheitis (commonly referred to as LT) |
| 12 Week | Combo Vac 30 |
| 13 Week | Avian Encephalomyelitis (commonly referred to as AE) |
| 16 Week | New Castle |
Table 2. Lighting program for the leghorn.
| Age | Amount of Light (L) and Dark (D) |
| 0 to 3 Days | 22(L):2(D) |
| 3 days to 1 Week | 20(L):4(D) |
| 1 to 2 Week | 18(L):6(D) |
| 2 to 3 Week | 16(L):8(D) |
| 3 to 8 Week | 14.5(L):9.5(D) |
| 9 Week | 14(L):10(D) |
| 10 Week | 13.75(L):10.25(D) |
| 11 Week | 13.50(L):10.50(D) |
| 12 Week | 13.25(L):10.75(D) |
| 13 Week | 13.0(L):11.0(D) |
| 14 Week | 12.75(L):11.25(D) |
| 15 – 17 Week | 12.5(L):11.50(D) |
| 18 Week | 13.50(L):10.50(D) |
| 19 Week | 14.5(L):9.5(D) |
| 20 Week | 15(L):9(D) |
| 21 Week | 15.5(L):8.5(D) |
| 22 Week | 15.75(L):8.25(D) |
| 23 Week | 16(L):8(D) |
| 24 Week | 16.25(L):7.75(D) |
| 25 Week throughout production cycle | 16.5(L):7.5(D) |
Table 3. Temperature control during a layer cycle
| Week | Temperature (F) |
| 1 | 90 |
| 2 | 85 |
| 3 | 80 |
| 4 | 75 |
| 5 | 70 |
| 6 throughout layer cycle | 70 |
Table 4. General Feeding Guidelines for Layers.
| Nutrient | Starter | Grower | Developer | Pre-Layer | Layer |
| Protein % | 20.0 | 18.0 | 16.0 | 14.5 | 15.0 |
| Met. Energy, Kcal./lb. | 1325-1375 | 1350-1400 | 1375-1425 | 1350-1400 | 1300-1450 |
source: http://www.ag.ansc.purdue.edu
Topics: Poultry | 35 Comments »
July 27th, 2008 at 1:27 pm
where can i buy cages for leghorn here in the philippines? thanks
December 11th, 2008 at 2:13 pm
what is a good place wherein you can put up this kind of business (actually which is allowed by the government).
April 30th, 2009 at 1:09 pm
Will you please send me a copy of feeding schedule for egg layers for 16 weeks old and above likewisa for lighting program please, ASAP
April 30th, 2009 at 1:10 pm
Please provide me thru email a Feeding Schedule for Egg Layers with 16 weeks old age and a Lighting Program for the same age, ASAP
May 7th, 2009 at 10:39 am
where in binangonan rizal or near do i find egg producer?
September 26th, 2009 at 3:13 pm
hi, do you have chicks/layer type for sale? i,m from cavite and planning to put up this kind of business soon. please email me asap thanks
September 26th, 2009 at 3:14 pm
please include some guidelines on how to care and how to produce more eggs or a short of training guidelines thanks
September 26th, 2009 at 3:16 pm
my cp number 09182717918 and landline 0468713612, hoope to hear from you soon, ty
September 30th, 2009 at 2:40 pm
please email me the list of chicken egg producers in davao city/region, surigao city and butuan city/agusan del norte. I also need info about suppliers of itlog na pula also in butuan city/agusan region, surigao city, and davao city.
thanks a lot
November 17th, 2009 at 9:05 pm
Pls give me advise what will be my first steep, im planning to start this kind of business?
January 30th, 2010 at 10:37 am
Gud Day..I’m planning to put up commercial egg production business.where and to whom i could buy these leg horn breed. Probably in La Union or Isabela. Please give me information.
March 2nd, 2010 at 10:23 am
I want to put up an egg shop here in Davao City..Do you know who can supply eggs?Please contact me @ 09187306451
May 16th, 2010 at 11:57 pm
I am planning to raise 250 layers commercial egg production. I want information on the how many cages I would need and details of what type and size house I need. I would require a cost for the feeding apparatus for water and stock feed.
The location is in the highlands of Papua New Guinea
Please advice me.
Regards
Paul Berry
July 9th, 2010 at 12:07 pm
I want to have an egg business. i want to buy egg direct from the egg producer. call me at 09279639316
September 5th, 2010 at 12:10 pm
i have 2750 layer in my farm. im worried they are dying with liver problem. and reduce egg production 10%. i dont know what to do.
September 8th, 2010 at 3:35 am
i want to know where can i buy day old chicks,im in tandag surigao del sur,500 chicks per week,thanks
September 10th, 2010 at 4:48 am
Hi..
Kindly give me some information where I can buy white leghorn pullets or chicks for commercial egg production in Pangasinan and Tarlac area. Thanks.
Jose
September 17th, 2010 at 9:23 am
hi!i want to know where i can buy leghorns for egg production.Im from Isabela.
September 28th, 2010 at 2:57 pm
i want to put up a egg shop here in davao city where can i buy @ wholesale price?
October 13th, 2010 at 5:32 pm
HELLO,
I want to have an egg business for siargao. i want to buy egg direct from the egg producer. call me at 092095933397
Thanks
October 21st, 2010 at 5:20 pm
i would like to request if you have a list of hatching eggs producers in the philippines. especiall ross 308 or lohman breeds.
October 23rd, 2010 at 10:26 pm
Can I ask for the feeds formula for egg laying business. I am interested to put up an egg laying business.
November 20th, 2010 at 6:42 pm
i would like to ask where can i buy this leg horn in bicol. i am planning put my own egg laying business also.
December 21st, 2010 at 11:52 am
Im from bicol and I would like to ask where can I find leg horns in bicol. I would like to put layer business in sorsogon. thanks.
January 9th, 2011 at 6:27 pm
kindly give me some info. where i can buy white leghorn for commercial egg production buss..im from bataan.thanks
January 14th, 2011 at 2:15 pm
greetings, were can i buy leghorns, i want to try egg production business, tnx
February 13th, 2011 at 10:26 pm
Where can i buy an egg incubator?
April 27th, 2011 at 1:48 pm
where can i buy cheap second hand layer cages?? thanks
May 3rd, 2011 at 3:00 pm
hi.. i am planning to sell chicken eggs, quail eggs and salted eggs here in pangasinan. I am looking for a supplier, the nearest supplier in my place the better. Hope you can help me with this. Thanks!!
May 12th, 2011 at 8:38 pm
Sir,madam,
where can buy metal cages for layer chicken, and white leghorn pullets.
May 12th, 2011 at 8:42 pm
sir, madam,
kindly provide me detail where can i buy white leghorn pullet and their metal cages.
May 13th, 2011 at 7:43 pm
hi! i want to know where i can buy plastic laying cages for leghorn en how much? im from Ozamis City.
August 11th, 2011 at 4:36 pm
hi good day! i would like to try in my backyard raising leghorn just a small quantity as a self project. i would like to ask if you can give me supplier of layer cage and where i can buy ready laying leghorns? i hope you can help me on this.
thanks
August 28th, 2011 at 5:54 pm
where can buy metal cages for layer chicken, and white leghorn in or. mindoro? need your reply assap.Thanks
August 28th, 2011 at 6:02 pm
where can i buy metal cages for chicken layers, and white leghorn layers ? need your reply asap.Thanks