CAB invests in modular single-stage incubators from Pas Reform
(originally published in Asian Poultry, July 2008)

Malaysia's CAB has a long and successful history, starting with its first poultry farming activities in Penang, Malaysia way back in the 1970's. The company has grown to become one of the largest food producers in Malaysia, providing poultry, marine and frozen food products around the globe. Having monitored the development of single-stage incubation technologies for several years, CAB has elected to install its new PS broiler hatchery project in Penang, with modular single-stage Smart Incubators from Pas Reform.

Significant savings with GP farm

Cab Cakaran’s new grandparent (GP) farm is set on 11.000 acres and is being developed in three phases. It is set in the middle of a rubber plantation and when completed, will have 10 houses, each set 1 km. apart, with room to accommodate another five houses if required. Established as a joint venture company of CAB Cakaran Sdn Bhd (CAB) and the Kedah State Economic Development Corporation (SEDC), it is expected to produce 1.1 million PS chicks a year when the third phase is completed by 2013.

CAB founder and CEO, Mr. Chuah Ah Bee, said the company invested MYR 11 million to develop the first phase, which was expected to produce its parent stock chicks of  450.000 by June. Currently there are three closed houses, each with a capacity to hold 7.400 chickens. The first package of GP chicks arrived in Malaysia from the U.S. in November and the eggs were set to hatch in May.

Christopher Chuah, Director said the GP farm project was part of the company’s expansion plans but not due to take off for some time. 'We initially wanted to expand our downstream processing operations but decided to put that on hold and establish this instead', he says. 'The first house was completed in just 80 days. Our initial production, at least for the first three months will be for our own breeding farms. After that, we may be able to supply to other local breeder companies'. CAB sees a lot of benefit in establishing the farm, apart from the 20% cost saving.'The bird flu has resulted in an import embargo on PS chicks from many countries and the PS that we have been getting locally has often not met with our expectation', explains Bukit Perak GPS Farm managing Director, Vic Loo.
'With this farm in production now we bring in chicks of a single age. They are kept for 65 weeks to produce eggs. This way, we are assured of good quality and there will be no lapses in supply', he adds.

Modular single-stage incubation

The hatchery is within an industrial area in Kedah,  30 km away from the farm. It has been equipped with Pas Reform modular single stage hatchers. Eggs are collected and batched accordingly. They are then transported daily in cold trucks and stored in a temperature controlled room to await placement in the incubators. CAB Cakaran selected Pas Reform's Smart incubation system for a number of reasons - most notably chick uniformity and bio-security. Pas Reform's SmartSet™ setter has been engineered specifically to enhance uniformity. The setter is divided into small, separate units, each with its own climate control system for up to 19,200 eggs. This provides uniform incubation conditions, which encourages equal, synchronized embryonic development for each individual egg in the machine: a factor proven critical to achieving a narrow spread of hatch.

'Reducing the spread in hatching time, and consequently in the duration to first feed and water intake, promotes excellent uniformity in the day olds, which simplifies farm management and improves performance and results', explains Mr. Chuah Ah Bee. And a short spread of hatch has an additional benefit: because they are of higher quality and in better condition, vent sexing of day-old-chicks becomes easier and thus cheaper.

Eggs from the GP breeder farm are collected and transported in cold trucks to the PS hatchery, where they are set and hatched in modular single-stage incubators from Pas Reform

Bio-security

Pas Reform has also met CAB's rigorous bio-security protocols, with cabinets constructed of high quality, smooth-walled 'food safe' anodized aluminium, stainless steel and polystyrene. Smart's robust, highly durable cabinets are resistant to strong disinfectants and corrosion. The absence of closed air ducts improves hygiene and sanitation, as does the incorporation of the cooling circuits into the walls of the hatchers, which also greatly reduces cleaning time.

With its setting in the middle of a rubber plantation, the farm is far from the main road and isolated from human habitat. Still, precautions have been taken to ensure good biosecrurity. All persons entering the farm have to pass through the three stage shower rooms that have only one entry and one exit point. 'Once you go in, you cannot turn back. As soon as the door is shut, the shower comes on automatically', explains Mr. Loo. 'In the same way, all vehicles entering the premises have to go through the disinfectant spray. Our workers stay on the farm and we send food to them three times a day. This is passed through a UV light before it is passed to them', he says. Each house is managed by three workers and two supervisors monitor 5 houses. The hatchery is staffed by a manager, three other workers and cleaners. All in, the project is managed by less than 30 people.

Hatchery management training

'CAB has also commissioned onsite hatchery training, to fully familiarize personnel with the process of single stage incubation', says Dr. Tan Ee Seng, Pas Reform's Sales Director in Asia. 'Because we never underestimate the importance of people to the success of any hatchery operation, we have provided a tailor-made training programme for CAB's hatchery professionals'.