Spent leghorn Hens Converted Into a Feedstuff1

01996 Applied Poultry Science, Inc.

SPENTLEGHORN HENSCONVERTED INTO A FEEDSTUFF' J. J. LYONS2 and J. M. VANDEPOPULIERE Depament of Animal Sciences, University of Missouri, Columbia, MO 65211 Phone: (573) 882-6754 FAX: (573)882-6827

PXmaFAudience: Egg Producers, Nutritionists, Renderers

disposal of these birds through composting DESCRIPTION OF PROBLEM or burying. The USA commercial Leghorn industry maintains approximately 240,000,000 hens in production. Considering the length of the laying cycle, molting programs, and down time between flocks, some 144,OoO,O00 hens are available for processing yearly. Historically, the majority of the hens have been utilized in pot pies and soup. The industry has been faced with processing hens that have been selected for smaller body size. They also have a problem with brittle bones during processing. Due to the smaller body size and bone problem, there has been a shift away from the use of spent hens and toward the use of broiler and roaster type buds to provide meat and soup stock. This change has left some egg producers without a spent hen market, necessitating the

The utilization of the spent hen as a feedstuff could provide a positive economic return as well as eliminate a potential disposal problem. Previous work reported by Haque et al. [l] demonstrated that extrusion processing of complete diets containing freshly ground whole hens produced nutritionally adequate broiler diets. This study evaluated the effect of heating or dehydrating ground spent hens in a fluidized bed oven in combination with steeping in an insulated chamber or extruding to produce feedstuffs.

MATERIALS AND METHODS Several types of spent hen ingredients were developed using different processing techniques for nutritional evaluation. The processes involve four separate pieces of

1 Contributionfrom the Missouri AgriculturalExperiment StationJournal Series Number 12,294.

The use of trade names in this publication implies neither endorsement by the Missouri Agricultural Experiment Station of the equipment mentioned nor criticism of similar equipment not mentioned. 2 To whom correspondence should be addressed

Research Report LYONS and VANDEPOPULIERE equipment. The Pellet Pro@[2] used a screw conveyer to apply pressure to the moist mass, forcing it through a 1/4" screen which produced a spaghetti-like material. The formed spaghetti-like material was then elevated into a second unit, a Jet-Pro@ [3] heater-dehydrator. This gas-fired unit provided hot air delivered through a perforated metal floor with sufficient force to create a fluid action to enhance product dehydration. The third phase, steeping, captured the hot dehydrated product in an insulated drum and stored it in a hot state for 30 min. Extrusion, the fourth step, was a process employing high pressure and high temperature generated using a Triple F [4] friction screw. The moisture level of the ingredient delivered to the extruder was approximately 25%. Following extrusion, the product was allowed to air dry for 72 hr. Wheat middlings were added to the ground hen at a 1:l ratio, dry matter basis, to improve handling and dehydration characteristics. Ingredients were prepared using spent hens removed from their cages and held in coops for approximately 24 hr prior to killing by cervical dislocation. The hens were ground through a 6" grinder [5] equipped with a 1/4" hole orifice plate. The ground spent hen material was processed through a Pellet Pro@ or mixed with wheat middlings and then formed through a Pellet [email protected] spaghetti-like material, was conveyed into the Jet-Pro@unit, heated with 360°F air, and dried to 90-95% DM except for the product scheduled for extrusion, which was dried to 75% DM. In order to study the effect of continued heat treatment on the microbiological population, some products were held in an insulated steeping drum at 230°F for 30 min. Four feedstuffs resulted from these procedures: 1. SH = Spent ground and formed in a Pe&t Pro , heated and dried in a Jet-Pro , and steeped. 2. SH-WM = Spent hens ground with wheat middlings at a 1:l ratio on a dry matter basis and treated as in #1 above. 3. SH-WM-NS = SH-WM without being steeped. 4. SH-WM-E = SH-WM partially dried, extruded, and air dried, but not steeped.

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19 The finished spent hen ingredients were treated with 2 lb. Santoquin per ton, ground through a 1/4" hammer mill screen, and stored in a freezer until used in preparing experimental diets. Researchers took samples of each ingredient aseptically at the time of production and submitted them to the University of Missouri Veterinary Medical Diagnostic Laboratory [6] for Salmonella assay and ConAgra Frozen Foods Laboratory [7l for aerobic plate, coliform, yeast, and mold assays. Samples were also submitted to the University of Missouri Experiment Station Chemical Laboratories [8] for proximate and amino acid analyses and pepsin digestibility. The corn, soybean meal, and wheat middlings used in these studies were analyzed for protein and amino acids [8]. The chicken broiler starter diets (Table 1) were formulated using the Brill program [9] and the 1994 Nutrient Requirements of Poultry edition [lo] with ingredient values adjusted using assay values obtained for the specific ingredient supplies used in this study. In Experiment 1,three of the experimentalspent hen ingredients were formulated at three levels to provide effective spent hen levels of 3, 6, and 9%. In Experiment 2, diets provided spent hen levels of 2,4,6, and 8% using estimated spent hen MEn values of 4100 and 5800 kcal/kg. Day-old male chicken broilers (Ross x Hubbard-High Yield) were obtained from a local hatchery. The broilers were weighed and distributed on a weight basis, equalizing the weight in each cage. Ten broilers were placed in each cage and four pens were placed on each diet using a randomized complete block design. Feed and water were supplied ad libitum. The broilers and residual feed were weighed on day 21. The data were subjected to statistical analysis [ l l ] usingSAS@software [12]. Means were compared using the least significant difference [13] when si@icant (P < 0.05) F values were found based on experiment-wide analysis of variance.

RESULTS AND DISCUSSION The microbiological results of samples produced by different processing procedures appear in Table 2. The ground raw hen was

JAPR SPENT LEGHORN HEN FEEDSTUFF

20

TABLE 1. Composition of broiler diets using processed spent hens (Experiment 1)

*S ent hens processed through a Weiler and Co.,Whitewater, WI 53190 Model 6 grinder equipped with a 1/4"hole

oriice plate. *Processed using the Jet-Pro procedure, Atchison, KS 66002 using an inlet air temperature of 360°F w t h an exit product temperature of 190°F. %he dried product was steeped in an insulated chamber at 230°F for 30 min. DMixedto provide an approximate 1:l ratio of ground whole hen and wheat middlings on a dry matter basis. %he blend was dried to ap roximately 25% moisture usin the Jet-Pro procedure and then extruded through a Triple F extruder (Insra-Pro fnlernational, Des Moines, LA f03.22) and spread on cardboard to air dry for 72 hr.

FSup lied 0 45% sodium chloride and the following per kg of diet: Mn, 154 m Zn, 154 m , Fe, 143 mg; Cu, 8.8 m I, 1.A mg; 'Se, 0.11 m t (manufactured,by Poult7 Co.,, El Dorack, AR 71750); vitamin A, 9680 cholecalciferol, 4,235 I U vltamin E, 15 1IU,wtamin B12, 1 I( nboflawn, 7 3 mg; niacin, 60.5 mg; D-pantothenic biotin, 0.24 mg (manufactured acid: 18.2 m ; menadione, 1.8mg; folic acid, 1.5 mg; yridoxine, 2 k m ,thiamineil.2 bv Roche dtarnins and Fine Chemicals Division, &offman-La Roclfe, Inc., Nutlev. J 07110).

FI+~

positive for Salmonella, aerobic plate colonies, coliform, yeast, and mold. All heat treatments produced Salmonella-negative results. The spent hens that were dried and steeped exhibited a marked reduction in aerobic plate colonies, coliform, yeast, and mold. When the spent hen-wheat middling mix was only heated and dried, it had a relatively high aerobic plate colony and yeast count. However, steeping the heated product markedly reduced these values. Extrusion of the spent hen and wheat middling product was the most effective treatment in reducing the aerobic plate colonies. The extrusion data is consistent with the findings of Tadtiyanant et al. [14]. The chemical composition of ingredients used in these studies are detailed in Table 3. The SH is high in protein, ether extract, and ash. The amino acid profde of the spent hen ingredients allows for the substitution of soybean meal, corn, and fat at the levels tested

16

without the need for elevated levels of amino acid supplementation above the control diet (Table 1).The calcium and phosphorus of the test ingredientsreplaced a portion of the limestone and dicalcium phosphate. The dietary levels of the spent hen ingredients listed in Table 1 range from 3 to 18% (Experiment 1). When the wheat middlings used to improve processing were subtracted, the effective SH level were approximately 3, 6, and 9% within each processing technique. Body weight was significantly better than the control on the 6 and 12% levels of SH-Wh4 (Table 4). The extruded product (SH-WM-E) supported performance similar to the control; however, the two higher SH levels were significantly better than the control. Feed consumption was similar on all diets producing no significant differences. All of the diets except SH-WM-E-12% and SH-3% had significantly better feed conversion when compared to the control.

Research Report 21

LYONS and VANDEPOPULIERE

COLIFORM^

SALMONELLA* AEROBIC pqm COLOrnES

YEASJ?

MOLD^

Per g Raw, ground C

Posit iveD

82,000

70

200

140

SHCEF

Negative

3500

< 10

< 10

< 10

SH-WM-NS~~

Negative

9100

30

180

20

SH-WMCEF

Negative

1900

< 10

< 10

< 10

Negative

20

< 10

< 10

< 10

[ I

I

SH-WM-E~~

1

'Spent hen processed through a Weiler and Co., Whitewater, WI 53190 Model 6 grinder equipped with a 1/4" hole onfice plate. DSalmonella serogroup B 9rocessed usin the Jet Pro procedure, Atchison, KS 66002 with an inlet air temperature of 360°F and exit product temperature of ~ ~ O O F . FThedried product was steeped in an insulated chamber at 230°F for 30 min.

GMMiuedto provide an approximate 1:l ratio of ground whole hen and wheat middlings on a dry matter basis.

%he blend was dried to ap roximately 25% moisture usin the Jet-Pro procedure and then extruded through a rriple F extruder (Insta-Pro fnternational, Des Moines, IA pb322) and spread on cardboard to air dry for 72 hr.

Based on the feed conversion data in Experiment 1, the estimated energy level of 4100 k d k g MEn may be too low. Calculating to equalize feed conversion values, researchers obtained an estimated MEn value of 5800 kcalkg and used it to compute one set of diets in Table 5 (Experiment 2). Body weights at 21 days were comparable on all diets in Experiment 2 (Table 6). As in Experiment 1, the diets containing the higher SH levels and using a value of 4100 kcaVkg MEn in formulating the diets improved feed conversion over that of the control. When the higher MEn value of 5800 kcaVkg was used, feed conver-

I

sion was comparable to the control; however, at the 4 4 % levels, it was signifcantly poorer than comparable diets calculated using a value of 4100 kcal/kg. This study supports the use of a ME, value between 4100 and 5800 kcaVkg for SH. There were no si&icant leg problems or mortality rates. The processing cost is difficult to determine using experimental pilot production units. In general, the capital cost and operating expense of a dehydrating-steepingunit would be less than that of a dehydrating-extrusion unit.

JUR SPENT LEGHORN HEN FEEDSTUFF

22

TABLE 3. ComDosition of ingredients used in formulating broiler starter dietsA ~

~

SPENT HEN INGREDIENTS~

CORN

SBM48%

WHEAT MIDDS

89.00

90.00

88.00

94.70

91.80

96.00

Protein, %

8.07

50.44

14.66

29.57

2858

41.28

Ether extract, %

3.80D

22.36

22.06

S H - W M ~ SH-WM-E~ Dry matter, %

3350D

MIL, kcalkg Ash. %

4.60D

LOOD

2mD

244OD

3130E

S H ~

39.53

3130E

4100E

-

-

-

8.86

8.90

14.67

ca,%

0.10

0.33

0.10

1.15

1.18

2.38

Phosphorous (total), %

0.33

0.73

0.90

1.04

1.06

1.30

Phosphorous (non-phytate), %

0.11

0.27

0.30

Pepsin digestibility, Yo

-

-

-

0.77

0.77

82

1.30

82

84

Taurine

1

0.14

I

0.06

I

0.12

I

0.20

I

0.20

I

0.14

Valine

I

0.41

I

2.60

I

0.76

I

1.54

I

1.46

I

2.22

Methionine

I

0.19

1

0.77

I

0.26

1

0.57

I

0.54

I

0.73

I

3.06

Isoleucine

0.28

Leucine

0.85

Tvrosine Phenvlalanine

Hyd roxylysine

I I

0.25 0.37 0.00

2.42

I I I

3.98

1.84 2.60 0.02

0.52

I I I

1.00 0.40 0.63 0.00

1.20

I 1 I

2.21 0.83 1.24

0.07

I

I

1 I

1.14 2.06 0.79 1.15 0.04

1.74

I I

1.20 1.68 0.08

Histidine

0.24

1.37

0.42

0.74

0.71

0.94

Ornithine

0.01

0.03

0.01

0.02

0.02

0.03

Lvsine

0.32

3.23

0.65

1.62

1.55

2.17

Arginine

0.45

3.74

1.03

2.12

1.83

2.72

Tryptophan

0.06

0.63

0.18

0.26

0.26

0.34

Research Report LYONS and VANDEPOPULIERE

23

WEIGHT

DIE?

FEED CONSUMFITON

FEED CONVERSION 1

I Control

I I I I I I I I I I I

ISH-WM. 6%

I SH-WM. 12% ISH-WM. 18% ISH-WM-E. 6% ISH-WM-E. 12% ISH-WM-E. 18% ISH. 3% ISH. 6% ISH. 9% IPooled SEMc

I I

1036 1060

I I

1.30a

85sa

USa

I

1056

I

1.23d

822abcd

1033

12

I

18

I I I I I I I I

1.26bcd

SOab

I I I I I I I

79Sd

814cd 831abcd 82Ybcd 816bcd 843abc

1023 1061 1042 1041 1050 1046

I I

12Icd

I I I I I I

1.26bcd 1.2gab 1.261.27abc 1.23d

I I

0.01

I

1.2Sbcd

*Diets fed from day 1to day 21. BSeeTable 1for diets. 'Standard error of the mean a 4

Means within a column with no common superscripts differ significantly (P10.05).

TABLE 5. Comoosition of broiler diets usina Drocessed went hens (ExDeriment 21 INGREDIENT

Corn,ground SBM (48% CP) SH4'

SHB3' Animal fat DL-methionine Limestone Dicalcium phosphate

157

1.46

1.35

1.24

1.14

1.45

1.34

1.23

1.12

Constant ingredien tsD

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

*ME,,of 1400 kcakg was used in the dietary calculations. of 5800 kcalkgwas used in the dietary calculations. 'Spent hens processed through a Weiler and Co.,Whitewater, WI 53190 Model 6 grinder equipped with a 1/4" hole onfice plate and processed using the Jet-Pro rocedure, Atchison, KS 66002 using an inlet air temperature of 360"Fwth an exit product temperature of 190"PPThe dried product was steeped in an insulated chamber at 230°F for 30 min. DSup lied 0.45% sodium chloride and the following per kg of diet: Mn, 154 mg; Zn, 154 mg; Fe, 143 mg; Cu, 8.8 m 6 I, 1.64 m g Se, 0.11 m Manufactured by ConAgra Poult Co., El Dorado, AR 71730). Vitamin A, 9680 1 cholecalciferol, 4,235 I&; vitamin E, 15.1 IU; vitamin BIZ,z p g ; riboflavin, 7.3 mg; niacin, 60.5 mg; D-pantothenic doxine, 2.4 m ,thiamine, 1.2 m ;biotin, 0.24 mg(Manufactured acid, 18.2m ;menadione, 1.8m ;folicacid, 1.5mg; 07110. bv Roche dtamins and Fine Caemicals Division, E f m a n - L a Rocie. Inc., Nutlev.

6

JAPR SPENT LEGHORN HEN FEEDSTUFF

24

TABLE 6. Broiler erformance when fed diets containing spent hen meal calculated with MEn levels of 4100 and 5800 kcal/kg (Experiment 2)

E

*Diets fed from day 1 to day 21 BSeeTable 5 for diets 'Level of spent hen meal in the diet DME,, value used for spent hen meal when calculating diets to meet the 1994 NRC broiler starter standard EStandard error of the mean a-c

Means within a column with no common superscripts differ significantly (P50.05).

CONCLUSIONS AND APPLICATIONS 1. Processing ground spent hens in a fluidized bed oven followed by steeping or extruding

produced Salmonella-negative ingredients with a marked reduction in the number of aerobic plate colonies, coliform, yeast, and mold. 2. The amino acid composition of processed spent hens permits substitution at levels up to 8% for corn, soybean meal, and fat in broiler starter diets without the need for elevated levels of added synthetic amino acids when compared to the control diet. 3. Broiler body weight and feed conversion at day 2 on all diets containing processed feed spent hens was as good as or better than weight and conversion on the control diet. 4. The spent hen processing techniques studied produced feedstuffs that can be utilized by the feed industry.

REFERENCES AND NOTES 1. H a q u e , A.K.M.A., J.J Lyons, a n d J.M. Vandepopuliere, 1991. Extrusion processing of broiler starter diets containing ground whole hens, poultry byproduct meal, feather meal, or ground feathers. Poultry Sci. 70:234-240.

2. Pelle Pro@ is a pellet extruder unit manufactured byJet-Pro&, 1117Sante Fe, Atchison, KS 66002. 3. Jet-P o@fluidized bed dehydrator is manufactured

by Jet-Pro&, 1117Sante Fe, Atchison, KS 66002. 4. Triple F extruder is manufactured by Insta-Pro@

International, Des Moines, IA 50322.

5. Spent hens were rocessed through a Weiler and Co., Whitewater, WI 3190 Model 6 grinder equipped with a 1/4" hole orifice plate.

f

6. Assays conducted by University of Missouri Veterinary Medical Diagnostic Laboratory, Columbia, MO 65205

7. Assays conducted by ConAgra Frozen Food Co., Columbia Analytical Laboratory, Columbia, MO 65202.

8. Assays conducted by the University of Missouri Experiment Station Chemical Laboratories, Columbia, MO 65211.

Research Report 25

LYONS and VANDEPOPULIERE 9. The Brill Corporation, 6525 The Corners Parkway, Suite 214, Norcross, G A 30092.

12. SAS Institute, 1988. SAS/STAT@User’s Guide. SAS Institute, Inc., Cary, NC.

10. National Research Council, 1994. Nutrient Requirements of Poultry, 9th Edition. Natl. Acad. Press, Washington, DC.

13. Snedecor, G. and W. Cochran, 1976. Statistical Methods. 6th Edition. The Iowa State University Press. Ames, IA.

11. The experiments were conducted using randomized complete block design with the performance of chicks in each cage being the experimental unit. Each batteIy of ten cages was a block for a total of four blocks. The block by dietary treatment interactionwas used as the error term.

14. T a d l i y a n a n t , C., J.J. Lyons, a n d J . M . Vandepopuliere, 1993. Extrusion processing used to convert dead poultry, feathers, egg shells, hatchery waste, and mechanicall deboned residue into feedstuffs for 721515-1527. poultry. Poultry

lci.