The Big Dutchman Colony 2+ installation, incorporating patented communal (group) laying nests and plastic slats, contributes to the optimum production of saleable eggs from a flock. The extensive experience of Big Dutchman design engineers and application specialists in the E.U. and North America has contributed to the evolution of the Colony 2+ system, which provides the maximum number of saleable eggs by limiting downgrades from soiled shells and cracks. Reducing downgrades is an important consideration given that the average negotiated value for eggs was $7.54 per dozen over the first quarter of 2025.

The Big Dutchman Colony 2+ system contributes to high-quality eggs based on specific design features:

• The Colony 2+ nests encourage laying by providing a secure environment for hens. This potentially reduces floor-laying to a fraction of one percent in flocks that are subject to appropriate rearing and also management after transfer to the laying barn. Factors contributing to optimal production with minimal loss include compatibility between rearing and laying installations, post-transfer training of the flock, achieving uniform development and maturity at point-of-lay, and achieving an even distribution of lighting in the laying house.

• The Colony 2+ nest incorporates a floor that tilts through 90 degrees during the dark period of the day or at preset intervals, excluding broody hens and preventing soiling of the plastic mat that is effectively self-cleaning with each cycle of rotation. The divided nest floor is initially raised in the center at the beginning of the closing cycle, allowing gentle roll-out onto the centrally placed egg belt. This patented feature is unique to Big Dutchman Colony 2+ nests.

Open Nest

Closed Nest

• The solid nest mat prevents upward movement of cold air into the nest, contributing to hen comfort and utilization.
• Big Dutchman floor barn systems can be equipped with plastic slats that potentially reduce entry accumulation of soil on the feet and litter entering the nest.

• The egg belt is located in the center of the nest bank with a short roll-out distance, protecting eggs from damage. Big Dutchman design engineers specified an extra-wide (20-inch) belt to allow separation of eggs during transport.

• The EGGTRAX egg transfer unit contributes to impact-free movement of eggs from collection belts to cross conveyors or sorting tables. With the EGGTRAX Ultra option and a thicker 1.6mm egg belt, longer nest row lengths are also possible.

• Nests are available in 18-inch or 21-inch depth in either the standard or XL configuration. Depending on the arrangement of nests within the house, a single wall nest installation is available with a belt width of 9.6 inches.

Functional features of the Colony 2+ system include:

• Big Dutchman Colony 2+ nest systems are available in either single or double-tier arrangements, depending on house dimensions and flock capacity, appropriate to either new buildings or as retrofits to existing barns.

• Big Dutchman Colony 2+ systems can be supplied with either a gable roof with full-length open ridge ventilation or a flat surface to increase the available house area for the flock.
• A smooth galvanized step rail is installed at the entrance to the nests, contributing to hen comfort and the cleanliness of the nest pad.
• The frames for the Colony 2+ nest are constructed of powder-coated steel, and the legs are fabricated from stainless steel for a prolonged operating life.
• Plastic slats are fabricated from material that resists deterioration over time, and installations are supported by a substantial galvanized framework.
• All sheet metal components are powder-coated over galvanized surfaces. Nest roof tops are fabricated from laminated wood with a durable waterproof coating.

The Big Dutchman Colony 2+ system incorporates perches with roosting space conforming to both E.U. and UEP welfare standards.

Big Dutchman supplies all feeding components including outside silos, surge bins for weighing and distributing feed, and transport augers to transfer feed to hoppers within the barn.

Champion® chain feeders are installed with specially designed troughs equipped with lips that prevent wastage.

Water is supplied by suitably placed nipple drinkers with drip cups.

Big Dutchman Colony 2+ installation showing litter area, plastic slats, perches; Champion feeding circuit; nipple drinker lines; communal nests with flat tops; LED illumination and gable air inlets.

Big Dutchman can provide comprehensive ventilation installation, including fans, inlets, evaporative cooling pads, and controllers to optimize the environment of houses, contributing to achieving the genetic potential of flocks.

Big Dutchman design engineers can configure either new installations or retrofits by incorporating the Colony 2+ group-laying nest system into turn-key installations equipped with feeding and ventilation.

Big Dutchman technical service representatives provide guidance to producers on flock management, maintenance, and operation to optimize return on investment.

This update of U.S egg-production statistics, costs and prices is sponsored by Big Dutchman USA for the information of producers and stakeholders

MARCH HIGHLIGHTS

• March 2025 USDA ex-farm blended USDA nest-run, benchmark price for conventional eggs from caged hens was 474 cents per dozen, down 266 cents per dozen or 35.9 percent from the February 2025 value of 740 cents per dozen. The corresponding March 2023 and 2024 values were respectively $2.71 and $1.87 cents per dozen. For annual comparison, average monthly USDA benchmark price over 2023 was 146.0 cents per dozen compared to 247 cents per dozen for 2024. Stock levels and prices prior to the onset of flock depletions due to HPAI indicated a relative seasonal balance between supply and demand. Future nest-run and wholesale prices will be largely dependent on consumer demand for shell eggs and products and the rate of replacement of pullets and hens depleted due to HPAI. Other considerations include diversion to shell sales from the egg-breaking sector in an interconnected industry.
• Fluctuation in wholesale price is attributed in part to the amplification of upward and downward swings associated with the commercial benchmark price-discovery system in use. An additional factor influencing pricing is the proportion of shell eggs supplied under cost-plus contracts accentuating the upward and downward price trajectory of uncommitted eggs. Highly pathogenic avian influenza was the major driver of price with a high incidence rate. Approximately 40 million hens and at least 2.0 million pullets were depleted in 2024 with to 33 million birds, in 32 complexes or farms year to date.
• March 2025 USDA average nest-run production cost for conventional eggs from caged flocks over four regions (excluding SW and West), applying updated inputs was 74.7 cents per dozen, down 1.4 cents from February 2025 at 76.1 cents per dozen. The March average nest run production cost for other than caged hens was estimated by the EIC to be 93.7 cents per dozen down 1.6 cents per dozen from February. Approximately 60 cents per dozen should be added to the USDA benchmark nest-run costs to cover processing, packing material and transport to establish a realistic cost value as delivered to warehouses.
• March 2025 USDA benchmark nest-run margin for conventional eggs attained a positive value of 399.3 cents per dozen compared to a positive margin of 663.9 cents per dozen in February 2025. Average nest-run monthly margin for 2024 was 170.8 cents per dozen compared to 64.2 cents per dozen over 2023 and 155 cents in 2022.
• March 2025 USDA benchmark nest-run margin for all categories of cage-free eggs attained a positive value of 444.3 cents per dozen compared to a positive margin of 820.7 cents per dozen in February 2025. Average nest-run monthly margin over 2024 was 440 cents per dozen compared with 100 cents per dozen in 2023, relatively unaffected by HPAI compared to the preceding and following years.
• The February 2025 national flock (over 30,000 hens per farm) was stated by the USDA to be down 0.5 million hens (rounded and a probable undercount) to 289.5 million compared to the revised January 2025 value of 299.0 million and relative to 326 million before the advent of HPAI in 2022. Approximately 3.5 million hens returned to production from molt in December together with projected maturation of 26 million pullets, with this number offset by depletion of an unknown number of spent hens.
• February 2025 pullet chick hatch of 27.9 million was down 0.4 million (-1.4 percent) from January 2025 despite increased industry requirements to replace depopulated flocks.
• February 2025 exports of shell eggs and products combined were up 15.2 percent from January 2025 to 425,000 case equivalents representing the theoretical production of 5.6 million hens. Shell egg exports totaling 259,000 cases were dominated by Canada (84 percent of volume) and the “Rest of Americas” nations including the Caribbean (13 percent). With respect to 166,000 case equivalents of egg products, Canada (35 percent of volume), Japan, (27 percent), Rest of Americas (15 percent) and Mexico, (9 percent) collectively represented 86 percent of shipments. Volumes exported are based on the needs of importers, competition, availability in the U.S. and FOB prices offered.

TABLES SHOWING KEY PARAMETERS FOR MARCH 2025.

Summary tables for the latest USDA March 2025 flock statistics, costs and unit prices made available by the EIC on April 9^th 2025 are arranged, summarized, tabulated and compared with values from the previous March 7^th 2025 release reflecting February 2025 costs and production data as applicable. Monthly comparisons of production data and costs are based on revised USDA values.

VOLUMES OF PRODUCTION REFLECTING THE ENTIRE INDUSTRY

*USDA Revised

• Revised USDA/EIC Note 1. Texas excluded to maintain confidentiality

PROPORTION OF U.S. TOTAL HENS BY STATE, 2024

Based on a nominal denominator of 280 million hens in flocks over 30,000 covering 95 percent of the U.S complement.

USDA has amended inclusion of specific states in regions and eliminated Texas data to protect confidentiality of Company flock

Sizes

1. Values rounded to 0.1%

Rate of Lay, weighted hen-week (USDA) 82.0% FEBRUARY 2025. 82.6% MARCH 2025

*Revised USDA

*Revised, using data from USDA Livestock, Dairy and Poultry Outlook March 17^th 2025 taking into account demand from the food service sector and presumably including the effect of HPAI depopulation.

EGG INVENTORIES AT BEGINNING OF MARCH 2025:

EGGS BROKEN UNDER FSIS INSPECTION (MILLION CASES) FEBRUARY 2025 5.99 JANUARY 2025, 6.18*

EXPORTS FEBRUARY 2025: (Expressed as shell-equivalent cases of 360 eggs).

*Representing 2.1 percent of National production in FEBRUARY 2025 (1.3% shell, 0.7% products).

COSTS AND UNIT REVENUE VALUES¹ FOR CONVENTIONAL EGGS FROM CAGED HENS

Notes: 1. Excludes SW and West

Components of Production cost per dozen:-

Ex Farm Margin (rounded to nearest cent) according to USDA values reflecting MARCH 2025:-

474.0 cents per dozen¹- 74.7 cents per dozen = 399.3 cents per dozen (February 2025 comparison: 740.0 cents per dozen – 76.1 cents per dozen = 663.9 cents per dozen.

Note 1: USDA Blended nest-run egg price

1. Unrealistic USDA prices based on promotional prices with few participating stores, non-representative of shelf prices!

COSTS AND UNIT REVENUE FOR EGGS FROM CAGE-FREE HENS

Components of Production cost for cage-free eggs, per dozen:-

Ex Farm Margin (rounded to nearest cent) according to USDA values reflecting negotiated price for MARCH 2025:-

Cage-Free brown 537.0 cents per dozen¹- 93.7 cents per dozen = 443.3 cents per dozen

February 2025:- 916.0 cents per dozen - 95.3 cents per dozen = 820.7 cents per dozen

1. Contract price, nest-run loose. Range 135 to 235 c/doz. unchanged since July and totally unrealistic.

1. Negotiated price, loose. Range $6.00 to $8.98 per dozen
2. Unrealistic USDA values based on promotional prices with few participating stores non-representative of shelf prices!

(Insert Fig 12 Quarterly CF and organic)

* Conventional (non-organic) feed

Feed prices used are the average national and regional values for caged flocks. Excludes organic feeds with prices substantially higher than conventional.

This update of U.S cage-free production is sponsored by Big Dutchman USA for the benefit of producers in North America

Depopulation was carried out as a result of HPAI through the fourth quarter of 2024 and continued through 2025 to date but with lower intensity in March. The USDA Cage-Free Report covering March 2025, released on April 1^st 2025, documented the complement of hens producing under the Certified Organic Program to be 20.4 million (rounded to 0.1 million), down 0.1 million from February 2025. The number of hens classified as cage-free (but excluding Certified Organic) and comprising aviary, barn and other systems of housing apparently increased by 1.7 million hens or 1.6 percent from February 2025 to 105.4 million, with negligible flock depopulation of laying hens but with loss of pullets during the month.

Average weekly production for Certified Organic eggs in March 2025 was up 0.1 percent compared to February 2025 with a questionably high average weekly production of 84.3 percent. Average weekly flock production for cage-free flocks other than Certified Organic was up 2.1 percent in March 2025, but with a high average hen-month production of 83.0 percent, up from 82.7 percent. Seasonally, younger flocks increase the availability of cage-free and organic eggs in response to pullet chick placements 20 weeks previously, especially in anticipation of periods of peak seasonal demand.

According to the USDA Egg Markets Overview the categorization of U.S. flocks according to housing system among the total of 285 million hens on March 1^st was:-

Caged, 159 million (55.9% of 285 million hens);

Cage Free, 105 million (37.0%) with 87% in barns and 8% each on free-range and pasture;

Organic, 20 million (7.2%) with 91% in barns and 4.5% each on free-range and pasture:

There is no adequate explanation for the high production rate especially if the reported number of hens is lower than actual, and in view of a possible undercount following HPAI flock depopulation.

Losses during Q1 of 2025 comprised:

Caged flocks, 19.3 million representing 6.8 percent of hen population

Cage-free flocks, 11.0 million representing 3.9 percent

Organic flocks, negligible, 0.1 percent

Negotiated nest-run grade-ready cage-free price for March 2025 averaged $5.37 per dozen, down 30.8 percent from $7.77 per dozen in February 2025, reflecting an imbalance between demand relative to supply. The March 2025 advertised U.S. featured retail price for cage-free eggs over only three regions (NW, SW and SC.) was $4.99 per dozen, apparently down 37.5 percent or $3.80 per dozen from February 2025 based on 153 stores. This compares with 62 stores in February and reflects few promotions as the year has progressed reflecting the incidence rate of HPAI during January and February.

The recorded average wholesale price of $5.37 per dozen plus a provision of $0.60 cents per dozen for packaging, packing and transport, results in a price of $5.97 per dozen delivered to CDs. The average three-region advertised promotional retail price of $4.99 per dozen corresponds to a theoretical average retail negative margin of -16.4 percent (-4.5 percent last month) for promotions offered by the few stores featuring cage-free eggs. Margins are presumed higher for non-featured eggs including pastured and other specialty eggs at shelf prices attaining in excess of $9.00 per dozen in high-end supermarket chains. Retailers maximizing margins especially on Certified Organic, free-range and pastured categories restrict the volume of sales, ultimately disadvantageous to producers.

Prism Controls Inc. previously serving agriculture for 45 years as PMSI, will unveil innovative software for their egg flow control system in addition to other products on their Booth 1231 during PEAK 2025.  Prism Controls development engineers and sales representatives will be available to discuss the Gen 4 REF Egg Flow software along with updated and existing products including the ECO Controller, and the ThERM™ Fire Detection and Response installation.

GEN 4 REF EGG FLOW SOFTWARE

This next-generation package responds to the needs of high-density cage-free aviary systems.  In contrast to traditional cage housing, hen populations in aviaries are widely scattered, frequently with selection of nests in specific tiers and areas of a house.  The AI-powered Gen 4 Egg Flow allows dynamic and zone-based operation of egg collection to optimize saleable eggs.  The approach by Prism divides houses into small zones including rows and tiers allowing for specific adjustments to egg flow based on real-time monitoring.  The software allows collection systems to respond to variable loading on the conveyor belt, the rate of egg production in different areas of the house and nest preferences according to the age and training of the flock.

Gen 4 REF Egg Flow software by Prism Controls provides real-time visualization of data with monitoring of egg flow.  The AI capability automatically adjusts belt speed to ensure a smooth transition from nests to the grader input.  Variable conveyor belt speed obviates frequent starts and stops minimizing shell damage during collection.  Prism Gen 4 REF Egg Flow software generates data that can be applied to detect deviations from normal operation. Reports are generated to facilitate responses by management.

ECO BARN CONTROLLER

This unit is designed specifically for barn-housed flocks. The computer-based system offers precise environmental control within the house contributing to optimal temperature, humidity and air quality.  The ECO Controller monitors feed and water consumption, egg production and will record bird weight and mortality.  Environmental and production variables are displayed on a large touchscreen for ease of management.

The ECO Controller logs operational activities and activates alarms to identify problems that require correction. The unit offers remote monitoring from either a central or remote location. This is of special interest to managers of contract barns on multipurpose farms where constant observation of flocks is not possible The ECO Controller can also be configured to monitor multiple houses on the same or different farms. 

ThERM™ FIRE DETECTION AND RESPONSE SYSTEM

Prism Controls developed the ThERM™ Detection and Response System in response to the increased incidence of fires reported in recently constructed multi-tier layer houses. ThERM™ detects smoke particles by constantly monitoring up to 50 locations within a house or compartment. Smoke is generated at an early stage of an incident attributed to faulty electrical components that may include fans, panels and defective wiring.  ThERM™ can distinguish between a fire at an early stage in contrast to the presence of dust and dander suspended in the atmosphere of a house.  In a typical event, an overheated fan generates smoke which is detected in the initial alert stage. Detection of smoke particles results in activation of alarms and messages to farm personnel to respond to smoke and temperature outside predetermined tolerance levels.  Alarms can also be directed to first responders if available. Mitigation of damage is achieved by the ThERM™ overriding ventilation systems, shutting down gas-fired heaters and fans and closing inlets thereby depriving an incipient fire of oxygen.

ThERM Control panel activates detection, alarm, shutoff response and notification

Click here to check out our video!

Prism Controls will be at Booth #1231 during PEAK.

Prism Controls offers design, installation, maintenance and service

This special edition of EGG-NEWS details the products to be demonstrated by Big Dutchman USA at the 2025 PEAK trade show on Booth 821.  The product range includes innovations, introductions, upgrades of existing products and a display of tried and tested equipment contributing to efficiency and flock productivity.

Heidy Mobile Grader for Parent Broiler Rearing Flocks

This unit was developed to rapidly and accurately weigh broiler breeder pullets and cockerels during the rearing period to differentiate among three weight groups. Separation with supplementary feeding according to weight class will contribute to flock uniformity at transfer.  The Heidy Mobile Grader can weigh up to 850 birds per hour with separation among three pre-determined weight classes.  Data is recorded and displayed and can be transferred to a remote database.  The unit is constructed of stainless steel and can be decontaminated using a high-pressure washer bor optimal biosecurity.

Click for video

Duo Chain Feeding System for Breeders –

The MaleChain is designed to save floor space and to contribute to uniformity.  The design of the corners and trough comprise a single line for installation in new houses or as a retrofit.  The FeMaleChain is a complementary installation for hens. The male and female lines are equipped with appropriate grills.  The chain feeding loop is located in a single trough with a center divider.  The chain distributes feed from a single hopper in both directions and feed is rapidly distributed along a house with a length of up to 500 feet.  The feed line can be suspended or rest on litter with the ability to adjust height.

Turkey Feeding Systems

Big Dutchman will demonstrate three systems designed for specific life stages of turkeys: -

• The UniGROW 360 incorporates a patented pan feeding system designed for poults through transfer.  The three-strut grill facilitates feeding without the risk of entrapment.  An anti-scratch ring prevents wastage.

• The Vista 360 – This starter pan can be used from day old through grow-out and is designed for ease of operation and to limit wastage.  The Vista 360 incorporates a flooding capability for starting poults that closes automatically when the pan is lifted.

• Gladiator System – The Gladiator feeding pan is engineered to withstand the stresses imposed by heavy turkeys.  The lip of the pan is designed to reduce feed wastage.  Conversion efficiency is optimized by adjusting the feeding level using a twist and lock feature.  Bruising is minimized by the flexible suspension of the pan allowing movement on the suspension tube.  Individual pans can be removed for maintenance.

Turkey Drinkers

The Big Dutchman patented Turkey Drinker supplies water through the entire cycle of production.  Drinkers incorporate a twin-nipple design delivering water to a cup with a water level that responds to intensity of drinking.  The central pendulum that triggers the nipples ensures an adequate quantity of water in the cup but obviates spillage.

Colony 2+ System

 The Colony 2+ single-tier open access aviary system is designed for barns but is compatible with existing multi-tier buildings.  The system is supplied with INTEGRA plastic slats. The design of colony nests contributes to maximum recovery of clean saleable eggs. Nests are equipped with a patented tilting floor to exclude hens at night.  The nest row has a flat top optimizing house area available for the flock. The Colony 2+ system is available with the proven Big Dutchman ChainFeeder and nipple drinker lines.  To complete packages, Big Dutchman can supply ventilation installations including controllers, fans, inlets for new installations and upgrades.

Big Dutchman NATURA® Filia Rearing System

 This two-tier rearing installation is compatible with Big Dutchman NATURA® Step and NATURA® Visio aviary laying systems.

The rearing system is designed to achieve uniform maturity, optimal body weight and subsequent egg production consistent with genetic potential.

Designed to comply with U.S. and E.U. welfare requirements, features include moveable partitions to confine the flock to small groups during early rearing and to facilitate vaccination and handling.  The NATURA® Filia System incorporates bridges and ramps to encourage movement from the floor to both tiers.  The NATURA® Filia System is equipped with a chain feeding circuit on each tier and drinking lines that can be adjusted according to the growth of the flock.

NATURA® Step Aviary Systems

Both width configurations of the Step System are designed to optimize flock production and achieve the highest proportion of saleable eggs from a flock.  The NATURA® Step System is a true aviary allowing hens access to all levels and the aisles encouraging natural behaviors including foraging, dust bathing, roosting, feeding and egg laying within nests.  The Step concept is based on strategically placed platforms allowing hens to move among tiers.  This provides hens with access to the entire system and for the flock to be distributed evenly within the house. The nests are staggered along the middle tier are equipped with patented tilting floors. Polypropylene belts gently transfer eggs to EGGTRAX™ transfer units and then to EGGCELLENT™ elevators designed for high-volume collection.  Top and bottom tiers are equipped with polypropylene manure belts with the option of ventilation to reduce moisture content.

NATURA Step XL

Big Dutchman NATURA® Visio Aviary Systems

The NATURA® Visio aviary comprises two tiers each equipped with feeding lines, drinkers and nests.  The design incorporates a step concept encouraging vertical movement of hens between the upper and lower tiers contributing to even distribution of the flock within the house.  Shell downgrades are reduced to a minimum by the design and location of nests on both tiers.  Eggs roll from the nests onto two eight-inch-wide belts of polypropylene moving product to a single elevator.  The nest floor tilts through 90° to restrict entry during the dark phase of each day.

Each tier is equipped with a Champion™ chain feeding system using a wide trough with a specially designed lip to reduce wastage.  Hens have access to drinker lines on each of the tiers equipped with 360° nipples incorporating drip cups.

Big Dutchman sales representatives and technical service specialists will be available on Booth 821 to demonstrate products and to provide advice and information on the operation of the systems.