A newly expanded Aviagen poultry feed mill in Athens, Alabama is producing  more feed while consuming far less energy, reducing its carbon emissions, and cutting its annual utility expenses. Aviagen completed a multi-million dollar expansion of its feed mill in 2010, adding production capacity with new equipment and procedures that ensure the biosecurity of feed for Aviagen’s pedigree operation in Tennessee and to 115 Aviagen poultry farms in Alabama.

Now with a full year of operation behind it, the mill has increased feed production by more than 30 percent, more efficient processing equipment has allowed the company to reduce its electric, natural gas, and diesel costs by $169,836 and cut its overall carbon dioxide emissions by 615 tons.

After the plant upgrade, electric consumption dropped 15 percent and natural gas use has decreased by 28 percent.  The plant now produces pellets that are denser thus allowing Aviagen trucks to deliver more feed per load, which means fewer trips for the company’s diesel-powered  trucks. In the first year, the company reduced its total truck load count, saved fuel, and by driving fewer miles, reduced its carbon emissions by 43 tons.

“We grew capacity, ensured biosecurity and cut costs.  But the added benefit is that we enhanced the sustainability of our feed mill operation by reducing energy consumption across the board,” said Richard Obermeyer, Aviagen’s director of feed production.