Dr Narahari a seasoned professional in the space of Meat and Poultry processing industry in India and has spent over 32 years working with reputed organizations in India and Middle east and held Middle and Senior positions. Graduated from Bangalore veterinary college during the year 1989 and completed PG diploma in Animal Husbandry from ITCPH, Philippines under Netherlands fellowship programme. His organization NH ProPOWER Consultancy services, Bangalore offers end to end solutions for Meat and Poultry processing, Further processing, Retailing and QSRs, currently doing projects in India, Middle East and Africa.

Meat and poultry are nutrient-dense foods that supply high-quality protein, essential amino acids, iron, zinc, and vitamin B12. The same features that make them nutritious, such as high moisture, abundant nutrients and a relatively favourable pH, also make them highly perishable. The scale of the post-process/post-harvest/post-slaughter spoilage issue is particularly important in India. The Department of Animal Husbandry and Dairying reported a total meat production of 10.50 million tonnes in 2024–25, with poultry contributing approximately 49% of the total. A NABCONS study published in 2022 estimated post-harvest losses of 2.34% for meat and 5.63% for poultry meat. If the estimated poultry loss rate were applied illustratively to 2024–25 production, the quantity affected would be approximately 0.29 million tonnes. Such loss also wastes the feed, water, veterinary inputs, labour, energy, packaging, transport and processing capacity already invested in the product. This article aims to explain the scientific and operational principles of cold-chain management in the meat and poultry industry and to highlight its importance in maintaining food safety, product quality and Shelf life.

Why rapid cooling matters
After slaughter, blood circulation and natural defence mechanisms in the organisms cease. However, the residual heat remains in the carcass and helps endogenous enzymes to continue their action, causing enzymatic or autolytic spoilage. This is the beginning of spoilage. Microbial spoilage develops later in the meat products as microorganisms multiply. The exposed tissues of the meat or poultry can acquire microorganisms during dressing, evisceration, cutting, and handling. Lower temperatures help reduce the rate of spoilage by inhibiting enzyme activity and microbial growth.
However, the concept of cold chain is more than just storage at a lower temperature. From slaughter to consumption, cold chain management involves a coordinated system of temperature, time, hygiene, airflow, packing, and documented monitoring to ensure the safety and quality of the products.

Microbial contamination may include spoilage organisms and pathogens. Spoilage may become visible as slime, discolouration, excessive drip, rancid flavours or objectionable odours. Pathogenic contamination is more dangerous because organisms such as Salmonella, Campylobacter, pathogenic Escherichia coli and Listeria monocytogenes may be present without producing any obvious change in appearance, smell or taste. Refrigeration slows microbial multiplication, enzymatic reactions and lipid oxidation, but it does not sterilize the product or correct poor hygiene. Also, some psychrotrophic microorganisms (Eg., Shewanella putrefaciens, Candida spp) can continue to grow slowly at refrigeration temperatures and cause spoilage during extended refrigerated storage.

Poultry generally deteriorates faster than intact red-meat carcasses because slaughter and portioning create a large exposed surface, while skin folds, feathers and intestinal contents increase the opportunities for cross-contamination. Mincing creates an additional risk by increasing surface area and distributing surface contamination throughout the batch. Temperature and exposure time must therefore be controlled. Even a brief rise in temperature during loading, transport or retail display can shorten the product’s remaining shelf life.

The cold-chain journey and its principles
The cold chain begins immediately after post-mortem inspection. Primary chilling removes carcass heat rapidly and uniformly, while secondary chilling maintains the required condition during holding, cutting, deboning, packing and dispatch. For example, European Union Regulation No. 853/2004, establishes that, after post-mortem inspection, the animals must be immediately taken to a refrigerated environment in the slaughterhouse. This medium must guarantee an internal temperature of the meat that does not exceed 3°C, in the case of offal, and ≤ 7°C for the rest of the meat, and it will be ≤ 4ºC for poultry, subject to the applicable legislation and processing system. However, these limits do not replace process validation. Regulatory compliance mandates that these temperature limits serve as benchmarks rather than absolute substitutes for process validation. The thermal history of the product must be empirically verified to ensure that the “slowest-cooling part” (typically the geometric centre) reaches the target temperature within a short duration. This requirement necessitates monitoring chilling curves to ensure a continuous, steady decrease in temperature to prevent any thermal plateaus that could allow for pathogen recovery or exponential growth.

A graph of the temperature of the product vs time is called a cooling curve. This provides stronger evidence about the product temperature than room temperature alone. A cold room can show the correct air temperature, but the centre of a carcass or dense carton or tightly packed pallet may remain warm. Representative product-temperature measurements can identify overloading, insufficient refrigeration capacity, blocked airflow, excessive door opening, defrost effects and poorly positioned evaporators. Also surface temperature and exposure time may contribute to microbial growth. Therefore, monitoring points should be selected through temperature mapping and process validation.

The industry employs various low-temperature chilling and freezing systems. They offer different advantages, and their applications vary by product type. Air chilling uses forced cold air and depends on temperature, velocity, humidity, carcass size, and spacing. Immersion chilling cools poultry rapidly but requires strict water-quality and cross-contamination control. Spray chilling combines cold air chilling with intermittent water spray, and can reduce dehydration of the products. Blast freezing uses very cold, high-velocity air, while plate freezers are suitable for flat, uniformly shaped packages. Warm products should not enter a long-term store designed mainly to hold already-frozen goods. A validated freezing process should be used to reduce their core temperature to the specified level, commonly −18°C or below.

The product quality should be suitable for the target market. Chilled beef is generally stored at temperatures between 0 and 4°C (without freezing). Therefore, its shelf life is limited, and the temperature must be kept constant. Superchilling holds the product slightly below its initial freezing point and can extend storage while limiting ice formation, although temperature uniformity is critical. Frozen storage at −18°C or below substantially slows microbial and chemical deterioration but does not reverse earlier temperature abuse. Freezing rate, packaging, fat content, storage duration and thawing practices influence drip loss, oxidation, texture and overall acceptability.

Importance of hygiene, zoning and packaging
Low temperature cannot compensate for contamination from hands, clothing, knives, conveyors, crates, drains, aerosols or poorly cleaned surfaces. Hygienic plant design should establish one-way movement from dirty or live-animal areas towards cleaner cutting, packing, chilling and dispatch zones without backtracking. Raw and ready-to-eat operations require effective separation. Protective clothing, handwashing, knife sterilization, pest control, drainage, condensate management, sanitation procedures and microbiological verification are essential components of cold-chain control.

Figure 1: Cold chain in meat and poultry industry and the principles of cold chain

Packaging supports temperature control but does not replace it. Vacuum packaging reduces oxygen and may extend chilled shelf life, while modified-atmosphere packaging can suppress selected aerobic spoilage organisms and help maintain product colour. However, packaging changes the microbial ecology rather than eliminating microorganisms. Seal integrity, gas composition, product temperature and the possible growth of anaerobic or facultative organisms must therefore be considered during shelf-life validation. Shelf life should be established for the actual formulation, initial microbial load, processing method, packaging system and distribution pattern rather than copied from a generic table.

Distribution, retail and monitoring
Refrigerated vehicles should maintain the temperature of pre-cooled products rather than perform primary chilling. Vehicles should be cleaned, inspected and pre-cooled before loading. Loading must be rapid, doors should remain open for the shortest practicable time and cartons should be arranged to preserve airflow. Overloading, warm loading, damaged door seals and delays at transfer points can create temperature gradients and warm pockets. At retail, products should move quickly into cold rooms or display units. Display cases should not be filled above their designed airflow line, while cutting and mincing should be undertaken in small batches under chilled conditions.

Documented monitoring converts refrigeration from an assumption into verifiable control. Records should include product core or surface temperature, room and vehicle temperature, door-opening duration, refrigeration performance, sanitation results, lot identity and handover time. Calibrated data loggers, time–temperature indicators, GPS-linked sensors and Internet of Things platforms can provide continuous histories and real-time alarms. When a deviation occurs, personnel should isolate the product, evaluate its time–temperature history and safety, document its disposition, correct the immediate problem, identify the root cause and verify the effectiveness of corrective action.

Cold chain capacity, compliance and sustainability
Cold chain capacity should be designed based on peak throughput and total heat load, rather than average production and room volume alone. The product mix, incoming temperature, fresh-to-frozen ratio, pack size, chilling or freezing time, dwell time, door openings, dispatch frequency, weekend stock and future growth are all things designers need to consider. Refrigeration calculations should consider product heat, transmission through walls, air infiltration, people, lighting, motors and defrost loads. A bottleneck in chilling, blast freezing, staging, loading docks or refrigerated transport can compromise the entire system even when the nominal storage capacity appears adequate.

In India, compliance requires an appropriate FSSAI license, hygienic infrastructure, product and labelling standards, traceability and proof of temperature control. Export operations may also require APEDA approvals, veterinary certification and compliance with residue monitoring and specifications required by the exporting country. Codex CXC 58-2005 proposes a risk-based approach to meat hygiene. European regulations and the UNECE ATP Agreement constitute established references for hygienic production and temperature-controlled transport.

Conclusion
A reliable meat and poultry cold chain is not simply a cold room or refrigerated truck. It is an uninterrupted, validated and documented management system. When temperature, time, hygiene, airflow, packaging, capacity and human discipline are controlled together, the cold chain reduces spoilage, extends saleable life, supports market access and protects public health and the economic value embedded in every kilogram of product. In the future, cold chains should combine food safety with environmental sustainability through improved insulation, efficient compressors, lower-global-warming-potential refrigerants, renewable electricity, heat recovery, preventive maintenance and digital traceability. Sustainable cold-chain development is important because refrigeration protects food availability, but inefficient cooling systems can also contribute substantially to energy demand and greenhouse-gas emissions.

References are available on request.

However, despite its widespread use, SCC presents several practical challenges, including its highly hygroscopic nature, reduced feed stability, accelerated degradation of certain vitamins, and the formation of trimethylamine (TMA) during microbial metabolism. These limitations, coupled with the industry’s growing focus on efficiency, sustainability, and precision nutrition, have driven the search for more advanced nutritional solutions.

Why Liver Health Matters More Than Ever
In poultry, the liver is the primary site of lipogenesis, accounting for nearly 80–85% of total fatty acid synthesis. Every day, it coordinates the conversion of nutrients into energy, regulates lipid metabolism, synthesizes proteins, and supports numerous physiological functions essential for growth and production. When lipid metabolism becomes impaired, triglycerides accumulate within liver cells, leading to excessive fat deposition, poor feed utilization, reduced growth performance, and an increased risk of fatty liver conditions. These metabolic disturbances can significantly impact both biological efficiency and economic returns. Consequently, maintaining optimal liver function is no longer viewed merely as a health objective; it has become a key driver of productivity and profitability in modern poultry production.

Kolin Plus® : A New Generation Phytogenic Solution
Developed as a scientifically validated phytogenic alternative to synthetic choline chloride, Kolin Plus® represents a new approach to metabolic nutrition. Rather than functioning solely as a nutrient replacement, Kolin Plus® supports liver health and fat metabolism through multiple interconnected biological pathways. Formulated from carefully selected botanical ingredients rich in bioactive compounds, Kolin Plus® works by influencing key metabolic processes involved in lipid synthesis, fat mobilization, fatty acid oxidation, and energy utilization. This multi-pathway mode of action enables the bird to utilize nutrients more efficiently while supporting optimal hepatic function. Backed by transcriptomic research and performance validation studies, Kolin Plus® exemplifies the shift from conventional nutrient supplementation to scientifically driven metabolic optimization.

A Transcriptomic Window into Poultry Metabolism
One of the most exciting developments in animal nutrition has been the application of transcriptomics to understand how dietary interventions influence biological functions.
Transcriptomics enables researchers to evaluate thousands of genes simultaneously and identify the molecular pathways affected by nutritional interventions. To unravel the molecular basis of Kolin Plus® activity, liver gene expression profiling was conducted in broilers challenged with choline-deficient diets. The analysis identified key genes and signaling pathways involved in lipid synthesis, mobilization, oxidation, and overall hepatic lipid regulation. The gene expression patterns were studied for four groups normal diet: normal, choline chloride deficient, Kolin Plus®, and CCL using microarray on day 42. The hierarchical cluster analysis was carried out on 12,614 differentially expressed genes (DEGs) with a similar expression.

Regulating Fat Synthesis at Its Source
One of the most significant findings from transcriptomic research was the modulation of genes involved in hepatic fat synthesis. Key genes associated with lipogenesis—including PPARG, ACACA, ACLY, and LIPC were regulated in a manner that supports healthier lipid metabolism. These genes play important roles in: Fatty acid synthesis, Triglyceride accumulation, Lipid storage, Hepatic lipid regulation. By influencing these pathways, Kolin Plus® helps create a metabolic environment that favours efficient nutrient utilization while reducing excessive fat deposition within the liver. (Table 1, Fig1)

Figure 1. Effect of KP on gene expression related to de novo lipogenesis.
Activating the Fat-Burning Machinery
While reducing fat synthesis is important, optimal metabolic health also requires efficient utilization of stored fats. The transcriptomic analysis revealed enhanced expression of genes associated with fatty acid oxidation, including:  CPT1A, PPARGC1A, HADHB, PNPLA2
These genes are directly involved in transporting fatty acids into mitochondria and converting them into usable energy through β-oxidation. In practical terms, this means the bird becomes more efficient at utilizing dietary energy rather than storing it as excess fat.
Further studies demonstrated increased circulating levels of L-carnitine in supplemented birds.
L-carnitine serves as the transport system that carries long-chain fatty acids into mitochondria, where they are oxidized to generate energy. Improved L-carnitine status has been associated with:
– Enhanced fat utilization
– Reduced carcass fat deposition
– Improved energy efficiency
– Better production performance
This finding provides an important physiological link between molecular changes and measurable production outcomes. ((Table 1, Fig 2)

Fig 2: Effect of KP on catabolism of lipids (lipolysis and beta-oxidation of fatty acids.

From Molecular Science to Farm Performance
The true value of any nutritional intervention lies in its ability to improve on-farm performance.

Research Studies has demonstrated benefits including:
– Improved body weight gain
– Better feed conversion ratio (FCR)
– Reduced fat accretion
– Enhanced livability
– Improved European Production Index (EPI)
These improvements reflect the practical impact of optimizing lipid metabolism and liver function.  Rather than acting as a simple replacement for choline, this approach supports multiple interconnected pathways that collectively improve metabolic efficiency.

Sustainability Through Better Metabolism
Modern poultry production increasingly demands solutions that are not only effective but also sustainable. Improved lipid utilization means more dietary energy is directed toward productive purposes rather than being lost through inefficient metabolism.
This can contribute to:
– Better feed efficiency
– Lower resource utilization
– Reduced environmental impact
– Improved economic sustainability
As the industry continues to pursue precision nutrition and sustainable production systems, metabolic optimization will play an increasingly important role.

Conclusion
The future of poultry nutrition is moving beyond simple nutrient supplementation toward a deeper understanding of how nutrition influences biological systems. Advances in transcriptomics and nutrigenomics have shown that phytogenic technologies can regulate gene expression, optimize lipid metabolism, support mitochondrial function, and enhance metabolic efficiency.
By influencing key pathways involved in fat synthesis, lipid transport, and fatty acid oxidation, these next-generation nutritional solutions help improve liver health, nutrient utilization, and production performance. Kolin Plus®, backed by transcriptomic validation and performance studies, exemplifies this scientific approach by supporting metabolic health through multiple biological pathways rather than functioning as a conventional choline replacement alone.
As the poultry industry continues to focus on efficiency, profitability, and sustainability, scientifically validated phytogenic solutions such as Kolin Plus® are redefining metabolic management and shaping the future of precision poultry nutrition.

Introduction

Why it matters in modern poultry production
– Rapid multiplication of Eimeria can produce substantial intestinal injury within a short period.
– Subclinical coccidiosis may reduce feed efficiency, growth and flock uniformity without dramatic clinical signs.
– High oocyst contamination of litter increases exposure and repeated infection pressure.
– Effective control requires attention to parasite biology, farm management and appropriate anticoccidial programmes.

Etiology
Seven major Eimeria species are recognized in chickens. E. acervulina and E. maxima are frequently encountered, while E. tenella is particularly pathogenic and associated with severe caecal disease and haemorrhage (Yaqub et al., 2023). Species differ in preferred intestinal sites, lesion patterns and pathogenicity.

Transmission
The principal route is faecal–oral transmission. Birds ingest sporulated oocysts from contaminated litter, feed, water, equipment or the environment. Moisture, oxygen and suitable temperature favour sporulation, allowing infective oocysts to accumulate and maintain the infection cycle (Pal et al., 2023).
Life Cycle of EIMERIA

Ingestion of sporulated oocysts → release of sporozoites → epithelial invasion → multiplication → gamete formation → oocyst formation → faecal shedding → environmental sporulation.

Clinical Signs
Severity depends on Eimeria species, infective dose, bird age, immunity and environmental management. Signs include reduced feed intake, depression, ruffled feathers, drooping wings, enteritis, diarrhoea or dysentery, poor growth and increased mortality in severe cases (Pal et al., 2023).
– Reduced body-weight gain and flock uniformity
– Poor feed conversion and production performance
– Diarrhoea or blood-stained droppings in severe infections
– Dehydration, weakness and depression
– Mortality when tissue damage and blood loss are extensive
Species-specific sites

Post-Mortem Lesions
Post-mortem examination helps identify likely Eimeria species and estimate the distribution and severity of intestinal damage. Lesion patterns should be interpreted with clinical findings, litter condition, performance data and, where appropriate, laboratory diagnosis (Pal et al., 2023; Yaqub et al., 2023).

Key lesion patterns

Prevention and Control
Effective control integrates anticoccidial programmes with litter management, hygiene, stocking-density control, ventilation and sound flock management. Continuous or inappropriate use of a single anticoccidial can contribute to reduced efficacy and resistance selection; rotation, shuttle programmes, combinations and vaccination are among approaches used for longer-term control (Usman et al., 2011; Chapman, 2017; Noack et al., 2019).

Anticoccidial programmes
– Rotation changes the active ingredient or mode of action between production cycles.
– Shuttle programmes use different anticoccidial strategies during different feed phases.
– Combination programmes can broaden anticoccidial activity and may help address reduced sensitivity when appropriately designed (Chapman & Rathinam, 2022).
– Vaccination can provide controlled exposure to selected Eimeria strains and support protective immunity.

Ionophore vs Chemical

Combination programmes
Combining compatible anticoccidial activities can broaden control and reduce dependence on a single mode of action. Programme selection should consider disease pressure, previous anticoccidial history, susceptibility patterns, compatibility and label requirements (Chapman & Rathinam, 2022).

STALLEN’S DUAL APPROACH TO COCCIDIOSIS CONTROL
Stallen South Asia offers a dual approach to coccidiosis management with Manacox Plus, bringing together ionophore and chemical anticoccidial activity in one formulation. This approach is designed to support practical, structured coccidiosis-control programmes while reducing dependence on a single mode of action.

MANACOX PLUS
Manacox Plus is a dual-active anticoccidial formulation combining an ionophore and a chemical anticoccidial. It contains Monensin Sodium 8% + Nicarbazin 8% for practical coccidiosis prevention programmes in broilers.
Key Product Points

WHY A DUAL APPROACH
Using monensin sodium together with nicarbazin brings ionophore and chemical anticoccidial activity into one formulation. This can fit structured prevention programmes where the objective is effective control without unnecessary reliance on a single mode of action. Use should follow the approved label and veterinary guidance.
Practical use
– Use within a planned farm coccidiosis-control programme.
– Maintain good litter quality, ventilation, stocking density and drinker management.
– Review anticoccidial history and flock response when planning future programmes.
– Follow approved dose, withdrawal period and compatibility instructions.

References are available on request.

Introduction

Gut: The First Line of Immune Defence
The intestinal defence system consists of several interconnected components, including the mucus layer, intestinal epithelial cells, tight junctions, antimicrobial substances, gut microbiota and gut-associated lymphoid tissue (GALT).

The epithelial cells form a physical barrier between the intestinal contents and the internal tissues. Tight-junction proteins such as occludin, claudins and ZO-1 regulate the movement of substances between epithelial cells. The mucus layer provides an additional protective environment, while immune cells located within and beneath the intestinal mucosa continuously monitor microbial and dietary antigens.
Thus, the intestine acts as both a selective absorption system and an immune surveillance system.

Gut Microbiota and Immune Development
The intestinal tract contains a complex microbial ecosystem. A balanced microbial population can contribute to pathogen exclusion, production of microbial metabolites, maintenance of intestinal integrity and modulation of host immune responses.
Beneficial microorganisms and their metabolites communicate with intestinal epithelial cells and immune cells. Among these metabolites, short-chain fatty acids (SCFAs) such as acetate, propionate and butyrate are particularly important because they can influence epithelial health, immune-cell activity and inflammatory responses. Therefore, gut microbiota and immunity have a bidirectional relationship. A healthy microbiota supports a healthy intestinal barrier and balanced immune signalling. At the same time, the immune system regulates microbial populations and helps maintain intestinal homeostasis.
What Happens When Gut Health Is Compromised?
Commercial poultry are exposed to several factors capable of disturbing gut integrity, including coccidiosis, bacterial pathogens, mycotoxins, heat stress, poor water quality, nutritional imbalance and dysbiosis.

A compromised gut can result in epithelial damage, disruption of tight junctions, increased intestinal permeability, inflammation and oxidative stress, altered immune response and reduced performance. This process is sometimes described as increased “intestinal permeability” or “leaky gut.”

When intestinal integrity is compromised, nutrients may not be utilized efficiently and microbial products can interact more extensively with host immune mechanisms. The bird may consequently spend additional nutrients and metabolic resources on inflammation and tissue repair rather than growth or egg production.

Coccidiosis, Mycotoxins and Heat Stress

Coccidiosis is a classic example of the gut–immune relationship. Eimeria infection damages intestinal epithelial cells, alters intestinal morphology and stimulates an inflammatory and immune response. Consequently, coccidiosis control is not only a parasite-management issue but also a gut health, nutrition and immune-management issue.

Similarly, mycotoxins can affect intestinal integrity, oxidative status, microbial balance and immune function. Their impact may therefore extend beyond the feed itself to the overall gut–immune axis.

Heat stress is particularly important in tropical poultry production. Heat stress can alter feed intake, intestinal physiology, microbial balance and barrier integrity, potentially increasing inflammatory and oxidative stress. Maintaining gut integrity during heat stress is therefore an important component of maintaining flock resilience.

Gut Health and Vaccine Response
An effective vaccination program depends on the bird’s ability to recognize antigens and develop appropriate humoral and cellular immune responses. This requires adequate availability of energy, amino acids, vitamins, minerals and antioxidants. Therefore, gut health indirectly supports the nutritional foundation required for immune responses. A healthy intestine facilitates nutrient digestion and absorption, while intestinal inflammation or damage can increase nutrient requirements for tissue repair and immune activity. It is important, however, to recognize that good gut health alone does not guarantee vaccine success. Vaccine quality, administration, maternal immunity, biosecurity, disease pressure, nutrition and environmental conditions also influence the final immune response.

Nutritional Support for the Gut–Immune Axis
Nutrition is one of the most important tools for supporting the gut–immune relationship. Zinc contributes to epithelial integrity, cellular proliferation, enzyme activity and immune-cell function. Selenium is an important component of antioxidant defence systems and supports cellular protection and immune function. Vitamins A and E also contribute to mucosal integrity, antioxidant protection and immune responses.
Nutritional interventions such as probiotics, prebiotics, postbiotics, organic acids, enzymes, yeast-derived products, MOS and β-glucans may be used as part of integrated gut-health programs. MOS can support gut health through microbial interactions and pathogen-exclusion mechanisms, while β-glucans can interact with innate immune pathways and influence immune-cell activity. However, responses depend on product source, structure, dose, bird age, diet and challenge conditions; therefore, these products should be evaluated based on scientific evidence and field performance rather than assuming that all products have identical effects.

Practical Approach for Commercial Poultry
A successful gut-health program should not depend on a single feed additive. It should combine:
– High-quality and properly stored feed
– Regular mycotoxin monitoring and management
– Good drinking-water quality and sanitation
– Effective coccidiosis control
– Appropriate vaccination and biosecurity
– Heat-stress management
– Balanced amino acid, vitamin and mineral nutrition
– Appropriate use of probiotics, prebiotics/postbiotics and other gut-health products
– Monitoring of litter quality, feed intake, FCR, mortality and flock uniformity

Conclusion
The gut and immune system should be viewed as two interconnected components of the same biological defence network. A healthy intestinal microbiota, intact epithelial barrier and properly functioning GALT provide the foundation for balanced immune development and response. For commercial poultry, the concept is simple: “Protect the gut to support immunity, and support immunity to maintain flock resilience.”
Gut health is therefore not only about digestion and FCR. It is closely connected with nutrient utilization, immune development, disease resistance, vaccine responsiveness and ultimately flock productivity.
The future of poultry nutrition will increasingly focus on managing the gut–microbiota–immune axis through integrated nutrition, health and farm-management strategies rather than addressing individual problems in isolation.

India is now the world’s second-largest egg producer and among the largest producers of broiler meat. The sector turns over roughly ₹2.7 lakh crore a year, accounts for about 16 per cent of livestock output, and supports close to five million livelihoods.

For a business that began as a rural side activity, it has become one of the fastest-compounding parts of Indian agriculture — poultry’s share of agriculture and allied output has climbed from 2.9 per cent in 2011–12 to 5.0 per cent in 2023–24.

A record price season
The headline numbers are strong. On 5 September, the National Egg Coordination Committee’s average declared rate stood at ₹5.64 per egg across 34 markets, ranging from ₹4.90 in Hospet to ₹6.20 in Kolkata. Delhi was quoted at ₹6.00, Barwala at ₹5.43 and Ludhiana at ₹5.48. That is a comfortable band for layer farms that were selling below ₹5 through much of last year.

Broilers have swung harder. Farm-gate live bird prices in the Delhi region touched ₹140 a kilogram in July against roughly ₹90 a year earlier, while retail chicken moved from about ₹240 to nearly ₹300 a kilogram. Prices have since cooled as the monsoon supply cycle normalised — north Indian integrators were quoting live bird in the mid-₹90s per kilogram in late August — but the annual average is still tracking well above FY25. Care Edge Ratings estimates broiler realisations recovered about 5 per cent year on year in FY26, with live bird averaging ₹99 a kilogram in February–March 2026, more than 20 per cent above the bird-flu-depressed fourth quarter of Fy25.
Data Box 1 · Necc Egg Rates, 5 September 2026 (₹ Per Egg)

Why the margin is not where the price is
Feed accounts for 65 to 70 per cent of the cost of producing a broiler and roughly 68 to 70 per cent of the cost of producing an egg. In a business with that cost structure, a 15 per cent move in feed wipes out a 10 per cent move in output prices. That is precisely what has happened this year.

Compound poultry feed is now selling at about ₹4,400 a quintal against roughly ₹3,600 a year ago. Maize, the energy backbone of the ration, has moved from ₹18–19 a kilogram in April to ₹27–28 a kilogram. Soybean is ruling near ₹6,900 a quintal, well above the ₹5,708 minimum support price for the 2026–27 season.

Data Box 2 · The Cost Side

Two structural forces are behind the maize spike. First, ethanol. Grain-based distilleries have become a large, price-insensitive buyer of maize, and poultry feed mills are now bidding against a sector backed by a national blending mandate. Nearly 60 per cent of India’s maize output already goes to livestock, with poultry alone accounting for roughly 47 per cent of livestock maize consumption. Second, soybean meal. India is short by an estimated 1.5 million tonnes ahead of the new crop, and soybean acreage this kharif is down 4.5 per cent year on year at 10.6 million hectares.

“India is short an estimated 1.5 million tonnes of soybean meal before the new crop arrives — and soybean acreage this season is down 4.5 per cent.”

The policy knot: imports, GM corn and a farm lobby
The livestock and feed industry have asked the Centre to permit imports of about 1.5 million tonnes of soybean meal to bridge the gap. The soybean processing industry has opposed the move, arguing that domestic supply is adequate and that imports would discourage farmers from expanding oilseed acreage. It is a familiar standoff: the same protein deficit, the same two lobbies, a different year.

Poultry industry representatives have also pressed for approval of genetically modified corn, on the argument that higher-yielding maize would give both the feed and ethanol industries cheaper raw material. Under this year’s trade arrangement with the United States, India retained protection on corn and soybean — both predominantly GM crops there — while agreeing to allow imports of distillers’ dried grains and red sorghum for animal feed. That is a partial valve, not a solution. DDGS can replace part of the energy component of a ration; it cannot replace the protein that soybean meal supplies.

For business readers, the policy question is simple to state and hard to settle: India cannot simultaneously run an aggressive ethanol programme, protect oilseed growers from imports, and supply a poultry sector growing at 7 to 8 per cent a year with cheap feed. Something has to give, and so far, the adjustment has been borne by poultry farmers and, downstream, by consumers.

Volumes keep climbing anywayRemarkably, none of this has slowed production. India produced 149.11 billion eggs in 2024–25, second only to China, with commercial farms accounting for about 84.5 per cent of output and backyard poultry the rest. CareEdge estimates egg output at around 155 billion in FY26, rising to roughly 163 billion in FY27, with total meat production moving from about 11 million tonnes to 12 million tonnes over the same period.

Data Box 3 · Production Trajectory

Poultry India puts broiler production growth at 6 to 7 per cent a year for 2026–27, concentrated in Andhra Pradesh, Tamil Nadu and Telangana, with the layer segment expanding more moderately on the back of productivity per bird, automation and value-added products. Andhra Pradesh alone accounts for 18.4 per cent of national egg output, Tamil Nadu 15.6 per cent and Telangana 13.0 per cent; the top five states together produce 64.4 per cent of India’s eggs.

Exports remain a modest but real business. India shipped poultry products worth USD 317.79 million in FY26, with the UAE, Oman, Maldives, Indonesia and Japan the leading destinations. Against a sector of roughly USD 31 billion, exports are still a rounding error — which is itself the opportunity, constrained mainly by disease-free-zone certification and processing infrastructure.

The demand headroom argument
The most persuasive case for investing in Indian poultry is not this year’s price cycle. It is the consumption gap. Per capita egg availability is around 100 to 105 eggs a year against the National Institute of Nutrition’s recommended 180. Per capita chicken consumption is roughly 5 kg a year against a global average close to 17.5 kg. Industry estimates suggest that a one-kilogram rise in per-person chicken consumption would add about 1.43 million tonnes of annual demand.

That headroom is being converted by three commercial forces rather than by policy: quick-service restaurants, organised retail, and the shift from live-bird wet markets to chilled and frozen products. Vertically integrated producers — who own the hatchery, the feed mill, the contract farms and increasingly the processing plant — have been the main beneficiaries, because integration is what buffers a business against the feed-price whiplash described above.
The value-of-output data makes the compounding visible. Poultry meat and eggs generated about ₹56,200 crore of output in 2011–12. By 2023–24 that figure was ₹2.67 lakh crore — a growth rate of 9.3 per cent a year for meat and 6.1 per cent for eggs, against 5.3 per cent for milk and 2.1 per cent for cereals.

“Poultry’s share of agriculture and allied output has risen from 2.9 per cent to 5.0 per cent in twelve years. Few segments of Indian agriculture have compounded faster.”

The recurring tax: disease and weather
Avian influenza remains the sector’s single largest tail risk, and 2026 has been an active year. India reported eleven H5N1 outbreaks on farms in Kerala in December, killing roughly 54,100 birds. In February, about 6,000 birds were culled at a research centre in Patna, with movement restrictions imposed across a nine-kilometre surveillance zone. In March, more than 22,000 birds were culled in Bilaspur district of Chhattisgarh, and in April Karnataka reported its first case of the year at a farm near Bengaluru.

The direct culling loss is rarely the biggest cost. The bigger hit is the demand shock: consumers step away from chicken for several weeks after every widely reported outbreak, and prices in unaffected states fall alongside those in affected ones. Q4 FY25 was a textbook case, and the strong February–March 2026 realisations look impressive partly because they are measured against that depressed base.

Weather has compounded the problem this season. A prolonged heat wave followed by a delayed and unevenly distributed monsoon raised bird mortality and cut egg production in several states, adding to the cost per marketable bird. For layer units, higher mortality in an inflated-feed environment is a double penalty: the feed has already been consumed before the bird is lost.

The industry’s answer, so far, is largely defensive — stronger vaccination protocols, farm-level biosecurity training and surveillance, alongside a push for indigenous vaccine development that would reduce cost for small and mid-sized farms.

What the ratings agencies see
For all the noise, the credit view is constructive. CareEdge describes FY26 as a year of stabilised operating performance — healthy production growth, resilient demand across retail, institutional and food-service channels, improved supply-demand balance and a recovery in profitability with a strong finish in the fourth quarter. Its FY27 outlook for the sector is stable.
The distinction worth drawing is between the organised and unorganised halves of the industry. Integrators with feed-buying scale, forward contracts and processing margins have ridden the cost cycle. Independent broiler and layer farmers, who buy feed at spot and sell birds at spot, have absorbed it. That gap is quietly accelerating consolidation — the most consequential structural trend in the sector right now, and one that will show up over the next few years in contract-farming penetration and in capital-market activity among the larger integrators.

Public support remains focused on the entrepreneurial end. The National Livestock Mission continues to offer a 50 per cent capital subsidy for parent farms, rural hatcheries and brooder-cum-mother units, aimed at small and rural producers rather than at large integrators. It builds capacity; it does not address the feed-price problem that is currently setting margins.

What to watch for the rest of FY27
• The soymeal decision. Whether the Centre permits the 1.5 million tonne import the livestock industry has requested is the single biggest swing factor for margins this year.
• New-crop maize and soybean arrivals. A good kharif arrival could pull feed back toward ₹4,000 a quintal; a poor one locks in current costs through the festive season.
• Ethanol demand for maize. The structural competitor for feed grain is not going away and will keep a floor under maize prices.
• Winter avian influenza. Outbreak seasonality peaks between December and March. Watch for demand shocks rather than culling losses.
• Festive and winter demand. Egg consumption typically strengthens from October, which should support NECC rates even if feed stays elevated.
• Consolidation and capital. Cost pressure is a filter. Expect more contract farming, more integration, and more interest in the sector from public and private capital.

“The bottom line for anyone with capital in this business: India’s poultry demand story is intact and structurally under-served, but 2026 has demonstrated that returns in this sector are set on the input side, not the output side. The operators who will do well over the next eighteen months are not the ones betting on higher chicken prices. They are the ones who have solved for feed.”

References are available on request.

Cyanosis (purple head) is observed in breeder males, typically around 35–40 weeks of age, and is sometimes used as a management indicator (Figure 1). The condition is not limited to one breed or line and may be transient, with color changes throughout the day; cyanosis appears after feeding, then disappears during the day. Affected birds show no respiratory distress, and necropsy reveals few gross lesions except occasional flaccid hearts. Echocardiography has detected aortic insufficiency (AOI) in a significant proportion of affected males, and laboratory findings show elevated hematocrit and hemoglobin concentrations, suggesting increased blood viscosity and potential compensatory polycythemia, a condition where an overproduction of red blood cells compensates for a lack of oxygen. This information is intended to provide physiological context and support practical management decisions, rather than to imply differences between breeds or genetic lines. There is no evidence of a genetic basis for this condition; therefore, management should be the focus to reduce field incidence.

FIGURE 1: An example of affected (left) and unaffected (right) broiler breeder males.

AVIAGEN Brief: Cyanosis (Purple Head) in Broiler Breeder Males | © 2026 Aviagen

PRACTICAL MANAGEMENT OF MALE CYANOSIS

FEEDING AND PHYSICAL STRESS
Cyanosis typically occurs during periods of peak physical stress, such as feeding or mating, when oxygen demand spikes and the heart may struggle to keep pace. For this reason, feed distribution should be completed within three minutes to prevent uneven gorging and panic. Male exclusion grills must be intact to prevent males from stealing hen feed, which increases their body mass and oxygen demand while physically restricting their air sacs. In addition, verify water quality, drinker space, and water line flow rates to ensure they meet the requirements for broiler breeder males. Field observations have also suggested that behaviors such as litter consumption may contribute to transient episodes in some flocks, although the underlying mechanism remains unclear.

BODY WEIGHT AND CONDITION CONTROL
Rear males to a body weight profile that meets or slightly exceeds current breed standards, as these higher profiles help prevent conditions such as Valgus-Varus Deformity (VVD), also known as ‘X-legs’. Achieving and maintaining good body weight and uniformity in male populations is as critical as it is in females, because cyanosis occurs less frequently in well-managed, well-fed males. Over-fleshed males (with a Dimpled U-shaped breast; score 5) are at higher risk since muscle tissue is oxygen-expensive. Therefore, target a fleshing score of 2.5–3 (a Standard V or Standard U-shaped breast; score 2-3) to minimize risk (Figure 2).

FIGURE 2: Scoring system to assess bird body condition (fleshing).

VENTILATION
Oxygen demand peaks during feeding, regardless of temperature. Increase ventilation 10 minutes before and during feeding to maximize oxygen availability. Maintaining good air quality and effective air exchange is important, as suboptimal ventilation, elevated ammonia or carbon dioxide levels, and reduced oxygen availability may add to physiological stress and contribute to symptom expression, even in open-sided housing systems.

TRIAGE AND CULLING
If cyanosis is observed, monitor the bird’s recovery post-feeding. Persistent cyanosis indicates heart failure and warrants culling.

MORPHOMETRIC DOCUMENTATION OF CARDIAC ABNORMALITIES
STUDY OVERVIEW
Research by Floyd D. Wilson et al (2016) documented a high prevalence of left ventricular dilated cardiomyopathy in mature broiler breeder males, both cyanotic and clinically normal. To better contextualize these findings within commercial production, the study also incorporated comparisons to market-age broilers.

KEY FINDINGS
Both cyanotic and normal broiler breeder males showed extensive left ventricular chamber dilation, with no significant difference between groups. Older males (average 42 weeks of age) had significantly higher left and right ventricular weight-to-total heart weight ratios compared with market-age broilers (average 7 weeks of age).

Morphometric data indicated that the left ventricle chamber area-to-total ventricle area ratio increased from 3.2% in broilers to 10% in broiler breeder males; 33% of males had left ventricular volume ratios above 10%, with 13% above 20%. The right ventricle-to-total ventricle weight ratio (RV/TV) increased from 0.18 in broilers to 0.25 in males, and 36% of males exceeded the threshold for right ventricular hypertrophy, although ascites was not observed. Left ventricle wall area-to-body weight ratios were similar between age groups.

Histopathology revealed only minimal endocardiosis, with no substantial changes suggestive of dilated cardiomyopathy.

Collectively, these findings suggest that left ventricular enlargement in broiler breeder males is primarily due to dilation rather than hypertrophy, possibly linked to systemic hypertension and aortic insufficiency, and they highlight the need for further research into the relationship between cyanosis, cardiac dilation, and breeding performance.

CONCLUSIONS AND RECOMMENDATIONS
The combined evidence from pathological and morphometric studies underscores the complexity of health challenges in broiler breeder males. Cyanosis and cardiac dilation are prevalent and multifactorial, impacting both flock management and productivity. Management strategies should prioritize rapid feed distribution, strict control of body weight and uniformity, sufficient drinker space and flow rates, and enhanced ventilation during feeding. Continued research and vigilant health monitoring are essential for optimizing breeder welfare and performance.

Yet despite the widespread use of organic trace minerals (OTMs), one important misconception continues to exist in the industry: that all organic trace minerals are the same.

Looking Beyond Inclusion Levels
When evaluating trace mineral programs, discussions often focus on inclusion rates, mineral concentration, and cost per ton of feed.

However, the true value of a trace mineral is not determined simply by how much is added to a formulation. Rather, it is determined by how much of that mineral is available for absorption and utilization by the bird. This distinction becomes increasingly important in modern poultry production.

Many producers experiencing challenges like, inconsistent performance, reduced meat quality, or variability in the flock focus on nutrient inclusion. Yet nutrients can only contribute to biological functions if they successfully reach the absorption sites where they are needed.

As poultry genetics continue to advance, nutritional efficiency has become just as important as nutritional adequacy. This shift is causing nutritionists to move beyond a simple question of: “How much mineral is in the feed?” to a more important question: “How much mineral is actually available to the bird?”

Understanding the Challenge: Mineral Antagonism
Trace minerals perform important functions throughout the bird’s body. Zinc, copper, and manganese act as cofactors for numerous enzymes involved in bone formation, connective tissue development, collagen synthesis, skin integrity, antioxidant defense, and immune function.

However, the digestive tract is a highly complex environment. As minerals move through digestion, they encounter changes in pH and interactions with dietary compounds such as phytate, fiber components, and even other minerals. These interactions can reduce mineral availability before absorption occurs.

This phenomenon, referred to as mineral antagonism, helps explain why increasing mineral inclusion does not always result in improved mineral utilization. Simply feeding more minerals does not necessarily mean the bird receives more minerals. In many situations, the challenge is not supply. The challenge is bioavailability.

Dietary antagonisms can reduce mineral availability before absorption occurs, limiting nutrient utilization despite adequate inclusion levels

Organic Trace Minerals: A Category, Not a Chemistry
To help improve mineral bio-availability, the industry increasingly adopted organic trace minerals. However, the term “organic trace mineral” can create confusion. Some assume that all OTMs provide similar benefits because they belong to the same category. In reality, organic trace minerals represent a broad group of products that may differ substantially in:
· Ligand type
· Ligand-to-mineral ratio
· Molecular structure
· Bonding characteristics
· Electrical charge of the molecule
· Stability in Upper Digestive Tract
These differences influence how minerals behave in the gastrointestinal tract and how effectively they remain available for absorption. In other words, two products may both be labelled as organic trace minerals while functioning very differently inside the bird.

Why Chelation Matters
Among organic trace minerals, one class stands out from the others: bis-chelates. The word chelate originates from the Greek word chela, meaning crab claw or pincer. Similar to two crabs holding a metal securely giving it the maximum protection a Chelate forms when a ligand connects to a metal atom at more than two points. A 2 five member rings connected to the metal with two points of contact is the most stable complex found in nature. This structure helps provide protection compared with less defined mineral associations. However, not all organic trace minerals are true chelates. True chelates require a neutral charge to protect the mineral and enhance stability. Not all organic trace minerals (OTMs) provide a neutral charge; therefore, not all OTMs are true chelates. Some products are better described as complexes, proteinates, or other association forms. While they are still classified as organic trace minerals, they can differ significantly in chemical stability and behavior during digestion. The degree of protection provided by the mineral structure ultimately determines how vulnerable the mineral may be to antagonistic interactions.
Differences exist among chelates, too. There are chelates where one ligand is bound to the metal and then there are bis-chelates where two ligands are bound, creating a neutral charge and making the molecule less susceptible to antagonism. (see image)

Why Molecular Structure Matters
Research continues to demonstrate that mineral structure influences stability and bio-availability. When minerals dissociate during digestion, they become charged ions that are more likely to interact with negatively charged compounds such as phytate, fiber complexes and other minerals. These interactions can reduce availability before absorption occurs.

For this reason, increasing attention is being given to mineral structures specifically designed to maintain stability throughout digestion. One such approach is bis-chelation technology.

Bis-chelated trace minerals are characterized by a defined molecular structure consisting of one mineral ion bound to two ligands, creating two stable chelate rings. This unique architecture helps maintain structural integrity while moving through the digestive tract.
An equally important feature is their neutral molecular charge. Because neutrally charged molecules are less likely to participate in unwanted interactions, the structure helps protect the mineral, reducing opportunities for antagonism and supporting mineral availability until absorption occurs.

Bis-chelated trace minerals feature a defined molecular structure designed to support stability and mineral availability during digestion.

The Future of Trace Mineral Nutrition
As poultry production evolves, mineral nutrition must evolve with it. The industry’s next opportunity may not come from increasing mineral inclusion rates but from improving how effectively minerals are utilized by the bird. This requires looking beyond product categories and focusing on the scientific characteristics that influence mineral availability. Organic trace minerals can provide significant advantages over traditional inorganic sources. However, not all organic trace minerals are created equal. Their molecular structure matters. Their stability matters. And ultimately, their ability to deliver minerals to the animal matters.

As nutritionists continue searching for ways to improve performance consistency, skeletal integrity, meat quality, and return on investment, bis-chelated trace minerals are an increasingly important technology because they combine defined structure, enhanced stability, and optimized bioavailability into a scientifically designed mineral solution.

Contact your local NOVUS representative to learn more about bis-chelated trace minerals from the company that brought the technology to the animal agriculture industry over 20 years ago.

Dr. Partha P. Biswas, Former Associate Professor & HoD,

Because more poultry meat and eggs are being produced worldwide, people are asking for better, more sustainable ways to farm. This means finding new and better ways to feed animals in the future. From 2000 to 2020, global egg production went up by more than 41%, increasing from 51 million to 87 million tonnes, with an average annual growth rate of 3%.In 2023, poultry meat production hit 145 million tonnes and is still rising. With 6.29 million tonnes produced in 2020, India is fast approaching the level of production in the USA (6.29 million tonnes) produced in 2020. With an average egg size slightly lower than that in the USA (average weight of a standard large chicken egg 56.7 grams (2 oz) in the USA as against 50 to 55 grams in India), the Indian egg sector estimated that they have already overtaken the USA in terms of the number of eggs produced. India produced 149.11 billion eggs in the 2024–25 period, while the United States produced approximately 105 billion eggs in 2025. This growth is making it more important to find sustainable ways to feed animals.Even though raising poultry is less harmful to the environment compared to other types of animal farming, it still has some negative effects, such as increasing global warming, making water too rich in nutrients (eutrophication), and making soil too acidic. Low-carbon poultry feed is now moving from just an idea to real, practical use. Feed is responsible for about 70% of the total carbon footprint in poultry farming, so it’s the biggest area where we can cut down on carbon emissions. To make poultry farming more sustainable, we need to change how we get, mix, and use feed. Soybean meal and fishmeal have been the main sources of protein for animals, used in everything from chicken farming to fish farming. But keeping on using them at the same levels is bad for the environment. The reason we’re looking for alternatives isn’t because these materials don’t work well for animals—they are very effective. It’s because they cause serious environmental and economic problems, especially for systems that try to be sustainable and manage fish resources properly.

CIRCULAR AND ALTERNATIVE INGREDIENTS
Producers are actively moving away from relying entirely on conventional corn and deforestation-linked soy. Feed formulations are increasingly incorporating agro-industrial by-products, former foodstuffs (circular feed), and alternative protein crops like rapeseed and peas.
Life Cycle Assessments show that feeds formulated with these by-products can have a carbon footprint nearly 40% lower than traditional raw material feeds.

THE “BIG THREE INGREDIENTS” OF POULTRY FEED
Poultry sector consumes ~60% of India’s maize (~20+ million tonnes annually).Soybean meal demand: ~6-7 million tonnes domestically. In commercial broiler and layer operations, dry fish meal is rarely used When added at strategic levels, typically 3-8% in starter feeds and 2-5% in grower phases, fish meal enhances palatability, encouraging birds to consume more feed during critical early stages. This increased intake, paired with high digestibility, results in superior weight gains and improved FCR. In the layer segment, specialized demand exists for producing enriched eggs. The long-chain n-3 fatty acids (like DHA) in marine lipids transfer efficiently into the yolk.

1. SOYBEAN MEAL (THE PROTEIN BASE) : Soybean meal is the main source of protein in chicken feed around the world, but it has a big impact on the environment. The protein in soybean meal is high in lysine, which is first limiting amino acid in most chicken diets. This makes it a great match for grains like corn and wheat. India does not allow growing or bringing in raw genetically modified (GM)soybeans or seeds. India’s soybean production fell a lot during the 2025-2026 growing season, reaching about 11 to 12.7 million tons, which is much lower than before, causing a serious shortage of supply. When there are not enough non-GM soybeans locally, they get them from certain African countries. Non-GM soybeans are more expensive than GM ones. Even though GM soybean meal has been allowed sometimes to meet the protein needs for animal feed, there are worries about the effects on the environment. These worries include carbon emissions from cutting down forests in important areas like the Amazon and Cerrado, more risks for climate change, loss of wildlife, and pollution from farm chemicals running into water.

2.CORN / MAIZE (THE ENERGY SOURCE) : Corn provides the bulk energy in most poultry diets. While corn generally has a lower carbon footprint per kilogram than soy, birds eat much more of it. The primary carbon issue with corn is its heavy reliance on synthetic nitrogen fertilizers. Manufacturing these fertilizers is extremely energy-intensive, and applying them to fields releases nitrous oxide (N₂O),a green house gas nearly 300 times more potent than carbon dioxide. Tractor fuel for plowing is another important issue.

3.FISH MEAL (THE SPECIALITY PROTEIN) : Though used in far smaller amounts (typically for young chicks or breeder birds), fish meal has a complex environmental footprint. The issue of TMA accumulation leading to a fishy flavor in brown-shelled eggs arises from a genetic defect in up to 10% of brown-feathered hens. Normally, TMA is oxidized in the liver into a harmless compound by the action of the enzyme trimethylamine oxidase. The synthesis of this enzyme depends on the expression of the FM03 gene, located on chromosome 8. In the case of anon-synonymous mutation in the FM03 gene (designated T3295),hens cannot oxidize TMA, which then accumulates in the yolk. Poultry diets restrict fish meal to 5-10% of total feed due to ecological inefficiencies. Fishmeal is sourced from small forage fish like anchovies and sardines, which are crucial to the marine food web. Overfishing these species endangers higher trophic levels, leading to decline predatory fish, marine mammals, and seabirds.Moreover, forage fish populations are vulnerable to climate change, causing unstable fishmeal supplies and significant price volatility.India is the third-largest producer and exporter of fishmeal. Fig.1:

Fig.1: Typical poultry feed mix

ECONOMIC HURDLES TO TRANSITION OF CIRCULAR PROTEINS
The transition to circular proteins, such as microbial biomass, insect meal, or fermented agro-industrial waste, is essential for stabilizing ecosystems and is crucial for a sustainable livestock industry. However, commercial feed mills face significant economic barriers due to scale, commodity pricing, and supply chain maturity, making it challenging to replace traditional soybean meal. Here are the primary economic hurdles commercial mills face today:

THE PRICE PARITY GAP
Decades of agricultural subsidies, optimized supply chains, and massive economies of scale keep their prices relatively low and stable (historically ranging from $600-$750 per ton for soy, and $1,500 to $2,000 for fishmeal). In contrast, alternative proteins like Black Soldier Fly Larvae (BSFL) or microalgae carry immense initial capital expenditures (CapEx) to build high-tech bio-manufacturing or fermentation facilities.
Although insects like Black Soldier Fly Larvae (BSFL) raised on organic waste represent the ultimate circular protein, converting low-value biomass into high-value feed with a minimal land and water footprint. BSFL defatted protein meal and de-oiled powder generally trade between ₹110 and ₹250 per kg in Indian market & wholesale price roughly between $1,320 and $3,000 USD per ton.

SCALE AND VOLUME CONSISTENCY
Commercial feed mills produce feed continuously, requiring tens of thousands of tons of standardized ingredients every single month. Currently, very few alternative protein manufacturers can guarantee that volume without interruption. If a mill alters its highly specific formulation to include 5% insect meal, and the supplier falls short on delivery, the mill has to halt production, re-calibrate its software, and reformulate the diet using different ingredients. This downtime is extraordinarily expensive.

HIDDEN COSTS OF NUTRITIONAL REBALANCING
Soybean meal and fishmeal are highly dependable. Nutritionists have a clear understanding of how these ingredients function within the digestive systems of fish and birds. When a mill uses insect meal or a plant-based alternative to fishmeal, the amino acid profile changes. As a result, the mill needs to purchase additional synthetic amino acids, such as L-methionine or L-lysine, along with specific feed enzymes to compensate for the missing nutrients. This helps maintain the animals’ growth rates. Even if the base alternative protein is priced competitively, these added ingredients increase the overall cost of the final feed formulation.

RETROFITTING MILL INFRASTRUCTURE
Feed mills are designed to handle, grind, and pellet traditional grains and meals. However, alternative ingredients often have very different physical properties. For instance, some insect meals contain significantly more fat than solvent-extracted soybean meal. High levels of lipids can cause blockages in extruders, reduce the quality of feed pellets (making them prone to breaking during transport), and damage machinery. To effectively use these new ingredients at high levels, mills usually need to invest heavily in upgrading their equipment, such as adding new vacuum liquid-coating systems for fats. Many mills are reluctant to make these costly investments due to financial concerns.

REGULATORY APPROVAL COSTS
The global feed industry has strict rules to stop harmful substances from getting into the food chain. To get approval for a new type of protein, like microbial biomass or insect protein, used in animal feed, companies must do many expensive and time-consuming tests. These tests check for safety, look for heavy metals, and measure how well the protein is digested. This process can take many years.The cost of these tests ends up being passed on to the feed producers, which raises the cost of the ingredients. Unless these alternative proteins can be made in large amounts and sold at prices that are as good as soy or wild-caught fish, they are probably only used in special, high-end, or environmentally friendly feed products, not in regular, mass-produced feeds..Fig.2:

Fig.2: A picture showing how to raise chickens in a way that is good for the environment, people, and the poultry industry. It shows how being efficient with resources, taking care of the chickens’ health and happiness, keeping the farm safe from disease, making sure the chickens are productive, and making the whole food system strong and able to handle challenges are all connected and important.

THE GLOBAL RACE TO DECARBONIZE LIVESTOCK DIET

CIRCULAR INGREDIENTS & CARBON REDUCTION
Upcycling Waste: Using agricultural and slaughterhouse by-products (like DDGS, fruit pomace, and rendered fats) reduces reliance on land-intensive virgin crops and prevents landfill methane. The sustainable use of fruit and vegetable residues (FVRs) in poultry feed formulations has gained considerable attention due to their potential in advancing animal health However, certain challenge such as anti-nutritional factors, palatability issues, and processing techniques are also associated while incorporating these residues into poultry diets. Fermentation technologies create new opportunities to recover nutrients from agricultural residues and improve their value in poultry diets.

Carbon-Optimized Formulation: Modern feed software integrates Life Cycle Assessment (LCA) data to dynamically select ingredients based on their carbon footprint, not just cost and nutrition. LCA is a measurement of the emissions generated during its cultivation, processing, and transport. The software can calculate the exact environmental cost of using raw protein crops (like soy) versus supplementing with synthetic amino acids. It optimizes the diet to prevent protein overfeeding, which simultaneously lowers the feed’s initial GWP (Global Warming Potential) and reduces the nitrogen output (and offensive odors) in the poultry droppings.

THE SHIFT TO DDGS (DISTILLERS DRIED GRAINS WITH SOLUBLES)

Cost Advantage: Maize-based DDGS (₹17-₹20/kg) is significantly cheaper than soymeal (~₹40/kg), driving rapid adoption in the poultry industry.
Substitution Limits: DDGS can replace 25-30% of maize demand. Insect protein and algae can replace small portions of soy (5-10%).
Ongoing Conventional Reliance: Despite these alternatives, conventional ingredients will still make up 60-70% of overall feed requirements.
PRECISION NUTRITION
Targeted Diets: Formulating feed to match exact amino acid and energy needs improves the Feed Conversion Ratio (FCR).
Lower Emissions: Preventing protein overfeeding reduces nitrogen in manure, which directly lowers harmful nitrous oxide (N₂O) emissions downstream. Fig.3

Fig.3: Alternative protein sources for animal feed in a circular bioeconomy could include things like leftover materials from farming and food processing, meals made from insects and worms, leftovers from biorefineries, proteins made by microbes, and by-products from aquatic sources.

BETWEEN REALITY AND RHETORIC: LOW-CARBON POULTRY FEED
Moving from using a wide variety of ingredients in poultry feed to providing exactly what the birds need at each stage of growth is key to creating real low-carbon feed. While some talk about replacing soy with new ingredients, the actual science is about making tiny, precise changes. It’s about giving birds exactly the right nutrients they need, in the right amounts, so nothing is wasted. Real reductions in carbon emissions from poultry feed don’t come from using popular or fashionable ingredients. They come from making sure every part of the feed works as efficiently as possible. Ensuring every gram of feed is used well is the best way a farm can help the environment. Instead of providing too much crude protein, experts can use specific synthetic amino acids like L-Methionine, L-Lysine, and L-Threonine.This helps reduce the total amount of crude protein in the birds’ diets. By cutting crude protein by just 1.5%, farms can lower their carbon footprint by about 70 kg of CO₂ equivalent per ton.

CONCLUSION
Despite having significant potential, incorporating insects, algae, fermented products, and agricultural and industrial by-products into chicken feed continues to face multiple challenges. These challenges include scientific, technical, economic, and legal difficulties. For insects, key issues include variability in their nutritional content based on their diet, high chitin content that complicates protein digestion for chickens, higher production costs compared to traditional protein sources, and the absence of established international safety and quality standards. Consumer acceptance of chicken products derived from insect-based diets remains uncertain, which may hinder large-scale adoption. The effort to reduce the carbon footprint in chicken feed presents a mix of real benefits and exaggerated claims. While some measurable progress is achievable, the extent and impact of these improvements often fall short of what companies assert. Reducing the carbon footprint in chicken feed is neither a complete solution nor a total myth; it represents incremental steps within a broader system that is not sustainable. The true advantages come from the following areas:

– Integrating a circular bioeconomy into feed production
– Minimizing reliance on imported protein
– Utilizing waste materials effectively
– Developing better alternative ingredients

The industry must shift from making grand promises to achieving tangible improvements. This involves recognizing and celebrating small achievements, such as 5-10% reductions, while also being honest about limitations and working towards broader changes that extend beyond mere feed modifications. This conclusion reflects both the actual progress being made and the gap between marketing claims and real-world outcomes, offering a balanced assessment of the industry’s current position regarding sustainable feed promises. Hybrid feeding systems that combine commercial and alternative feed sources generally provide the most consistent results, although maintaining mineral balance is essential during the laying phase.

REFERENCES
1.Vincent Guyonnet (2025) : Chapter 2 World Egg Production and Marketing Trends, In book: Handbook of egg science and technology (pp.9-26) Publisher: CRC Press. DOI:10.1201/9781003254430-3.
2.Hairui Yu et al (2025): Sustainable poultry farming: mitigation of greenhouse gas emissions in poultry farming through nutritional and environmental modulations. World’s Poultry Science JournalVolume 81, 2025 – Issue 4: Pages 1081-1141.
3.Dheeraj Kumar et al (2025): Alternative feed ingredients in poultry diets: A review of nutritional potential, processing technologies, and challenges. International Journal of Veterinary Sciences and Animal Husbandry 2025; SP-10(9): 16-19.
4.Yadi Oktariansyah*& Mustafa Kamal (2026): Alternative Feed Use in Poultry Chickens: Impacts on Feed Efficiency and Physiological Parameters—A Systematic Literature Review. Journal of Natural Sciences ISSN 2721-5571 (Online) Vol.7, No.1 March 2026: 41-53.

FERMNUTRAL: A POSTBIOTIC INNOVATION TO MAXIMIZE GUT HEALTH AND EFFICIENCY IN POULTRY PRODUCTION

Gut Health: The Key to Modern Poultry Production
The expression of the genetic potential of poultry largely depends on intestinal health. The gastrointestinal tract houses nearly 70% of the immune cells and constitutes the primary barrier against enteric pathogens. However, during the early stages of life, immune immaturity increases susceptibility to infections and microbiota imbalances, particularly under intensive production systems.

Traditionally, antibiotic growth promoters (AGPs) have been used to improve productive performance and reduce health-related challenges. However, their continuous use has been associated with antimicrobial resistance, intestinal dysbiosis, and concerns regarding food safety and public health.

In this context, postbiotics have emerged as a sustainable alternative. They are defined as preparations of inanimate microorganisms and/or their bioactive components, including short-chain fatty acids, bacteriocins, exopolysaccharides, peptides, and cell

wall fragments. Unlike probiotics, postbiotics offer greater stability, safety, and consistency, making them an effective alternative to AGPs (Zhong et al., 2022).

Postbiotics vs. Probiotics: A Real Competitive Advantage
The probiotics most commonly used in poultry production, such as Lactobacillus spp. and spore-forming Bacillus spp., present certain limitations when compared with postbiotics.

Lactobacillus species are heat-sensitive microorganisms; therefore, their survival during feed pelleting and storage may be compromised. In addition, factors such as chlorination of drinking water can reduce their viability and, consequently, their biological efficacy.

In contrast, Bacillus spp. exhibit high resistance to elevated temperatures due to spore formation. However, their beneficial effects may depend on successful intestinal germination and on the physiological and microbiological conditions of the host. Furthermore, these bacteria do not permanently colonize the gastrointestinal tract, meaning that their biological impact may depend on continuous administration through feed or drinking water.

Postbiotics exhibit high stability during feed processing and storage, as well as in chlorinated drinking water, because they do not rely on cell viability. Moreover, their bioactive compounds can exert their effects immediately upon ingestion, without requiring germination or intestinal colonization. This allows for a faster, more reproducible, and more consistent response (De Marco et al., 2018).

FermNutral: Bioactive Profile of a Full-Spectrum Postbiotic
FermNutral is a postbiotic developed and manufactured by CPBIO through the controlled biological fermentation of the Clostridium butyricum CPBIO3000 strain using natural raw materials. (Figure1)

The product is supplied as granules with demonstrated stability at temperatures exceeding 80°C (simulating the feed pelleting process). The recommended inclusion rate for poultry is 300–500 g/t of feed. FermNutral is produced under FAMI-QS, FDA-cGMP, and ISO 9001/14001/18001 certifications, which have been maintained since 2001.

FermNutral contains a diverse range of bioactive compounds generated during the fermentation process, including teichoic acids, lipoteichoic acids, butyricin, antimicrobial peptides, and exopolysaccharides.

Within its short-chain fatty acid (SCFA) fraction, butyric acid represents approximately 40% of the total SCFAs. Other SCFAs are present at lower concentrations, including acetic acid (21.6 mg/kg) and propionic acid (81.6 mg/kg).
The vitamin fraction includes vitamin E (13.9 IU/kg), vitamin B1 (17.2 mg/kg), vitamin B2 (5.08 mg/kg), vitamin B5 (57.3 mg/kg), vitamin B6 (98.3 mg/kg), vitamin B12 (0.34 mg/kg), folic acid (30.9 mg/kg), and vitamin K3 (1.97 mg/kg). The mineral profile provides calcium (15.2%), total phosphorus (0.76%), iron (760 mg/kg), zinc (42 mg/kg), magnesium (3,600 mg/kg), and chromium (11.67 mg/kg). Additionally, FermNutral contains 17 amino acids, including glutamic acid (1.37%), alanine (0.59%), valine (0.46%), leucine (0.50%), and lysine (0.29%). Altogether all amino acids are between 10-12% in product.

This unique combination of bioactive metabolites, nutrients, vitamins, minerals, and amino acids supports intestinal integrity, microbial balance, immune function, and productive performance in poultry.

Figure 1: A postbiotic product derived from biological fermentation of Clostridium butyricum CPBIO3000 using natural raw materials

FermNutral: Bioactive Compounds
FermNutral contains a wide range of bioactive compounds generated during the fermentation process, with butyric acid being the predominant short-chain fatty acid (SCFA), representing approximately 40% of the product. Butyrate serves as a major energy source for enterocytes and promotes epithelial renewal, mucin synthesis, and the expression of tight junction proteins. These effects contribute to maintaining intestinal barrier integrity and reducing intestinal permeability.
In addition, butyrate exhibits immunomodulatory and anti-inflammatory properties through its ability to regulate epigenetic processes, promote goblet cell differentiation, and stimulate the activation of regulatory T lymphocytes. It may also enhance intestinal serotonin release, which has been associated with the gut-brain axis and productive performance. Acetic and propionic acids complement these effects by regulating the intestinal environment and inhibiting undesirable microorganisms.

FermNutral also provides teichoic acids and lipoteichoic acids, which are recognized by Toll-like receptor 2 (TLR-2) on the intestinal mucosa. These components modulate both innate and adaptive immune responses, promoting a balance between immune defense and tolerance while helping to control intestinal inflammation (Pasquina et al., 2013; Muhammad et al., 2021).

Furthermore, FermNutral supplies butyricin (a bacteriocin), bioactive peptides, and antimicrobial peptides produced during fermentation, which contribute to the control of undesirable microorganisms and the modulation of intestinal microbiota. Exopolysaccharides are also present and have been reported to stimulate secretory IgA production and strengthen the mucosal barrier. In addition, the product’s vitamin and mineral profile acts synergistically to support immune function, antioxidant status, intestinal integrity, and productive performance.

FermNutral in poultry production
Several experiments conducted in China and Thailand have demonstrated the efficacy of FermNutral in poultry production. In a study at Guizhou University (China) comparing a control diet with additives such as FermNutral, Clostridium butyricum, protected sodium butyrate, and tributyrin in broiler chickens, the postbiotic (FermNutral) was confirmed to improve weight gain (+13%) and reduce feed conversion ratio (-11.68%) compared with the control and other experimental treatments.

In addition, another experiment carried out in a commercial broiler farm in China found that FermNutral reduced the feed conversion ratio (1.73 vs 1.77) and improved viability (+1.94) and the European Production Efficiency Factor (EPEF; 338.70 vs 315.30) in relation to the control diet.
Likewise, in a commercial broiler farm in Thailand, the use of FermNutral increased weight gain (+4.2%) and EPEF (+11.70%) and reduced feed conversion ratio (-7.69%). Furthermore, other trials conducted at Guizhou University (China) showed that FermNutral increased villus height in the duodenum (+9%), jejunum (+4%), and ileum (+8%), and improved the villus height to crypt depth ratio (V/C) in the duodenum (6.92 vs 6.27) and jejunum (5.71 vs 5.04).

Figure 3 : FermNutral effect on Immunoglobulins

Additional results from this experiment reported that FermNutral decreased the population of Escherichia coli in the duodenum (0.014 vs 0.234) and jejunum (0.0004 vs 0.013). Moreover, it promoted the growth of Lactobacillus in different intestinal segments, as determined by the relative abundance of microorganisms through 16S rDNA sequencing. (Figure 2) Finally, the inclusion of FermNutral in the diet improved the concentration of IgA (+13%), IgG (+19%), and IgM (+24%) compared with the control diet. (Figure 3)

Figure 2 : 16S rDNA sequencing to determine relative abundance of microorganisms in Poultry Intestine

Other trials conducted on a commercial farm in China with 48-week-old laying hens showed that FermNutral improved laying rate (+1.4) and shell thickness (+0.05 mm), while reducing feed conversion ratio (-0.06) and broken eggs (-2.6%), without affecting other productive performance parameters.

Likewise, in an experiment carried out at Henan Agricultural University, China, using 50-week-old laying hens, FermNutral increased egg weight (61.63 vs 59.77 vs g) and improved feed conversion ratio (2.08 vs 2.11 vs), while reducing dirty eggs (0.17 vs 0.45 %), broken eggs (0.32 vs 0.47 %), and unfit eggs (0.15 vs 0.28 %). These results demonstrate that FermNutral is an innovative and differentiated alternative within the new generation of postbiotics.

References
De Marco S, et al. (2018). Probiotic cell-free supernatants exhibit anti-inflammatory and antioxidant activity. Evidence-Based Complementary and Alternative Medicine.
Liu H, et al. (2023). Postbiotics modulate gut health and laying performance in laying hens. Animal Nutrition, 14, 244–256.
Muhammad I, et al. (2021). Lipoteichoic acid from Bacillus subtilis improves immune function of broiler chickens. Antioxidants, 10(9), 1414.
Pasquina LW, et al. (2013). Teichoic acid biosynthesis as an antibiotic target. Current Opinion in Microbiology, 16(5), 531–537.
Zhong R, et al. (2022). Gut microbiota and its interactions with postbiotics in animal production. Frontiers in Microbiology, 13, 831495.
About CPBIO – A Global Biotech Company, Based on the global practice of Charoen Pokphand Group in the agricultural, animal husbandry and food industry chain, CPBIO has extensively and deeply participated in the health cause of animals, the earth and human beings with the thinking of the whole industry chain. Organizations and individuals in large-scale validated products and solutions.

About CPBIO – A Global Biotech Company, Based on the global practice of Charoen Pokphand Group in the agricultural, animal husbandry and food industry chain, CPBIO has extensively and deeply participated in the health cause of animals, the earth and human beings with the thinking of the whole industry chain. Organizations and individuals in large-scale validated products and solutions.

Moisture Optimization and Mold Control:
An Integrated Approach to Improving Feed Quality,
Shelf Life, and Feed Mill Profitability in Tropical Climates

Dr. Maloshrie Bora, Senior Program Manager – Feed Safety, Trouw Nutrition South Asia

Across India and South Asia, feed manufacturers today face a common challenge: producing safe, stable, high-quality feed while navigating increasingly variable climate conditions, fluctuating raw material quality, rising production costs, and greater demands for feed efficiency.

Among the many factors that influence feed quality, moisture management remains one of the most underestimated. Yet moisture directly impacts pellet quality, nutrient preservation, feed hygiene, shelf life, production throughput, and overall profitability. Improper moisture management can result in shrinkage, spoilage, mold proliferation, nutrient losses, increased fines, and reduced mill efficiency. Conversely, optimized moisture control can generate significant economic returns while improving feed quality throughout the supply chain.

The Hidden Economics of Moisture Loss
During feed manufacturing, moisture is lost at several stages, including grinding, conditioning, pelleting, cooling, storage, and transportation. Industry observations indicate that feed mills can lose between 0.5% and 1.5% moisture during production, resulting in direct shrinkage and reduced profitability. A feed mill producing 500 tonnes per day can lose approximately 5 tonnes of saleable product for every 1% moisture reduction. In an industry where margins are constantly under pressure, minimizing process losses represents a substantial opportunity for value creation.

Why Adding Water Alone Does Not Solve the Problem
A common industry practice for compensating moisture losses is the addition of water during feed processing. While this may appear straightforward, water possesses high surface tension and does not distribute uniformly throughout the feed matrix. Instead, free moisture often remains on the surface of feed particles, increasing water activity and creating favourable conditions for microbial growth. The challenge for the modern feed industry is therefore not simply increasing moisture content, but ensuring moisture is effectively distributed and retained throughout the feed while maintaining microbial stability.

Mold Growth: A Feed Quality and Profitability Threat
Molds are among the most significant biological threats to feed quality. Beyond visible spoilage, molds consume valuable nutrients, reduce energy content, affect feed palatability, shorten storage life, and create conditions favourable for mycotoxin production. The economic implications can be significant. Raw materials often constitute up to 80% of total feed production costs. Any reduction in nutritional value, shelf life, or feed volume directly impacts both manufacturers and producers downstream.

Emerging Scientific Approaches to Mold Inhibition
Advances in feed preservation technology have moved beyond conventional organic acid applications. Modern solutions increasingly combine multiple modes of action to optimize efficacy under practical feed manufacturing conditions. These technologies typically integrate:
Organic acids
– Buffered acid systems
– Moisture management agents
– Surfactants and emulsifiers
– Synergistic bioactive compounds
Such approaches improve moisture distribution, enhance contact between active ingredients and microbial cells, and prolong preservation effectiveness throughout storage. This scientific evolution reflects the industry’s transition from simple preservation strategies toward integrated moisture and microbial management systems.

Commercial Validation: Integrating Moisture and Feed Hygiene
Research and commercial evaluations have demonstrated that moisture management and mold control must work together. In one reported study, the addition of plain water alone reduced feed shelf life by approximately 33%. However, when moisture was combined with an integrated mold inhibition program, shelf life improved compared to untreated feed while preserving feed quality and stability. Additional commercial applications have shown benefits including:
– Improved feed mill throughput
– Enhanced pellet durability
– Reduced reprocessed fines
– Better moisture retention
– Improved production efficiency
– Greater feed stability during storage
These findings highlight that effective moisture optimization depends on simultaneously managing microbial risks

A Modern Approach for South Asia
Recognizing the unique challenges faced by feed manufacturers in tropical climates, Trouw Nutrition has developed integrated solutions specifically designed to optimize moisture management and feed hygiene.

Among these solutions is the Fylax® portfolio, which combines organic acid technology, moisture management agents, surfactants, and the proprietary ActiProp® technology platform. The objective is to improve moisture distribution, enhance mold inhibition, preserve nutrient value, and support feed mill efficiency within a single integrated program. ActiProp® technology works by increasing mold cell wall permeability and improving access of active ingredients to microbial targets, resulting in enhanced preservation performance compared with conventional approaches. At the same time, moisture-management components facilitate more uniform distribution of moisture within the feed matrix, helping improve operational efficiency and shelf-life outcomes.

In today’s feed industry, moisture management can no longer be viewed simply as a processing parameter—it is a critical driver of feed quality, feed safety, and profitability. As feed manufacturers across India and South Asia face increasing challenges from humidity, raw material variability, and shelf-life pressures, an integrated approach that combines moisture optimization with effective mold control is becoming essential. By preserving nutrient value, reducing shrinkage, improving pellet quality, and enhancing microbial stability, modern feed hygiene solutions can help mills achieve greater operational efficiency while delivering safer, more consistent feed to livestock producers. Ultimately, successful feed preservation is not just about preventing spoilage—it is about maximizing value throughout the feed-to-food chain.