1. UN ECE Convention on Long-Range Transboundary Air Pollution Průhonice, Czech Republic April 2006 COSTS OF BAT’s IMPLEMENTATION FROM PIG PRODUCTION IN SPAIN; A NEW APPROACH Carlos Piñeiro 1, Pilar Illescas 2, Gema Montalvo 2 and Manuel Bigeriego 3 1 PigCHAMP Pro Europa S.A. 2 Tragsega S.A.; 3 Spanish Ministry of Agriculture, Fisheries and Food

2. Methodology The calculation have been carried out according to the methodology set out in the IPPC Reference Document on Best Available Techniques for intensive Rearing of Poultry and Pigs Current costs should be used for all calculations Capital expenditure should be annualised over the economic life of the investment (deducting any grants). Annual running costs should be added to the annualised cost of capital. Changes in performance should be taken into account The calculations are based on an amortisation rate of 5% (current rate of interest commonly incurred by farmers).

3. Categories of techniques Techniques may be described by one of the following categories: Feed Housing Manure or slurry storage Application of manure or slurry to land

4. Units used for assessing cost (I) CategoryUnits Feed € per place per year Housing Manure or slurry storage € per m 3 or tonnes per year Manure or slurry land application

5. Units used for assessing cost (II) CategoryUnits Feed € per place per year € per kg pig produced Housing Manure or slurry storage € per m 3 or tonnes per year Manure or slurry land application

6. Units used for assessing cost (II) Strong requirement from the Spanish producing sector to present it so. But also, it is very logical. Cost are also expressed as € per kg pig produced Assumptions for the calculations: –Equivalences: 1 sow productive place produces 20.00 pigs marketed/year 1 gestating place produces 26.60 pigs marketed/year 1 lactating place produces 80.00 pigs marketed/year 1 nursery place produces 5.79 pigs marketed/year 1 grower place produces 2.94 pigs marketed/year 1 pig marketed produces 1.25 m 3 of slurry –Pig marketed = 100 kg body weight

7. Results Feeding techniques SYSTEM Extra-costs (€/place and year) Extra-costs (€/kg pig produced and year) Phased feeding of growing pigs 1.520.0052 Low protein diet supplemented with amino acids 0.39 – 2.61 Time variation (soya bean and aminoacids prices) 0.0013 – 0.0088 Phytase supplemented diets -0.191 – 0.015-0.0006 – 0.0001

8. Results Animal housing. Gestating sows SYSTEM Extra-costs (€/place and year) Extra-costs (€/kg pig produced and year) Reduced manure pit 5.69 – 6.830.0021 – 0.0030 Littered system 47.61 – 55.35 (new buildings) 72.71 – 80.45 (existing buildings) 0.0179 – 0.0208 (new buildings) 0.0273 – 0.0302 (existing buildings) Frequent slurry removal00

9. Results Animal housing. Nursery SYSTEM Extra-costs (€/place and year) Extra-costs (€/kg pig produced and year) Manure channel with sloped side walls 0 – 0.23 (new buildings) 1.27 – 2.67 (existing buildings) 0 – 0.0004 (new buildings) 0.0022 – 0.0046 (existing buildings) Partly-slatted floor 0 (new buildings) 0.88 – 2.25 (existing buildings) 0 (new buildings) 0.0015 – 0.0039 (existing buildings) Frequent slurry removal00

10. Results Animal housing. Finishers SYSTEM Extra-costs (€/place and year) Extra-costs (€/kg pig produced and year) Manure channel with sloped side walls 0 – 0.73 (new buildings) 6.45 – 7.74 (existing buildings) 0 – 0.0025 (new buildings) 0.0219 – 0.0263 (existing buildings) Partly-slatted floor 0 (new buildings) 3.61 – 4.33 (existing buildings) 0 (new buildings) 0.0123 – 0.0147 (existing buildings) Littered system 20.16 – 25.72 (new buildings) 36.51 – 42.07 (existing buildings) 0.0686 – 0.0875 (new buildings) 0.1242 – 0.1431 (existing buildings) Frequent slurry removal00

11. Results Slurry storage techniques SYSTEM Extra-costs (€/m 3 and year) Extra-costs (€/kg pig produced and year) Flexible cover for slurry lagoon 2.300.0288 Natural crust00

12. Results Spreading techniques SYSTEM Extra-costs (€/m 3 and year) Extra-costs (€/kg pig produced and year) Rapid incorporation by ploughing of pig slurry 0.53 – 0.610.0061 – 0.0076 Rapid incorporation by cultivation of pig slurry 0.23 – 0.260.0029 – 0.0033 Slurry application by trailing hose machine 0.79 – 1.210.0099 – 0.0151 Slurry application by trailing shoe machine 0.92 – 1.410.0115 – 0.0176 Open slot shallow arable injector 1.01 – 1.410.0126 – 0.0176

13. Conclusions € per kg pig produced can be calculated for every Member State conditions It is more easily understood than € per place per year or € per m 3 per year, in the production sector Calculations can be also performed for poultry It is easier to calculate the cost in the whole process and its final influence We propose to consider this methodology for future revisions

14. Thank You (in special to Martin Ryan and DEFRA)

15. Evolution extra cost low protein technique

16. Littered system for gestating sows (I) Technical description: –Building capacity: 30 places –Building surface: 42 m 2 –Floor: 100% concrete slat Assumptions for the calculations: –Concrete solid floor life: 10 years –Dunghill life: 15 years –Repairs (for both): 1% investment costs –Interest rate: 5% –Straw cost: 0.04 – 0.10 €/kg –Straw need: 2.92 kg per sow and week –Ratio occupation building: 85% –Manpower: 2 hour per week (manual); 0.78 h per week (mechanized) –Manpower cost: 15 € per hour (manual); 30 € per hour (mechanized with tractor and fuel) –Slurry produced per sow: 2.50 m 3 per place per year –Slurry application cost: 0.70 €/m 3 –Pit need: 25.2 m 3 –Pit construction cost: 10 €/m 3

17. Littered system for gestating sows (II) New buildings UnitsCapital cost (€)Total cost (€/unit) Investment cost Dunghill construction€3412 Annual cost Dunghill amortizationPlace10.96 Dunghill repairsPlace1.14 StrawPlace5.16 – 12.90 Manpower (mechanized)Place40.50 Pit costPlace-8.40 Slurry applicationPlace-1.75 TotalPlace47.61 – 55.35

18. Littered system for gestating sows (III) Existing buildings UnitsCapital cost (€)Total cost (€/unit) Investment cost Floor substitution€1120 Dunghill construction€3412 Annual cost Floor amortizationPlace4.83 Dunghill amortizationPlace10.96 Floor repairsPlace0.37 Dunghill repairsPlace1.14 StrawPlace5.16 – 12.90 Manpower (manual)Place52 Slurry applicationPlace-1.75 TotalPlace72.71 – 80.45

19. Littered system for finishers (I) Technical description: –Building capacity: 1440 places (10 rooms) –Building surface: 1450 m 2 –Floor: 100% concrete slat Assumptions for the calculations: –Concrete solid floor life: 10 years –Dunghill life: 15 years –Repairs (for both): 1% investment costs –Interest rate: 5% –Straw cost: 0.04 – 0.10 €/kg –Straw need: 2.10 kg per pig and week –Ratio occupation building: 85% –Manpower: 2 hour per place per year (manual); 0.80 h per place per year (mechanized) –Manpower cost: 15 € per hour (manual); 30 € per hour (mechanized with tractor and fuel) –Replacement of concrete slat: 2540 € –Concrete solid floor price: 15 €/m2 –Slurry produced per pig: 2.50 m3 per place per year –Slurry application cost: 0.70 €/m3 –Pit need: 910 m3 –Pit construction cost: 10 €/m3

20. Littered system for finishers (II) New buildings UnitsCapital cost (€)Total cost (€/unit) Investment cost Dunghill construction€6825 Annual cost Dunghill amortizationPlace0.46 Dunghill repairsPlace0.05 StrawPlace3.72 – 9.28 Manpower (mechanized)Place24.00 Pit costPlace-6.32 Slurry applicationPlace-1.75 TotalPlace20.16 – 25.72

21. Littered system for finishers (III) Existing buildings UnitsCapital cost (€)Total cost (€/unit) Investment cost Floor substitution€41600 Dunghill construction€6825 Annual cost Floor amortizationPlace3.74 Dunghill amortizationPlace0.46 Floor repairsPlace0.29 Dunghill repairsPlace0.05 StrawPlace3.72 – 9.28 Manpower (manual)Place30.00 Slurry applicationPlace-1.75 TotalPlace36.51 – 42.07