Nellie's Free Range Eggs

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Tag: Jesse Laflamme

"Nest Run" eggs just out of the egg packer on the farm

Adventure of the Egg – From Farm to Table

How does an egg make it from one of our Nellie’s small family farms to your home?

At the Farm

The journey begins in a nesting box, inside the barn, where one of our hens lays her egg. She will typically lay one egg per day, usually in the morning hours. From there the egg will slowly roll down the inclined, padded surface of the nesting box to the conveyor belt that runs the length of the barn. It will usually sit motionless on the belt until about 11AM when the farmer turns on the belt and gets ready to pack eggs in the packing room. The conveyor delivers the egg, along with several thousand others from that morning, to the packing station. A packing machine gently loads the eggs from the conveyor into plastic trays. The farmer, and if they are lucky a family member or two, run the packing machine, pull out any cracked eggs, and carefully stack the trays of eggs onto a pallet. Each pallet contains 900 dozen eggs. The pallet is then rolled into the adjacent cold storage room that is kept at 45 degrees.

On the Road

Once a week, one of our fleet of Nellie’s “Rooster Cruiser” trucks will turn into the farm and roll up to the small loading dock next to the cold storage room. At that time, the week’s worth of eggs, somewhere between ten to twenty thousand dozen, depending on the farm, will be loaded onto the truck. The truck will make a few more stops at other farms in the area until it is full and then proceed to one of our two processing plants in Pennsylvania or New Hampshire.

In the Plant

At the plant, the egg will now be rolled into our “nest run” cold storage area. When we are ready to run the eggs from that farm, the egg trays are loaded into our egg washer where they first go through an Organic citrus-based solution. Brushes do a gentle scrub before they get a sanitizing rinse.

At this point things get pretty technical as each individual egg is photographed and cataloged by the computer. The camera is looking for specs of dirt, cracks and other imperfections. It is also gauging the size of the egg so that down the line it will know to send them to the correct packing station for Large, Extra Large, Jumbo and so on. Each egg is also tapped lightly by a tuning fork at this stage to test for hairline cracks that the camera cannot see. Broken or otherwise problematic eggs are pulled from the line automatically. A little less than 1% of them are simply thrown out to become pig feed for other farms and other are sent to a “breakers” line where they are cracked into our liquid egg products. The intact eggs move up the line to the packaging station based on their size and are automatically placed into cartons, never being touched by human hands. From there they go into master cases and are put back onto a truck.

To the Store

From here, the trail can get a little complicated. Sometimes, our trucks will deliver right to a grocery chain’s central warehouse and they will redistribute them to their individual stores. In other cases, we might deliver them to an independent distributor to haul for us. And in some cases, we might even deliver our eggs to a big factory farm where they are “cross docked” and loaded onto other trucks that do individual store delivery. That’s because we don’t operate a big enough fleet to drive to individual stores, nor would we have enough eggs of our own to deliver even if we did. So in those cases where a big caged egg company is also the sole egg distributor for a given location, we have to “ride along” with them. That’s why you can see our trucks backed up to these mega farms. It’s not because we’re picking up eggs there, it’s because we’re delivering them there! Not an ideal situation, but for us, the only way to get our eggs where they need to go.

On Your Table

The final leg of the journey is from the store’s back room out to the egg shelf, and then home to your kitchen table. The typical time from nest to table is about 25 days. That is well within what USDA recommends for fresh egg consumption and still leaves plenty of time for you to store in your refrigerator before eating. We print the “Best By” date right on our carton as to when we recommend you consume the eggs by. But don’t worry, eggs are very resilient to spoiling and it’s possible to eat them beyond that date and be fine. We don’t recommend that of course, but typically you only lose a little bit of freshness. A good test if you’re not sure of an egg’s freshness is to drop it into a bowl of water. If it sinks, it’s still fresh. If it floats, that means that the egg has had time to develop air pockets between the shell and the egg and it’s time to toss it.

Once your eggs are safely home from the store and in the fridge, it’s time to cook them up!  If you’re looking for recipe inspiration, here are some of our favorites.

Jesse Free Range Post Shot

Is Pasture Raised Better than Free Range?

-By Jesse Laflamme

At Nellie’s, we recognize that the egg aisle is a confusing place.  We hope that over time, our brand can earn your trust so that instead of having to understand every industry term out there like cage free, free range, or pasture raised, that you can simply reach for our package with confidence because you know we’re doing the right thing for hens, farmers, and for you. My family has been raising chickens for three decades.  We have the hard won expertise that comes from doing something for a long time and constantly improving on it as you go. I think that makes our company very unique in the egg industry. We hope that our customers come to understand that we care so much about our hens that if there was a better way to raise them —­ we’d be doing it.

For many decades, the egg aisle has been almost entirely caged eggs coming from hens living truly horrific lives. Finally, after years of advocacy and the growing awareness of consumers about this barbaric form of agriculture, things are beginning to change. We expect that caged eggs will be a thing of the past within the next 10 years.  That’s great news for chickens, and for all of us. But, it also means that there will now be lots of less scrupulous companies trying to jump on the bandwagon. In most cases, this will be the former caged producers now producing cage free eggs, but essentially using the same industrial approach they used in the past. It will represent a marginal improvement in hen welfare, because they will finally be able to move around. But the facilities where they are raised will in no way represent what a consumer would consider to be a farm in terms of scale, crowding, cleanliness or transparency.

On the other side, there is also a group of companies competing to persuade customers that our Certified Humane Free Range standard, which you can read about here, is somehow not sufficient or adequately humane.

Outdoor Space Isn’t An Arms Race

The Certified Humane Free Range standard was developed by scientists and animal welfare experts. It calls for 2 sq. ft. of outdoor access on grass per hen. Now, this may not sound like much if you imagine a bunch of hens all occupying their own little 2’ X 2’ patch of grass. However, it’s important to note that this is just an average over a huge flock, and that not all of the hens use the pasture space at the same time. Not even close. Hens are actually a lot like people in this regard. Whether it’s cool outside, hot outside, or a perfect 70 degrees, a great many of them would simply prefer to be inside at any given moment. In fact, in a typical flock, there are hens that never want to leave the barn. It’s safe, comfortable, cool in the summer, warm in the winter, and there’s fresh water and feed. As a company, we don’t force hens to go outside. We give them ample ways to access the outdoors, and then let the hens decide. If you spend time watching our girls, you will see a steady stream of hens entering and exiting the barns. At any given point in time, the hens that are outside have far more than 2 sq. ft. apiece. And they are very social birds, so while they don’t wish to be crammed into giant warehouses, or tiny cages, they do want to huddle into little groups and cliques to cluck about whatever is on their minds. So there is always more grass and dirt areas open than occupied.

Pasture Raised brands are advertising that they offer from 35 sq. ft. to 108 sq. ft. per hen and suggesting that 2 sq. ft. is insufficient. More is not better in this case. More is just more. And it costs the farmers more to own and maintain that extra space for no discernible purpose that we can see. Agriculture land is scarce and expensive, so forcing small farm families to operate and maintain an excess of it just to brag about how much square footage each hen gets seems insincere and gratuitous to us.

There is a category of very small farms that can make the larger space work economically. But those are typically mixed use, hobby-style, micro farms that exist in a completely separate economic climate, selling to farmers’ markets, CSAs, and to their local area at considerably higher prices. Mainstream grocery distribution requires a higher level of efficiency in order to even get on the shelf. So we support this other style of farm wholeheartedly, just as we support backyard chicken coops, but they are a very small piece of the larger change we seek.

Our bottom line at Nellie’s is first, what is right for the hens? We believe that we understand that better than anyone in the industry and follow the independently audited standard set by Humane Farm Animal Care for Free Range. Second, we want to do what is right for our farmers, and that means helping them raise hens humanely without undue costs. Third, by doing the latter, we can deliver great eggs to our consumers at a reasonable price

It is an exciting time to be in the business of producing humane, ethical eggs. In my lifetime, I have not seen the industry change this dramatically or quickly. Over the next year, we believe many more consumers will begin to decide what they think a reasonable egg farm should look like. We believe that a small family farm producing to the Certified Humane Free Range standard is the best way to meet our country’s egg demands in a humane, sustainable way. We don’t believe that means there is no such thing as too much space for hens, and we’re pretty sure the hens don’t either. So we will continue to try to balance the needs of hens, our farmers, and our loyal customers as best we can.