Nellie's Free Range Eggs

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Tag: Small Farms

"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.

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Nellie’s Free Range Small Farms Outdoor Access Policy

About a decade ago, we made the decision to stop growing our home farm here in New Hampshire to meet the rising demand for our eggs and to instead partner with dozens of small, family farms that need a market for their free range eggs. That was a great decision, for many, many reasons that I’ve touched on in this blog, but it is also considerably more complex than just building more barns on our property. These are independent farms, spread across the country. So it is vital that we have a great relationship with them to insure that our high standards of quality and humane animal care are never compromised.

One of the ways we do that is by having an Outdoor Access Policy that each farmer agrees to adhere to. Why? Well here’s a little fact you may not know. It’s much safer and easier for a farmer, even conscientious ones like ours are, to keep their hens inside the barns. The flock represents their family’s livelihood, and without their flock, and the eggs they lay, that livelihood could disappear. So naturally, they want to protect it. And while the pasture is something hens clearly enjoy, it’s not as safe as being inside. Threats include predators like foxes and weasels, Avian Influenza from passing migratory foul, cold weather, and even rain and standing water. Hens are a bit like kids, they don’t always know what is good for them and can easily become sick by too much exposure to chilly, cold weather or rain. On top of all that, the farmers want them to learn to lay their eggs in the nesting boxes inside, otherwise, the labor to collect the eggs becomes untenable. So for all these reasons, it can be tempting to keep the girls inside. Most of our farmers enjoy seeing their hens in pasture every day so much, they don’t need to be encouraged to open up the doors, but to make absolutely sure that all our flocks are getting the same humane treatment, we have our policy.

Some of the stipulations include:

  • If the temperature is below 45 or above 93 degrees Fahrenheit, we recommend keeping the hens inside.
  • If there is rain, snow or standing water, we recommend keeping them inside until it clears.
  • During the short period when the hens are laying their first eggs, the farmers need to train them to lay in nests to ensure they do not lay eggs outside.
  • During high-risk periods where a disease like Avian Influenza is a known hazard for that area, in consultation with our team of experts, we may request that they keep the flock inside.
  • Lay times – most of our hens become accustomed to laying in the morning hours. In order to accommodate laying in nest boxes rather than pasture, they may keep the flock inside during the morning lay hours.

They must record their decisions and any exceptions to normal outdoor access due to the above conditions in log books that our auditors can review each week.

This is one of the many ways we are working to help restore human-scale agriculture back to a country with 320 million mouths to feed. It’s a balance between doing everything we can to help the farmers be successful and reduce their risk, while at the same time insuring that we’re farming in a way that is moral and responsible.