Local feed for local birds: How extruded-expelled soybean meal could reshape poultry supply chains

By Tanner Thornton, MS
Graduate Research Assistant, University of Tennessee
Knoxville, Tennessee

I grew up in Tennessee, though my early experience was with cow–calf operations rather than poultry. That background taught me the importance of maximizing local resources, a lesson that still resonates as I study poultry systems today.

One persistent challenge I see is the continued dependence of broiler production on feed ingredients processed far from where the birds are raised. Despite Tennessee producing over 1.6 million acres of soybeans each year,¹ the state lacks a solvent extraction facility. As a result, soybeans are typically shipped out of state, processed at large crushing plants and returned as meal — a supply chain that wastes time, fuel and money while introducing unnecessary risk and inefficiency.

This disconnect between where soybeans are grown and where feed is produced highlights the need for more regionally integrated, flexible processing solutions tailored to Tennessee’s agricultural strengths.

Why EE-SBM makes sense

Solvent extraction plants require extremely high throughput, typically hundreds of thousands of bushels per day, to be economically viable. This scale of operation demands major capital investment and consistent volume, which is why states like Tennessee lack this infrastructure.

One alternative that addresses these geographic and logistical challenges is extruded-expelled soybean meal (EE-SBM). It is produced using a combination of heat and mechanical pressure, with no solvents, no hexane and no massive industrial infrastructure, making it an especially attractive option for states like Tennessee.

EE-SBM also has a nutritional advantage: It retains approximately 6% to 8% residual oil, compared to less than 1% in solvent-extracted soybean meal.² This oil contributes directly to the energy density of poultry diets, reducing or even eliminating the need for supplemental fat sources such as poultry fat or refined soybean oil.

The nutritional advantage is particularly valuable for small- and mid-sized feed mills, where blending and storing added fats can be logistically challenging and expensive. By providing both protein and energy in a single ingredient, EE-SBM simplifies formulation, reduces the number of inputs in batching and streamlines delivery. These benefits also improve formulation accuracy and operational efficiency.

Moreover, studies have shown that EE-SBM, when properly processed, maintains high amino acid digestibility and delivers consistent metabolizable energy.³^,⁴

Supply chain gaps, geographic realities

Broiler production remains a cornerstone of Tennessee agriculture. In 2023, broiler cash receipts totaled $794.4 million, representing a 91% increase from $416.0 million in 2011.⁵^,⁶ Meanwhile, soybean growers continue to produce substantial volumes, especially in the western part of the state.⁷

These two industries are deeply intertwined. Poultry now consumes 67% of all US soybean meal, with broilers accounting for the largest share.⁸ This share has steadily increased over time, further tightening the link between soybean and poultry production.

At the same time, feed remains the largest operating expense for broiler producers, often representing over two-thirds of production costs. This mutual dependence underscores the need to align feed sourcing with local crop production.

Yet despite this synergy, most of Tennessee’s soybeans are shipped out of state, often to solvent extraction plants in the Midwest or northern Alabama, and the resulting meal is hauled back to integrator feed mills. According to the National Oilseed Processors Association, the majority of US crushing capacity is concentrated in the upper Midwest, with only two plants located in northern Alabama and one in north Georgia⁹ This long-distance loop adds cost, inefficiency and vulnerability to a system that could otherwise thrive on local coordination.

Evidence from research, industry

Multiple studies have shown that EE-SBM, specifically Insta-Pro International’s ExPress^® soybean meal, can match or outperform traditional solvent-extracted soybean meal in broiler diets. In a study by Meyer and Bobeck (2021), male Ross 308 broilers fed diets containing ExPress soybean meal and high-shear dry-extruded corn demonstrated over a 6% improvement in feed-conversion ratio and nearly 13% higher weight gain, reaching market weight 4 to 5 days earlier than birds fed traditional solvent-extracted soybean meal.¹⁰

Karr-Lilienthal et al. (2006) evaluated commercial EE-SBM samples processed at 150° C to 160° C (302° F to 320° F) and found high protein solubility, low urease activity and consistent amino acid profiles, confirming EE-SBM’s suitability as a high-quality protein source.¹¹ More recently, Salih et al. (2023) showed that replacing solvent-extracted meal with EE-SBM improved intestinal villus height and absorptive surface area, supporting better nutrient utilization in broilers.¹²

Together, these studies demonstrate that EE-SBM is a nutritionally viable alternative to solvent-extracted soybean meal, with additional benefits that may support its use in regional poultry feed systems.

Research vision, local Impact

Our lab is partnering with Insta-Pro International to process Tennessee-grown soybeans into consistent-quality EE-SBM. While our pen trials are still in the planning phase, we aim to evaluate broiler performance, feed conversion and energy utilization using controlled pen trials. We also aim to quantify true metabolizable energy and, ultimately, validate EE-SBM on a commercial scale. These data will help establish formulation benchmarks for EE-SBM produced in-state and support its adoption as a primary feed ingredient in regional poultry systems.

Beyond nutrition, EE-SBM presents clear economic and environmental advantages. It keeps feed dollars within Tennessee, supports rural jobs and reduces transportation-related emissions by shortening the supply chain. These benefits are especially valuable in today’s environment, where feed and fuel costs fluctuate and global trade remains unpredictable.

Finally, the system supports circular agriculture: Soybeans are grown in-state, processed locally, fed to broilers raised nearby and the resulting litter is returned to cropland as fertilizer. It’s a closed-loop model that reflects both resource efficiency and common sense.

Final thoughts

We’ve grown used to centralized, long-distance supply chains for poultry feed. But it’s time to ask whether that model still makes sense in today’s agricultural landscape. Tennessee has the birds. Tennessee has the beans. What it lacks is the infrastructure to connect the two. EE-SBM could be the missing link.

As feed and fuel prices fluctuate and global supply chains face ongoing uncertainty, building flexible, regionally aligned feed systems is no longer optional. It’s essential. EE-SBM isn’t a theoretical solution; it’s a proven technology that aligns with the agricultural strengths already present in states like Tennessee.

I believe we’re entering a new chapter in feed strategy, one that values proximity, resilience and common sense. Sometimes the best solutions aren’t new. They’re just processed a little differently.

References

1. 1. Menard J. 2024. Tennessee Agri-Industry Brief: Soybean Production Fact Sheet (RR 23-004-D). University of Tennessee Institute of Agriculture.
   2. Insta-Pro International. Why You Should Formulate with ExPress® Soy Meal. 2020. Retrieved from https://www.insta-pro.com/en/blog/nutritionandtechnologies/why-you-should-formulate-with-express-soy-meal/
   3. Meyer MM, Bobeck E A. Growth performance of male broilers fed ExPress® soybean meal and high-shear dry-extruded corn. J Appl Poult Res. 2021:30;100191.
   4. Karr-Lilienthal L K, Bauer LL, Utterback P L, Zinn KE, Frazier RL, Parsons CM, Fahey GC. Chemical composition and nutritional quality of extruder/expeller soybean meals for poultry diets. J Agricult Food Chem. 2006;54(21);8108–8114.
   5. Menard J. 2024 Tennessee Agri-Industry Brief: Poultry Fact Sheet (RR 23-003-B). University of Tennessee Institute of Agriculture.
   6. Tennessee Department of Agriculture. Sharing in the Success: Tennessee Agriculture 2013 Annual Report and Statistical Summary. Nashville, TN.
   7. Menard J. 2024. Tennessee Agri-Industry Brief: Soybean Production Fact Sheet (RR 23-004-D).
   8. S. Soybean Export Council. SoyStats 2024: Soybean Meal U.S. Use by Livestock. Retrieved from https://soystats.com/soybean-meal-u-s-use-by-livestock/
   9. National Oilseed Processors Association. (n.d.). Member Map. Retrieved from https://www.nopa.org/map/
   10. Meyer MM, Bobeck E A. Growth performance of male broilers fed ExPress® soybean meal
   11. Karr-Lilienthal L K, Bauer LL, Utterback P L, Zinn KE, Frazier RL, Parsons CM, Fahey GC. Chemical composition and nutritional quality
   12. Salih FS, Khedr N, Ahmed T, Mohammed L S. Impact of extruded-expelled soybean meal on carcass traits and intestinal morphometry in broiler chickens. Advanc Anim Vet Sci. 2023:11(3);410–416.