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A low-pressure sprinkler system should not be confused with the standard fogging systems. While fogging systems deliver a fine mist, low-pressure sprinklers produce a larger water droplet that does not hang in the air but drops straight to the floor. As the droplets hit the birds, they are stimulated to stand up and migrate to feed and water.

The settings in the controller can be configured to match any management scheme by varying the starting and ending set points for dates, times and temperatures in both cooling and activity modes. The following is an example of a typical operating sequence. 

Sprinkling encourages bird migration to feed and water

As the building temperature increases and the building goes into tunnel mode, the sprinkler system begins to activate its first stage setting at 2 degrees above set point.   The system runs for 10 seconds every 30 minutes. The birds react by standing and releasing the heat trapped under their bodies, which is removed by the ventilation system.  

In the second stage, the sprinkler system increases output at five degrees above set point by operating for 20 seconds every 15 minutes. The trapped heat is released more often as the bird's activity increases and the additional sprinkling begins to create some evaporative cooling on the birds.  

At eight degrees above tunnel mode, the sprinkler control enters into its third stage increasing to 20 seconds every seven minutes. Wind speed should be at least 600 feet per minute, creating wind chill and evaporative cooling on the birds minimizing any felt heat stress.

GrowerSELECT control with sprinkler head assemblies

If outside temperatures continue to rise and the barn controller activates the evaporative cooling system, the sprinkler system will drop back to either stage two or three.   The large water droplets hitting the birds continue to stimulate their activity, encouraging frequent migration to the feeders and waterers.  

Increasing the evaporating cooling set point to 12 degrees above when the tunnel doors are activated may save up to 80% of the water normally used during the initial cooling stages.  

The building is also operating at a low humidity level allowing the birds to more efficiently cool themselves through natural respiration.  

Producers may also see increased cool cell pad life, as the system will operate less frequently allowing more time for the pad to dry between cycles.

Georgia Poultry booth at 2017 IPPE show

Georgia Poultry highlighted two new products, scheduled for release later this spring, at this year's show in Atlanta.

Classic Flood Light Kit illuminates control pan to encourage bird activity.

The Classic Flood Light Kit provides supplemental light to attract birds to the end control pan. The elevated activity level increases feed line run time to keep the feeders full, particularly when starting a new flock.

The Classic Flood Light Kit installs under the control unit directly projecting light into the feed pan below. This arrangement eliminates the shadows common with other add-on kits that mount on top or to the side of a control unit.

Six, long-lasting LED lights.

The mounting plate features six; long-lasting LED lights separated into two banks on either side of the feed pan. The kit can be installed on any existing Classic Flood control pan and is hardwired directly into the control unit. This integration into the control unit removes the need for additional power cords or outlets.

GrowerSELECT sprinkler control with drop assemblies.

The GrowerSELECT Sprinkler System offers producers a system to increase bird activity for improved weight gain and more efficient heat removal.  

The system turns on at short preset intervals sprinkling the birds with large water droplets.   As the droplets hit the birds, they stand and release captured heat underneath allowing ventilation airflow to remove it from the building.  

This elevated activity also causes the birds to migrate to the feeders and waterers promoting increased weight gain and improved feed conversion.  

Low pressure (50 psi), rotating sprinkler assemblies cover approximately 450 square feet each and are available in different drop lengths to match varying building configurations.  

The HSWS-01 control unit automatically increases the run time and frequency of the system operation to cope with increasing heat stress as the building temperature increases.  

Look for more information on these new products on our blog, website, and Facebook page later this spring.

Hog Slat bins feature the industry's heaviest galvanized coating.

Steel corrosion, commonly referred to as rust, is an oxidization process occurring when iron in steel is exposed to oxygen and water. Rust causes steel to thin over time, reducing its strength and causing product failure.

Paint coating protects steel from elements until damaged.

Any coating, which provides a barrier to moisture and oxygen, protects steel from corrosion. A painted surface provides an effective barrier until it is broken allowing moisture and oxygen to come in contact with the steel beneath. Rust develops at the breakage point and can even extend under the protective paint barrier.

Galvanized coatings protect steel even when damaged.

Similar to paint, a galvanized coating forms a protective barrier to protect steel from moisture and oxygen. Galvanized coatings also provide a second method of protecting steel by electrochemically "sacrificing" the zinc in the present of corrosive elements.   In other words, the zinc corrodes, until it is depleted, instead of the metal underneath. Because it is physically bonded to the metal, galvanized coating does not allow rust to extend beneath its surface.

Heavier G100 galvanized coatings offer 10% longer service life.

Galvanized coatings are expressed in ounces per square ft with conventional coatings designated as G30, G40, G60, and G90. These refer to thickness of .30, .40, .60 and 90 oz./ft², respectively. Corrosion resistance is directly proportionate to the amount of zinc coating on the steel. Therefore we would expect the service life of G90 steel to be roughly three times that of G30 in the same environment. Likewise, increasing the galvanized coating on a feed bin from G90 to G100 increases the bin's service life by 10%.

Galvanized steel is an excellent choice for use in feed bin fabrication, as it does not degrade when exposed to the sun's ultraviolet rays like painted coatings or poly bins.

In addition to heavier galvanized coatings, Hog Slat bins are manufactured from stronger Grade 55 steel, come with an improved ladder design and water deflecting Weather Edge™. Every bin is backed by an extended 5-year warranty. To see more go to Bulk Feed Bins.  

By Austin Baker
Ventilation Director, Hog Slat Inc.

WindStorm 54" fans

As the industry continues to increase wind speeds in broiler houses, we need to be mindful of maintaining a balance in a tunnel ventilation system.   A ventilation system operating at a high static pressure does not necessarily mean it is optimized for wind speed.

I was recently called on to troubleshoot the ventilation system on a new broiler farm. The owner was concerned because the static pressure in the new buildings was running between .10" and .14" while the static pressure in several older buildings of similar size was closer .20" - .22”. He suspected the fans in the newer buildings might not be operating correctly and not delivering their maximum ventilation rates.

Inexpensive WeatherFlow wind meter for smartphones

We selected a spot 50' in front of first tunnel fan and recorded a reading of 715 fpm with a static pressure of .22" in the older facility. In the new building recordings from a similar location registered 805 fpm with a static pressure of only .14”. In other words, the new house was operating with a lower static pressure but still delivering almost 100 fpm higher wind speed.

In fact, we were able to increase wind speed and reduce the static pressure in the older house by shutting off two fans. The static pressure went down to .12", and the wind speed accelerated to 770 fpm.

Tego Tunnel Doors

Here's a simple test to perform in any house to find the balance point. Put the house in full tunnel mode and pick a spot 50’ in front of your fans to measure wind speed. Take a measurement with all fans running and then turn off a fan. Go back to the original measuring point and take another reading. If the wind speed went down then, the system is operating correctly. If it stayed the same or went up, then continue the process until you see a drop in airspeed. This exercise will tell you if you need to take action to correct the restrictions on the system. For example, cool cell pads may be clogged or not sized correctly, or the tunnel doors are restricting the airflow.

By Paul Horne
Gas-Fired Products Inc.

Radiant heat has gained wide acceptance across the industry for heating the brooder area of poultry houses.   Because radiant heat delivers heating energy directly to the birds and floor, radiant offers significant advantages compared to forced air heat including; 15-25% more efficiency, drier litter, and creating a heat-storing thermal reservoir for the birds at floor level.

An additional benefit is the varying temperature gradients allowing the birds to seek their particular comfort zone. Temperature distribution graphs represent the heat profiles for each radiant heating product. Knowing the expected heating pattern for each style of radiant heater helps producers choose the best product for their particular application.

In the following diagrams, we show typical layouts for a 66' x 300' center brooder area for each type of radiant heaters. These are general layouts and not unique to a particular building design or geographical area. Each facility requires a heat loss calculation to determine the actual Btu/hr. needed.

Heating pattern for GRO40 brooder

40,000 BTU brooders with a round canopy project an even, circular heat pattern on the surface below. The emitter extending below the canopy reduces center hot spots and increases the overall diameter of the heat pattern.

Brooders normally have the lowest initial cost and offer a broad range of equipment options, including direct spark or pilot ignition systems which can be controlled individually or in zones. Installation is straightforward and flexible, allowing for multiple floor layouts. Brooders can be winched to different heights during the flock to change the heat pattern. Stainless brooders offer added corrosion protection for houses using litter treatments. It is important to thoroughly clean brooders after each flock to maintain optimal efficiency.

Heating pattern for GROTube

Straight radiant tube brooding systems deliver a large pear-shaped heat profile with the highest floor temperatures located directly under the first tube and with lower temperatures at the far end. Typical tube lengths range between 30 ft.-60 ft. long with heating capacities ranging between 100,000 to 150,000 Btu/hr.

Straight tube heaters are mounted near the ceiling and are not raised and lowered like radiant brooders. Each model has a recommend mounting distance from the ceiling based on clearance to combustibles. Because straight tube heaters draw fresh air from outside the brood chamber, there is less maintenance than systems that bring their combustion air from inside the house.

Tube heaters have the advantage that they can be either a single stage or a two-stage unit, where the low fire will result in a different and smaller heat pattern.

Heating profile of Big Foot heaters

Another radiant product type is the U-Tube heater, which offers an improved rectangular heat pattern when compared with the straight tube heaters. Because the heat inputs are lower, the hot spot under the burner is less intense than with the larger heat input straight tube heaters. Angling the reflectors towards the building sidewalls results in extended heating footprint. Sizes range from 12 ft. to 15 ft.long rated at 60,000 – 90,000 Btu/hr.

U-Tube heaters share the same advantages and disadvantages common to all tube heaters; higher installation costs along with the convenience of being mounted up out of the way and reduced maintenance.

Their biggest advantage lies in the improved heat patterns. The heat patterns are larger with a more rectangular shape than brooders and more even temperature distribution than straight tube heaters. The rectangular heating profile of U-Tube heaters provides uniform heat distribution throughout the brood area. Chicks can easily move in and out of the temperature gradations seeking their individual comfort zones.

When a local FFA chapter asked for industry support, Georgia Poultry's Heath Whiddon jumped at the chance. Heath explained, " My involvement in FFA throughout my middle school and high school year shaped my career path in animal agricultural. After graduating from UGA, I worked for Perdue Farms before joining Georgia Poultry as outside sales rep."

Heath and kids examine 4-hole nest used in chapter project

Clifton Ridge Middle School in Macon, GA recently started an FFA chapter and chose as their SAE (Supervised Agricultural Experience) a project involving laying hens. Local Perdue Farms Director of Operations, Wally Hunter and live production manager, Tim Little alerted Heath about the project and joined with Georgia Poultry in supplying the school with a 4-hole and 10-hole nest.

FFA advisor, Rick Burrell looks on as Heath highlights nest features.  

Heath bought the nests to Clifton Ridge and met with the students and FFA advisor, Rick Burrell. " I assembled the 4-hole to show the kids so they could build the 10-hole unit on their own, "said Heath. " I took a few minutes and explained how vertical integration worked and answered the questions from the kids. They were especially interested in how my FFA involvement helped my career in the poultry industry.... and they also wanted to know what farmers did with the chicken litter." Heath continued, "Getting kids involved is critical to the future of our industry. I was glad for the opportunity to help out, and hopefully, we see some of the kids enter the poultry business down the road."

Clifton Ridge hens adapt to new nests  

The project currently involves 12 laying hens of different breeds with the students offering eggs for sale to the school faculty and district personnel.

When Larry Nightingale constructed a 50' x 500' building to produce cage-free eggs on his 700-acre farm in Pulaski, IA, utilizing the manure from the 20,000 laying hens was an important consideration. "A deep pit has less moving parts than a scraper system and having 12 months of storage allows us to apply all the manure in the fall after the crops are out," explained Larry.

Access door to manure pit

  The eight-foot-deep pit under the building consists of a steel reinforced concrete floor with eight-inch formed perimeter walls. Two openings, with slider doors, permit access on each side to remove the litter from the pit with a skid loader. Cross section with plastic flooring and nests suspended above pit

The nests and flooring are suspended above the pit with a support system constructed from 8-inch "I" beams spaced on ten-foot centers. The "I" beam framework sets in pockets in the pit walls and is supported in the center by steel posts.

Potter's colony nests

 A double row of single-tier Potter's colony nests runs down the middle of the building. Curtain fronts on the nest provide the hens with a secure, dark laying area with AstroTurf® covered floors sloping to the center collection belt.   The nest floors rise to exclude the birds from the nest during the night.

GrowerSELECT chain feeder with additional roost bars located on plastic flooring.

18’ of raised plastic slatted flooring extends on each side of the nest boxes with the chain feeding and water lines located there.

  Unique triangle supports used on the GrowerSELECT chain feeding trough provide additional roosts for the hens.

Precast concrete scratch area  

One noteworthy design feature is the pre-cast concrete used for the scratch areas located along the outside walls. 4' x 10' solid concrete slabs were placed on the support beams roughly four inches lower than the plastic slats. Manually operated access doors located above the scratch area permit the birds to access outside pasture runs.

Windstorm galvanized fans with sidewall curtains used in the natural/ power ventilation system

The natural/ power assist ventilation system provides the birds with a comfortable year-round environment.   Three 52" Windstorm pit fans cycle on timers during the winter drawing air through ceiling inlets. As the temperature increases, the sidewall curtains start to drop to allow natural airflow to cool the interior. At approximately 80 degrees the system switches to tunnel ventilation with the sidewall curtains closing and end tunnel curtains opening as the ten Windstorm 54" end wall fans stage on.   Although deep pit structure may have a higher initial cost, there are several advantages for integrated farming operations. 12 months of storage allows fall application for maximum crop utilization. As Larry pointed out, a deep pit is virtually maintenance free with no moving parts compared to using a scraper or belt system to remove the manure from under the slatted area to a separate storage pit.

The pen gestation continues to evolve as producers gain "real world" experience managing production systems.

In 2012 Prestage Farms remodeled an existing finishing complex into breeding and farrowing units and installed stanchions in the pen gestation. You can read more about the remodel project here.   Production Manager, Russ Goss, explained some of the changes made in new sow units built this year,   "In the new facilities, we increased the square footage from 19.5 to 23 per sow, and the stanchion width changed from 19" to 24" on center. In addition, the rodded stanchion dividers were increased from 18” to 48”.

"Extending the dividers changed the behavior of the dominant sows in a pen. Shorter dividers enabled the boss sow to disturb the other animals, and you would see some of them repositioning during the feeding period. The 48" divider prevents the aggressive animals from reaching the shoulders of their pen mates. Instead of going down the line and disrupting other animals, they quickly figure out they can't move anybody and just return to their spot."

"The other thing we see is at any one time 50% of the animals in a pen will be lying in the stanchions.   They never laid in the shorter stanchions, but would always be lying around the "donut" in the middle with their backs against the pen perimeter gating.   A sow always wants to lay with her back against something. She feels secure in the longer stanchions and she appears comfortable staying there, but is also free to leave and move around the pen."   Russ continued, “We have noticed that after the initial fighting to establish the pecking order in the pen, the sows are noticeably calmer and quieter compared to our stall barns.”

"Using pen gestation with stanchions fits our system and personnel. The ESF systems are really an intriguing concept... being able to feed and track sows individually in loose housing. Maybe it's our genetics, but I don't think it's that important for us to feed a sow individually all the way through gestation. From our experience, we can effectively condition the sow the first 6 weeks in gestation. However, if we do not have all sows in the ideal condition, we will group them together and set all feeders in the pen accordingly.

A move to 21-day weaning along with an increasing born live, sent Great Lake Pork, headquartered in Allendale, Michigan in search of the best method for ad-lib feeding in farrowing. 

"Improved sow genetics resulted in more pigs farrowed plus we wanted to boost pig weights by weaning later. We needed to push more feed to the sows and increase consumption," commented Great Lakes Pork, partner Joel Phelps.  

After trialing several different feeder and water combinations, Great Lake Pork settled on a Hog Slat's SowMAX with a floor mounted cup waterer.   "We feel the stainless steel SowMAX dispensers are more durable and easier to install on the different feed bowls in our system. The sow activated trigger mechanism is more reliable than models incorporating plastic balls or electronic timers, " said Joel.  

"We have barns where the ad-lib hoppers are hand-filled and those with automated delivery systems; the results are the same, one just requires a little more labor. We fill the feeder starting on day one and let the sow have all the feed she wants.   That's the beauty of ad-lib, there's no guessing like with hand-feeding, sows eat as individuals when they are ready."  

"Although we don't weigh individual litters, we know the sows are milking well, and they are doing it without losing body weight. They are coming out of the farrowing houses in very good condition which helps in the breeding barn."  

Joel finished by saying; “ As soon as we finished the trial and decided on the equipment we made the switch across the entire system, 18 sow farms in all. That was over three years ago and we’ve never regretted it. It has been a good decision for us.”

Potter's colony nests

A group of Missouri farmers is developing production systems needed to meet the growing demand for cage-free eggs. The producers contract with local egg companies to provide facilities that meet established humane standards for egg production. Unlike typical industry contracts, the farmers are also responsible for purchasing the birds and feed along with supplying labor.

Side doors allow chicken access to outdoor pasture

Farms produce either free-range or pastured eggs. Free-range hens have access to exterior areas equal to 2 sq. ft. per bird, while the pastured designation requires 108.9 sq. ft. per hen.   The farms receive 17-week old pullets that begin laying at 19 weeks with full production reached at around 24 weeks.

Center egg gathering belt with AstroTurf pad

The 50’ wide buildings feature a double row of colony nests down the center of the room, allowing nine sq. ft. of nest area per 100 hens.   Curtain fronts on the nest provide the hens with a secure, dark laying area with AstroTurf® covered floors sloping to the center collection belt.

Raised flooring with either pan feeders or chain feeding

12’ of raised plastic slatted flooring extends on each side of the nest boxes with the feed and water lines located there. A 9-1/2' lowered scratch area runs along each sidewall.

Windstorm 36" panel  fans and 54" exhaust  fans

The ventilation system is a combination power/ natural design with a 36” fan and ceiling inlets providing minimum air requirements. Two 52” fans stage on as the weather warms with the sidewall curtains dropping to supply the increased airflow. Hot weather triggers high-pressure misters on with 36” box fans increasing air circulation. Some of the larger facilities also add evaporative cooling systems with tunnel ventilation fans for extremely hot weather and eliminate the sidewall curtains, misters, and 36" stir fans.

Automated access doors to outside runs with portable shades outside.

Hens are locked out of the nests overnight until 5:30 am. Egg collect begins at 9 am with the sliding side doors opened at 10 am to allow the hens access to the outside runs. Chickens can move freely in and out of the buildings during the day choosing their environment. In the outside lots, the hens have access to portable shades along with supplemental feed and water.

Manual egg packer and automatic version

A second egg collection occurs mid-afternoon. Smaller facilities hand pack the eggs from the center collection belt while larger operations utilize an automated packing machine. Walk-in egg coolers capable of maintaining 45-degree temperatures hold the eggs until the farm’s weekly pickup. The building’s side doors remain open until after dark with the interior lights left on to draw the hens in before closing up for the night. Approximately ½ hour before shutting down the building lights, the nest floors lift up gently pushing the hens out of the colony nest and blocking access until the next morning.