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The biggest benefit of solid sided finishing facilities may be the hardest to measure.  

Recently we published an article highlighting some key factors contributing to the growing popularity of solid sided curtain finishing houses.   These included heat savings, reduced maintenance, and improved ventilation.  

While the heat savings and reduced maintenance cost might be the easiest to track, the most significant benefit may come from improving the pig’s environment.  

The tendency when hearing heaters running continuously on a cold winter morning (especially after paying the latest LP bill) is to start easing the variable speed down or lowering the "on" cycle time for the minimum winter fans. Simple logic; cut the minimum winter rate by half from 2 cfm/pig to 1 cfm, and reduce LP usage by half.  

Unfortunately, this also increases the building's relative humidity along with higher gas and dust levels. The poorer environment can cause slow growth and increase the pigs’ susceptibility to disease. In some cases, this decreased lung function will hurt performance throughout the pig's production cycle. Lower ventilation rates can also jeopardize worker's health and cause the building's interior to deteriorate quicker.  

Solid sided finishing buildings, with insulated sidewalls replacing curtains, do not reduce the amount of minimum ventilation required to provide a good environment. Instead, the higher R-value walls significantly reduce the amount of heat loss compared to a curtain. The BTUs normally generated to replace heat loss through the curtains can instead be exhausted through the fans to improve the building's interior climate and pig performance.  

To illustrate the amount of BTU lost through a curtain sided finisher compared to a solid sided building we calculated the heat loss for a typical sized single wide finishing unit.  

Size: 1100 head Dem:
41’ x 224’
Inside Temp: 70
Outside Temp: 30
Pig Size: 12 lbs.
Ceiling: R-30
5’ Curtain: R-1
3’ x6” Concrete Wall: R-5
5’ x6” Insulated Wall: R-19
Minimum ventilation rate: 2 cfm/head  

Ventilation Heat Loss
1100 head x 2 cfm/head= 2,000 cfm
2,000 x 60 = 120,000 cf/hr
120,000 x (70-30) x.018                           = 86,400 BTU/Hr      

Curtain Sided  

Ceiling 41 x 224 = 9,184 sq. ft.
9184 x (70-30) / R-30                                = 12,245 BTU/Hr    

End Walls 41x 8 x 2 = 656 sq. ft.
656 x (70-30) / R-19                                  = 1,381 BTU/Hr  

Concrete side wall 2’ x 224 x 2 = 896
896 x (70-30) / 5                                        = 7,168 BTU/Hr  

Curtain 5’ x 224’ x 2 = 2240
2240 x (70-30) / 1 =                                   = 89,600/ BTU/Hr        

Solid Sided  

Ceiling 41 x 224 = 9,184 sq. ft.
9184 x (70-30) / R-30                                 = 12,245 BTU/Hr    

End Walls 41x 8 x 2 = 656 sq. ft.
656 x (70-30) / R-19                                   = 1,381 BTU/Hr  

Concrete side wall 2’ x 224 x 2 = 896
896 x (70-30) / 5                                         = 7,168 BTU/Hr  

Insulated Side wall 5’ x 224’ x 2 = 2240
2240 x (70-30) / 19 =                                = 4,715/ BTU/Hr  

When we compare the curtain heat loss (89,600 BTU/ Hr) to the heat loss through the solid wall building (4,715 BTU/Hr.) the difference is close to 85,000 BTU/ Hr.    

The 85,000 BTU lost through curtain comes very close to equaling the amount of BTU exhausted through the ventilation system. To think of it another way, it’s like doubling the ventilation fans and not getting the benefits. BTUs lost through the building just disappear.   BTUs exhausted by the fans remove moisture and dust from the building creating a better growing environment for the pigs.        

  Minimize the effects of fire losses in livestock and poultry buildings by following these basic guidelines and implementing a fire plan.  

According to the U.S. Fire Administration, agricultural fires annually account for $102 million in property damage and result in 25 fatalities. One-third of these fires occur in livestock and poultry operations with larger production facilities increasing the potential for catastrophic losses from replacement costs and interruptions in production schedules.  

Firestops or draft barriers
Firestops act as draft barriers to reduce the rapid spread of fire through an attic.   Firestops consist of using a flame resistant material, such as 5/8-inch rated sheetrock covering both sides of a truss that contacts the roofline. Since any openings in the barrier reduce its effectiveness, the sheetrock should be notch to fit around the purlins. Install firestops every 100 feet of building length.  

Breakaway walkways
Use lightweight framing in the middle section of connecting hallways. If a fire breaks out in one building, a tractor and loader could be used to remove the center part preventing the fire from spreading to other buildings down the walkway.

Fire escape doors
Provide an exit door every 125 feet of the exterior wall to prevent areas where people could be trapped.   Individual farrowing and nursery rooms should include some type of exterior escape door; site fabricated “kick-out” door, 36”x 36” window, or narrow walk door.  

Lighting protection
Any metal structures, such as bulk bins, located next to the buildings should be grounded with a ground rod for lightning protection. Install a surge protection device on the electric entrance panel.  

Incinerator and generator
Incinerators should be 50 feet or more from the buildings. Generator rooms inside a building should include walls with a 2-hour fire rating to delay the spread of a generator fire.

Fire extinguisher
Install a 10-pound ABC dry chemical fire extinguisher at exterior doorways and electric panels.   Provide additional units every 100 feet of building length. Fire extinguishers need to be checked monthly by the farm personnel and annually by an outside source. Have spare extinguishers to replace any used until they are recharged.

Electrical systems
Return all repairs to the original installed condition. Three wire nuts and a roll of electrical tape, or whatever tape maybe handy, is a temporary fix but is often forgotten. Do not use electrical drop cords in place of permanent wiring. Do not bypass safety devices, sensors, breakers, fuses or other devices in a system; they are there for a reason.  

Train all employees on how to cut off the electrical power to individual buildings and the location of the primary cutoff for the entire facility.  

Heaters
Heaters and brooders are probably responsible for more barn fires than any other single source. Maintain heaters in good working condition, inspecting and servicing the heater components frequently, removing flammable foreign material, such as rodent nests, insects, and dust. Inspect rubber gas hoses for cracks. After any cleaning or servicing that requires removal of any part of the gas system check for leaks. Gas sniffers are cheap, typically $100 or less.  Train all employees on how to shut off the gas to the entire facility.  

Heat lamps cords are highly susceptible to damage because they are frequently moved.   Inspect the outside covering and replaced when the cord becomes worn or cracked and never repair damaged areas with electrical tape.  

Fire plan
Every farm should have a written plan detailing how employees should respond to fires and where to go in case of an emergency. Have all emergency numbers posted where all employees can access them and include the farm’s 911 address. Implement and schedule quarterly fire drills.      

For the last 20-plus years, the industry standard for finishing houses has been some variation of a total slat, double-curtain building design. This style of construction utilized lower cost curtain construction on the sidewalls.   As the design migrated north, some of the earliest adaptions to the buildings consisted of adding insulation to the sidewalls. Producers and builders used insulated or heavier weight curtains, removable bubble foil insulation and even eliminated the north curtain altogether replacing it with a solid insulated wall.   A growing trend in new construction has seen a move away from curtain-sided finishing buildings. Several key factors have driven this movement to totally enclosed structures for finishing hogs.

    Heat savings. Replacing the sidewall curtains with high R-value insulated, solid wall can significantly reduce the amount of heat needed when starting pigs. A simple heat loss comparison of a 200-foot exterior wall pointed to savings of up to 0.25 gallons of propane per hour. This building loss calculation also did not take into account the amount of heat needed to counter cold air leaks through tears or holes in the curtain or infiltration around the edges.

Improved minimum ventilation.
The winter fans create a negative pressure inside the building drawing air from outside. Since even the best installed and maintained curtains are not airtight, cold outside air leaks in from around the curtains instead of entering through the ceiling inlets. Solid sidewalls eliminate curtain air leaks, so all the air comes through the ceiling inlets at a higher velocity. This cold, high-velocity air mixes with warmer room air near the ceiling before it swirls to pig level.  

Reduced maintenance.
With no curtains, hardware or curtain machines to repair or replace, producers can eliminate the annual fall maintenance program saving time and money during the busy harvest season.  

Improvements in fail-safe protection. Sidewall curtains provide fail-safe protection against power outages. A simple curtain drop device connected to the winch handle allows the curtains to drop down to prevent suffocation.   In practice, this system many times does not function as intended because of poor repair and maintenance. Advanced alarm system technology linked to environmental controls alert barn operators almost immediately of power outages or drastic room temperature changes.

Several producers have remodeled existing curtain-sided buildings into solid sidewalls after seeing the benefits.   The conversion is relatively straightforward with extra 2x6 studs added to the sidewall framing, exterior steel siding, 6-inch batt insulation and interior wall covering of plywood, Fiber Reinforced Plastic, poly board or metal siding.  For interior panels in animal contact areas, do not allow the panel edge to extend over the concrete wall and cover all panel joints with aluminum batten strips.    

It is a standard production practice to use water driven medicators to administer medications, vaccines, and supplements to livestock and poultry.  With good water quality and routine maintenance, virtually all brands of water driven medicators do an excellent job of accurately delivering the correct dosages.  

Poor water quality causes most of the problems producers experience when using this type of injection equipment.   Water with high levels of dissolved chemicals (hard water) and impurities like sand and scale, can cause damage to seals, plungers, and pistons. Also, as some producers have moved to ABF production, chemicals used for water treatment have proved particularly corrosive to the moving parts of water driven medicators.

Electric pumps used in the water treatment industry have proved effective in overcoming the problems with water quality and harsh chemicals.   Drinking water does not travel through the pump; instead, it receives a signal from an in-line water meter. Based on the water flow passing through the meter, the electric pump injects accurate dosages from the stock tank directly into the water line.  

The primary electric medicator currently in use for livestock and poultry production is the peristaltic pump. Peristaltic pumps use a roller device to squeeze stock solution through a hose or tube. The primary wear part is inexpensive tube kit that is easy to replace. Peristaltic pumps are excellent at delivering accurate dosages at low water flows, typical when starting new flock or group.  See Stennicator

Another type of electric pump uses a molded PTFE or Teflon diaphragm to dose chemicals. The Teflon diaphragm features excellent chemical resistance. Wear is virtually nonexistent on this part as the pumping movement amounts to only about 1/8" of flex. Diaphragm pumps handle low flows exceptionally well and also provide accurate metering at higher flows typically found at the end of a grow out period.  

The direct injection design of electric medicators allows operation in poor water conditions that damage water driven medicators.  

Adding a water-based medicator adds flexibility to your management options.   It's easier and quicker to switch medications and supplements in the water compared to using feed additives. Also, sick animals will drink water even if they aren't eating well.  

Most show pig producers with more than a few pigs have automated their water supply by installing a water line and either nipple or cup drinkers in each pen.   Plumbing a medicator into this water system is relatively straightforward.   Start by installing a ball valve in the PVC pipe and plumbing a by-pass to direct incoming water through the medicator. The by-pass can be constructed of PVC pipe with ball valves, or an alternative method uses hose bibs with 5/8" drinker hose.   This alternative method is ideal for use in multiple locations, simply remove the hoses, detach the unit from the wall and move the whole assembly to the next barn.       To use the medicator, dry powders or liquid concentrates are dissolved in water (according to package directions) creating a stock solution. The suction hose from the medicator is placed in the stock tank (typically a 5-gallon bucket). The water flow from the drinking system passes through the medicator, drawing solution from the stock tank and mixing the stock solution into the pig’s drinking water.  

The Dosatron DM11F medicator is one of the best choices for use with show pig herds. Because it is water powered, it requires no electricity to use, making it easy to move.   The DM11F automatically compensates for changing water flows and pressures providing consistent, repeatable dosing.   Its diaphragm water motor also enables the DM11F to operate at water flows as low as .02 gallons per minute. The ability to accurately dose at low flow rates is vital with young pigs and smaller group sizes.   To learn more about the DM11F medicator click here

The use of bait stations improves the effectiveness of any rodent control program. Stations protect baits from rain and dirt, helping the rodenticides stay fresh and potent longer while providing security against access from children and pets. Bait stations also provide an environment where rats and mice feel secure when feeding on baits.

Rodents are creatures of habit and travel along established paths between their nests and food supply. They will not go out of their way to visit bait stations outside their normal traffic areas. Look for signs of rodent activity such as droppings, tracks and gnawing to locate pathways. Place mouse stations 10-13 feet apart as mice seldom venture more than 50 feet from their nests. Rats range much farther afield allowing station placement to be between 25 and 50 feet apart.

Do not use mouse stations when rats are present as the bigger rodents will gnaw through the thinner plastic and expose the baits. Consider using white colored bait stations for those locations on the south exposure of buildings. The interior temperature of black colored stations can increase by as much as 30° which may melt some bait formulations.

Securely fasten stations to walls or floors to prevent them from being moved out of the traffic pathway. Use tent stakes to anchor bait stations to the ground for exterior placement. T-style stations are very versatile in their applications. Nylon ties are used to fasten them to gate rails, rafters, and even feed pipes.

Check bait stations on a monthly basis as part of the routine barn maintenance program adding fresh bait as needed. Rodents will often refuse to eat spoiled or stale bait. Observe the condition of the stations themselves as plastic can become brittle, especially the lid hinge. Stations with rotating hinges will outlast models with thin bendable strips of plastic called living hinges. During periods of heavy infestation, it may be necessary to check daily to ensure an adequate supply of bait. Stations are available with clear lids to allow a visual check of bait levels without opening the lid.

It is important to be patient when dealing with rat infestations. Rats are suspicious of new objects in their territory, and it may be several weeks before they use a new bait station. Leave stations in place even after a heavy infestation is under control. Rats are more likely to enter bait stations that have become part of the "terrain" when baiting occurs in following seasons.

Go to bait stations for pricing and ordering information.  

Providing your flock with proper nesting boxes ensures they have a comfortable, secure place to lay their eggs. Without nests, the hens will seek locations on their own, making egg collection more difficult.

Allow one nest box per 4 - 5 hens. It is not necessary or even desirable to provide additional nest boxes. Besides the initial cost, extra nests require more bedding material, encourage chickens to roost in the empty slots, and take more time to clean.   Install the nests at least 18" to 20" above the floor preferably on a wall away from the roosting area.   Because chickens like to roost in the highest part of the house, do not place the nests higher that the roosting perches. If possible try not to place the nests above feed and water to prevent contamination from nesting material and droppings.

The nests should be designed with 45° sloped roof to prevent the hens from roosting on top.

Provide a perch just below the opening for the birds to land on before entering. Nests with foldable perches allow the nest to be shut off at night to prevent roosting. Simply fold them up at night to restrict access and in the morning lower the perches for the chickens to use.  

Nests will become dirty from broken eggs, bedding material or droppings and will need occasional cleaning. Choosing nests constructed from metal or plastic with removable bottoms makes the job much easier.

Flock owners can also replace straw or wood chip bedding with plastic nesting pads that are simple to pull out for cleaning. To see all the Farmstead nests go to  Farmstead Nest  

Part three of our series on treating swine drinking water.

Jesse McCoy, CWS, Business Unit Specialist, Water Treatment, Neogen Corp.

Following proper terminal line disinfection and water disinfection, the next step in a creating a beneficial water program is modifying the pH. For any animal to reach its full genetic potential, we must manage the water to achieve the correct pH level in its gut.   The pH is a measure of acidity and alkalinity. A pH of 7 is neutral; less than 7 is considered acidic and over 7 alkaline. Water pH is a major factor in determining the effectiveness of various water treatments.   Adjusting the pH into the acidic range benefits the animal's GI tract by creating a detrimental environment for pathogenic biology. Other research points to improvements in nutritional impacts of feed at lower pH levels with organic (chemically organic – so containing carbon) acids. There may even be benefits we still don’t understand yet with pH reduction in livestock while realizing the benefits.   The available data reflect these benefits, regardless of their mode of action.  

Terminal line disinfection in this research trial was achieved with a 3% solution of Peraside (peracetic acid disinfectant) administered into the lines with a sump pump upon depopulation. The solution sat in the lines overnight and was flushed the next morning with fresh water. All drinkers were triggered to ensure proper function before placing the pigs. Disinfection was achieved with 5ppm of MaxKlor (stabilized chlorine dioxide), and the pH was set to a pH of 6.5 to 6.8 using Dyne-O-Might (blended organic/mineral stabilized with iodine)

Water meters measured flow rates and triggered electric pumps for a precise chemical injection. This equipment ensured every gallon received the targeted treatment even with the small dosing requirements needed. Simple tests with a pH meter, at the drinkers, were used to show the pH level was maintained in the proper range.  

By adding pH adjustment to a water treatment program, the animals can finally move from survival in the barns to thriving and reaching their genetic potential.    

Maintenance. We all know it's important but it’s not something anybody gets excited about doing.

When I started out in the business one of the old hands told me, "You don't even need to see the records to know if a farm is meeting its production targets. If the grass is mowed, the interior is clean and the all the equipment is working they’re doing a good job raising the pigs."  

Every farm operation faces the challenge of having too many things to do and too few resources to do them. It's easy to start using reactive maintenance (if it ain't broke, don't fix it) compared to planned preventive maintenance that prevents costly breakdowns.   Good feeding, watering, and ventilation equipment certainly isn't cheap and the better it's cared for the longer it will last.

The new smartphone app, BarnRX reminds producers when it's time to perform basic maintenance tasks. Available for either Apple or Android phones, the app comes preloaded with a monthly task list that can be checked as completed. In addition, the app allows an operator to add unique tasks to customize the maintenance list. Further customization is also possible by setting up multiple buildings.

The BarnRX app also contains an industry news feed, a listing of service techs on call, and a direct link to the Hog Slat website for ordering repair parts. The final feature is promotion section with cost-saving specials and mobile coupons only available with the BarnRX app.   To see more, watch a video, and download the app, go to www.barnrx.com

Zone heating is an accepted management practice to provide supplemental heat in wean/finish buildings.   Many production systems utilize 17,000 Btu radiant gas brooders with modulating controls panels regulating the amount of heat emitted by the brooders.   

While the modulating controllers are the most popular choice, initial lab tests suggested the Hi/Lo type control panels would yield significant fuel savings. A field test comparing the two systems was set up on a farm in Indiana.

The layout of the test setup is shown in Figure 1. The 40' x 200' test rooms were in the same building separated by a wall with 18 brooders installed in each room. The 17,100 Btu brooders were mounted three feet above the floor.   The Modulating Control thermostat sensor and High/Lo thermostat sensor are shown as T1 and T2, respectively. The Brooder temperature set point was 85°.  

A gas furnace provided auxiliary heat for each room with its thermostat location indicated by the T in Figure 1.   The outdoor temperature was measured using a thermocouple as shown as T3. All sensors were four feet above the floor level. A gas meter was mounted in each room to record the fuel consumption of the corresponding control system.  

Figure 2 shows the results of the field test with a 20.7% fuel savings for the Hi/ Lo regulated brooders.    

Why did these savings occur?

At high demand, the gas consumption is the same for both control panels at the maximum input. At low demand, the gas consumption is the same for both control panels at the minimum input.  

The savings occur between the two extremes. It is more cost-effective for the brooder to switch between high and low than to maintain the temperature with the less efficient pressure settings in between.    

What about temperature swings under the brooder?

The internal temperature of the brooders only varies by two degrees.  This temperature variant is in the brooder and is reflected not on the temperature recorded on the floor below.  

Also, a style Hi/Lo panel is easier to integrate into a whole house environmental control system. The Hi/Lo input ties directly into the computer protocol instead of the separate low-tech sensor used with a modulation control.

For more information go to Gro17000 brooder.