Blog posts tagged with 'GrowerSELECT®'

As livestock and poultry housing became larger and we developed more sophisticated feeding methods, the use of multiple bins in tandem was more common.  While this set-up allowed for greater flexibility in feeding, the front bin of the pair was often prone to plugging.

If we look at the anchor bearing that is present in the rear bin, one would notice that it has a restrictor tube over the shaft.  This restrictor tube fills the core of a flexible auger and prevents feed from filling the core and overloading an auger. This restrictor is not present in the front bin.  When the slide is opened feed overloads the system faster than the auger will move it away.  The obvious solution is to cut the opening down by closing off the slide to restrict feed flow.  This can cause other problems as a feed flows tends to flow only down one side of the bin.  A better solution is to use baffles in the boot to restrict feed flow.  This works to prevent plugging but can cause feed bridging in the bin.

Over the last several years Hog Slat developed and tested a unique solution to this problem.  The final product is called the Extended Anchor Bearing.

Described simply, the Extended Anchor Bearing extends the rear tube restrictor to the front bin.  The auger core is filled in and feed cannot overfill the system.

The Extended Anchor Bearing ships complete with a 14’ restrictor tube, replacement bearing and fastening hardware.  The 14’ restrictor tube is cut to length and inserted it the auger core.  The new bearing is installed and the auger reattached.

If an extended anchor bearing would help you prevent auger overload, visit the Hog Slat website to find the model that fits your flexible auger fill system.

One of the newest tools utilized by Hog Slat’s engineering group is a 3D printer.  About the size of a small refrigerator, the 3D printer generates plastic prototype parts from computer generated 3D models.

A member of Hog Slat’s engineering group, Andrew Mitchell took a few minutes to show us how it worked.

“Here’s a feed line drop adaptor we designed for the Grow-Disk™ system,” explained Andrew as he pulled up a 3D model on his computer screen. “We needed to develop a model that would work on both metal and plastic tubes.  Since these tubes have slightly different diameters, we wanted to test the fit before proceeding with molding.”

The cube in the screen represents the printer’s chamber, and the white image is a digital model.  The program divides the object into digital cross-sections and the printer builds the object in layers.   The printer makes multiple passes spraying very thin layers of plastic until the final shape is complete. 

“You can almost compare the printer to a giant glue gun that accurately places liquid plastic down in precise layers,” Andrew said, “The process can take from several hours up to several days depending on the size of the item.  The maximum size part we can print is 10” x 10” x 12” tall”

“We were able to take the prototype drop adaptor and test it on both the metal and plastic feed tubes. We made a few small dimensional adjustments and proceeded with complete confidence that the final part would fit as we intended.”

Frank Harris, Head of Hog Slat’s Engineering Department, spoke with us about the development of the GrowerSELECT product line.

What is the focus of the GrowerSELECT product line?

Hog Slat wanted to directly source products to reduce final cost to the end user. We knew we could lower the cost if we reduced the number of people that handled a product, and in many cases improve the quality.

Replacement motors for fans and feed systems were the first items we started to direct source.  OEM Fan and feed auger companies do not produce their own motors; they all buy from the same motor companies.

We did not just buy off-the-shelf motors. We specified certain improvements in the motors based on our experience.  For instance, one problem according to our service department was motor shaft breakage.  We changed the shaft diameter blend radius and specified a hardened shaft of 1144 steel. We eliminated the problem.

Some people may have the perception that GrowerSELECT products are just cheap generic copies. How would you answer that?

I am not going to tell anybody that we invented feed systems or fans. However, in almost every case we are able to look at existing products and make improvements.

We evaluate every item developed for the GrowerSELECT lineup in three different ways.

First, from an engineering standpoint.

Can we make this product out of different material? Can we make it easier to manufacture?  Can we change the shape or size to eliminate problems?

Second, we evaluate from a repair standpoint with feedback from our service departments.

What are you fixing out in the field?  Where is this product failing?  What would make the product easier to service?

Third, and most importantly, we evaluate from our customer’s standpoint.

Is this the right product? Is this the right size?  What is giving you the biggest headache in using this product?   What changes would you make?

After gathering this information, we conduct the Process Failure Effect Mode Analysis or PFEMA.  Simply put, this is a logic method for determining why a product fails and how to correct it.  We document the process and can refer back to it when problems arise.

We then create detailed 3D computer models of the proposed product and subject it to computer-simulated stress tests.

Wait a minute; you can test the product before it is even built?

Yes, here’s a good example.  When we first designed the blue plastic hopper for the SowMAX, we did not have a lip at the top.  When tested via computer simulation, we realized it might crack when impacted, for example if a feed cart banged into it.  We added the lip to strengthen the hopper and eliminated a potential problem.

Another example is the GrowerSELECT® clear upper boot, injected from impact-resistant polycarbonate.  It does not have to be as thick as plastic boots used by other manufacturers to have a superior breaking strength.  We were able to “tweak” the material thickness and avoid adding unnecessary additional cost to the end user.

The next part of the process is to send the drawings to a manufacturer and order sample parts to test against a quality control process known as PPAP or Production Part Approval Process.

Okay, what does that mean?

It is the same quality control process the automobile supply industry uses.  It means we take the sample products and measure them against the drawings we created.  We particularly identify those measurements most critical to the quality of the product.

Once we are satisfied that the sample batch is correct, we then order a small production run.  This first-production run is then field tested.  Our service group installs them on farms, and we monitor the results.

After field-testing is completed, we release the product to manufacturing.

Before receiving those released products into warehousing, our Quality Control department conducts a series of QC checks.  Keith Riley, QC department head, creates an Incoming Inspection Document for each item.  This establishes a benchmark of quality checks used to test production parts.  This is not only done the first time we receive the product, but every time that product arrives from the manufacturer.

How many people work in Hog Slat’s engineering department?

We have nine engineers and six Quality Control members. We have a good core of experienced engineers with several younger guys that we have hired…I like to say we have just the right blend of “gray hair” in the group. I have to say the younger guys have a great “toolbox” they bring with them. They are contributing with new technology.  A good example is the 3D printer we recently added to the department.  It is allowing us to perform some things we had not been able to do before.

What are future goals for your group?

Continuous improvement of products.  Just because we have a product developed doesn’t mean we quit trying to make it better.  We think we can improve motors. One of the principle reasons we are able to offer a two-year warranty is that we have such a very small percentage of motors returned under that warranty. But, we have some ideas that will improve these motors even more.

Hog Slat has a very unique position in the industry.  We are responsible directly to the end user.  It is our own people installing and servicing the products we sell.  We cannot pass off problems to someone in the supply chain; we are the entire supply chain to the end user.

We have access to company farms to test new products.  We have feedback from our own service crews.  Our goal is to use these resources to improve product offerings and get those improvements to the market faster.

One of things I think we are the best at is identifying the optimum place in the world to manufacture a product.  We are not just throwing everything to Southeast Asia.  In fact, we have moved several products back to the United States. A good example is Classic Flood feeders, we started overseas but now these parts are molded in the U.S.

We do a lot of final assembly at our locations in Clinton, NC and Humboldt, IA.  We source items from the U.S. and other parts of the globe, bring those components in to test, then assemble the end products.  Using this process we have more control over the quality of the final product.

In our blog post highlighting Hog Slat’s engineering department (see Engineering Grower Select) Frank remarked, “In almost every case we can look at existing products and make improvements.”

The GrowerSELECT® Curtain Machine is a great example of making changes to existing products to improve performance and reduce maintenance.

If you have ever “hung” a curtain machine, you will appreciate this feature. After placing a lag bolt in the wall about ½” short of flush, you simply hang the machine from a single keyhole slot in the back of the cabinet. It is much easier to level and add the four mounting lag bolts because the unit remains supported.

The Curtain Machine includes three sealed ball bearing head pulleys instead of two.  The extra pulley is added to increase the choices for installing the main cables.  Use the two outside pulleys to cable the machine on both sides of the building.  Single-sided installations have the off side cable routed through the top pulley.

One of the highest mortality items on a screw type machine is the load block.  Other curtain machines use bronze, brass or nylon. However, the GrowerSELECT machine utilizes a self-lubricating, low friction acetal plastic for both the insert nut and load block slides.   For a more in-depth comparison see our blog post, “More Than You Ever Wanted to Know about Curtain Machine Load Blocks.”

The Curtain Machine features dual limit switches.  The primary limit switches set the travel length, with secondary or redundant switches backing these up. If the first switch fails and engages the secondary switch, the machine shuts down and must be serviced before operating again.  Also included is an auxiliary switch, used to activate a fan after the curtain closes.  Other brands charge extra for this feature.

Another feature you will appreciate is the local control switches, standard with the GrowerSELECT Curtain Machine.   A toggle switch sets the machine in manual and overrides the ventilation control.  This is a great safety feature that prevents anyone from activating the unit while it is being serviced.  In addition, it certainly makes it easier to set the limit switches compared to performing this task from a remote controller.

Eventually, any curtain machine will have to be serviced, and this is where the GrowerSELECT Curtain Machine shines.  Note the cutouts in the galvanized housing. You can slip the entire motor assembly out of these slots after loosening three mounting bolts.  It is much easier to service the motor outside of the cabinet.

The entire screw assembly will also come out through these cabinet slots.  It’s still a big job, but it’s possible to slide the entire assembly out for servicing rather than dismantling the screw inside the cabinet.

Although not groundbreaking, the GrowerSELECT Curtain Machine is an example of Hog Slat’s commitment to engineering better products.  Click on Curtain Machine for pricing and ordering information.

Nearly all of Hog Slat’s competitors try to dismiss the GrowerSELECT® product line as “just a cheap copy.” However, every time I work with Hog Slat’s engineering department I realize how misguided this perception is.  Nothing is ever “just copied.”

I was quizzing Hog Slat engineer, Tim King, about the features and benefits of GrowerSELECT’s Curtain Machine.   He explained to me that one of the highest replacement items on a screw type machine is the load nut. As the load block moves up and down the Acme screw, the friction generated causes the insert to fail.  If friction is reduced, wear and maintenance of the insert is reduced.

1. Grower Select – Aluminum Block/Acetal Insert
2. Brass Block
3. Aluminum Block/ Brass Insert
4. Steel Block/ Nylon Insert

For the GrowerSELECT Curtain Machine, Tim selected acetal plastic to be used for the insert and cabinet slides.  Acetal is one of the strongest non-reinforced plastic available to replace metal bushings.  It is able to reduce friction within the curtain machine because of its low friction coefficient.  So why is this plastic a better choice than the brass or nylon inserts shown in the pictures?

To get a better understanding of Coefficients of Friction, consider these ratings of various materials used for bearings.

Steel on steel dry contact is .80, if you apply grease it becomes .16

Brass on steel dry contact is .35, grease it and it is now .19

Nylon on steel dry contact is .25 and with lubrication moves to .15

Acetal on steel dry rating is .15.

1. Nylon
2. Grower Select Acetal
3. Brass block
4. Brass insert

These ratings aren’t telling anyone anything they didn’t already know. Keep a bearing greased, and it will last a long time. What is interesting though is the rating for an acetal load nut without grease is the same as any of other insert materials with grease.

As a matter of fact, the acetal load nut does not even have a grease zerk.  However, we still recommend greasing the Acme shaft with general purpose Lithium grease, primarily to prevent surface rust on the shaft.

I wish you could put your hands on the four inserts in the picture.  The acetal has a slippery, almost oily feel to it; different than the nylon insert.  It is a denser, heavier plastic that is less brittle compared to nylon.

The real advantage is in the day-to-day maintenance on your farm.  The best intentions (like greasing a curtain machine) get lost in the bustle of all the work.  Why not choose a curtain machine with features that reduce maintenance?   Click on Curtain Machine for more information.

Located in McLeansboro, IL, L&L Farms began their hog farming operation in 1994 raising 400 sows. Since then, Jeff and his family along with the help of quality employees have grown their breed to wean operation to 4,000 sows housed in 2 locations.  We spoke with owner, Jeff Lueke:

Jeff, you have purchased several Grow-Disk™ systems, why did you decide to install this feeding system?

I really felt like we were gaining efficiencies in the farrowing department. We saw how it could provide advantages to our employees, allowing them to be more efficient and manage more sows. Within our operation we also set target goals. These goals consisted of narrowing down the wean to first service interval, drive a heavier pig out the door at weaning, and increase lactation length leading to subsequent larger litter sizes for pigs. In our management plan, we felt that these two products, SowMAX and Grow-Disk, would be a big help to reach our target goals by getting more feed to the sows.

How many Grow-Disk™ systems have you installed?

3. All have been installed into our farrowing barns, but I would not hesitate to install them into any application.

How do you use Grow-Disk™ to feed the sows?

We combine the Grow-Disk with the SowMAX. We feel that the combination of these products delivers a very good program. We basically want the sows to have access to full feed. Between these two products we feel that we can deliver that to our sows very efficiently. The system still gives us flexibility to limit feed intake because we include the Sow Drop. The Sow Drop allows us to limit feed intake if we want to, whether it is in early lactation, pre-farrowing, or for the first three days post-farrowing. In post-farrowing we schedule to feed five times throughout the day, in pre-farrowing we schedule to feed twice a day.

How have the Grow-Disk™ systems performed for you? What benefits have you seen?

I have no complaints; I do believe that we are getting more daily feed intake from our sows with the system. The system is hands-off, requiring less labor to feed. With this automatic feeding we are able to keep feed available, and produce less wastage.

Why did you choose Grow-Disk™ instead of a flexible auger system for your project?

My local sales contact, Carl Herrmann, shared with me some of the advantages that Grow-Disk can offer. Knowing that it was a new product, and knowing that I’ve had success with Hog Slat products in the past, it made me anxious to try it. I think its heavy duty, reliable, and I have not been disappointed.

Switching gears, tell us about your routine feeding with SowMAX.

The system that we set up is basically designed to keep feed available for the sow to access at all times, but not have so much feed supply that if there was a malfunction we would have a pit full of feed. The system allows us to make that work. At most any time there’s 12-20 lbs. of feed available to the sow. If that particular sow wants to get up at 6 a.m. and eat 15 pounds of feed, it’s there. If a sow wants to eat five small meals throughout the day she has the opportunity to do that as well. I think that we forget that hogs are somewhat individuals like people, and may all have a little different idea of how they want to eat. In the past when we fed with a scoop and cart, the sows got trained to jump up and eat whenever it was time to feed. Even if a litter of piglets just started nursing, the sow still jumped up to eat. The sows are much more content and apt to eat at their convenience than they are when you decide when it’s time to feed.  For daily management of the SowMAX, we clean and make necessary adjustments to the feeders twice a day. We have been able to keep SowMAX feeders cleaner compared to other systems. The feeders are simple and easy to utilize and maintain.

What advantages have you noticed with SowMAX over how you fed sows in the past?

We have been able to accomplish our management goals by incorporating SowMAX into our operation. I do believe we have raised heavier pigs. We have noticed that SowMAX wastes less feed and requires less maintenance compared to a solid tube. Having the ability to keep fresh feed in front of the sow all day has been a great benefit.

Do you use any other Hog Slat equipment?

We incorporate Hog Slat’s concrete slats, penning, boar carts, Sow Drops, farrowing crates, and Tridek flooring, among others into our operation.  I’ve found this equipment to meet my standards for over 20 years.

Do you have any suggestions for other hog farmers looking into the GrowerSELECT® product line?

It’s a viable program that should be looked at. I think it is cost efficient for the performance. It would be an asset to any building project.

Most producers have a checklist for basic equipment repairs between groups to prevent costly and time-consuming problems later. One commonly overlooked item is the feed delivery system. Whether you choose to have the auger inspected by a service crew or do the work yourself, the following is a checklist of essential feed system maintenance items for producers to consider.

Remove the Feed
The most important and basic procedure for auger maintenance is to empty all the feed from the system. Feed left in the auger tube will draw moisture and cause the auger flighting to rust.

Upper and Lower Boots
The metal lower boots should be visually inspected for worn or rusted areas, bent slide gates and damaged access covers. GrowerSELECT® components can be used to replace individual items including body weldments for all flexible auger sizes. Go to GrowerSELECT Unloader Components.

Grower Select clear upper boots can replace existing solid boots so potential problems with feed delivery are easier to spot.  Injected from impact-resistant transparent polycarbonate, GrowerSELECT boots will fit any 16” bin opening and are available in 30° or straight models. Go to GrowerSELECT Clear Boots

Anchor Bearings
Auger bearings are a high wear item and should be checked whenever they are squealing or rattling. To inspect the anchor bearing, loosen the U-bolts holding the bearing, pull the bearing out from the tube and clamp a vise grip on the auger to hold it in place. Inspect the anchor bearing for visible wear and excess play. If the bearing needs to be replaced, select a GrowerSELECT anchor bearing that matches the size and brand of your system. Go to GrowerSELECT Anchor Bearings

Flexible Auger
Auger that is more than ten years old or installed with multiple turns should be examined for wear. Examine the auger to look for sharp edges concentrating on the elbow areas. Also check the distance between the flighting making sure this distance has not been compacted or stretched. To remove the auger for inspection; detach the anchor bearing from the auger and allow the auger to retract inside the tube. Go up to the drive unit and open the inspection plate on the control unit. Loosen the hex head bolt on the clamp holding the auger to the tube anchor. Holding the auger solid, rotate the anchor counterclockwise until the auger is free. Go back to the boot area and pull the auger out the back end of the system.

There are several options for repair.
A) Replace the entire auger.
B) Cut out and replace only the worn section.
C) Turn the auger end for end and replace. This will place the worn section of auger in a straight section of the tube instead of in an elbow section.

Grow-Flex™ auger is available custom lengths that are cut to order. Go to Grow-Flex™ Auger

Elbows
Many (most?) 10-year auger systems have duct tape over small holes in the tube where the auger enters the barn. Now is the time to replace the high wearing elbow sections while the auger is removed from the system.

Gear Head Oil
The oil in auger gear heads should be completely replaced every two years. Remove the bottom and side plugs allowing the oil to drain out of the gear head. Replace the bottom plug and refill with oil until it reaches the level of the side plug. Replace side oil plug. GrowerSELECT Gear Oil is specialty 80W-90 oil designed for use in any existing auger gear head. Purchase GrowerSELECT Gear Oil here.

Pinion Gears
It is also a good time for a visual inspection of the pinion gear connecting the motor shaft to the gear head. The teeth of the pinion should be sharply cut; pinions with rounded teeth should be replaced. There is a GrowerSELECT replacement pinion gear for most existing auger systems….Go to GrowerSELECT Pinion Gears

Feed Level Controls
Faulty feed controls can cause feed outages or wastage when they malfunction. There are many options of GrowerSELECT feed level controls available for replacements. The HS529 is a direct replacement for feed level controls mounted in the feeders. The Proxy Plus (HS10) and the Proxy Classic (HS09) are GrowerSELECT replacements for existing proximity switches.
This may also be a great time to consider a complete change in feed control switches. The Grower Select Drop Tube Control Switch (HSDTC01) is an excellent option for controlling the feed system. This type of switch removes the electrical components from inside the feeders helping minimize switch failure due to electrical problems.

Feed Bins
Older feed bins may have rusted areas or even pinholes in the exterior metal sheets. An excellent product to restore these areas and extend the bin’s useful life is AMC100L; an aluminum based coating that provides corrosion and weather protection. It is available in DIY kit form containing 1 quart of AMC100L, 1 pint of rust remover and 4 pieces of seam tape. This starter kit will cover 200-300 sq ft. Purchase the AMC100L-K kit here.

Producers have also upgraded feed bins with a simple feed level indicator called the Bin Flag. This low-cost device (just over $100) allows operators to check bin feed levels without climbing. No wiring is required for operation and the installation is all done from the outside. The Bin Flag can also be connected to building alarm system for dialer notification of feed outages. Go to Bin Flag.

Contact a local Hog Slat store (see store listings) or go to http://www.hogslat.com/feeding-systems-componentsto order feed system repair items. Hog Slat stores also have service crews available for on-farm repairs and inspections.

Many producers utilize Grower Select® products to lower their production costs. Paying 30% less for repair parts reduces maintenance costs in livestock or poultry buildings and increases the bottom line.

There may some hesitation by producers to take advantage of these savings because they are not sure which Grower Select® part number to use when repairing Chore-Time® or AP® feed systems.

To make the correct selection easier, we have created a new cross reference for Grower Select® feed system parts. Simply find the OEM part number in the list and cross reference to the matching Grower Select® part number. Download the Grower Select® Feed System Parts OEM Cross Reference Sheet.

Our new Fall/Winter catalog also contains the Cross Reference list.

To order a FREE copy online, click on Catalog Request.

I recently had the opportunity to spend a couple of days at EuroTier 2014 (read more……). I asked the same question to the Hog Slat sales teams and country managers, ” What items are selling in your market?”

The answers varied, but they all had one common factor….SowMAX.

From German Country Manager, Karl-Heinz Wöste, “German producers understand feeding lactating sows as individuals results in heavier pigs at weaning. The SowMAX system accomplishes this task while reducing labor. Producers also like how simple the SowMAX is….no electronic ear tags to lose or motors to fail.”

“Our customers are adding SowMAX feeders to existing units” explained Rafal Bozek, Country Manager of Poland. “They tried a few units and saw the results…heavier pigs at weaning. For our producers, the SowMAX is the most durable unit on the market. 100% stainless steel. No plastic parts like competitive products. Simple to use too. Fill the hopper and sow eats as little or as much as she wants every day without wasting feed.”

To see more on the benefits of SowMAX click here……

In an earlier blog post we reported the interest shown in the SowMax (see more….) at this year’s EuroTier.  Shown is German sales rep Ulf  Maroske as he explains features and benefits to a customer at the show.  We later received this email from Ulf concerning a customer who purchased 20 International farrowing crates and 50 SowMAX dispensers to fit on existing crates this October.

“When visited my customer last week the piglets were 14 days old. He placed the sows with the highest piglet losses in the last farrowing in the Hog Slat International crates. He told me had piglet losses of .6 per sow in the new crates compared to 1 piglet per sow in the old crates. This is nice result.”

“When I asked him how satisfied he is with our SowMAX he gave me the short answer.  Today he regrets that he installed 50 of them…if he had know the SowMAX worked so well he would have equipped all 90 farrowing crates with them.”

“Compared to his other feeding system he has significantly less feed wastage.  Now the sows eat more, the amount is 10kg (22 lbs.), that was not possible before. The sows are much quieter during feeding time”

To see (more…..)