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Blog posts tagged with 'cool cell'

Ag Evaporative Cooling Systems Compared - Part 1, Troughs
Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather.  Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs.  We compare several key features of Hog Slat's Evap System against competitive brands.

Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather. Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs.  In part one, we compare Hog Slat’s trough design and features against competitive brands.

GreaterCapacity-600x300

Hog Slat’s Evap System features a square trough to increase the water reservoir by over 24% when compared to 8″ PVC pipe. This extra capacity allows water draining from the pads to be collected for re-circulation without overflowing. In a typical 80′ system this adds up to 168 gallons compared to only 128 gallons for an 8″ diameter PVC trough.

The trough cover is designed with more inches of open area to permit faster drainage away from the bottom on the pads.  If bottom of the pads remain saturated, they can get soft and in extreme cases sag and fall out of the system.

The Hog Slat trough cover is designed with more inches of open area to permit faster drainage away from the bottom of the pads. If the pad bottoms  remain saturated, they can get soft and in extreme cases sag and fall out of the system.  We show a comparison of  the amount of open area per linear foot of trough.

The most secure method for supporting the trough is to place the bottom directly on a concrete base.  This type of installation eliminates the need for support brackets.  The flat bottom of the Evap System sits directly on a concrete pad without additional supports.  Troughs with round bottoms such as a pipe or U-shaped troughs require the use brackets to hold them on the concrete.  The bottom doesn't sit directly on the concrete, with damage to the trough resulting from the brackets cutting into the plastic.

The most secure method for supporting the trough is to place the bottom directly on a concrete base. This type of installation eliminates the need for support brackets. The flat bottom of the Evap System sits directly on a concrete pad without additional supports.
Troughs with round bottoms such as a pipe or U-shaped troughs require the use brackets to hold them on the concrete. The bottom doesn’t sit directly on the concrete, with damage to the trough resulting from the brackets cutting into the plastic.

For installation requiring brackets, the Evap System design provides better support.  The heavy Bi-Fold bracket is a full four inches wide and spreads the bearing load over a greater area compare to single leg brackets.  The bracket also features two support legs instead of one to prevent twisting.

For installation requiring brackets, the Hog Slat design provides better support. The heavy Bi-Fold bracket is a full four inches wide and spreads the bearing load over a greater area compared to narrow  brackets. The bracket also features two support legs instead of one to prevent twisting.

Hog Slat's wide 4" bracket allows mounting on a 4x4 post when building framing lumber is not available or system is installed away from the building.

Hog Slat’s wide 4″ bracket allows mounting on a 4×4 post when building framing lumber is not available or system is installed away from the building.

Trough repairs are simple and leak free by using two couplers.  Repairs to round bottom trough is time-consuming and often leaks.

Trough repairs are simple and leak free by using two couplers. Repairs to round bottom trough are time-consuming and often results in leaks.

See Part 2, Pad & Fasteners

See Part 3, Pumps & Sumps

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Ag Evaporative Cooling Systems Compared - Part 2, Pad and Fasteners
Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather.  Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs.  We compare several key features of Hog Slat's Evap System against competitive brands.

Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather. Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs. In part 2, we compare pad, distribution and fasteners of Hog Slat’s Evap System against competitive brands.

The Evap System features a large capacity spray bar with more holes per running foot to reduce pad streaking.  Attaching the sections with bell connectors eliminates the dry areas in the pad common with coupled spray bars.

The Evap System features a large capacity spray bar with more holes per running foot to reduce pad streaking. Attaching the sections with bell connectors eliminates the dry areas in the pad common with coupled spray bars.

Pad saturation is enhanced because the top deflector angles the water flow to the outside of the pad.  By directing the water to the outside surface, the water is pulled through the pad wetting the full 6" width.  Designs with the water deposited in the middle of the pad may not utilize the entire pad.

Pad saturation is enhanced because the top deflector angles the water flow to the outside of the pad. By directing the water to the outside surface, the water is pulled through the pad wetting the full 6″ width. Designs with the water deposited in the middle of the pad may not utilize the entire pad.

The Hog Slat system features three robust, easy-to-remove, Tri-Knob nuts with brass inserts to hold each aluminum pad retainer in place.  Each section of the deflector and pad retainer is joined with connector clips to prevent dips or bows in the installation.

The Hog Slat system features three robust, easy-to-remove, Tri-Knob nuts with brass inserts to hold each aluminum pad retainer in place. Each section of the deflector and pad retainer is joined with connector clips to prevent dips or bows in the installation.

Manufactured from heavyweight Saturation Grade Kraft paper for high absorption rate and glued with proprietary resins mixed with additives for fire resistance and fungus protection. H2PAD pad is then triple cured in precisely controlled ovens and cut to exact lengths.  3/4" ProTec edging extends pad life by protecting against UV and mechanical damage.  Additional ProTec coating is available on the pad bottoms to guard against premature damage.

Manufactured from heavyweight Saturation Grade Kraft paper for high absorption rate and glued with proprietary resins mixed with additives for fire resistance and fungus protection. H2PAD pad is then triple cured in precisely controlled ovens and cut to exact lengths. 3/4″ ProTec edging extends pad life by protecting against UV and mechanical damage. Additional ProTec coating is available on the pad bottoms to guard against premature damage.

See Part 1, Troughs

See Part 3, Pumps & Sumps

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Ag Evaporative Cooling Systems Compared - Part 3, Pumps & Sumps
Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather.  Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs.  We compare several key features of Hog Slat's Evap System against competitive brands.

Most commercial broiler farms utilize an evaporative system to provide cooling during hot weather. Although there is no substitute for regular maintenance and cleaning, choosing the right system can reduce repairs. In part 3, we compare  pump and sump tanks options for Hog Slat’s Evaporative System.

The jet pump system has several advantages starting with an open drip proof; air cooled motor that does not have to operate in water.  Repairs are less expensive because a jet pump has two components, the motor can be replaced separately from the impeller assembly.  Repairs are easier with a jet pump as the assembly is above ground, and you don't have to pull the pump out of a sump like a submersible pump to perform repairs. The strainer basket protects the impeller assembly from debris.

The jet pump system has several advantages starting with an open, drip proof, air cooled motor that does not have to operate in water. Repairs are less expensive because a jet pump has two components; the motor can be replaced separately from the impeller assembly. Repairs are easier with a jet pump because the assembly is above ground, and you don’t have to pull the pump out of a sump tank like a submersible pump to perform repairs. The strainer basket protects the impeller assembly from debris.

 Side discharge design delivers high volumes than competitors center discharge pumps so water reaches the ends of long pad runs.  3/4 hp pump is available in 115 or 230 models.

Side discharge design delivers higher volumes than competitors center discharge pumps so water reaches the ends of long pad runs. 3/4 hp pump is available in 115V or 230V models.

The Hog Slat pump is specially designed for cool cell system application and not just adapted from other industries.  Re-designed vortex impeller results in lower head pressure and higher volume, the result is an efficient 1/2 hp. pumps with the same output as normal 3/4 hp. submersible pumps.

The Hog Slat submersible pump is specially designed for cool cell system applications and not just adapted from other industries. Re-designed vortex impeller produces lower head pressure and higher water volume, resulting in an efficient 1/2 hp pump with the same output as normal 3/4 hp submersible pumps.

The Hog Slat tank design does not require it to buried in the ground like conventional T-Tank sumps.  On systems where trough height determines an above ground installation the tank will set directly on a concrete pad. For below ground installations, the Evap System tank features a molded lower lip with a rounded profile to help prevent it from "floating" out of saturated ground when the tank is empty.

The Hog Slat sump tank design does not require it to buried in the ground like conventional T-Tank sumps. On systems where trough height permits an above ground installation, the tank will set directly on a concrete pad. For below ground installations, the Evap System sump tank features a molded lower lip with a rounded bottom profile to help prevent it from “floating” out of saturated ground when the tank is empty.

See Part 1, Troughs

See Part 2, Pad & Fasteners 

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Swine Air Filtration Basics

While speaking with Perry Hartman, a sales rep for Hog Slat in Minnesota, I was brought up to speed on a topic that is quietly gaining some momentum in the industry…air filtration.   Southern Minnesota is an area that has seen rapid growth in pig numbers in the past several decades.  This high hog density has made herds there very susceptible to PRRS outbreaks.  To combat this, area producers have turned to air filtering to prevent herd infections.  Perry has been involved with 6 different projects and is currently working on the 7th.  These projects have ranged from a boar stud to a complete 5,000 head sow complex. Perry credits a close working relationship with Dr. Darwin Riecks of the Swine Vet Center in St. Peters, MN in making these projects a success.

Some of the leading technical information has come from an U of M test farm in Morris, MN.  There are three different buildings that have been outfitted with three different brands of filters and are tested for effectiveness against the PRRS virus.  From this initial research, it was determined the PRRS virus can be transmitted over 5 miles in distance and the greatest risk comes at temperatures between 40°-60° with a light 3-7 mph wind.

Using this information, a basic strategy has evolved around filtering the minimum air flow coming into the building.  A typical farrowing room has ceiling inlets for winter/transition air flow.   Minimum winter air flow can be effectively filtered by placing filtering boxes in the attic over the inlets.


To permit installation and future service to the attic filtering system, an access is built in the end of the building gable with a stairway and locked door.

A catwalk is built inside to allow access to inlet filter boxes.

Galvanized boxes are installed between the rafters to mount the filters in. A pre-filter is installed to protect the filter from dust. The building structure needs to be examined for cracks that must be sealed and caulked to prevent unfiltered air from short circuiting the ventilation inlets.   By filtering the incoming air during the periods of highest disease threat (40-60°) some producers feel that temperatures above this will kill the virus effectively.

A complete filtration system goes past the basics and includes filtering the maximum air flow coming through the cool cell system.   Every situation requires careful calculation but a rough rule of thumb is to provide twice as much air filtering area as existing air inlets.

Retrofits for farrowing buildings have involved extending the roof line and adding a hallway to mount the filters in.   The filtering pads are installed in the new exterior wall and are protected by an outside curtain.

Pre-filters are installed over the filters to prevent clogging of the system by dust and debris.

A tunnel ventilation system, as used in many gestation and GDU buildings, require adding an extension on the gable end and creating an area that is large enough to mount the filter system. An “accordion” style arrangement of filter mounting is used in many cases to achieve the desired amount of filtering area.

This is brief overview of the basics for air filtering as it has evolved to date.  Again there is no “canned” solution as they are retrofits to existing ventilation systems.  Each must be examined carefully and correctly sized to prevent excessively high static pressures that could damage fan motors and the filters themselves.  Perry has invaluable knowledge of filtration systems gained through field experience over the last couple of years.

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Increased Ventilation Rates Pay Dividends

As every chicken grower knows, hot weather takes its toll on performance. Feed consumption and daily gain are difficult to maintain when temperatures reach and remain in the high 90s and above. Tunnel ventilation increases bird comfort resulting in improved performance. So is any type of tunnel ventilation good enough? Is there a return on adding fans for increased air speeds above the industry 550 fpm standard? Mike Lucariello, a Tyson grower from Wheaton, MO has a unique perspective on the question. Several years ago Mike remodeled six) 40’x400’ broiler houses to company specs including insulating the north side of the houses and adding insulated curtains to the south side. Fan power was increased to create a system capable of generating wind speeds of 550 feet per minute. Performance was excellent and his farm’s closeouts routinely ranked at the top. Last year Mike built two new 55’ x 600’ drop-ceiling houses. These houses feature improved side and ceiling insulation, energy efficient 52” Windstorm fans, Gro40 brooders and Tego tunnel doors. The wind speed in the new houses was calculated at 700 fpm. The first group was placed in these houses in February and the performance and energy use was excellent. The real test came this summer. A flock was placed on June 22. For the next six weeks the area experienced very hot and humid weather with temperatures staying in the 90s and moving into the 100s on a few occasions - the kind of weather that hurts bird performance and causes mortality to increase. The flock was caught and processed on August 2. Mike is on a competitive contract with Tyson so his performance is compared with other farms for the same week. These were excellent results especially considering that was an averaged total, (with 141,000 of the birds coming from the old houses and only 96,800 caught out of the newer houses with improved ventilation). Birds from the new house averaged 4.08 lbs. vs. 3.81 lbs. from the older houses. We would expect similar differences in Feed Conversion and Average Daily Gain. Another thing to consider is these are small birds... big 8 lb.+ birds would benefit even more from increased air speeds in the 700 fpm range. This winter is the time to take a look at retro fitting your existing ventilation system, especially if you have or are switching to big birds. Put a call in now to your local Georgia Poultry sales rep. They’ll visit your farm and help you put the cost of the retro together... it will pay big dividends in the heat next summer and put money back in your pocket.

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Evaporative Cooling System Checklist

Tunnel Ventilation systems along with evaporative pad systems are effective at reducing summer temperatures in swine and poultry buildings. Here are some tips to keep your houses running at peak efficiency.

1) Bleed off water to control mineral content

As water is circulated and evaporated in a pad system the concentration of minerals is increased.  This is especially true in areas that have hard water with its higher levels of dissolved minerals. It is suggested that 5% to 10% of the circulated water should be continuously bled out of the system. Alternatively you can also dump and replace the sump tank water weekly. Products such as Scale-Stop or Cool-N-Kleen Cool Cell Descaler can be effective in controlling scale buildup for farms with very hard water when coupled with bleed off.

2) Check pH

Desired pH level of the water should be between 6 and 9.  The pH levels outside of the this range shorten pad life by leaching out the stiffening agents in the pad. You can alter the pH of the water by adding one of the descaler agents listed above or Grower Select’s Kool-Cell Kleen.

3) Eliminate dry spots on the pad

Dry areas on the pads allow uncooled air to enter the building.  Simply put,  if the pad’s not wet it’s not cooling. Dry streaked areas on the pad are a clear sign that you have clogged holes in the distribution system.  Remove the cover and unstop the clogged holes in the header system.  It is a good practice to clean the distribution system by opening the ball valves and flushing water through at least once a month.

4) It’s a pain…but you have to clean the filters

Install a spin down water filter with a clear housing and 60 mesh screen on the system and keep it clean. It will prevent clogged distribution pipes and dirty pads. The poorer the water quality the more often the filters need to be cleaned. Installing a filter with a ball valve will simplify the chore.

5) Prevent algae growth

Although H2PADs are treated with an fungicide and come with ProTech edging to prevent algae from adhering to the pad surface, this does not completely eliminate the problem.  Treat the system  water with a good preventive product like Bio-Stop or Grower Select’s Kool-Cell Kleen to keep algae under control. In addition,  the pads should be allowed to dry out once every 24 hours to improve the longevity of the pad.  Program your ventilation system to allow the fans to continue to run awhile after the pad system is turned off at night.  This will pull air through the system, drying the pads out and killing any algae spores.

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New Lease on Life for Broiler Houses

Kip and Michelle Cullers took a hard look at their existing broiler operation and decided changes needed to be made. First put into operation in 1989, the six 22-year old buildings were in need of major renovation to qualify for premium payments.

After exploring their options with MoArk, a leading producer of specialty eggs, the Cullers next contacted Mike Lucariello who heads up Georgia Poultry’s operations in the area.

Working with the existing 40’ x 400’ dimensions, Mike put together a layout designed to house 12,500 hens per building. The layout features two rows of Wadeken center belt nests set up on a flat deck of plastic slats with a lowered center scratch area. New chain feeders and the old drinker systems, outfitted with cups, were installed on the deck area between the nests and the exterior walls.

The ventilation system was upgraded with the addition of seven 52” Windstorm fans and a 5’ x 55’ cool cell system on each side of the building. The system also unitizes the existing curtain system that can be manually activated during mild weather.

To complete the project, a 20’ x 40’ egg room was added to each building. The bulk of the egg collection is done in the morning with center belts moving the eggs to the end of the building where they are placed into flats, stacked on wheeled racks and moved to the egg cooler until pick up every Tuesday and Friday.

Kip commented, “We had complete confidence in turning the project over to Mike. He’s been in the chicken industry for a long time and has broiler and laying houses of his own. We are especially pleased with the way the ventilation system performed last summer. The tunnel system combined with the cool cell system kept the hens comfortable; in fact, we experienced no loss of production despite the record heat we had.”

Kip continued, “Michelle is responsible for the day-to-day operations on the farm. She does an outstanding job keeping up with the paperwork necessary for organic egg production. Plus she manages two full time employees and four part timers who gather eggs. I help out with repair and maintenance as the farming operation and travel allows.” (In case you are wondering whether you have heard Kip’s name before, you may have. He holds the record for soybean production at 160.6 bushels per acre and travels worldwide speaking about his production methods).

To find out more contact us at 800-949-4647. We’ll sit down with you, explain your options and help you put together a plan and cost estimates for remodel or new projects.

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Changing Fan V-belts

Just saw some interesting info from Billy Farmer. Billy is the store supervisor in Georgia, and had just attended the 2012 Poultry Tunnel Ventilation Workshop at the University of Georgia. They always put out great technical informational at their workshops and this piece caught my eye.  We all know that we should change v-belts on belt drive fans when they get worn but….why?

V-belts don’t actually stretch as is commonly referred. They get thinner as they wear. Because they get thinner, the belts will start to ride lower in the pulley groove. When this happens it’s just like the pulley becoming smaller. As the fan spins slower it moves less air. CFM delivery is directly proportional to the fan speed. Spin the fan 10% slower and it moves 10% less air. Reducing the CFM capacity of a building by 10% can spell disaster in terms of pig and broiler performance during the heat of the summer.

How do you know when to replace a V-belt? 

A quick visual check will determine if  a V-belt is worn and needs to be replaced. If the belt is riding above the pulley groove, it is doing its job. If the belt is bottomed out in the groove and/or riding below the top of the groove, it’s time to replace the V-belt.

While you have the V-belt off, you should take time to inspect to the pulley itself. A new pulley has a sharp V-shaped groove. A pulley that is more U-shaped is worn and needs to be replaced before you put on the new V-belt.


To make the job of replacing V-belts less expensive, Hog Slat developed our own line of V-belts called GroBelts. They are constructed of compressed rubber embedded with low stretch nylon cords. Hog Slat and Georgia Poultry stores carry a complete selection of the most popular sizes in stock. If you can’t make it to a local store, you can also order on line at http://www.hogslat.com/v-belts-grobelt-drive-belts and we’ll ship them directly to your door.

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WeatherFlow - Wind Meter for Your Smartphone

ITM-WeatherFLow in package-IMG 

The old saying, “ You can’t improve what you can’t measure,” applies to measuring wind speed in a hog or poultry house.  Gauging wind speed of tunnel ventilation or velocity out of an inlet without an anemometer (wind meter) is like trying to regulate building temperature without a thermostat.

The WeatherFlow wind meter is a great new product that allows you to use your smartphone as an anemometer.  At only $35, it is so affordable that every producer should add it to their ventilation “toolkit.” View our setup and use demonstration below to see just how easy the WeatherFlow wind meter is to use.

WeatherFlow app

First download the FREE app
at either the Apple store or Google play store.

WeatherFlow Start Screen

Then open the app and click on

the small green box in the upper left-hand corner.

WeatherFlow Settings

Click on Settings

WeatherFlow FPM

Click on Speed Units and set it to Linear Feet per Minute

WeatherFlow Time

Next click on Maximum Sample Period and Set it to 30s

WeatherFlow Take reading

Now just plug the WeatherFlow into your smartphone’s earphone jack,
and you are ready to take your first measurement.
Click on Take a Reading 

WeatherFlow with phone

Hold the wind meter away from your body and about five feet off the floor.

Take the measurements at least 40’ from the tunnel fans.
Measurements should be taken on a calm day as windy days can influence readings inside the house.
For the most-accurate results, take a reading 30 seconds long and repeat with a pause of one minute in between.

To order your WeatherFlow wind meter go to http://www.hogslat.com/weatherflow-wind-meter.

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Grower Select Curtain Machine

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.

curtain machine keyhole

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.

Curtain machine top

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.

Curtain machine drive block

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.”

Curtain machine Aux switch

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.

Curtain machine switches

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.

GS Curtain machine close up mounted_edited-1

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.

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