Blog posts tagged with 'engineering'

The size of individual sow farms continues to increase; just a few years ago 2,400 head units were considered large, but new sow farms under construction this year range between 5,000 to 14,000 head in size.

Building cross-section comparison

Designing the central production facility into two or three larger buildings has many advantages including smaller land requirements, less underground utilities to bring to the site, shorter roadways to build and maintain, fewer walkways between buildings and less linear footage of exterior building walls.

Because of increased pig capacities and the desire to minimize the number of buildings, it was necessary to increase the buildings widths up to 190 feet.  Instead of the 4/12-pitch roof used on standard farm buildings, these jumbo-wide facilities utilize a two-piece rafter with a 1/12-pitch roof line resting on a center support wall in the middle.  Almost 6 feet high at the heel with a center height of 13 feet, the rafters are designed more like a large floor joist. The outside appearance resembles a steel frame building more than conventional wood framed structures.

Breeding/ Gestation

Galvanized gestation stalls

Totally slatted flooring is a common feature of newly constructed B&G buildings. While past layouts consisted of a solid laying area with slat sections in the rear of the pen or stall only, new construction plans incorporate slats over the entire floor with stainless feeding troughs fastened in place. This arrangement allows long-term flexibility to reconfigure the pen layout in the future if needed.

Group housing with stanchions is the predominant type of housing under construction this year. Largely through trial and error, the industry seems to have settled into pen configurations containing eight to twelve sows. This pen size permits closer grouping by size and condition and promotes easier visual inspection.

Whether the production system chooses gestation stalls, stanchions, or ESF, most equipment is specified with hot-dipped galvanized equipment instead of painted finish. The extended equipment life provided by the galvanized finish makes this an economical business decision.

One advantage reported with stanchion systems is longer equipment life resulting from moving the water away from the front of the stanchions. Locating a cup or swinging water pipe with nipples in the center of the pen reduces the deterioration of feed pipes and stall fronts by minimizing water contact with these areas.

Farrowing

Large pen farrowing crates with SowMAX feeders

Jumbo style layouts permit designing a double farrowing building with an extra wide 8-foot center alleyway to aid in animal and people movement between rooms.

Almost every new construction project increases the length and width of the farrowing crates and creep area from the standard 5′ x 7′ footprint up to 6’ wide by 8′ long, with some systems choosing 8’6″ long crates. Longer framed sows and reduced piglet crushing rates from using wider pens have driven this trend. Again, the equipment will have a galvanized finish with a combination of cast iron, TriDek, or plastic slats for flooring choices.

Most production systems will incorporate some provision for ad-lib sow feeding. Besides reducing farm labor, ad-lib sow feeding is the most efficient method for feeding individual sows to reach full milk production potential. The type of systems can range from electronic transponder metering devices to sow activated hopper type feed dispensers.

Swinging rafters on new farrowing house

Projects of this size require builders with an expanded skill set. A builder must be able to provide professional project management, understanding of regulatory issues, and increased insurance coverage. It is also critical for any construction firm undertaking projects of this size to have sufficient financial backing and the ability to manage large cash flows.

For more information about Hog Slat’s construction projects and swine production equipment offerings, contact your nearest sales representative by clicking here.

How can we make the claim of selling the strongest, heaviest feed bins on the market at the best possible price to swine and poultry growers?

Traditional multilevel supply chain vs. Hog Slat’s Direct Distribution

Simple. Our direct distribution system eliminates the additional markup that dealers have to add to the bin’s price. Instead, that money goes back into building a stronger bin manufactured from heavier steel. These longer lasting bins are built with 5-10% more steel, by weight, than competitive brands.

Compare the features.

Most manufacturers only use 50,000 psi structural steel for the bin sheets and legs to reduce costs.  Hog Slat bins are constructed entirely of GRADE 55 structural steel.  The bin sheets, legs, roof sheets, bottom cone sheets…the entire bin.

Heavy, dent resistant bottom cone sheets.

The bottom cone sheets of a bin are subjected to extra abuse from hammers and mallets used to dislodge bridging feed.  That’s why we used thicker steel to resist dings and dents.

Heavy 10 gauge collar

We build the bin collar out of heavier 10 gauge steel to eliminate having to add additional reinforcing collars. The collar is stamped to reduce variations in dimensions compared to rolled or spun collars.

Every Hog Slat / Georgia Poultry bin is manufactured in-house for complete control of raw material purchasing and manufacturing operations.  Our facility includes state-of-art rolling, stamping and finishing machinery to ensure precise fit and finish.

Get a quote on your next bin and see for yourself. Call 800-949-4647, go online www.hogslat.com or stop in at a local Hog Slat or Georgia Poultry store. (click for store locator)

Management expert Peter Drucker is often quoted as saying that “you can’t manage what you can’t measure.” We believe this is particularly true when it comes to developing, improving and testing ventilation fans.

Hog Slat’s Wind Tunnel

Hog Slat’s AirStorm and Windstorm ventilation fans are designed and tested using an Airflow Performance Test Chamber, or as it more commonly known, a Wind Tunnel. Measuring 10′ x 10′ x 28′ long, the Wind Tunnel was constructed according to AMCA standard 210 and installed at the Clinton, NC facility in May 2015.

Fans to be tested are fixed in place on one end of the Wind Tunnel.

Air Forcing fan powered by a 20 HP motor

A 48″ axial vane fan, powered by a 20 hp motor, located on the opposite end of the tunnel, forces air into the chamber.

Nozzle Wall

After passing through a series of mesh straighteners, the air is then forced through a nozzle wall consisting of metal cones that can be opened and closed to change available square inches of space.

Pressure transmitters feed data to the automated recording system.

Two devices, called Differential Pressure Transmitters, measure and record the static pressure differential on each side of the nozzle wall.  To maintain precise accuracy, the transmitters are calibrated monthly and are also returned to the manufacturer for a factory re-calibration once per year.

One of the key features of Hog Slat’s test chamber is the automated recording system that records data without any manual input from an operator. The Wind Tunnel is ramped up from zero to maximum static pressure while up to two data points per second are recorded in real time. This automated recording system is a custom program developed by a team from Hog Slat’s engineering group. This allows Wind Tunnel technician, Matt Parker, to supply the engineering group with a complete fan performance graph instead of limiting the information to only a few selected data points.

Technician Matt Parker views display screen readouts.

Lead engineer for ventilation products, Tyler Marion explains; “Having a Wind Tunnel in-house allows us to quickly break down a fan by critical components and test multiple variables quickly. We are able to test different motor/fan combinations, shutter designs, and cone styles to constantly improve the fans Hog Slat delivers to our customers.”

QC testing fan blades

Hog Slat’s Wind Tunnel is not only used for fan testing and development, it also serves as a Quality Control check on products received from suppliers. The photo above shows a galvanized prop mounted in standard fan ring. In this case, the initial run of product from the vendor is being checked against the approved sample. This testing continues for each production run to ensure the same performance levels from lot to lot. QC checks are also run for completed fans pulled from inventory and checked against published standards for airflow, CFM/watt and motor amperage.

Matt tests a Windstorm 36″ Box Fan using the Thrust Tester.

A new addition to our fan testing equipment is the device called a Thrust Tester. The Thrust Tester measures the amount of thrust (lbf or pounds of force) a stir or circulation fan develops.  It also measures the thrust efficiency ratio of a fan by dividing the lbf by kWs used. Although the Thrust Test is a stand-alone unit, it is tied into the Wind Tunnel transmitters to record the data. Matt also records centerline velocity at distances five times the prop diameter.

To see more on Hog Slat’s complete line of AirStorm fiberglass and Windstorm galvanized ventilation fans go to www.hogslat.com or call 800-949-4647.

Broiler houses at a Georgia farm.

When it comes down to it, the cost of manufacturing a high-quality product is the same for most companies producing equipment for the livestock and poultry markets. Most companies have identified the most efficient methods to build an anchor bearing, motor, feeder, nipple waterers, etc.

The real cost difference comes from the delivery of those products to the end user. The standard model of distribution, in our industry, involves a manufacturer producing a product line, warehousing it, and employing a sales force to establish a dealer network.

The dealer network stocks the equipment, maintains a storefront, hires salespeople, installs, and services the production systems in a local area for the brand of equipment they represent.

This particular type of distribution model has changed very little over the history of the livestock and poultry production industries. Each member of this distribution model is an independent business entity and is free to add whatever margins they deem necessary (or possible) to the final cost a producer pays.

GrowerSELECT supply chain removes extra margins to reduce the final cost to end users.

Sold through a different type of distribution model, GrowerSELECT goes directly to livestock and poultry growers through our network of regional local stores. Because we own the distribution chain from top to bottom, we add only ONE MARKUP over our cost.

Our cost is based on finished goods plus ONE MARKUP vs. MULTIPLE MARKUPS from the typical distribution model.

Also, we would suggest that we are the low-cost producer for most products. Wait a minute; the first paragraph said the cost of manufacturing was the same for everyone.

True. But if a brand has a loyal dealer network, the pricing to the dealer network will not be challenged. A loyal dealer will continue to buy brand name products even if the cost is excessive.

GrowerSELECT auger motor with 2-year warranty.

Name brand motors are a perfect example of this. An auger or fan company buys a motor from a motor manufacturer, puts their logo on it and sells it to a local supplier. The local supplier sells the motor to the end user adding little value to the final price. A local supplier has few other options. Their volume of a particular motor isn’t high enough to go directly to a motor manufacturer, and they have little negotiating power with their chosen brand vendor. The brand company has little incentive to lower the cost to a loyal dealer network. In fact, a brand company can charge different prices in different geographical locations depending on market pressure.

Compare this with GrowerSELECT motors. Our network of over 70 store locations and turnkey construction business allows for large purchases of motors direct from a manufacturer. We forecast purchase amounts for each store location and ship directly with minimal warehousing cost. Local retail pricing continually drives us to buy at a more competitive price.

The conventional distribution chain is directed from the TOP DOWN versus the GrowerSELECT model which is driven from the BOTTOM UP. Lower pricing for comparable products is the result.

The GrowerSELECT distribution model also affects product responsibility. Because we interact directly with the end users, we deal directly with any problems arising with the installed products. We sell it; we service it, and the end user works with one company.

The traditional marketing chain allows room for some question regarding who is responsible for dealing with equipment failures when those problems arise. The manufacturer can blame poor installation, dealer system design, or a number of other reasons (excuses) for a product’s failure. A local supplier can blame the brand company for poor design or manufacturing flaws. The GrowerSELECT distribution system eliminates “finger pointing” and focuses on providing accountability to each and every customer.

Our customers produce commodities. The lowest cost commodity producer is always the most successful. Our mission is to provide our customers long term value at the lowest possible cost.

Ask yourself this question; “Are all the manufacturers, distributors, dealers, installers, and service personnel creating ADDED VALUE in the distribution chain I buy from?” If you hesitated while answering that question, take the next step by changing the way you buy and implementing GrowerSELECT equipment into your operation.

To contact a sales representative in your area or find our nearest locations to you, click here.

Margin Stacking is a term that may or may not be familiar to you.  It refers to the cost or profit margin that each member of the supply chain contributes to bring a product to the end user. Every manufacturer, distributor, and dealer adds their own margin and the final cost includes these “stacked margins.”

This type of distribution system has evolved over time and in many cases is the best method to deliver products efficiently to consumers.  The margins charged by these “middle men” aren’t evil or bad as long as they add value to a product through manufacturing, warehousing, installation or technical support.

We would all agree that the structure of the poultry and hog industries has changed a great deal in the last 20 years, and some parts of the supply chain have changed along with it.  At one time, local dealers sold, mixed and delivered complete feed to production sites.  As producers became larger, they quickly moved to reduce the number of people involved in formulating and manufacturing feedstuffs and realized substantial cost savings.

The supply chain to deliver feed systems and ventilation systems has not changed for decades.  Companies design and manufacture products, warehouse, finished goods and hire representatives to “set up” local dealer networks. The dealers provide a storefront, promote the brand locally, order and stock parts, hire salespeople and installation crews.  The industry is still delivering production equipment to the end user the same way it did when the number of producers was much larger.

Hog Slat developed the GrowerSELECT® line to collapse the supply chain, reduce margins and lower the final cost.  How?

Hog Slat established a network of company stores in the major livestock and poultry production areas of the U.S.   This system was backed up with distribution centers totaling over 600,000 square feet. We control distribution costs and the margins charged against the final purchase price.

The resulting volume of goods sold through our store system and large turnkey construction business enabled Hog Slat to justify the investment needed to manufacture feed and ventilation systems for our customers. We design and control the manufacturing process and the costs involved.

Typically, manufacturing companies do not have retail systems in place to deliver, install and service systems on a local level. Local dealers do not have volumes large enough to hire engineers to design and manufacture products for their local markets.  Hog Slat is the only equipment supplier in the poultry and swine industries to integrate the supply chain vertically.

If you have priced any GrowerSELECT equipment, you have probably been pleasantly surprised at the cost savings. You may have even hesitated to buy it because of the low price.   After all, “you only get what you pay for” is true. Buying products through the traditional distribution means you are paying the built in margin stack.  If you are ready to stop paying “margin stack” on feed and ventilation systems contact one of our local stores about GrowerSELECT, go online to www.hogslat.com  or call 800-949-4647.

Hog Slat will be exhibiting at this year’s World Pork Expo with many new and further developed swine equipment products, highlighting Hog Slat’s GrowerSELECT product line.

At the show, Hog Slat will have a large variety of equipment on display in both the exhibition hall (Booth V165 VIB) and at the Hog Slat hospitality tent (Tent G234). Equipment that will be on display includes Hog Slat’s Grow-Flex Feed System, Grow-Disk Feed System, Slats, and an introduction to Hog Slat’s AirStorm fans. We invite you to stop by the Hog Slat booth to see what’s new at the show.

Enjoy FREE ADMISSION to the 2015 World Pork Expo, courtesy of Hog Slat. You may redeem your admission voucher by registering online at www.worldpork.org by May 28th and use voucher code HogSlat2015. Or, present a hard copy of our voucher (available through the Hog Biz, local Hog Slat retail stores, or your local sales contact) during on-site registration the day of the expo.  Expo registration is located in the Animal Learning Center inside Gate 15.

Craving some good BBQ? Stop by the Hog Slat hospitality tent anytime during expo to enjoy Vinny’s BBQ, located in Dakota City, IA. Vinny’s will be serving lunch and dinner both Wednesday and Thursday of the expo.

The World Pork Expo is held June 3rd-5th in Des Moines, IA at the Iowa State Fairgrounds. Visit us at the show in booth V165 in the Varied Industries Building and Hospitality Tent G234. We hope to see you at the show!

As my family and I traveled through Iowa last weekend, I couldn’t help but take notice of several finishing buildings that had been sitting empty for the last year or so. The curtains were down and pit fans running…they were filled with pigs again. Even though pigs are hard on equipment, nothing is harder on buildings than just sitting empty. Motors seize up; bolts and latches rust in place and the gating needs some general repair. To help with gating repairs, Hog Slat manufacturers a DIY product called Cut and Weld panels. Cut and Weld panels allow producers to build gating “on-site” to the exact length needed.

Cut and Weld panels are available in two lengths; 6’-9’ and 9’- 12’ long. Cut and Weld panels are a standard 31 ½” high panel with one end upright tacked in place instead of welded solid.

You simply tap the upright loose and slide it along the horizontal rods until you reach the length desired.

You then weld the rods to the upright and top angle and cut off the excess.

Then, depending on the application, you can choose from a full range of tabs, pipes, latches, etc. to complete the gate. Finish the project off with a coating of Hog Slat blue spray paint to help prevent rust and you’re ready to install a gate fitted to the exact size you needed.

The DIY Cut and Weld panels and all the accessories are in stock at every Hog Slat store located in the Midwest.

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.

As the swine industry searches for alternatives to stall gestation, another option has emerged and is in the process of being refined.  Stanchion Housing refers to short stall-like dividers that are added to open pen gestation to separate and protect the animals as they are fed.  It is a refinement over traditional open pens where sow are fed on the floor and group size must be limited to reduce fighting.

To date all the systems have been designed with standard gestation stalls in which the sows are weaned and remain until they are bred and preg checked.  Typically this would be about a 45 day inventory of the total sow numbers.

Looking at the total number of animals in a breeding group, a decision can be made on total numbers of sows per pen.  Current stanchion systems range from 10 head per pen all the way up to over a hundred.  Many producers choose to break a farrowing group into two or three different pens as this allows for grading and sorting weaned animals by body score.  Placing sows in similar groups reduces fighting and allows for uniform feeding.

After total number of sows per pen is determined, the next design consideration is the amount of square footage per animal.  Current EU welfare regulations require 24 sq ft. and some producers have chosen to follow that guideline, but systems exist that range from this level all the way down to 17 sq ft./sow.

Two critical design elements have proved themselves in the existing layouts.  First, long narrow pens are preferred as this prevents a boss sow from blocking feed stanchions.  The second design feature is placing the stanchions head to head in the center of the pen rather than placing them along the alleys.  Because the stanchions are not in the alleys, the sows can be viewed from the rear during feeding for problems.  It also allows for easier animal movement in and out of the pens as the gates are not part of the stanchions.  In addition, the number of feed lines needed is reduced.

The first stanchion systems featured trickle feed equipment where the feed slowly dribbled in front of the sows at meal time, the idea being a slow placement of feed in front of the sows would hold them in the stalls and prevent boss sows from “wolfing down” their feed and moving up and down the line stealing feed.    In practice, the additional cost and upkeep of a trickle system did not justify its use and has been omitted on new installations.   Current systems use standard feed drops that dump the entire ration into stainless steel troughs or on a solid concrete floor.

Equipment used in a head-to-head layout consists of stanchions that are 40” tall and 19” long.  These dimensions protect the face and ears of the individual sow from aggressive pen mates.  Ideal width has been determined to be 20” as this prevents other sows from crowding in to steal feed.   Early systems used solid dividers; as we gained more experience with head-to-head systems,  the use of open dividers was adopted.   The Hog Slat equipment used to configure this layout is an adaption of our standard gestation stall which has been used throughout the industry for over 30 years.  The stanchions are constructed of solid horizontal rods with angle top and bottom rails, the entire unit bolts together with galvanized floor spacers and double top spacers for added stability. This style of stanchion fits completely with the standard 40” gestation penning used in the rest of the pen layout.   The result is a well-designed system that goes together without a great deal of “field fabrication”. AquaChief cup waterers are added at the rate of one per 11 animals to provide fresh water.

Many of the stanchion systems are remodels, the layout of which has to be adapted to existing slat /solid configurations. If building new projects most producers opt for using total slats as this allows for more flexibility in the event of changes in the welfare regulations.

Stanchion systems require a high degree of stockmanship to operate successfully.  Boss sows must be culled ruthlessly and individual care of animals is more difficult than standard stall systems.  However, for many production systems, stanchions are a better alternative than Electronic Sow Feeding. Stanchions allow group housings of animals without the costs and high maintenance associated with ESF stations.

For more information please contact your local Hog Slat rep or contact us by email at frichards@hogslat.com.

I have sold or been involved with swine concrete slats for over 30 years.  For the last 18 of those years I have represented Hog Slat products.  I believe that our slats are the best in the industry and have the most consistent quality. But new slats all look good when they are getting unloaded off the delivery truck. What about when they are 5 years or 10 years or even older?

Last week I was at  Hog Slat’s production plant in Humboldt, Iowa taking pictures of slats.  The plant manager, Dave Shiflett said “You want to see some old slats that we pulled out of a barn recently?”

“Sure”

So we go out behind the plant and he explained that we were called in to replace some slats from local production site.  This particular site was built in 1994. One barn has slats produced by Hog Slat and the other barn has slats from a competitor.

Comparing slats

He said “The slat on the left is a Hog Slat slat and the one on the right is from the competitor.  Notice the difference in surface wear on each slat.  The competitor’s slat has rock showing because the top surface has been eaten or worn away.  I grabbed our slat out of the other building that they were not replacing for comparison.”

“Interesting, but they’re not from the same building”

“No but same site which means same water, same feed and same management.  Pretty good comparison of 17 years old slats I would say”

So we started talking about the reasons for the better wear on the Hog Slat product.

Dave said “It’s the denser concrete we use in our mix.  Everybody that has ever poured any concrete knows the less water you use in mixing concrete, the harder, stronger concrete you get.  The standard mix is a 4” slump, which you have to use to be able to place and screed the concrete in the form.  We use a ZERO SLUMP mix in our slats. Let me show you what I mean inside.”

So we go inside and Dave has slump cone in which he places some of our concrete mix and pulls the cone. He adds water to an additional batch to represent a standard 4” concrete mix.

concrete slump

“Note how the concrete mix on the right has sagged down 4” vs. the zero slump concrete on the right? All the rest of the slat manufacturers have to use a wetter mixture because they don’t have equipment that allows them to work a drier mix. Like I said earlier less water means a stronger, denser concrete that wears better and holds up longer in the barns.”

As the industry’s production buildings get older this comparison bears keeping in mind.  Most new slats look the same when they are placed in the barn and you really can’t tell the difference from the outside. Buying slats for a new building or replacements in an existing structure is an important decision that producers should take under careful consideration.  Looking at 17 year old slats is a chance to get some valuable insight that may help with that decision.