Blog posts tagged with 'gestation'

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.

Hog Slat’s newest feed drop hangs straight under the feed pipe to reduce twist. Available in two models; HSSD60C for mounting on Grow-Disk metal pipe or HSS55DC for model 55 PVC pipe.

The Center Drop is molded from UV stable polypropylene to prevent damage from sunlight and cold temperatures.  An open-top design permits direct installation on feed pipe and a large access plug allows access to inside of the feeder. A plastic clip for record cards completes the exterior features.

The Center Drop features positive open/close shutoff.

Large adjustment dial permits single-hand regulation feed settings from one to eight pounds.

Nylon wheel reduces wear on lifter cord and the weighted ball securely seals bottom opening.

To order go to http://hogslat.com/hog-slat-center-drop-sow-feeder-8-lb

Hog Slat’s Drop Tube Assembly completes the installation to a metal pipe.  Available in 2″ or 3″ models, the flared top reduces feed spillage and provides a flexible mount to sow drops.

To order go to http://hogslat.com/grower-select-adjustable-drop-tube-assembly-4 

One of the benefits we list for the Grow-Disk system is a “superior chain.”  The feed chain with molded plastic disks is the main component of the system, physically moving feed to a feeder or sow drop.

I dropped in on Hog Slat’s engineering group to see what I could find out.  I found Tim Hawkins, the project engineer for the Grow-Disk product line. Tim led me to a complicated looking run of 12 corners occurring in less than eight feet with intersecting vertical and horizontal corners.

“The drive unit is off of it now,” Tim explained,  “but we ran different brands of chain through this setup to show accelerated wear. Look at this…..see the metal filings in the bottom of the corner? Those showed up when we ran the last batch of electroplated chain through the unit.  The process of electroplating weakens steel causing it to wear faster.”

“This confirmed the difference between using hardened steel compared to galvanized or electroplated chain.  Hardened steel is high carbon steel given heat treatments of quenching followed by tempering.  The result is tough steel chain that resists wear without being brittle. We can run a hardened chain for days and never see filings like that.”

“With most chain feeding systems you have to adjust for “chain stretch” after the systems have operated for awhile.  We don’t think the individual chain links stretch but as they go around corners constantly rubbing together they elongate because of wear.”

“The only reason, to galvanize steel, is to prevent rust.  With the fat and oils in the feed, the chain doesn’t rust in the tube.  Most brands of feeding chain is galvanized for it’s appearance before installation.  A new bag of Grow-Disk may have some surface rust on it, not a big deal.”

We next looked at how well the plastic disks are fastened to the chain.

“We placed each brand of chain link in a load cell and attached it to a winch, measuring the force needed to pull the disks off the link.”

“Most of the disks pulled off at 300 lbs., although one slipped at only 160 pounds!  We applied over 600 lbs. of force to the Grow-Disk disk before it slipped.”

“First of all, the disks are manufactured from nylon, a stronger, denser plastic instead of polypropylene.
Second, if you look closely at all the chains the connector welds are smooth, except on the Grow-Disk chain….see the little knob?  That knob prevents the nylon disk from slipping…the nylon has to break instead of just slipping.”

“Most feeding chain suppliers buy general purpose chain with the knob removed. By using a chain fabricated “in-house” and designed specifically for feed systems, we can produce a superior product.”

“A strong plastic disk is important because the drive sprocket powering the entire system makes contact with each, single disk for a brief moment.  If an individual disk slips this causes the chain to be slightly out of alignment causing possible jams.”

You can be confident using Grow-Disk chain knowing you are buying the very best even though the cost is usually less.

Hog Slat streamlined distribution system reduces margin stacking.  We manufacture and source products direct to you….eliminating extra dealer margins.

Good product engineering does not add cost to a product but instead takes manufacturing processes into account to reduce costs. It costs no more to spec a hardened chain with knobs intact to provide a better contact for injecting the nylon disk.  The result is a superior product that lasts longer on your farm.

Grow-Disk systems, read more…

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.

As the food industry responds to animal welfare issues, many producers have started to consider alternative options to stall-based gestation systems. We took a few moments to speak with Hog Slat’s national sales manager, Fritz Richards, about group housing systems.
Can you describe the options available and the advantages and disadvantages of each?
Hog Slat first took a hard look at the Electronic Sow Feeding or ESF systems. Sows are housed as groups and fed in stations that identify sows individually by means of RFID ear tags. This type of equipment seemed to offer slight advantages that would offset some of the management tools which producers would lose going to group housing from stalls. Such as the ability to feed animals as individuals and maintain dynamic farrowing groups. We looked at both domestic and international systems, touring and speaking with experienced growers. There were some differences that came to the forefront.

Like?
This type of system is a major paradigm shift for US producers. The US industry has developed a very straight forward system of handling gestation sows. Sows are weaned into a stall, bred there and sow condition is managed by individual feeding. ESF is a completely different management style. First, the animals must undergo a two to four week training process with up to five percent of them eliminated as untrainable. Second, because computers, scanners, RFID tags and low voltage lines are necessary for ESF equipment a highly trained staff is required to operate the system successfully. With many production systems experiencing high turnover of farm staff, it becomes very difficult to perform the necessary maintenance and training.

Where do you see ESF working best?
Farms where the owner works in the unit every day and is able to maintain and repair the equipment in-house. The U.S. landscape is not like the situation we saw in Europe where as many as six service technicians are available in an area the size of a U.S. county. Getting timely repairs when the equipment is down should be an important consideration when considering ESF systems.

What other options have you looked at?
Free Access Stalls. In this system, the sows are housed in groups but are provided with access to individual feeding stalls. The stalls have a lockout mechanism on the rear gate that allows sow access and prevents other sows from entering. She is able to exit the stall at any time to go back in the pen area. Most designs feature an option for the herdsman to lock the sows in the stalls for treatment. We feel this may be the ultimate sow housing system.

Are Free Access Stalls available from Hog Slat?
We offer this equipment to producers, but, they need to remember that this is the most expensive option they can install. The square footage requirements per sow are high, (as much as 37 sq ft per sow) and the stalls with a locking mechanism are more expensive than a standard gestations stall.

What other options are available?
Floor feeding in pens actually predates stalls. This system is designed with five to eight sows per pen, and the feed is dropped directly on the pen floor. This system is successful if managed correctly. Grouping of the sows by size is critical as the strongest animals tend to get the most feed. It is the lowest cost alternative to gestation stalls.

What seems to be the most popular option?
Stanchions are the most popular system we see for new and remodel projects. This is group housing with short dividers or stanchions to protect the individual sow at feeding time. This design lends itself to a wide range of group sizes with a lot of flexibility in pen and building dimensions, which is important with remodel projects.

Why do you think it is so popular?
Stanchion production methods adapt well to current U.S. production practices. A farm’s current staff can manage a stanchion system because it utilizes the same feed delivery system and penning equipment as they are currently using.

What criteria are used in designing a stanchion system?
The first decision is how many square feet per sow will be allocated. Obliviously, square footage in the building is expensive, and this can range from 17 to 24 square feet per animal. This is a business decision each producer must weigh against projected welfare regulations.
A group sizing of 10 to 20 head per pen is common. Equipment is standard 40-inch high rod panels with 18” long divider stanchions, creating a feed space for each animal in the pen. The stanchions are open rod style set at 18” to 21” width. Experience has shown it is not necessary to use solid dividers on the side or front of the stanchion. The rod style protects the ears and head of the sow from aggressive animals and doesn’t restrict air flow as much as solid panels. In addition, rod style penning is more cost effective and has a longer life span.
We also design a breeding area with stalls equal to 45 days worth of sow holding capacity. Sows are weaned into this area until bred and formed into gestation groups.

How is the stanchion system managed?
Sows are fed using an automated feed system with individual drops. Sows anticipate each feeding and start lining up before the feed drops. You don’t see much shuffling between stanchions as they become conditioned to eating their portion and realize the other feeding slots will not have feed after they finish. The earliest systems utilized a trickle feed system where over a longer time, small amounts of feed were dispensed to hold the sow at their feeding space. Trickle feeding was proven to be unnecessary and just added additional cost to the scheme.
While the sows are eating, a herdsman moves along the alley noting animals that are not at the feed trough. He can mark them for later treatment or movement to a hospital area.

Are there any disadvantages?
Yes, animals cannot be individually fed. Sows that “fall out” of a group because of sickness or injury have to be removed to a hospital pen or stall. Despite the disadvantages, this has been a popular choice for many producers desiring to move into group housing.

How many stanchions have been installed by Hog Slat?
Hog Slat has built and installed over 150,000 spaces of stanchion housing in the U.S., from individual farms up to large production systems. We have gathered a lot of field experience completing those projects and can help any producer considering group housing systems.

The 2012 Pork Expo is in the books.  Great weather this year and great food.  Especially the 260 lb pork burger Vinny and crew from Hog Slat cooked up.  This wasn’t just an inedible gimmick either…..the slice I had was very good.

Walking around the trade show, I noticed there were a few companies with products to address the bin bridging and feed outage problems caused by using DDGS and other alternative feed ingredients……mechanical bin whackers in other words. One rep explained that his product was a much better choice than his competitor’s model and “ours is only about $1200 compared to theirs at $2000.” Wow. The price of the anti-bridging device is almost as much as the bin.

Quite a few companies displayed their version of Electronic Sow Feeding (ESF).   One says each feeding station will handle 60-65 sows, the next guy’s will handle 300.   All the computerized systems are easy to use; intuitive I believe was the term they used.  Everybody had a “system expert” who probably lives several states away from your farm.

Remember when everyone had to hook up their ventilation controls up to a computer in their office? Going to run the barn from the house was the idea. Most ended up with the plastic cover left on after a month or two. A couple of years ago, sorting scales were going to change the way finishing pigs were raised. Most of those are sitting outside rusting away now.

No doubt some producers will successfully adopt ESF technology. One thing is guaranteed, not all the companies offering ESF will be at this show five years from now. Choose carefully.

SowMAX ad lib dispenser

Claiming an Ad Lib Sow Feeder can save feed may seem like a contradiction of terms.  How can allowing a sow unlimited access to feed save money on feed?

It’s simple really…sows are individuals with different eating and consumption patterns.  Some days they’re extra hungry, some days they’re not. Sows also prefer to eat at different times of day.

It’s hard to guess right when feeding lactating sows.  Feed them too much and they don’t eat it all…it spoils in the feeder and you end up dumping it out and wasting feed.

That’s the beauty of the SowMAX ad lib dispenser.  The hopper is filled, either by hand or from an overhead auger system, and the sow decides how much she will eat.  She eats to appetite without wasting feed…..you’ll see heavier litters; sows stay in better condition coming out of lactation and reduced feed waste.

To learn more go to http://hogslat.com/sowmax-feed-dispenser