Blog posts tagged with 'poultry ventilation'

Look at all the factors before deciding to replace the pulleys on existing fans to increase wind speed. 

By Tyler Marion, Hog Slat Engineering Group

Your reaction on seeing the PRICE of Hog Slat’s Vent Actuator will probably be to dismiss it as a low quality item.  You get what you pay for.

Don’t let the price fool you.

The Vent Actuator is a great example of Hog Slat’s engineering expertise, combined with global sourcing and lean distribution chain.  

Engineering added features to increase the useful life of the unit.

24″ stroke length with a maximum speed of 1/4″ per second and adjustable limit switches.

Built-in potentiometer sends feedback to room controller to position air inlets.

800 lb. payload

Increased protection of interior electrical components with clamped extension boots and motor seals.  Overall, the Actuator’s Internal Protection Rating is 65 vs. competitive brands with ratings of only 53.  (See What is an IP rating?)

Hog Slat’s lean distribution chain model direct sources products and delivers them to the farm without an expensive and outdated dealer network.   (See eliminating margin stack)

All in all, a great product at a great price.

The Right Kind of Sticker Shock.  For ordering information go to HS667-24.

Gene and Phyllis Williams

“The chicken business works good with land and cattle,” Gene Williams commented as he looked out across the pasture next to his farm outside of Everett Springs, GA. “The land gives you a place to spread the litter; the chicken litter builds up the pastures, and the poultry checks provide a steady income when cattle prices are tough.”

Gene and Phyllis Williams have included poultry farming in building their family’s business for over 40 years. Starting with a registered Angus herd, they expanded into the poultry business by leasing two breeder houses in 1975, followed by building three new broiler houses in 1978. In 1994, the family business grew to include The Calhoun Stockyard, and again when oldest son Michael and his wife Shelby made the decision to build four new broiler houses in 2003.

Their middle son, Adam, and wife Jenny moved back to the farm in 2013. In 2014, the two older sons joined with younger brother, Jacob, and his wife Natalie, to purchase a neighboring land tract to form the Circle W Ranch entity. Central to this expansion was the construction of eight 66′ x 600′ broiler houses, each capable of holding 62,000 birds per flock.

Circle W Ranch with Eight 66′ Wide Broiler Houses near Everett Springs, GA.

The tunnel ventilated houses feature Windstorm 54″ exhaust fans, Hog Slat EVAP Systems, and TEGO tunnel doors, regulated by a Rotem control system. The GrowerSELECT feed system utilizes Classic Flood feed pansalong with supplemental feeders in the brooder section. One notable feature is a dedicated feed line with Hi-Grow feeders, used for the first ten days of a new flock and then winched up out of the way. Also, a special hanger line above each feed line permits storage of the Hi-Grow feeders inside the house.

Windstorm 54″ fans power the ventilation system. Shown with winter fan covers to reduce energy loss.

TEGO tunnel doors seal up cool cell openings and direct air up and across the ceiling to promote proper mixing.

Black arrow highlights dedicated starter line in raised position with feeders attached

The dedicated feed line for supplemental feeding in the brood area.

Still actively involved in the daily farming operations, Gene and Phyllis continue to influence the education and work ethic of the ten grandchildren joining the family workforce.

Three generations of the Williams family.

Rodney and Brett Bowden with new Airstorm 54″ fan

To the best of my knowledge, when we built them in 1989, these were the first tunnel/natural ventilated houses constructed in the state,” explained Rodney Bowden at his family farm near Clinton, NC.  “We’ve always had good results in the buildings, but the recent upgrades have improved our performance.”

Rodney added two GrowerSELECT 54″ AirStorm fans per house to increase airspeed and reduce the ambient temperature.  The durable AirStorm 54″ fans feature a fiberglass housing, plastic shutters, and a stainless steel prop.

GrowerSELECT Classic Flood feed pans

The next step in the upgrade was to replace the original feed pans with GrowerSELECT Classic Flood feeders. Rodney said, “Installing the new pans helps minimize wasted feed when the birds are young and has improved my feed conversion during grow out.”

These investments have paid off with an increased bird performance and helped Rodney settle in first place among his group several times since the upgrade.

Click GrowerSELECT for more information about our quality feeding and ventilation systems.  

Nameplate from GrowerSELECT fan motor

Today’s livestock and poultry operations rely on electric motors for a variety of feeding and ventilation functions. Used in buildings that can be both dusty and humid, with fluctuations in voltage and varying workloads we subject our motors to a very hostile work environment.

When selecting replacement motors, it is important to select motors that are both efficient and designed with a “safety factor” that will allow them to last under harsh conditions.

While you may be familiar with the term Service Factor or S.F., there are a couple of important designations found on a motor nameplate that may need more clarification.

Service Factor is defined as a motor’s ability to operate under a short-term load.   The higher a motor’s S.F. rating, the more durable the motor.  Motors with high S.F. are expected to last longer. To illustrate, a 1-1/2 Hp motor with a 1.5 S.F. can provide 2.25 Hp for short-term use.   However, it is not a good practice to continuously operate a motor above the rated workload. In other words, the same 1-1/2 Hp motor with  1.5 SF would not be selected to power a 60″ fan originally shipped with a 2 Hp motor.

Full Load Amps or F.L.A. represents the amount of current the motor is designed to draw at the rated horsepower. In the example nameplate, this means that when the motor is running under a full load at 230 volts, we can expect it to draw 5.4 amps. Motors with a lower F.L.A. for the amount of horsepower are considered more efficient to operate.

Service Factor Amps or S.F.A. represents the amount of current the motor will draw when running at the full Service Factor. In the example nameplate, the S.F.A. is eight amps at 230 volts.

Continually exceeding the S.F.A. shown on the nameplate can shorten motor life. Motors with a higher S.F.for the same horsepower have an increased “safety factor” and are expected to last longer under harsh conditions.

The most efficient, rugged motors are designed with a higher S.F., lower F.L.A., and higher S.F.A ratings. By comparing the information on a motor nameplate, we can select the best replacement motors for feeding and ventilation equipment.

Hog Slat designed the GrowerSELECT line of motors to help simplify a producer’s decision on selecting replacement motors. GrowerSELECT motors feature a high Service Factor (as high as 1.5) and higher  S.F.A. rating to increase motor life.  Each model number is a direct cross to the most popular brands of feed systems and fans used on producers’ farms. No matter what your existing brand of equipment we have a GrowerSELECT motor designed to replace it and save money while doing so. Shop GrowerSELECT motors.

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.

Mewborn farm entrance sign

“These chicken houses are my family’s life; they’re our investment,” stated Wesley Mewborn. “As a new grower, I trusted the folks at Hog Slat to provide the right equipment and follow up service. So far, they haven’t let me down.”

Wesley with Hog Slat service tech Dewayne Dunn

After spending 13 years in the retail hardware business, Wesley, and his wife, Robin purchased land near Kenansville, NC and constructed six, 46′ x 600′ broiler houses in Oct 2014.

52″ Windstorm Fans

A Hired Hand 4000 computer controls a total of 14 52″ galvanized Windstorm fans in each house along with winter air inlets. The arrival of warm weather begins the transition to evaporative cooling by opening the tunnel curtains and powering on the EVAP Cooling system.

GrowerSELECT feed line and Plasson drinker line.

The houses feature two GrowerSELECT feed lines using Classic Flood pan feeders with extended fins. Water is provided by four drinker lines regulated with a Plasson Water-On-Demand system.

“Raising chickens really just comes down to providing good air, feed, and water,” Wesley explained. “The more time you spend in the houses making sure that happens, the better the final results. The equipment in my houses provide me with the tools to be successful.”

Farm with recent six house addition in the background.

This spring, the Mewborn family added six more broiler houses to the farm. “We really didn’t change much,” Wesley said, “other than moving the brood area to the middle.”  We plan on installing the Hired Hand Farm Manager system to provide real-time remote monitoring. It will give me the ability to check conditions in the houses and even make changes when I’m not there. It ties into the Farm Alarm and notifies me when there’s a problem.”

Wesley and Macy

“Chicken farming is a great lifestyle for a family. My kids, Layla and Macy, come to the farm every day, and that means a lot. Robin and I feel like we are building a good business and good family.”

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.

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.

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 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.

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 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 are time-consuming and often results in leaks.

See Part 2, Pad & Fasteners

See 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. 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.

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.

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