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While LED lighting can bring broiler poultry growers significant energy savings, AgriShift^® Dim-to-Blue^® lighting offers more than being an environmentally friendly option. What makes AgriShift^® Dim-to-Blue^® technology uniquely beneficial, is that it is designed to influence and direct certain processes, recreating the best possible environment for your animal. New developments in LED lighting can now provide a customized light spectrum, intensity and photoperiod control for broiler environments. The utilization of this advanced LED lighting in broiler facilities can bring performance benefits, resulting in increased broiler production and improved animal welfare. 

Three characteristics of lighting should be considered when designing a lighting system:

1) light spectrum or color of the light

2) intensity of the light, and

3) photoperiod or the amount of time the lighting fixtures are on each day.

In the past, lighting systems (incandescent, fluorescent or high-pressure sodium lamps) had fixed color and intensity, with the only controllable variable being the length of exposure. With ONCE^® AgriShift^® Dim-to-Blue^® technology and lighting systems, it is possible to control all three key characteristics.  

Research shows that a typical chicken views a light source much differently than a human eye would. For instance, the graphs below show that humans and chickens perceive green light similarly, but chickens have enhanced sensitivity to reds, blues and ultraviolet light. Additional research has shown that different wavelengths can be used to enhance various aspects of development. For example, green light increases growth during the early stages of development by enhancing proliferation of skeletal muscle satellite cells, which repair and build muscle. Blue light is helpful in the growth and sexual development of poultry at a later age by elevation of plasma androgens, allowing the bird to put on more muscle mass. Combined green and blue light promotes myofiber growth due to more effective stimulation of testosterone secretion.       

By organizing individual LEDs to activate at predetermined voltage levels, it is feasible to implement a color-shifting technology, which is the foundation of AgriShift^® Dim-to-Blue^® lighting products for broilers

AgriShift^® Dim-to-Blue^® lighting systems shift the spectrum to mimic a natural sunrise and sunset. With no dimming, the system produces a full light spectrum, ideal for stimulating growth when beginning a chicks growth cycle. As grow out continues the lighting is gradually decreased to 30%, shifting the range from blue to green to promote muscle growth. When the system is fully dimmed (also known as moon lighting), the monochromatic blue is used to calm the birds at night or before catching.  

Using ONCE^® AgriShift^® Dim-to-Blue^® technology and lighting systems allow broiler farmers an environmentally friendly lighting option that not only saves on electrical costs but also improves animal welfare and increases broiler production.

To learn more click Dim-to-Blue®.

With the summer heat settling in it's not uncommon for ventilation problems to start showing up in broiler houses and swine gestation/ breeding buildings. Even facilities that have performed well in the past may experience issues.   One of the best yardsticks for evaluating a ventilation system is measuring wind speed. Windmeters ranging from an inexpensive smartphone unit to dedicated handheld devices are used to measure wind speed in feet per minute.  

If the wind speed is lower than desired the next step is to check the static pressure with either a portable manometer or on the ventilation control monitor.   With the ventilation system operating at full capacity, the house pressure should be between .05 to .08". Some broiler facilities will experience higher pressure due to increased air requirements.

If the static pressure is high, the most likely cause is restricted airflow through cool cell pads clogged with scale or algae.

Scale is the buildup of minerals hard water leaves behind as it evaporates during the cooling process. Heavy deposits of scale require the use of a broom to dislodge the debris and then rinsing them off the pad with a low-pressure hose nozzle. The best way to deal with scale is to prevent it from forming in the first place. Adding a descaler treatment to the water helps keep the minerals in suspension and prevents them from sticking to the pad.  

Nutrients in the water allow algae to grow and block the openings in the pad. Adding algaecides to the recirculating water kills the algae and prevents it from re-establishing. Allowing the pad to dry completely for several hours each day also stops algae growth.

But by far the most important management practice for cool cell maintenance is to drain and replace the water often. Even with the use of chemical agents, a build up of contaminants occurs in the trough. How often to replace the water depends on water quality and the amount of the time the system operates each day. Once a month is an absolute minimum during periods of heavy use to flush grit and dirt from the system.

If the static pressure is too low, the first reaction is to add fans to increase airflow.   In many cases, especially in buildings where the airflow seemed adequate before, replacing the fan belts and/or pulleys will restore proper air flow.   Slippage caused by worn belts and pulley cause fans to be less efficient and air delivery to suffer by as much as 20%. Plan to replace all fan belts on an annual basis with the metal pulleys needing replacement about every four years.   A visual check after installing new belt should show the belt riding high in the pulley groove. If the belt sinks into the groove, then the pulley should be replaced.  

Routine, scheduled maintenance on fans and evaporative systems is fundamental to providing broilers and pigs with adequate cooling during hot weather extremes.  

By Austin Baker
Ventilation Director
Hog Slat Inc.      

Inappropriate or poorly maintained slatted floors are the most common causes of physical injuries to pigs. Pigs with foot or joint pain will not get up as often to eat and drink resulting in lower Average Daily Gain and reduced performance.   The industry movement to group gestation housing also means better flooring is necessary to prevent injuries to heavy sows in open pens.   By some estimates, lame sows can cost producers from $180 -$400 for each animal suffering from foot-related problems.  

Well designed slats promoting good animal welfare possess several common characteristics. They are manufactured from high-density concrete, have a level, flat top for ease of walking and a uniform slat opening.

Manufacturing high quality begins with the slump of concrete. The less water added to the concrete, the stronger the slat. Dry-cast concrete, having a zero slump, only uses enough water to begin the chemical reaction.   When excess water is added to make the concrete easier to form, the excess moisture evaporates; creating pores in the concrete and reduces its strength and durability. The lower cement-water ratio in dry cast slats yields a finished product with higher strength and durability with fewer repairs needed over its useful life.  

Dry cast, machine-finished slat production requires fewer molds than comparable wet cast, hand-finished slats. Fewer molds mean less variation and a more consistent final product with a flat, level top and uniform slat openings. The level surface provided by flat top slats reduces joint injuries from twisting and slipping on uncomfortable floors. Uniform slat openings prevent the pigs' legs from getting caught in a narrowing opening and damaging their toes and claws.   Keep slats in good condition by using quick setting, abrasion resistant mortars to repair any exposed aggregates as normal wear occurs. Cover surfaces around feeders and waterers with an epoxy overlay coating to protect the concrete from acid compounds and heavy pig traffic. For more information on repairing concrete slats download “The Field Guide To Slat Repair and Replacement.”  

Well made concrete slats and proper maintenance provide pigs and sows with comfortable flooring to reduce foot and leg injuries.      

"When it comes to evaporative cooling most of the equipment problems we see are failures to do routine maintenance," explained Tyler Marion, an engineer with Hog Slat Inc. located in Newton Grove, NC. "Evaporative cooling is really a pretty simple concept, but you have to perform basic maintenance tasks to keep the system operating correctly."    

Flush, Don't Bleed
A standard industry practice involves "bleeding-off" a percentage of the recirculation water to prevent a buildup of scale on the pads. Scale is the mineral deposit left on the pad when the water evaporates. While bleeding-off is better than nothing, a much better practice is to dump all the water from the trough and replenish with fresh water that in turn helps to flush the containments out of the cool cell pads. How often the trough needs to be drained depends on the hardness of the water and how often the evaporative system operates. Monitoring the PH level is a useful method to determine when to change the water with readings above 8.5 indicating an excessive mineral buildup.

Use Preventive Chemical Treatments.
Paired with frequent water flushing, adding descalers and microbicides to the recirculating water pays big dividends in extending pad life. Descalers help keep minerals in suspension for more efficient flushing while microbicides reduce the growth and buildup of algae, bacterial and fungal slimes on the pads.   Never use chlorine bleaches to kill algae. Chlorine attacks the glue in the pads causing delamination.

Adjust the Float.
One of the most common reasons for premature failure occurs when water logged pad bottoms become soft and sag down.   Just because water doesn't spill out of the trough when the system shuts down doesn't mean the float is adjusted correctly. When properly set the water level should be 1" below the bottom of the pads. It is critical to check the water level in new installations after running the system for several days.

Be on the lookout for trough levelness to change as the building settles and the framing shifts. Also, as the pads age, they retain more water making float valve adjustments necessary.  

Clean the Trash Out
Trash and debris in the pump trap and water line filters reduce the amount of water circulating through the system. A telltale sign of reduced water flow is dry or streaked pads at the end opposite of the pump. Failing to remove debris from the trash basket on a jet pump also reduces its useful life. Clean the holes in the distribution pipe whenever dry streaks appear on the pad. Open the ball valve on distribution pipe opposite the pump end and run the system to flush out any gunk from inside the pipe at least once a month.  

Winterize the System.
Shutting off the water supply and draining the system are the basics for preparing an evaporative system for winter. In addition, remove the pump from the system and move it to inside storage. Just disconnecting the plumbing fittings and leaving the pump in place leads to damaged impellers and cracked housings.  

Performing basic maintenance allows evaporative cooling systems to operate efficiently and delays costly pad replacement.          

EXECUTIVE SUMMARY

The key objective of this study was to determine the effect of additional access to water on nursery pig performance over a 28-day period. A total of 2,017 weanling nursery pigs were allotted to one of two treatment groups: Control (SC): Dual Standard Cup Waterers; or Test (WC): Additional, 4 Nipple Horizontal Water Bar. Pigs were fed according to the standard, three phase feeding program in place in this commercial unit, and were offered ad libitum access to water and feed throughout the trial. Providing additional access to water with the water bar incrementally increased water disappearance by 0.03 gal/pig. In addition, a positive response in average daily feed delivered (ADFD) was observed in Periods 1 and 3 (14.8% and 9.2% higher, respectively, P<0.05); and 5.2% overall (P<.10) for WB versus SC pigs.   Moreover, ADG was 8.8% greater for WB versus SC pigs in Period 3. Overall, this study provides evidence that the provision of an extra water bar in the nursery phase can translate into 1.4 lbs more feed delivered per pig resulting in 1.1 lbs more gain per pig in 28 days.

OBJECTIVE
Given the well-documented correlation of feed and water intake, the objective of this trial was to determine if the provision of additional access to water would promote higher water consumption, and concomitant growth performance in weanling nursery pigs reared in a commercial environment over a 28-d period.  

METHODS
Pigs (n=2017) were mixed-sex housed in a single room within in a 4-room, commercial wean-to-finish barn, with a shared feeder between adjacent pens. Pigs were equally allotted to 42 pens to yield a stocking density of 48 pigs/pen (144 sq. ft./pen) Pens were allotted to one of two treatment groups as follows: Control (SC): Standard Cup waterers with 2 per pen located on the right and left sides of each pen, or; Treatment (WB): Control + an additional horizontal, 4-nipple Water Bar .  

Pigs were fed according to the standard, three phase nursery program routinely utilized in this commercial facility, and had ad-libitum access to feed and water throughout the 28-day trial. Water disappearance for the SC and WB groups was monitored via individual mainline water meters supplying water to the standard right and left-side waterers, and the additional water bar.  

Pen weights were monitored at the initiation of the study (Day 0) and thereafter at 7, 14 and 28 days. Feed intake was monitored by total feed delivered to each shared pen. All mortalities and removals over the course of the trial were also recorded.  

RESULTS
Table 1 shows the summary of water disappearance as measured by metered gallons of water. Observationally, the addition of the extra water bar increased water disappearance by 0.03 gal/pig/day or 17.6%. It was noted, however, that the overall consumption of water (as measured by water disappearance) was generally lower that expected for pigs of this age. In general, literature reports indicate nursery pigs typically consume 0.3 gal of water/lb of feed consumed.  

Table 2 provides a summary of performance. A positive response in average daily feed delivered (ADFD) was noted in Periods 1 and 3 (14.8%, 9.2% higher, respectively, P<0.05); and 5.2% overall (P<.10) for WB pigs. This increase in ADFD translated into 8.8% higher ADG for WB pigs in Period 3, however no other improvements in ADG or G/ADFD were noted within the three periods or overall.

Conclusion & Recommendations
This study provides initial evidence that the overlay of a 4-nipple water bar to the standard dual cup waterer system to provide additional access to water, and promote increased water consumption has measurable impact on improved feed intake (as measured by total feed delivered).  

Given the potential performance impact of improved feed intake together with the preliminary results of this trial, it is recommended that the study be repeated with the following modifications in order to more accurately assess the effect of increased access to water:

• Addition of feed weigh backs to the protocol to improve accuracy in feed intake monitoring.
• Collection of water disappearance data throughout the full study period.
• Consideration of calibration or replacement of water meters to improve accuracy of water disappearance monitoring.
• Randomization of the test variable (water bar) throughout the room to help better account for water line distances.
• Verification and standardization of waterer flow pressure to recommended levels for nursery pigs (8 fl. Oz./min)

Video tour of a 5000-sow farm located on a mountaintop near ShenNonh Dali in the Sichuan Province of China.

This remote sow unit produces and tests breeding stock from an 896 crate farrowing house, 4400 stall gestation building, 50 place boar stud, GDU/ Iso barn, and 15-room testing facility. Hog Slat designed the unit and supplied AirStorm fiberglass fans; feeding equipment including feed bins, sow drops, and Grow-Disk systems. Hog Slat's SowMAX feed dispensers provide simple, dependable ad lib sow feeding in the farrowing crates.

The simplest way to check feed volume is to climb up and look inside. Not anyone's favorite chore, wet or icy ladders can make this dangerous and at best it is an educated guess. 

Bin Flag level indicator mounts on the outside of a bin rotating to yellow when feed level drops below postition.

Level indicators, like the Bin Flag, give a visual alert when the feed drops below a certain point in the bin. They are inexpensive and can connect to an alarm system to send a remote warning. They do not record feed input or usage like a bin weighting system.  

Early attempts at adding load cells to bins had mixed results. Because the load cells were expensive, many systems were set up with load cells on half of the bin legs, or they used I-beams to span between two legs.   Inaccurate readings resulted when feed bridging caused one side of the bin to feed out faster than the other side.   At best, these early systems were 80% accurate and really were more of an expensive early warning system for feed outages than a serious feed management tool.  

The current generation of bin weighting systems gives producers the tools for accurate feed management.

BinTrac® offers a dedicated bin weighing system with a unique load cell assembly in which the bracket functions as the lifting mechanism.   This type of bracket assembly requires less than 1/2" of lift to install, requires no shimming or blocking and can be installed on existing and loaded bins.  

On each bin, the smart summing box gathers input from each load cell and sends it to the BinTrac Pro indicator control than can be located up to 250 feet from the bin. The BinTrac Pro Indicator displays information from up to four bins with a visual bar graph level indicator and digital readout of current weight, 24-hour feed usage, and recent fill weights.  

Load Cell and Summing Box mounted on a bin. BinTrac Pro Indicator.

By adding a HouseLINK™ module, this information is readily interfaced with the ventilation house controller. Options are also available to collect this data remotely via a wireless LAN system to record current inventories and monitor usage to predict and coordinate feed schedules.      

The Maximus® control system provides accurate feed management as a function of their whole house controller.  

Load cells mounted on bin legs send information to a junction box, which in turn transmits, to an individual relay box located inside the building. The relay boxes, representing each bin, are wired in series to the Maximus controller.  

The Maximus controller logs and displays the primary data on a Bin Overview screen (Fig.1) showing Feed Remaining, Amount of Feed Consumed in the last 24 hours, and Feed Consumed per head.   From there, the operator can drill down to an individual bin screen (Fig.2) to view greater detail. In this screen, the operator can also set various warning levels to trigger feed outage alarms by text or email.  

A new product scheduled for release later this year is an automated feed slide that can be configured to close a slide as one bin empties and automatically open the slide on a second bin. Bin slides can also be remotely opened from inside a building, eliminating the need for a farm manager to go outside and risk compromising biosecurity.  

Like all the functions controlled by the Maximus system, this feed data can be viewed and adjusted remotely from a smartphone, tablet or computer. The operator can also schedule personalized reports to be sent by email to other members of the production team.

Using LED style lighting reduces electrical usage by 75-80% compared to incandescent bulbs and 50-60% over spiral CFLs. In most situations, the financial payback period will be between one to two years.  

While all LED lights will achieve this expected energy savings, Once, Inc. offers their AgriShift Dim-to-Calm™ system specifically designed for use in swine facilities.  

Domestic swine were developed from wild boar species, which occupy shaded habitats and are most active at dawn and dusk. This fact suggests that swine have a visual system that is best adapted to dim light rather than the bright light of mid-day or darkness of nocturnal light.  

While humans see light primarily in the green and yellow spectrums, swine’s highest sensitivity is focused on the blue and green parts of the scale with little recognition of red shades. In other words, pigs perceive red lighting as darkness.

Dim-To-Calm lighting mimics sunrise to sunset photoperiods

Photoperiod requirements have not been well studied in swine, but it is evident a cyclical light: dark cycle should be provided. At all stages of production, swine benefit from at least eight hours of light and at least eight hours of darkness. The transition from light to dark periods should be gradual, much like natural sunrise and sunset, to reduce stress caused by sudden changes in light.  

AgriShift Dim-to-Calm LED technology provides producers a method to automatically control light intensity, color spectrum and photoperiod length for swine specific lighting. The dimming capability simulates a sunrise to sunset scheme and is regulated through the house controller by use of a slave dimmer or by an AgriShift master control. Additionally, the shifted spectrum provides a service light (red color) that allows workers to have continual access to the facility after hours without disturbing or interrupting the sleep cycles of the pigs. Some producers have also utilized an additional period of light at night during hot weather. By setting up a shorter sunrise to sunset sequence during the cooler evening hours, they can encourage finishing pigs to consume more feed.

10 watt LED fixture with slave dimmer

The AgriShift LED lights are 10-watt jelly jar type fixtures with output equal to a 75-watt incandescent. It's an innovative design with the minimal heat of LEDs allowing the use of a low-profile plastic jar measuring only 2” compared to a typical 5"-7" long jelly jar. Replacement is simple with the provided Edison pigtail connector screwing into the existing light socket, twisting the jelly jar adapter in place and connecting the base lamp to complete the installation. The expected life of the bulb is 50,000 hours and is backed by Once's 5-year replacement warranty.  

Many of the chemical products used in poultry and swine production are delivered through the water system.   Some simple best practices will keep your water-driven, volumetric proportioner, or as it more commonly called a medicator, in good working order.

1.Use a mixing device in the stock tank...and that doesn't mean a paint stick! 
Many of these products don't mix well in stock tanks and are difficult to keep in suspension. A small (1/200 hp.) agitation pump does a great job of keeping solids in suspension, is inexpensive to operate and is relatively low-cost at around $60. Maintaining a homogenous mixture in the chemical stock tanks aids in accurate chemical delivery.

2.Flush with clean water...from a clean bucket.  
After you finish injecting a product, take the hose out of the stock tank and let the medicator pull water from a clean 5-gallon bucket. The fresh water will flush any chemical residue from the seals and springs. Cleaning the system also prevents any problems with leftover chemical reacting with the next product used in the system.   3."Click-Clack" doesn't mean it's working... replace the seals.  
While it is easy to diagnose a broken spring or diaphragm when you don't hear the familiar "click-clack," a medicator will continue to operate with damaged seals. Harsh chemicals can weaken or damage the rubber seals over time, allowing the stock solution to leak causing inaccurate dosing rates.   To maintaining accurate chemical delivery, replace the rubber seals annually. There are replacement seals kits available for every brand of medicator on the market. It takes less than 15 minutes to do and the cost for most kits is under $20.

While you're at it... clean the inside too.
As long as you are taking the medicator apart, disassemble the entire medicator as far as you feel comfortable doing and soak the parts in soapy water to remove chemical or mineral deposits.  Let the part soak for 24-48, rinse and reassemble.  To remove a heavy mineral buildup, consider using a 50% vinegar soultion or CLR to soak the parts.  Check with the equipment manufacturer before using.

5.Check the suction hose...it works like a straw. 
A cracked or broken suction tube permits air to enter the system ruining accuracy. It's a good idea to periodically snip off the top part of the hose and reattach it to the medicator hose barb to prevent leaks.

These are general recommendations for the most commonly used chemicals.   Some chemical formulations may require more frequent maintenance and cleaning of medicator pumps for proper dosing rates.