Summary
Joe Buttigeig’s four-shed broiler farm sets an example of the adaptation of new technology in broiler farming. Located in Melbourne's West, only an hour’s drive from the CBD, you wouldn’t even know it exists. Fitted out with 12 high-efficiency ebm-papst AgriCool EC fans in each shed, ventilation noise is kept to a minimum thanks to direct-drive EC technology. The farm was built to the latest standards by shed manufacturer Eddy Dimech in 2010, and since then Joe has been interested in reducing power consumption while increasing comfort for his birds.
The fan retrofit was completed in 2014, reducing the total number of fans per shed from 24 to 12. The use of ebm-papst direct-drive EC fans resulted in a more stable temperature across the shed, improved bird spread, increased airflow, and a lack of hot-spots. The results indicate that the AgriCool system not only reduces electric consumption but improves overall bird spread Trials across four growing batches confirmed a significant decrease in electricity consumption, in three of the four batches resulting in a fan power saving of more than 80%. Lower noise, reduced fan maintenance, and increased air velocity were constants in all the trials.
The fan retrofit was completed in 2014, reducing the total number of fans per shed from 24 to 12. The use of ebm-papst direct-drive EC fans resulted in a more stable temperature across the shed, improved bird spread, increased airflow, and a lack of hot-spots. The results indicate that the AgriCool system not only reduces electric consumption but improves overall bird spread Trials across four growing batches confirmed a significant decrease in electricity consumption, in three of the four batches resulting in a fan power saving of more than 80%. Lower noise, reduced fan maintenance, and increased air velocity were constants in all the trials.
Setting
Technical trials were conducted in 2014, over the course of four full batches of 55,000 birds in standard 170m x 70m sheds. They were undertaken to test the energy efficiency, reliability and reduced noise output of the ebm-papst AgriCool shed ventilation system. All sheds were fitted with power metering and temperature and humidity sensors across the whole trial period. Because of their standard size, the sheds allowed for direct comparison between old and new technology. All trial sheds were fitted with power metering during the entire period with additional temperature and humidity measures taken both in and outside the sheds.
Background
Changing market conditions, including an aggressive retail climate and increasing electricity costs, are responsible for increased production costs and stagnant financial returns on poultry production (cf. Fig 1).
Fig 1: Australian capital city electricity price index. Source: ABC NEWS FACT CHECK, Electricity Price Index, https://www.abc.net.au, viewed 24/02/2017
In response to the growing pressure on Australian broiler growers, ebm-papst began their consultations. After years of research and development, the team at ebm-papst A&NZ was confident that they had produced a high quality, energy efficient ventilation system for the Australian broiler poultry market. Joe’s farm provided a perfect environment to test the AgriCool system thoroughly.
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“We are primarily ventilation and fan specialists and use our advanced fan design to achieve more efficient ventilation while saving on operating costs” – Christopher Hauck
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The upgrade
The test shed was retrofitted with twelve 1250mm high-efficiency, direct-drive, three-phase EC fans with inbuilt speed control from ebm-papst. A motorised shutter system, supplied by Agricultural Automation, was fitted on the air intake side of the fan. Sheds used for comparison were fitted with 16 conventional, belt-driven AC fans with staging controls and 8 sidewall fans for minimum ventilation. With the ebm-papst AgriCool climate control system the number of fans effectively reduced from 24 to 12 per shed, while keeping airflow at the same level.
The AgriCool system was installed into the existing tunnel-ventilated shed and control system, allowing Joe to continue using the existing control system. Agricultural Automation and HMI Electric provide installation, commissioning and programming of the fans, while ebm-papst provides a complete, secure system solution to the grower.
The comparison sheds were controlled via AgroLogic climate controllers using conventional on/off operation (also called staging). In an example scenario, a standard system would run four of the total 16 fans at 100% and gradually add on more fans as required. The ebm-papst AgriCool system with EC fans instead would have all fans operating at 20%, gradually increasing the speed of all fans to match the exact airflow requirements at any given time. This results in a more energy efficient system with even airflow across the whole width of the shed.
In addition, the AgriCool system has extensive safety and backup features. In the case of a controller or fan failure or cable break, the fan system is designed to compensate by providing pre-set adequate ventilation to the shed and notify the farm control system or nominated mobile phone of the issue. With no belt, pulleys, tensioners etc. needed to drive the fans from ebm-papst, no maintenance is required throughout their lifetime. This reduces running costs while providing peace of mind.
The AgriCool system was installed into the existing tunnel-ventilated shed and control system, allowing Joe to continue using the existing control system. Agricultural Automation and HMI Electric provide installation, commissioning and programming of the fans, while ebm-papst provides a complete, secure system solution to the grower.
The comparison sheds were controlled via AgroLogic climate controllers using conventional on/off operation (also called staging). In an example scenario, a standard system would run four of the total 16 fans at 100% and gradually add on more fans as required. The ebm-papst AgriCool system with EC fans instead would have all fans operating at 20%, gradually increasing the speed of all fans to match the exact airflow requirements at any given time. This results in a more energy efficient system with even airflow across the whole width of the shed.
In addition, the AgriCool system has extensive safety and backup features. In the case of a controller or fan failure or cable break, the fan system is designed to compensate by providing pre-set adequate ventilation to the shed and notify the farm control system or nominated mobile phone of the issue. With no belt, pulleys, tensioners etc. needed to drive the fans from ebm-papst, no maintenance is required throughout their lifetime. This reduces running costs while providing peace of mind.
Figure 2: Speed controlled, high-efficiency, direct-drive EC fans with built-in speed control
Figure 3: Standard belt-driven AC fan system with staging control
Results
With power consumption reduced by 80% in three out of the four trial batches, improved air velocity and lower noise, the AgriCool system exceeded expectations. The soft-start feature means that there is no in-rush of air to disturb the birds. Across all four trials, the birds in the ebm-papst shed were more evenly spread out due to a more even airflow and temperature across the shed, with no hot spots present.
Designed specifically for the harsh Australian growing conditions, the AgriCool system provides complete peace of mind. An inbuilt self-monitoring and backup feature ensure that there is always adequate ventilation to the livestock. Immediate alerts for any operational problems mean that the grower can be sure their livestock is being constantly monitored under high-level climate-controlled growing conditions.
Easily retrofitted to existing sheds and control systems, the AgriCool system’s expected return on investment in less than three years. Installation cost into new sheds is at a similar level to the cost of installing belt driven fans.
Designed specifically for the harsh Australian growing conditions, the AgriCool system provides complete peace of mind. An inbuilt self-monitoring and backup feature ensure that there is always adequate ventilation to the livestock. Immediate alerts for any operational problems mean that the grower can be sure their livestock is being constantly monitored under high-level climate-controlled growing conditions.
Easily retrofitted to existing sheds and control systems, the AgriCool system’s expected return on investment in less than three years. Installation cost into new sheds is at a similar level to the cost of installing belt driven fans.
The Details
The AgriCool Climate Control System
Material:
Tunnel Fans
Number of fans: 12
Fan type: 50 inch (1250mm) high-efficiency, direct-drive, three-phase EC fan motors with in-built speed control
Shutter system: Supplied by Agricultural Automation
Original system
Tunnel Fans
Number of fans: 16
Fan type: 50 inch standard belt-driven AC fans
Sidewall Fans
Number of fans: 8
Fan type: AC sidewall fans, to aid minimum ventilation
Material:
- Blades are of strong die-cast aluminum coated in highly anti-corrosive black paint
- Stainless steel shaft, nuts and bolts, bearings sealed for life
- Galvanised rotor plus additional coating against corrosion
Tunnel Fans
Number of fans: 12
Fan type: 50 inch (1250mm) high-efficiency, direct-drive, three-phase EC fan motors with in-built speed control
Shutter system: Supplied by Agricultural Automation
Original system
Tunnel Fans
Number of fans: 16
Fan type: 50 inch standard belt-driven AC fans
Sidewall Fans
Number of fans: 8
Fan type: AC sidewall fans, to aid minimum ventilation
Gallery