Energy Efficiency in Poultry House Lighting

Transcription

1 Page: 1 Energy Efficiency in Poultry House Lighting By Neil Burrow The poultry industry has experienced significant scientific gains in the past 50 years, creating stronger birds, increasing egg production, and as a result, yielding higher quality final products. With rising energy costs and looming federal mandates, producers are now faced with the challenge of achieving energy efficiency on their farms while maintaining increases in production and quality. The purpose of this paper is to assist electric cooperatives in providing energy efficient lighting options for poultry. This paper will focus on lighting efficiency in poultry houses, proving through both quantifiable data and anecdotal evidence that energy efficient lighting systems will lower electrical costs while maintaining precise poultry lighting standards. The purpose of this paper is to assist electric cooperatives in providing energy efficient lighting options. These options will both conform to poultry industry demands and decrease costs and energy usage for their customers. This paper will also address energy regulations put forth by local and federal governments. It will enumerate cost effective methods, including rebates, loans, and grants to aid farmers in making these changes. After reading this paper, your cooperative will be equipped with the necessary knowledge to understand lighting in poultry, better address customer needs, and adapt to our rapidly changing energy environment. Table Of Contents Section 1: Introduction and Lighting Options, page 2 Section 2: Chicken Broiler Houses, page 7 Section 3: Chicken Pullet and Laying Houses, page 11 Section 4: Turkey House Lighting, page 16 Section 5: Lighting Conclusions, page 19 Section 6: Financing, page 20 Section 7: Appendices, page 24

2 Page: 2 Introduction and Lighting Options New housing embodies new technology, so slowing investment can hinder future productivity growth, unless older houses can be effectively retrofited with newer equipment. This paper will focus on the benefits of installing energy efficient lighting in broiler, pullet and laying houses. Introduction to the Poultry Industry: The poultry industry earned more than $35 billion in cash receipts in Although the industry is growing, there have been fewer entrants into the market in recent years. In an analysis of the broiler industry, James McDonald states, New housing embodies new technology, so slowing investment can hinder future productivity growth, unless older houses can be effectively retrofited with newer equipment. 1 New lighting techniques that increase energy efficiency represent a form of this retrofitting, allowing existing farms to offset rising energy costs and grain prices. McDonald also points out that while many poultry companies are using larger contract farms, over half of broiler production in 2008 came from small farms. These small farms are presented with a large opportunity to save energy and enhance industry competitiveness. Introduction to the Farm Process: The chicken and turkey production process begins in the breeder house. Here, mature hens lay eggs that will eventually form baby pullets (chickens) and poults (turkeys). The eggs are sent to hatcheries where they are incubated and prepared for birth. When the baby chicks hatch, they are immediately transported to houses that correspond with their purpose. Broilers (birds for meat) are transported to a broiler house while layers (birds for eggs) are sent to a pullet house and then a laying facility. After broiler birds reach their desired weight, they are sent to a processing plant to be used for meat production. After hatching, laying hens must be developed in a pullet house until they start their reproductive cycle. They are then transferred to a laying house where they will lay eggs until they are no longer productive. After the reproductive cycle is complete, laying hens will again relocate to a processing facility to be used in mature poultry products. This paper will focus on the benefits of installing energy efficient lighting in broiler, pullet and laying houses. As you will see, broiler houses have specific lighting plans designed to enhance weight gain, strengthen the skeletal system, and develop a larger, healthier bird. Laying houses, and the pullet houses that hold birds before they enter the laying facilities, utilize lighting plans throughout the life of the hen to maximize reproduction rates. 1 McDonald, James, The Economic Organization of U.S. Broiler Production, USDA Economic Research Service, Economic Information Bulletin Number 38, June

3 Page: 3 Lighting Options: In the following section, each type of bulb available to poultry farmers will be analyzed. That Work With Standard Fixtures: Many small-scale farms may be reluctant to switch lighting systems because of high costs to install new lighting fixtures, ballasts, etc. The following five bulbs use standard light sockets. Incandescent bulbs are inefficient because nearly 90% of the power used by the bulb is released as heat rather than light Incandescent : These bulbs have been the traditional bulb choice in poultry farms. They are inefficient because nearly 90% of the power used by the bulb is released as heat rather than light. Although this may be an attractive benefit in the winter, the heat created is inefficient when compared with other heating options, and the heat produced by these bulbs will inevitably raise cooling costs in the summer. 2 Incandescent bulbs have a low up-front cost and a consistent light color. They have a lifespan of 1,000 hours or approximately two months if lit 16 hours/day. Although inefficient, incandescent bulbs have surprisingly seen an increase in their usage in poultry because they can be dimmed to a very low light level. Compact Fluorescent (CFLs): The most common household and commercial replacement for the incandescent bulb is the spiral CFL (see picture at left). These bulbs have a 10,000 hour lifespan or almost two years if lit 16 hours/day. They use 75% less energy than incandescent bulbs according to the EPA. 3 A 23-Watt CFL will emit the equivalent lumens (brightness) of a 100-Watt incandescent bulb. CFLs are currently available in sufficient wattage for all poultry houses, drop and open ceiling. A standard CFL does not have dimming capabilities. Because of their spiral design, dust and dirt can accumulate on CFLs in the poultry environment. CFLs are also more fragile to clean than a standard bulb. CFLs can be purchased as A-Lamps with a globe covering the spirals, and wet location coating is available to help ease cleaning of the bulbs. These solutions are not generally employed in poultry because of heat build-up in A-Lamps and additional costs of coating the bulbs. Most farms find it more profitable to use cheaper spiral CFLs and clean them carefully by hand. Because of their design, CFLs spread light more evenly throughout the poultry house, which prevents birds from clustering in one area. 2 Energy Star, US EPA, 3 Compact Fluorescent Light, Energy Star, US EPA,

4 Page: 4 The US Department of Energy states, Compact fluorescent lamps (CFLs) experience higher lumen depreciation compared to linear sources, but higher quality models generally lose no more than 20% of initial lumens over their 10,000 hour life. Finally, CFLs are often attributed with the negative stigma of lower performance late in their lifespan. Although this has some validity, the US Department of Energy states, Compact fluorescent lamps (CFLs) experience higher lumen depreciation compared to linear sources, but higher quality models generally lose no more than 20% of initial lumens over their 10,000 hour life. 4 In order to best combat this issue, farmers should buy Energy Star rated lamps which are guaranteed to perform at higher than 80% of their original lumen output after 4,000 hours 5 and/or buy lamps with a slightly higher wattage than normally required with an incandescent bulb. Throughout all of the cost analyses below, a slightly higher bulb wattage is used in order to more conservatively estimate savings. This will prove that the performance depreciation of CFLs, even when overstated, is not enough to defray cost effectiveness. At the date of publication, the CFL is the easiest and most tested method to immediately lower energy costs in poultry if the farm is not using a dimmer. Dimmable CFLs: Dimmable CFLs are on the market, but they are currently inconsistent in dimming to extremely low-levels in many houses (at or below ½ foot-candle). They are also much more expensive than traditional CFLs. If dimming is required, farms should use coldcathodes or set up CFLs on separate circuits so that fewer bulbs are used when less intensity is desired. Cold-Cathode : Cold-cathodes are a newer technology, a high efficiency fluorescent bulb that lasts approximately 25,000 hours. 6 Coldcathodes come with a globe surrounding their lighting mechanism making them similar to incandescent bulbs in terms of cleaning. They consume slightly more energy than spiral CFLs but are still extremely efficient when compared to incandescent bulbs. An 8-Watt cold-cathode corresponds to a 40-Watt incandescent bulb. The biggest benefit of cold-cathodes is that they can dim accurately to meet even the lowest light intensity requirements in poultry (usually to under ½ foot-candle). If a farmer needs more lumens than an 8-Watt cold cathode can provide, they should combine cold-cathodes with another lighting option, generally a CFL. 4 Lumen Depreciation, US Department of Energy: Energy Efficiency and Renewable Energy, 5 ENERGY STAR Program Requirements for CFLs, Energy Star, 10/30/03, 6 Cold Cathode Lamp Specifications. TCP,

5 Page: 5 Although recently featured in some poultry studies, LEDs cannot be recommended as a standard light fixture because they do not offer the same payback period, light color guarantees, or number of trials as the other fixtures above. Light Emitting Diode (LED): LED lights are exceptionally long-lasting (approximately 50,000 hours) and now come in a variety of colors and options. Although recently featured in some poultry studies, 7 they cannot be recommended as a standard light fixture because they do not offer the same payback period, light color guarantees, or number of trials as the other fixtures above. Some poultry producers are using colored lights to calm birds or increase reproduction. If houses are using blue or red lights, these lights can be changed to LEDs to save energy costs. That Require New Lighting Fixtures Tube Fluorescent and High Pressure Sodium bulbs show significant promise in the poultry industry. They are also some of the most energy efficient lighting options on the market today. These options are economically viable when compared to incandescent bulbs but their payoff period is generally a few years. Tube Fluorescents: Tube Fluorescents are similar in their output to CFLs but achieve even higher energy efficiency. They gained some popularity in the 1980s and are a popular choice in the Canadian poultry industry. In the United States, they have failed to achieve a significant market share because of high installation and maintenance costs. Because they are installed inside large fixtures, the cleaning of these bulbs is also an extremely tenuous process. If interested in tube fluorescents, the Ontario Ministry of Agriculture Food & Rural Affairs recommends the use of T8 Fluorescent bulbs. 8 The following link provides good information for interested customers: %20Bill%20Revington.pdf High Pressure Sodium (HPS) : HPS bulbs are extremely efficient (approaching 95 lumens per watt). This efficiency, however, is again offset by a costly installation and the inability to dim to low light levels. Although extensive testing has not been completed, tests have shown that birds do not react negatively to HPS light. 9 HPS bulbs are more popular in laying houses that do not use dimmer switches. 7 Van Wicklen, Gary, More Research Was Needed To Test LED Bulb Effectiveness, University of Delaware, 5/9/2006, 8 Clark, Steve, Energy Efficient Poultry Lighting, Ontario Ministry of Agriculture Food & Rural Affairs, January 2006, 9 Widowski, Tina & Vandenburg, Carien Lighting Sources For Broiler Breeders, University of Guelph, Poultry Industry Council For Research and Education, Factsheet 139, January 2003,

6 Page: 6 Conclusions: In choosing a lighting plan, all the options outlined above will improve energy efficiency and save money when compared to incandescent bulbs. Below is a chart that displays the energy efficiency of each lighting type. As shown, the energy efficient lights (CFLs, coldcathodes and HPS bulbs) all more than double the efficacy of standard incandescent bulbs. 10 Lumens Per Watt for Popular Poultry Lights At the present time, considering dimming requirements, up-front costs, and bulb lifespan, the most cost effective and easily manageable option for poultry houses across the country is replacing an older incandescent system with CFLs for standard lighting needs and cold-cathodes for dimming Incandescent CFL Cold Cathode HPS With a small initial investment (usually $500 or less), most farms can employ an energy-efficient lighting system. A successful poultry lighting plan will adapt one or more of these energy efficient lights to the requirements of individual farm owners. At the present time, considering dimming requirements, up-front costs, and bulb lifespan, the most cost effective and easily manageable option for poultry houses across the country is replacing an older incandescent system with CFLs for standard lighting needs and cold-cathodes for dimming. In the following sections, an appropriate lighting system will be properly matched with each respective farm type. 10 Keefe, T.J., "The Nature of Light," TCP,

7 Page: 7 Chicken Broiler House Lighting Universal standards are difficult to apply to broiler houses because of differing dimming requirements, strain crosses (breeds), flock lengths, and hours of light used per day across the industry. Broilers are extremely photosensitive, so proper light levels are absolutely essential in a broiler house because at a low light intensity, birds will be less active but still eat sufficient quantities of food to induce ample weight gains. Chicken Broiler Houses: Broiler houses comprise the largest sector of poultry sales. 11 A significant economic opportunity exists in broiler house lighting because many farms rely on incandescent bulbs. Universal standards are difficult to apply to broiler houses because of differing dimming requirements, strain crosses (breeds), flock lengths, and hours of light used per day across the industry. Despite these challenges, this paper will focus on using a combination of CFLs and cold-cathodes in order to achieve optimum lighting performance while minimizing energy usage and cost in broiler houses. General Lighting Procedures: There are extreme differences in lighting specifications across the broiler industry. Some broiler houses are solid walled and must generate all their light from artificial sources. Others have curtains that can be raised to benefit from natural light on sunny days. Broilers must receive approximately 3-5 foot-candles of light during brooding. This process lasts days and helps the chicks acclimate to their new environment (finding food and water sources) and strengthen their skeletal structure, digestive and circulatory systems, and immune system. After this initial brooding phase, light intensity is lowered (generally to around ½ foot-candle) and alternated with short periods of complete darkness for the remainder of growout. 12 Broilers are extremely photosensitive, so proper light levels are absolutely essential in a broiler house because at a low light intensity, birds will be less active but still eat sufficient quantities of food to induce ample weight gains. Low light intensity also lowers aggression and cannibalism. 13 Cold-cathode / CFL Lighting System: The following data is modeled after research by Auburn University 14 and the University of Arkansas Applied Broiler Research Farm. 15 The data simulates a 40 feet wide by 500 feet long house with 9.5 foot ceilings. CFLs are used in combination with cold-cathodes during brooding. In the brood area, CFLs must be placed on a separate circuit and should be located on a separate feed line and/or 11 Poultry Production and Value. USDA National Agriculture Statistics Service, April 28, 2008, 12 Donald, Jim, Controlling Light In Broiler Production. Auburn University Academic Poultry Engineering and Economics Newsletter, July 6, 2000, 13 Schwean, Karen, The Welfare of Poultry: Review of Recent Literature, Department of Animal and Poultry Science, University of Saskatchewan, 14 Donald, Jim, Auburn University, 15 Tabler, Tom, University of Arkansas Extension Service, Avian Advice Newsletter,

8 Page: 8 Experience in Auburn University testing indicates that temperature ratings in the 2700 to 2900-Kelvin range provide preferable flock behavior, as 4000-Kelvin bulbs add more blue color to the light spectrum. alternated every other bulb with cold cathodes. With all the house lights on, a combination of CFLs and cold-cathodes should reach well above 3-5 foot-candles of light. After the brooding period, the CFLs are turned off and the cold-cathodes are kept running. With all the cold-cathodes switched on, light levels should be able to reach at least 1 foot-candle and dim to light levels at or below ½ foot-candle. In comparing CFLs and coldcathodes, cold-cathodes are longer-lasting and have better dimming capabilities. Cold-cathodes represent a higher initial cost, but in the long term are the most cost and energy effective bulbs for dimming in broiler houses. Cold-cathodes are available in both a warm-white 2700-Kelvin temperature rating and bright white 4000-Kelvin temperature rating. Experience in Auburn University testing indicates that temperature ratings in the 2700 to 2900-Kelvin range provide preferable flock behavior, as 4000-Kelvin bulbs add more blue color to the light spectrum. These two bulbs have similar prices and identical lumen output. 16 Energy Analysis: The following chart is an analysis of the plan outlined above. Sixty 100-Watt incandescent bulbs are replaced by twenty 42-Watt CFLs (150-Watt equivalent) and forty 8-Watt cold-cathodes (40- Watt equivalent). More light power is provided during brooding than normally required in order to offset dust and bulb performance loss (as well as the associated buyer skepticism). From days 12 to 50, brood lights are switched off and the cold-cathodes are dimmed to approximately ½ footcandle. A medium-sized (6 pound) chicken is used for these calculations. It has an assumed flock length of 50 days and with cleaning time included, the farm should process six flocks per year. Incandescent Watts Per Day Days Intensity kw Energy Brooding Period: Day % 1296 $ Growout Period: Day % 1204 $ Per $ Combination of CFLs and Cold- Cathodes Watts per Day Days Intensity kw Energy Brooding Period: CFLs % 181 $18.14 Brooding Period: Cold-Cathodes % 69 $6.91 Growout Period: Cold-Cathodes Only % 175 $17.51 Per $42.57 Energy : Incandescent $ Energy : CFLs and Cold- Cathodes $42.57 Savings Per $ Notes: kw hour cost = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency was lost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to 44%. 16 Cold Cathode Dimmables. GoodMart,

9 Page: 9 Bulb Analysis: Despite energy savings of over $200, it is often argued that high bulb costs make this switch burdensome for farm owners. While it is true that energy efficient bulbs do represent a significant initial investment, the following chart proves that the longer lifespan of the bulbs actually makes the purchase of energy-efficient bulbs more cost effective because they are replaced less frequently. Per Lifespan in s Per Bulb New Per of New Per Lifespan in of Incandescent 1, $ $24.19 CFLs 10, $ $4.32 Cold-Cathodes 25, $ $17.28 of Incandescent Per $24.19 of CFLs and Cold- Cathodes Per $21.60 Savings Per of Purchasing New $2.59 Note: Incandescent bulb usage is scaled back to recognize that only 40 bulbs are lit after brooding period; For calculation purposes, dimming does not lessen bulb lifespan. As shown above, farmers will actually save $2.59 per flock over the lifespan of the energy efficient bulbs in addition to direct energy savings. With a lifespan of less than a single flock, incandescent bulbs will also need to be purchased and installed repeatedly, increasing both labor and energy costs. Total Analysis: This final study is a synthesis of the last two analyses. It includes a breakdown of the initial investment and the returns on that investment, displaying flock and cost data in a yearly format. Beyond operating costs, the environmental impact of energy savings is also exhibited. Initial Investment Bulb Total CFLs 20 $10.00 $ Cold-Cathodes 40 $12.00 $ Total Initial Investment $ Operating s Per Energy Savings $ Bulb Replacement Savings $2.59 Total Savings Per $ Data s Per Year 6 Payback Period (s) 3.24 Payback Period (Days)

10 Page: 10 Return on Investment and Operating Savings Return on Initial Investment, 1st Year 85% Operating Savings, 1 st Year $ Annual Return on Investment 185% Annual Operating Savings $1, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 14,999 Annual Energy Efficient Bulb kw Hour Usage 2,554 Total Annual kw Saved 12,445 % Change in Energy Efficiency 82.97% Over the course of the first year, including the cost of a full lighting replacement at the outset, savings in operating costs will be approximately $580. In terms of energy, almost 12,000 kw hours are saved annually, and the system is 83% more efficient than comparable incandescent bulb energy usage. All bulbs should be changed simultaneously after testing bulb color and light intensity. This will achieve better and more consistent bulb performance, as incandescent bulbs will not accurately dim alongside cold-cathodes on the same circuit. Conclusions and Additional Information: All broiler houses can benefit from an energy efficient lighting system. Cold-cathodes are the most viable bulb choice when dimming is required, and CFLs should immediately replace incandescent bulbs that are not on a dimmer switch. Please contact your local energy cooperative for more detailed cost analyses for large and small broiler birds, as well as comprehensive bulb information for poultry. Also, please note that due to the uniqueness of each farm, all cost studies will have slightly different results. The following two links will provide similar studies from the University of Arkansas and James Madison University. The dimmable CFLs featured in the 2 nd article are cold-cathodes:

11 Page: 11 Chicken Pullet and Laying Houses Many pullet houses rely exclusively on incandescent bulbs because of dimming requirements. There is no evidence that one type of lamp is better than any other for the rearing of growing pullets. When the pullets begin to age, day lengths are expanded so that the birds expect a long day (simulated spring) at the beginning of their reproductive cycle. Introduction: Layer hens are raised in a pullet house until they begin laying eggs. Lighting is extremely important in pullet and laying houses because it will affect the quality and quantity of eggs produced. Although lumen requirements and house size vary across the industry, this paper will explore general lighting options in pullet and laying houses that can be modified to fit specific farm requirements. It will use a quantitative approach to show the economic viability of energy efficient lights on both types of farms. Pullet Houses: Many pullet houses rely exclusively on incandescent bulbs because of dimming requirements. Some have delayed lighting upgrades because of lower electric bills relative to laying houses. Despite this apparent lack of industry momentum towards a lighting switch, poultry lighting experts Peter Lewis and Trevor Morris state, There is no evidence that one type of lamp is better than any other for the rearing of growing pullets. 17 Because egg quality and quantity is comparable regardless of light type, this section will show focus on cost benefits available by replacing incandescent bulbs with cold-cathodes. At the beginning of their life cycle, pullets are exposed to a large amount of light in order to orient themselves in a new environment and find food and water sources. After this initial brooding period, lighting plans generally shorten day lengths, simulating winter. When the pullets begin to age, day lengths are expanded so that the birds expect a long day (simulated spring) at the beginning of their reproductive cycle, generally between weeks. Because day length and light intensity have a direct impact on reproduction, dimming occurs at different intervals throughout the pullet process as long as a noticeable difference exists between lights on and lights off. 18 The following is an energy cost analysis for a pullet barn utilizing 300 dimmable bulbs. 8-Watt dimmable cold-cathodes accurately replace 40-Watt incandescent bulbs. 17 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom: Northcot, Wineland, Michael J., Importance of Proper Blackout Housing, The Poultry Site.Com, North Carolina State University,

12 Page: 12 Incandescent Per Day Days Watts Intensity kw Energy Brooding: First 3 Weeks % 4,536 $ Growout: Week % 7,056 $ Per $1, Cold-Cathodes Per Day Days Watts Intensity kw Energy Brooding: First 3 Weeks % 907 $90.72 Growout: Week % 1,411 $ Per $ Energy : Incandescent $1, Energy : Cold Cathodes $ Savings Per $ Note: kw hour cost = $0.10 As displayed above, cold-cathodes will save approximately $927 over a 17-week flock. Bulb : Cold-cathode bulbs last 25 times longer than incandescent bulbs, thus offsetting their high initial bulb cost. By using cold-cathodes, $55.94 per flock will be saved on bulb purchases. Per Lifespan in s Per Bulb of New Per of New Per Lifespan in Incandescent 1,000 1, $ $ Cold-Cathodes 25,000 1, $ $ of Incandescent Per $ of Cold-Cathodes Per $ Savings by Purchasing New $55.94

13 Page: 13 Total Analysis: This chart shows that the initial investment in coldcathodes of $3600 will be recouped in slightly over one year due to an 80% gain in energy efficiency. Initial Investment Bulb Total Cold-Cathodes 300 $12.00 $3, Total Initial Investment $3, Operating s Per Energy Savings $ Bulb Replacement Savings $55.94 Total Savings Per $ Data s Per Year 2.61 Payback Period (s) 3.66 Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year -29% Operating Savings, 1 st Year -$1, Annual Return on Investment 71% Annual Operating Savings $2, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 30,222 Annual Energy Efficient Bulb kw Hour Usage 6,044 Total Annual kw Saved 24,178 % Change in Energy Efficiency 80% The scenario above shows a savings of over $2,500 and over 24,000 kw hours of energy annually after the initial investment. Laying House: After weeks in a pullet house, hens are transported to a separate laying facility where they will lay eggs until they are approximately 80 weeks old. The laying house is an easier location to implement energy efficient lights because the majority of laying houses are not using dimmable lamps. If dimming is utilized, a cold-cathode plan, similar to the one displayed above, can be implemented. High Pressure Sodium bulbs are a more popular choice in laying houses in the southern United States; however, they require new ballasts and lighting installations making their payoff period much longer. Again, different types of light have not been shown to alter a hen s laying performance Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom: Northcot, 2006.

14 Page: 14 During the laying period, most houses require approximately 2 footcandles of light, which, in a high-rise house with lights lowered from the ceiling, can be produced by a 60-Watt (or lower) incandescent bulb and replaced by a 14-Watt (or lower) CFL. per day will be gradually increased in a step-up lighting plan; however, this scenario will show average costs and hours per day in a typical laying house in order to be easily applicable across the industry. CFLs are used in this scenario because they represent the most cost effective lighting plan, and dimming is not required. Incandescent Per Day Days Watts kw Energy Week ,132 $11, $11, CFLs In this barn, over $8,000 can be saved in energy costs between weeks Bulb Analysis: Per Day Days Watts kw Energy Week ,931 $2, $2, Total Incandescent $11, Total CFL $2, Savings Per $8, Note: kw hour cost = $0.10 Per Lifespan in s Per Bulb of New Per of New Per Lifespan in Incandescent 1,000 6, $0.60 1,852.2 $1, CFLs 10,000 6, $ $ of Incandescents Per $1, of CFLs Per $ Of Purchasing New $ The new bulbs will lower bulb costs by almost $300 per flock.

15 Page: 15 Total Analysis: Initial Investment Bulb Total CFLs 300 $4.50 $1, Total Initial Investment $1, Operating s Per Energy Savings $8, Bulb Replacement Savings $ Total Savings Per $8, Data s Per Year 0.79 Payback Period (s) 0.15 Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year 415% Operating Savings 1 st Year $5, Annual Return on Investment 515% Annual Operating Savings $6, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 87,799 Annual Energy Efficient Bulb kw Hour Usage 20,486 Total Annual kw Saved 67,313 % Change in Energy Efficiency 76.67% Conclusion: As exhibited above, CFLs can save almost $7000 a year and almost 67,000 kw hours of energy.

16 Page: 16 Turkey House Lighting Introduction: This section will serve to identify best lighting practices within the turkey industry. In order to use farm space more effectively, turkey growers normally employ multiple barns for different stages in a turkey's life cycle (up to 3 barns in a turkey s lifetime). 20 This lessens the need for dimmer switches in many turkey facilities because each stage will feature a slightly different lighting plan. Although day lengths vary between 12 and 23 hours, research has shown that 16 hours is the optimal day length for growing both male and female turkey broilers Turkey Broilers: Also known as growing turkeys, turkey broilers are raised for meat production. Turkey broilers need high light intensities during brooding to find food and water sources and lower light intensities for the rest of the growout period. Turkeys generally brood for 3-5 weeks and are then transported to a different house for weeks. Turkeys receive at least 5 foot-candles of light during brooding and at least 1 foot-candle for the rest of the flock. 21 Although day lengths vary between 12 and 23 hours, research has shown that 16 hours is the optimal day length for growing both male and female turkey broilers. 22 Breeding Turkeys: Female breeding turkeys also rotate between multiple barns. They are generally grown in a brooder house until they reach 29 weeks of age. Brood lights, usually on a different circuit, are utilized during the early portion of this period. After brooding, lighting plans generally use natural light or mimic natural day lengths for 3-4 months, employing hour days. Day lengths are then lessened to approximately 6-7 hours a day to simulate winter before the reproductive cycle begins. As the 29-week point approaches, day lengths are gradually extended to around 14 hours per day, simulating springtime at the beginning of the reproductive cycle. At 29 weeks, the hens are shifted to the laying barn where their production cycle will last approximately 26 additional weeks. In the laying barn, light is generally held constant at approximately 14 hours per day at a high light intensity to accentuate the birds perceptions of lights on and lights off. Male breeder turkeys (toms) are grown in separate barns. After brooding, they are generally grown for 14-hour days at a low-light intensity (2-3 foot-candles) to prevent aggressive behavior. Although colored light is employed on many farms, research has shown that white light is just as effective Poultry Production Phases, Purdue University, 21 Winchell, W., Lighting For Poultry Housing, The Canada Plan Service, The Poultry Site, 22 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom: Northcot, Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom: Northcot, 2006.

17 Page: 17 Analysis: The following cost analysis focuses on a generic turkey barn (broiler or laying) featuring sixty incandescent bulbs (100-Watt), which will be replaced by sixty 42-Watt CFLs (150-Watt equivalent). By using a stronger CFL, the study represents a conservative estimate of energy savings, adding more light than generally required to show the substantial cost benefit of switching to spiral CFLs. Turkey barns should use a light meter to determine the lumen output and exact wattage size of CFLs for their barn. As a general plan (discounting external factors such as the season and barn lighting layout), this analysis displays the value of CFLs over incandescent bulbs for any similar turkey house. The energy savings are presented in a monthly format so that they can be easily transferable to larger or smaller barns. kw Energy Incandescent Per Day Days Watts 1 Month Study ,520 $ kw Energy CFLs Per Day Days Watts 1 Month Study ,058.4 $ Energy : Incandescent $ Energy : CFLs $ Savings Per Month $ Note: kw hour cost = $0.10 It is shown that savings are $ per month in electricity costs. Bulb Analysis: The following chart shows monthly bulb cost after the initial change is made. Per Month Lifespan in Months Per Bulb of New Per Month At $10 per bulb, there will be an additional cost of $10.08 per month for new bulbs. of New Per Month Lifespan in Incandescent 1, $ $15.12 CFLs 10, $ $25.20 of Incandescent Per Month $15.12 of CFLs Per Month $25.20 of Purchasing New $10.08

18 Page: 18 Total Analysis: The next chart shows a yearly cost analysis and payback periods for a full lighting replacement. Initial Investment Bulb Total CFLs 60 $10.00 $ Total Initial Investment $ Operating s Per Month Energy Savings $ Bulb Replacement Savings -$10.08 Total Savings Per $ Payback Period Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year 172% Operating Savings 1 st Year $1, Annual Return on Investment 272% Annual Operating Savings $1, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 30,240 Annual Energy Efficient Bulb kw Hour Usage 12,701 Total Annual kw Saved 17,539 % Change in Energy Efficiency 58% By switching to spiral CFLs, even a small turkey barn accommodating only 60 bulbs will save over $1,200 and 20,000 kw hours of energy in the first year alone. After the first year, savings are increased to $1866 per barn.

19 Page: 19 Lighting Conclusions This paper indicates that energy efficient lighting can be used in poultry houses for a significant gain in energy savings. These general rules should be adopted based on circumstances present in poultry farms. Use cold-cathodes when low-light intensity and dimming is needed. If cold-cathodes are not able to fulfill the foot-candle requirements during brooding/growout, combine them with spiral CFLs on a different circuit and/or alternating bulbs to replace the need for incandescent bulbs. In houses where dimming is not required, spiral CFLs should be installed. They offer more uniform light coverage, more energy efficiency and lower costs than incandescent bulbs. High Pressure Sodiums are not as yet a proven solution because of long payback periods. Spiral CFLs should be cleaned by hand, but their long life and energy cost savings will outweigh any additional labor costs. Local electricity cooperatives are good sources of information regarding proper recycling of CFLs. Despite perceived bulb performance loss, most CFLs will lose less than 20% of their original foot-candles of light, and, as proven above, buying a slightly higher wattage CFL still garners appreciable financial benefits for the farmer. Considerable savings are possible even for those with smaller farms and minimal lighting needs.

20 Page: 20 Financing The initial cost of an energy efficiency transition can be significantly diminished through a variety of financing and rebate plans. A good starting point for most farmers is the USDA energy estimator tool that farmers can use to approximate their energy usage: Governmental Requirements and Rebates Renewable Energy Portfolio Standard: Federal and state governments are enacting new standards that require energy efficiency. Currently, thirty states sponsor a Renewable Energy Portfolio Standard (RPS or REPS), which mandates efficiency improvements by local cooperatives. Your state s energy efficiency program can be found at: es.cfm The 2007 United States Energy Bill announced that all incandescent bulbs would be banned between 2012 and 2014 Energy efficient light bulb upgrades can be counted towards REPS requirements. If current trends continue, mandates similar to REPS will likely spread throughout the United States. The 2007 United States Energy Bill announced that all incandescent bulbs would be banned between 2012 and As a result, immediate transition yields not only economic rewards but represents a preemptive compliance with government standards. Financing through Cooperatives Introduction: Financing for energy efficient measures can be difficult to obtain; however, this paper concludes that energy efficient lighting changes are financially beneficial in the long term and should be implemented regardless of whether a rebate plan is available. Energy savings will far outweigh the costs of such measures but a small cooperative rebate plan can be successful in creating demand and encouraging investment in energy efficiency. Cooperative Rebates: The most common financing plan offered by coops throughout the nation is a simple $2 rebate for CFL purchases. Other cooperatives offer rebates on fixtures for energy efficient 24 U.S. Energy Bill Phases Out Incandescent Light Bulb, Environmental Leader, December 18,

21 Page: 21 lighting, 25 or plans based on a percentage of money saved by the customer. 26 PAYS Model Pay As You Save: 27 At least two energy cooperatives are now offering energy efficiency programs with no up-front cost for their members. The programs are SmartSTART by the New Hampshire Electric Coop and How$mart by Midwest Energy. They are applicable in all cases where energy savings are greater than the total cost of the structural improvements: In a recent industry report, Mississippi State University gave 22 different options for improving energy efficiency in poultry houses The programs require an energy audit (provided free of charge in the case of How$mart), paying for the improvements with a guarantee of a lower energy bill for the customer. For example, if total savings are calculated as 100% of energy cost reduction, the program fees will amount to 75% of the energy savings (used to fund the improvements and pay the cooperative), and 25% of the savings will be seen in a lower monthly bill. Both programs require that individual farms and business owners complete the energy efficiency upgrades after an energy audit. In a recent industry report, Mississippi State University gave 22 different options for improving energy efficiency in poultry houses. 28 Since lighting comprised only two of these 22 options, these lighting changes can be combined with other energy efficiency upgrades, and an energy audit in poultry houses can represent a substantial economic benefit for both farmers and cooperatives. Financing through Governments Resources for Local Financing: The following links are comprehensive resources for government financing and energy efficiency programs, showing energy efficiency rebates, grants, and loans on a state-by-state database: 25 Rebates Offered - Shedding Light on Energy Efficiency, Jackson Electric Cooperative, 26 Energy Efficiency Rebates, Midstate Electric Cooperative, Programs/default.aspx. 27 Pays America, 28 Smith, Tom W. Jr., Reducing Energy s In Poultry Houses, Mississippi State University,

22 Page: 22 odtobegreen.c om/financiali ncentives.asp x For directories and state resources including local community development use: state_resources For resources about sustainable agriculture, please visit: Local Economic Development Organizations: When looking for help regarding energy efficiency rebates and programs, customers can be referred to local or state economic development organization. An online directory for economic development organizations is under construction at the following website: htm#gacc In 2008, the federal government gave almost $20 million to assist farmers, ranchers and small businesses for renewable energy systems and energy efficiency improvements. Rural Energy For America Program (REAP): Rural business can qualify for government subsidies based on energy efficient practices. In 2008, the federal government gave almost $20 million to assist farmers, ranchers and small businesses for renewable energy systems and energy efficiency improvements. For qualifying energy efficiency projects, the program offers a 25% grant (minimum $1500, maximum $250,000) and up to a 75% loan. More information is available online at USDA's website: If a lighting switch alone does not reach the required amount of savings or costs for the program, lighting upgrades can be combined with other energy efficiency projects to attain the required eligibility. Two poultry farmers in South Carolina received over $25,000 for energy efficiency improvements last year that included lighting system enhancements. 29 Research Grants: If member farms or businesses are interested in conducting research in sustainability and energy efficiency, Sustainable Agriculture Research and Education (SARE) offers grants of up to $150,000: 29 Six S.C. Projects Awarded Grant Funds From USDA, South Carolina Energy Office, September 20, 2008,

23 Page: 23 Conclusions: As energy costs continue to rise, an energy efficient lighting plan is an essential component of a sound long-term business model. As technology has improved, opportunities to cut costs while saving energy have become more readily available. The influx of government assistance programs as well as opportunities to save through local cooperative rebates have made upgrading a farm s energy profile more feasible and affordable than ever before. An energy efficient lighting plan is a rapid and manageable method by which poultry farms can drastically cut costs and remain viable and profitable businesses in the years to come. Contact Information: Neil Burrow Service Concepts 720 North High School Road Indianapolis, In (fax) [email protected] About Service Concepts: Service Concepts sponsored this paper for the purpose of distribution to electricity cooperatives and farmers across the nation to better address poultry lighting needs. In 1999, 32 rural electric utilities formed Service Concepts to foster innovation and enhance supplier relationships within the energy, telecommunications, and related industries. In order to address concerns over rising energy costs and the environment, Service Concepts facilitates relevant studies, educational programs, and manufacture-direct product relationships to support the adoption of energy efficient lighting. Service Concepts now serves electric utilities and their customers in every state in the United States. For more information, please visit. Acknowledgments: The broiler section of this paper was made possible with collaboration from the National Poultry Technology Center, Auburn University. Special thanks to Dr. Gene Simpson and Professor Jim Donald. For more information about poultry lighting and energy efficiency in poultry houses, please visit their website at

24 Page: 24 Appendix 1: Broiler House Analysis, Small Size Chicken (4 lb) with a 37-day flock length and seven total flocks per year. Incandescent Watts Per Day Days Intensity kw Energy Brooding Period: Day % 1296 $ Growout Period: Day % 792 $79.20 Per $ Combination of CFLs and Cold Cathodes Watts Per Day Days Intensity kw Energy Brooding Period: CFLs % 181 $18.14 Brooding Period: Cold-Cathodes % 69 $6.91 Growout Period: Cold-Cathodes Only % 115 $11.52 per $36.58 Energy : Incandescent $ Energy : CFLs and Cold-Cathodes $36.58 Savings Per $ Notes: KW / Hour = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency was lost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to 44%. Bulb Analysis: Per Lifespan in s Per Bulb of New Per of New Per Lifespan in Incandescent 1, $ $18.58 CFLs 10, $ $4.32 Cold-Cathodes 25, $ $12.79 of Incandescent Per $18.58 of CFLs and Cold- Cathodes Per $17.11 Savings Per of Purchasing New $1.47 Note: Incandescent bulb usage is scaled back to recognize that only 40 bulbs are lit after brooding period; For calculation purposes, dimming does not lessen bulb lifespan.

25 Page: 25 Total Analysis: Initial Investment Bulb Total CFLs 20 $10.00 $ Cold-Cathodes 40 $12.00 $ Total Initial Investment $ Operating s Per Energy Savings $ Bulb Replacement Savings $1.47 Total Savings Per $ Data s Per Year 7 Payback Period (s) 3.91 Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year 79% Operating Savings, 1 st Year $ Annual Return on Investment 179% Annual Operating Savings $1, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 14,616 Annual Energy Efficient Bulb kw Hour Usage 2,560 Total Annual kw Saved 12,056 % Change in Energy Efficiency 82.48%

26 Page: 26 Appendix 2: Broiler House Analysis- Large Size Chicken (7-8 lbs) with a 60-day flock and five total flocks per year. Incandescent Watts per Day Days Intensity kw Energy Brooding Period: Day % $ Growout Period: Day % $ Per $ Combination of CFLs and Cold- Cathodes Watts per Day Days Intensity kw Energy Brooding Period: CFLs % $18.14 Brooding Period: Cold-Cathodes % $6.91 Growout Period: Cold-Cathodes Only % $22.12 Per $47.17 Energy : Incandescent $ Energy : CFLs and Cold-Cathodes $47.17 Savings Per $ Notes: kw hour = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency was lost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to 44%. Bulb Analysis: Per Lifespan in s Per Bulb New Per of New Per Lifespan in of Incandescent 1, $ $28.51 CFLs 10, $ $4.32 Cold-Cathodes 25, $ $20.74 of Incandescent Per $28.51 of CFLs and Cold- Cathodes Per $25.06 Savings Per of Purchasing New $3.46 Note: Incandescent bulb usage is scaled back to recognize that only 40 bulbs are lit after brooding period; For calculation purposes, dimming does not lessen bulb lifespan.

27 Page: 27 Total Analysis: Initial Investment Bulb Total CFLs 20 $10.00 $ Cold-Cathodes 40 $12.00 $ Total Initial Investment $ Operating s Per Energy Savings $ Bulb Replacement Savings $3.46 Total Savings Per $ Data s Per Year 5 Payback Period (s) 2.86 Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year 75% Operating Savings, 1 st Year $ Annual Return on Investment 175% Annual Operating Savings $1, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 14,083 Annual Energy Efficient Bulb kw Hour Usage 2,359 Total Annual kw Saved 11,724 % Change in Energy Efficiency 83.25%

28 Page: 28 Appendix 3: Pullet Barn Analysis with 5-Watt cold-cathodes replacing 25-Watt incandescent bulbs. Incandescent Per Day Days Watts Dimmed To kw Energy Brooding: First 3 Weeks % 2,835 $ Growout: Week % 4,410 $ $ Cold-Cathodes Per Day Days Watts Dimmed To kw Energy Brooding: First 3 Weeks % 567 $56.70 Growout: Week % 882 $88.20 $ Energy : Incandescent $ Energy : Cold Cathodes $ Savings Per $ Note: kw hour cost = $0.10 Bulb Analysis: Per Lifespan in s Per Bulb of New Per of New Per Lifespan in of Incandescent 1,000 1, $ $ of Cold Cathodes 25,000 1, $ $ of Incandescent Per $ of Energy Efficient Per $ Savings by Purchasing New $74.59

29 Page: 29 Total Analysis: Initial Investment Bulb Total Cold-Cathodes 300 $11.00 $3, Total Initial Investment $3, Operating s Per Energy Savings $ Bulb Replacement Savings $74.59 Total Savings Per $ Data s Per Year 2.61 Payback Period (s) 5.04 Payback Period (Days) Return on Investment and Operating Savings Return on Initial Investment, 1st Year -48% Operating Loss, 1 st Year -$1, Annual Return on Investment 52% Annual Operating Savings $1, Annual Energy Savings Annual Incandescent Bulb kw Hour Usage 18, Annual Energy Efficient Bulb kw Hour Usage 3, Total Annual kw Saved 15, % Change in Energy Efficiency 80%