Field Demonstration of Advanced Lighting Technologies for Poultry Houses

Field Demonstration of Advanced Lighting Technologies for Poultry Houses Susan Watkins, Susan Sullivan, Joe Lacy and H.L. Goodwin Center of Excellence for Poultry Science University of Arkansas Division of Agriculture Funded by American Recovery and Reinvestment Act under The Department of Energy award DE-EE0000179 In Partnership with the Arkansas Energy Office and Arkansas Resource Conservation District Councils

Weeks Summer Weekly Energy Consumption Eight Week Grow-out August 1, 2006 September 20, 2006 Lighting Fans Feed Augers kwh 1400 1200 1000 800 600 400 200 0 One House 1 2 3 4 5 6 7

Poultry Operation Energy Saving Opportunities: Why Lighting? Feed augers/movement motors are a small percentage of the overall energy consumption little opportunity to improve efficiency. Fan motors are a high percentage of the overall consumption but have a higher replacement cost relative to the energy efficiency gains. Lighting efficiency improvement appears to offer the best opportunity for savings.

Incandescent Lighting Many poultry houses utilize incandescent bulbs Dimmable Low initial/replacement cost (50 /60 watt bulb) Least efficient lighting source Heating a metal filament till it glows Bulb production phasing out in next few years

Summer Flock Electricity Consumption Eight Week Grow-out Period 8000 7000 6000 One House 7275 Lighting (31%) 5000 4000 4566 Fans/Sump Pumps (63%) 3000 2000 1000 2258 451 Feed Augers, Misc. (6%) Total 0

Winter Flock Electricity Consumption Six Week Grow-out Period 6000 5000 One House 5415 Lighting (40%) 4000 3000 2000 1000 0 3010 2137 268 Kilowatt-Hours Fans/Sump Pumps (56%) Feed Augers, Misc. (4%) Total

Alternative Lighting Options Cold Cathode Fluorescent Lighting (CCFL) Dimmable Compact Fluorescent Lighting (DCFL) LED (Light Emitting Diode) Lighting In 2006 LED lighting not available for poultry house usage, therefore CCFL and dimmable compact fluorescent were choices evaluated

While Efficient: DCF and CC Have Challenges Dirt accumulation on CFL bulbs significantly reduces light output DCFL and CC bulbs sensitive to power fluctuations, resulting in a high failure rate CFL contain mercury, disposal challenges LED bulb options came on market 3 years ago Initial LED testing began at ABRF unit in November 2009

KELVIN

Incandescent-New Bulbs

Incandescent- Old Bulbs

Next Gen Illumination LED 10 watt bulb 400 lumens 120 light beam 35,000 hour life expectancy 3700 Kelvins Full range dimming capabilities and compatible with a range of dimmers currently used in the poultry industry3 year warranty 3 year warranty

Next Gen LED

LED Bulb-Luma Vue PAR- 38 (Parabolic aluminized reflector) 6.5 Watts 510 lumens 6,000 Kelvin 30,000 hour life span Full range dimming capabilities Compatible with a range of dimmers currently used in the poultry industry 160 light beam 3 year warranty

Luma Vue LED

Once Innovation-LED 15 watts 900 lumens@5,000k 6,400 Kelvin Full range dimming capabilities 90 Light Beam Output

July 2011 LED Lighting Once Innovation New Next Gen Ill. Luma Vue 3 YO Next Gen Ill.

ABRF Average Lighting Energy Usage KwH 3000 2500 2000 1500 1000 500 2112 2594 306 364 611 1472 Incan 1 Incan 2 Once Innovation Luma Vue Next Gen Ill. 0 Cold Cathode

ABRF Average Lighting Energy Cost Based on 9 cents/ KwH 250 232 $ 200 150 191 132 Incan 1 Incan 2 100 50 0 27 33 55 Once Innovation Luma Vue NextGen Ill. Cold Cathode

Performance Index Calculated by Average weight x livability Lighting electricity x Feed conversion x days

Performance Index 2.5 $ 2 1.5 1 1.987 1.726 1.02 Incan 1 Incan 2 Once Innovation 0.5 0.3256 0.2577 0.4132 Luma Vue 0 NextGen Ill. Cold Cahtode.

Project Outline Phase 1- Field Demonstration of LED bulbs suitable for poultry production Coordinated by the U of A Division of Ag Poultry Science Compared bulbs previously tested at U of A Farm to incandescent, cold cathode and DCFL Utilized 20- broiler farms in Arkansas 16 complexes participated All houses were tunnel ventilated, solid side walls or dark curtains Flock performance-energy use monitored for several flocks Began installations in March finished in July

Next Gen Illumination LED 10 watt bulb 400 lumens 120 light beam 35,000 hour life expectancy 3700 Kelvins Full range dimming capabilities and compatible with a range of dimmers currently used in the poultry industry3 year warranty 3 year warranty

LED Bulb-Luma Vue PAR- 38 (Parabolic aluminized reflector) 6.5 Watts 510 lumens 6,000 Kelvin 30,000 hour life span Full range dimming capabilities Compatible with a range of dimmers currently used in the poultry industry 160 light beam 3 year warranty

Efficient Lights/Power Secure-LED PAR-30 10 Watts 400 lumens 6,000 Kelvin Full range dimming capabilities Compatible with a range of dimmers currently used in the poultry industry 140 light beam 3 year warranty

Cold Cathode Cold Cathode Fluorescent Light bulbs 8 Watt 325 lumens 2700 Kelvin Clear bulb Dimmable No warranty

Cold Cathode Cold Cathodes Fluorescent Light bulbs 8 Watt 325 lumens 4100 Kelvin Frosted bulb Dimmable No warranty

Dimmable Compact Fluorescent 15 Watt Dimmable 1,100 lumens 8,000 hour life Base Must meet ANSI C78.21-2003 for use in standard E26 sockets

Brood Lights All farms had options of either 23 or 26 watt non-dimmable fluorescent bulbs Drop ceiling houses- 23 watt 1,600 lumens 12,000 hour life span High ceiling-26 watt 1,800 lumens 10,000 hour life span

Light Intensity Measurements For each farm-select one house Take 120 readings across the house Every 10 feet for 150 feet 8 readings are taken across the house and averaged Readings are taken: At each side wall Each inside water line Each Feeder line 2 readings off center For this presentation light intensity as measured in foot candles were averaged

Participating Producers Background Almost all were using: 100 W incandescent for brood 60 W incandescent for grow 2-150 W sodium for brood 1- using fluorescent tubes 2- using 110 W for grow 1-using 75 W for grow 1-using 15 W DCF-just really wanted to try LED Majority of houses 40-43 wide by 400-500 long

RESULTS

Average Foot Candles at Bird Height Brood and Grow Lights 2.48 Wall 1.40 Water line 3.00 Center 3.06 Feed line 3.89

Average Grow Light Foot Candle- 1.83 all 0 Water line 1.40 Center 2.60 Feeder 2.55

Average Brood Light Intensity (FC) Before and After New Bulbs- DCFL Farm Before After After 6 Flocks A (23) 1.32 4.41 1.71 B (26) 0.85 2.26 1.69 C (23) 1.06 3.72 1.83 D (26) 1.44 NR 1.68

Average Grow Light Intensity (FC) Before and After New Bulbs- DCFL Farm Before After After 6 Flocks A.56 1.68 0.66 B.18 1.72 1.01 2 C.54 2.02 1.06 D.90 1.51 1.06

Average Brood Light Intensity (FC) Before/After New Bulbs- 2700CC Farm Before After After 6 Flocks A (23) 1.92 4.18 2.08 B (23) 1.12 1.21.94 R C (FT) 2.15 1.64 1.52 R

Average Grow Light Intensity (FC) Before/After New Bulbs- 2700CC Farm Before After After 6 Flocks A.67.71 0.44 B.67.44.45 R C.90.42.41 R

Average Brood Light Intensity (FC) Before/After New Bulbs-LV LED Farm Before After After 6 Flocks A (sodiums) NR NR B (26) 3.05 3.15 C (26) 1.53 3.35 D (23) 1.22 2.47 1.56 Dropped 2.00 cleaned bulbs 1.41

Average Grow Light Intensity (FC) Before/After New Bulbs-LV LED Farm Before After After 6 Flocks A ND 1.17 B 0.83 1.34 C 0.70 1.24 D 0.86 1.25 1.07 Dropped 1.29 Cleaned bulbs 0.9

Average Brood Light Intensity (FC) Before/After New Bulbs-NG LED Farm Before After After 6 Flocks A (23).86 2.89 B (26) 2.52 3.59 C (26) 0.64 NR 1.44 2.07 1.38

Average Grow Light Intensity (FC) Before/After New Bulbs-NG LED Farm Before After After 6 Flocks A.54.67 B.86.79 C.41.71 0.56 0.53 0.46

Average Daily Gain for Light Sources 0.1350 0.1300 0.1294 0.1265 LBS 0.1250 0.1200 0.1170 0.1201 0.1150 0.1138 0.1111 0.1100 0.1050 0.1000 Pre-Incandescent DCFL CC LVLED NGLED PSLED

Work Horse Farm 10 house farm- each 43 x 500 Each house had 50-60 watt incandescent bulbs for grow lights every other bulb over feed line 38-100 watt incandescent bulbs in brood end, every other bulb over feed line 5 houses, left as is 5 houses- replaced the grow lights with the Next Gen LED Replaced the brood lights with 23 watt incandescent bulbs

Grow-out Incandescents

Grow-out NG LED

Metered Farm- NG LED/26 W CF Meter readings after the first and second flocks Incandescent NG LED Savings First Flock 1557 292 81% Second Flock 3343 631 81% Incandescent NG LED

Next Gen LED 50 bulbs/house- $35/NG LED- 50% rebate Cost of bulbs to retrofit 1 house $875 Electric cost = $0.10/KwH $135.60 --Savings/house per flock Estimated payback time 7 flocks/year = 1.0 years 6 flocks/year = 1.25 years Does not include the cost of compact fluorescents ~2.60 each

How do We Improve Life of CFL Bulbs need to be burned in Turned on for 24-72 hours straight Do not dim below 10% Utilize an incandescent on the circuit to provide enough resistance so dimmer can detect and properly dim Use caution when cleaning Don t buy cheap bulbs

Summary-LED Lighting Provides significant energy savings Far more durable than CFL and CC LED bulbs support good bird performance So far bird performance as good as if not better than on previous lighting Do have dark areas between LED bulbs May need to rethink brood bulbs for more light initially so lamp lumen loss not as dramatic