The number just about knocks you over when you look at it. Over three
years on six farms, New Life Mills of Hanover, Ont. has cut energy use
by a total of more than one million kilowatt hours by installing
compact fluorescent lights (CFLs) and dimmable CFLs.
A change in lighting and switching to dual-side ventilation curtain barns has reduced energy costs by $30,000 per year and decreased the number of airsacculitis condemns for a large Ontario producer.
The number just about knocks you over when you look at it. Over three years on six farms, New Life Mills of Hanover, Ont. has cut energy use by a total of more than one million kilowatt hours by installing compact fluorescent lights (CFLs) and dimmable CFLs.
In 2008-09, the farms’ energy use was 1,253 kWh less per day than in 2006-07 or 457,345 kWh less over the course of one year.
Energy Savings. New Life Mills of Hanover, Ont. has cut energy use significantly by installing compact fluorescent lights (CFLs) and dimmable CFLs, and improved air quality by utilizing curtain-sided ventilation.
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This results in cost savings of about $30,000 per year, and if electricity prices rise, so will the savings.
“I didn’t believe it,” says Bill Revington, general manager of farm operations for New Life. “But I did the math myself.”
Although renewable energy is getting the headlines these days, the low-hanging fruit can be found in energy conservation or using energy more efficiently.
“There’s lots of talk about renewables, but you can realize huge savings today with energy conservation,” he says.
New Life began to focus on energy costs about six years ago. Not only were energy costs rising, with talk of significant future increases, but Ontario was also threatened with looming energy shortages and rolling blackouts during the summer.
When the company built two new 26,000 square-foot barns in 2004 and 2005, it installed two-stage infrared tube heaters and dimmable T-8 fluorescent tube lights. It also decided to try curtain-sided dual ventilation in the new barns.
Initially, there were some challenges because no one in the company had worked with curtain-sided barns before. “Ventilation was the main thing. It’s a different mind set to turn off all the fans when you’re used to confinement rearing and turning the fans on.”
“It takes some getting used to, but we learned to do it differently,” says Revington.
But even during the learning stage, the barns were paying off. The energy savings came quickly, and the air quality is excellent.
“We used to have significant condemnations due to airsacculitis,” Revington says.
General manager of farm operations Bill Revington says that, although there is a lot of talk about renewables, huge savings can be realized by conserving energy.
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The condemnations have been cut to 40 per cent of what they were, and the results of having healthier birds goes straight to the bottom line.
The new barns use chimney fans for ventilation in winter and employ natural ventilation in summer. The combination has worked well.
“We get air movement even on hot, still days,” he says.
When young birds are in the barns and supplemental heat is needed, infrared tube heaters are used. The heaters radiate infrared heat to the birds’ level, warming the birds and heating the floor.
While New Life hasn’t broken out the cost savings from using infrared, others report savings of up to 30 per cent compared with natural gas forced air heating.
The curtain-sided barns are also equipped with sensors to measure light levels. As the curtains are raised, ambient light enters the barn, and the sensors determine how much and where supplemental lighting is needed.
The sensors and the dimmer system have further reduced energy use in the barn. The savings just from using sensors and dimmable lights is an additional 1,000 kWh per flock, according to a study.
“This was another thing I was initially skeptical of,” Revington says.
Overall, the Ontario Ministry of Agriculture, Food and Rural Affairs (OMAFRA) estimates that there is a 66 per cent reduction in energy use in the operation of a dual ventilation barn with fluorescent lights versus a traditional barn with incandescent lights and mechanical ventilation.
There may soon be additional energy savings. Revington says he is looking at the opportunities offered by LED lights. They consume even less power than CFLs and last longer. This is “exciting technology,” he says.
When New Life built its curtain-sided, energy efficient barns, it was breaking new ground. This was recognized in 2008, when the company received a Premier’s Agri-Food Innovation Excellence award.
The citation says, in part: “New Life Mills had a bright idea. They became early adopters of an automated system that dims and turns off artificial light in response to different levels of natural light coming into the barn. This technology has been good for their poultry, since proper light is essential for their growth and reproductive performance. The farm has also realized energy savings of 60 per cent. New Life Mills is sharing their data and experience with the rest of the industry.”
In addition, New Life installed the energy-efficient technology without the benefit of assistance from any government programs. Since then, government programs to help farmers increase the energy efficiency of their barns have become available.
“There are some good programs out there now,” says Revington.
These programs are not confined to new barns but also include help in retrofitting a barn.
The programs differ by province and may involve not just agriculture departments or ministries, but also hydro or power utilities. Government officials and equipment suppliers have details of the programs available for your operation and location.
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