Energy Efficient Lighting Options

NPTC Mission

Poultry Federation Annual Symposium

Improve Bottom Line Profitability Of The Live Production Sector Of The U.S. Poultry Industry By Providing Timely Applied Research And Education Resulting In Increased Efficiencies In Housing, Equipment, Energy, And Environmental Control.

Gene Simpson, Ag Economist National Poultry Technology Center Auburn University - April, 2013

Jess Campbell 334-844-3546 [email protected]

Gene Simpson 334-844-3514 [email protected]

NPTC Team Members

Bulb Types

Address Issues In New & Retrofit Poultry House Construction, Economics, Energy Efficiency, Maintenance, Ventilation, And Engineering

www.poultryhouse.com

Dennis Brothers 256-274-2129 [email protected]

Incandescent (Tungsten Filament) High Pressure Sodium Vapor (HPS) Cold Cathode (CCFL) Dimmable Compact Fluorescent (Dim-CFL) Non-Dimmable Compact Fluorescent (CFL) Light Emitting Diode (LED) Different Lighting Needs For Different Birds & Houses

Jim Donald 334-844-3544 [email protected]

Common EE Bulb Shapes A19 – Classic “Thomas Edison” Shape, 6-10 W, Mostly 8W

• • • • • •

Spiral CFL 9-65W

Concerns: Initial, Replacement, Operating Costs & Warranty **Growers/Cos Need To Make Wise Business Decisions**

Characteristics Of Bulbs •Incandescent – Energy Hogs, Short Life, Low Cost •HPS – Energy Hogs, Long Life, Moderate LD, High Cost

PAR30 (30/8”)– Floodlight, ~3.75” Wide, 7-11W, Parabolic Lens To Spread Light

•CCFL – Energy Effic., Long Life, High LD, Moderate Cost •Dim-CFL - EE, Med. Life, High LD, Moderate Cost

PAR38 (38/8”)–Floodlight, ~4.75” Wide, 7-12W, Parabolic Lens To Spread Light

Several Hybrids 10-12W

•CFL - EE, Long Life, Fair LD, Low Cost •LED – Very EE, Very Long Life, Low LD, Varying Cost

HPS 150W & Reflector (Draws ~188W)

*** Heat Is Biggest Enemy Of All Light Bulbs! ***

Example Lighting Uniformity Summary Sheet - Full

Lumen Depreciation All Lights Depreciate, But At Very Different Rates! Two Sources Of Lumen Depreciation: 1) Physical Deterioration Over Time – Can’t Control 2) Accumulation Of Dust, Dirt & Debris – Can Control

L

Lighting Uniformity • Need Quantitative Measure Of Light Output At Bird Level - Wall To Wall, End To End (Index) • We Use CV (Std.Dev./Mean) On 25-Spot Grid Sample

Lower CVs Denote Improved Lighting Uniformity.

Abbreviated Summary Table Of Bulbs Bulb Type Incandescent Incandescent Incandescent Cold Cathode (Dim) Cold Cathode (Dim) Dim Spiral CFL Dim Spiral CFL Spiral CFL – Non-Dim Spiral CFL “ Spiral CFL “ Spiral CFL “ Spiral CFL “ A19 LED (Dim) PAR30 LED (Dim) PAR38 LED (Dim) Hybrid LED (Dim)

Watts Lumens Lum/W 60 870 15 75 1,190 16 100 1,710 17 8 325 41 15 525 35 15 1,100 73 23 1,600 70 18 1,250 69 23 1,600 70 26 1,750 67 40-42 2,700 64 55 3,400 62 6-10 450-900 55-75 7-11 500-900 55-75 7.5-10 500-900 55-75 10-12 600-1000 55-75

Retail $0.50 $0.50 $0.50 $7.50 $12.00 $6.00 $6.50 $2.75 $3.00 $3.25 $7.50 $12.50 $10-25.00 $18-40.00 $26-45.00 $28-45.00

Life Mo.Warr. 1,000 N/A 1,000 N/A 1,000 N/A 22,000 24 18,000 24 8,000 12 8,000 12 12,000 18 12,000 18 12,000 18 8,000 12 8,000 12 25,000+ 24-60 25,000+ 36-60 25,000+ 36-60 25,000+ 36

LED Myths • • • • •

My Bulb Has Better “Bird Lumens” & “Bird Footcandles” My Bulb’s Power Factor Saves Big On Amps & Power Bill My Bulb Gives Better Bird Performance (Pounds, FCR, Etc.) My Bulb Is Required By Your Integrator My Bulb Is The Only Bulb That Qualifies For Rebates

• • • • • •

A Watt Is A Watt – Basis Of Power Bill, Not Amps Or P.F. Power Factor Has Very Small $$ Effect On Power Bill Any Performance Claims Are Highly Questionable Integrators Do Not Require Specific Brands Many LED Brands Qualify For Rebate Programs Bulb Specs, Warranty, Performance & Cost – All Critically Important In Making A Smart Business Decision!

Truths

L

House #

Brand

Model

Wattage

0Kelvin

XX

XXXXX

A19

8.0

3,000

Outboard H2O 3'9"

Feed Line 9'6"

Inboard H2O 12'6"

Comments: Date: 3/13/2012 PLS7200MR3 Dimmer Full Bright

(fc @ Floor)

0' (Wall)

5' Inboard

10' Inboard

15' Inboard

20' Inboard

Average

Post 1

0.45

1.08

2.26

1.67

1.11

1.31

Post 2

0.40

0.90

1.46

1.30

1.10

1.03

Post 3

0.38

0.66

0.90

0.98

1.10

0.80

Post 4

0.41

0.81

1.25

1.35

1.07

0.98

Post 5

0.54

1.12

2.14

1.74

1.07

1.32

Average

0.44

0.91

1.60

1.41

1.09

0.85

Uniformity Index

(CV*100)

45.9

Index Ranges From ~ 45-82. Lower Number Is More Uniform

Light Color (0Kelvin)

~3,0000K Yellow Hue

Color & Type Bulb Should Be Specified By Integrator

~5,5000K Blue Hue

0K

Plays Tricks On Eyes. Light Meter Is A Must For Correct Dim Levels

Pullet House Lighting • Use Low Light & Feed Restriction To Delay Sexual Maturity • Males & Females Usually Need Slightly Different Lighting Programs, Depending On Breed & Strain • Wide Variety Of Pullet Housing, Lighting Layouts, & Dimming Considerations. Specific Housing Layout, Breed, & Sex Situation Dictates Best Lighting Approach • Some Don’t Use Dimmers At All, Only Low Light (CFLs). Works, But Not Best. Flex. With Dimming, But Costs $$ • Cost Varies From $150-$1,000 Per House • Since Pullet Grower Pay Is ~Fixed, Little Upgrade Incentive • 3,0000K Or Lower Suggested – Company Decision • Better Synch Light Increase Ratios @ Move (10:1 vs. 6:1) • LEDs & Dimming - Help Stop Digging & Aid Synch Control

Reasons For Changing Hen House Lights • #1 Goal: Lower Power Bill While Maintaining Same Breeding & Laying Performance • Power Rates More Than Doubled Past Few Years • High Electrical Consumption By HPS (185+ Watts)

Hen House Test, 2009-13 • 12 Typical Clear Curtain Sided Hen Houses, 40’ X 400’ • Replaced 32 150Watt High Pressure Sodium Lights With 100 23 Watt Non-Dim CFL Bulbs (2,700 0K; 12,000 Hrs) • 1 House To Start – Under Close Company Supervision

• Non-Uniformity Of HPS Lighting & Shadowing

• 2 Rows ~ Over Nests On ~10’ Centers, Plus Supplements In Cool Cell & Fan Areas. Yields Uniform 5-8 fcs

• High Labor & Maintenance Of HPS

• Cost Of Rewiring & Bulbs 600+ FPM

• • • • • •

Light Emitting Diode (LED) Is Great Newer Technology Evolving Rapidly. LEDs Run Cool, Dim Smooth, & Last. High Cost Issues, But Prices Trending Down Past Year Most CCFL/CFL Mgt Problems Disappear With LEDs Many Shapes & Styles, Most Between 3,0000K & 5,5000K Issues With Some LEDs: Diode Quality, Heat Sinks & Fins, Lumen Depreciation, Warranty & Light Spread/Uniformity • High $$ Bulbs Disappearing At Flock End? • NPTC Is Evaluating 25+ LED Brands/Models/Shapes

LED Demos & Tests – North Alabama

Most LEDs Installed March 2012 On 3 Farms. Others Added Earlier & Since. Several More Added Thru Apr ’13 On 5 More Farms.

LED Demo/Test Farm Bulbs NewLume 12W Hybrid Starfire 12W Hybrid Lowe’s 8WA19 Res.(*2) LumaVue 7.5W PAR38 Selco 8W PAR30 Verbatim 8W A19(*5) Lastik 10W A19 Overdrive 10W A19 Wynn 8 & 10W A19

LumaVue 7.5W PAR38 NextGen 10W Finned PAR30 VisuaLED 8W A19 Industrial UniLight 8W PAR30 Overdrive 8W A19 5000K(*5) Overdrive 7.5W PAR30(*5) Overdrive 10W PAR38(*5) Overdrive 11W PAR30(*5) Unilight 10W PAR38 Once Innovation 12W Hybrid Overdrive 8W A19 3000K(*5) Greenlite 8W A19

*All LEDs Have 3 Year Warranty & Are Rated At 25,0000+ Hours. Cost Ranges From $10-$45+/Bulb

General LED Observations • • • • • • • • • • • • •

Few Failures @ 6+ Flocks – LEDs Reliable, Last & Low LD! Erratic Low-End Dimming With A Few, But Solvable Difference In Power Bills Insignificant Among LEDs A19s – Best Overall Lighting Uniformity; Lowest Cost PAR30s – Good Uniformity; Slightly Higher Cost PAR38s & Hybrids – Good Uniformity; Most Costly PARs/Hybrids Best In High Ceilings (More Lumens/Spread) Most LEDs Water/Air Tight. Little H20/NH3 Damage Seen Debris Buildup On Some Styles – Management Problem Seeing Move To Longer Warranties – 5 Years Seeing New 9-11W A19s With 800+ Lumens (Heat/Life??) Takes Time To Measure Length Of Effective Service Life Not Much Lumen Depreciation Seen In 1+ Year

LED Dimming Observations

LED Performance Observations

Normalized (100%=1.00 fc) Dimmer Curves - Selected Models

0.80

0.60

0.40

Ne w

0.20

0.00 100 95

• • • • • •

90

85

80

75 70 65 60 55 50 45 40 35 30 25 20 Percent Dimming Shown On Dial Or Display

House

*25 Spot Grid, 5’ OC Cost / Mean fc @ Low fc High fc Grid Bulb Warr Retail Warr Feed Line - In Grid In Grid Mean fc Uniformity o Type Watts Kelvin Yrs Cost Year Full Intens @ Full @ Full In Grid Index* Notes

15

10

5

0

LEDs Dim Smoothly & Much Lower. Seldom Flicker. Catch Crews Really Like LEDs - Hard To Abuse. Dimmer/Brand Differences - Handshaking Challenge Most Problems Seen @ Lowest Dimmer Settings Some Still Require 1 Incandesc/Circuit To Dim At All Unlike CCFL & CFL, Dimming Increases LED Life

Ownership Cost

Grid Uniformity Index Brand

1.00

Footcandles (fc)

• All Houses/Farms Similar, But Not Identical • No Significant Difference Seen Or Reported In: Mortality, ADG, FCR, Or Any Plant Issues • No Change Seen In Grower Settlement Or Ranking • Other Factors More Important Than Lighting • Birds Act More “Content” With Uniform Light • No Difference Seen In Light Color (0Kelvin) • Some LEDs Offer Excellent Economic Payback, But LEDs Are NOT A Performance Silver Bullet! Therefore, Cost & Warranty Are Critical!

Bulb

& Simple

Cash

Flow

Retail

Warranty

Cost/Bulb/Yr

Retail/50

Cost/Hse/Yr

SHF

1

LumaVue 38-7.5

$40.00

3

$13.33

$2,000

$667

SHF

2

NextGen 30-10

$40.00

3

$13.33

$2,000

$667

SHF

3

VisuaLED A-8

$25.00

3

$8.33

$1,250

$417

SHF

4

Unilight 30-8

$27.00

3

$9.00

$1,350

$450

SHF

5

Overdrive A-8 5K

$16.00

5

$3.20

$800

$160

VisuaLED

A19

8.0

3,500

3

$25

$8.33

1.51

0.33

2.07

0.97

46.8

SHF

6

Overdrive 30-7.5

$26.00

5

$5.20

$1,300

$260

Greenlite

A19

8.0

3,000

3

$20

$6.67

1.28

0.28

1.87

0.85

47.3

SHF

7

Overdrive 38-10

$31.00

5

$6.20

$1,550

$310

Overdrive

A19

8.0

3,000

5

$16

$3.20

1.29

0.11

1.70

0.85

50.1

SHF

8

Overdrive 30-11

$26.00

5

$5.20

$1,300

$260

PAR30 11.0 3,000

5

$26

$5.20

2.38

0.47

3.46

1.54

50.2

SHF

9

Unilight 38-10

$31.00

3

$10.33

$1,550

$517

50.8

SHF

10

Once Innovat 12

$40.00

3

$13.33

$2,000

$667

SHF

11

Overdrive A-8 3K

$16.00

5

$3.20

$800

$160

SHF

12

Greenlite A-8

$21.00

3

$7.00

$1,050

$350

Overdrive Overdrive

A19

8.0

5,000

5

$16

$3.20

1.92

0.45

2.88

1.25

Once Innov Hybrid 12.0 4,000

3

$40 $13.33

1.58

0.17

2.31

0.90

62.1

LumaVue

PAR38 7.5

5,000

3

$40 $13.33

1.74

0.19

2.62

1.05

62.5

NextGen

PAR30 10.0 3,500

3

$40 $13.33

2.62

0.12

2.38

0.85

69.5

Unilight

PAR30 8.0

4,000

3

$27

$9.00

3.56

0.39

5.89

1.92

74.0

Overdrive

PAR38 10.0 3,500

5

$31

$6.20

4.05

0.38

6.37

2.07

77.0

Overdrive

PAR30 7.5

3,500

5

$26

$5.20

2.84

0.32

4.81

1.43

79.2

Unilight

PAR38 10.0 4,500

3

$31 $10.33

5.50

0.32

8.80

2.71

82.2

Incandesc Required Incandesc Required

KA

1

NewLume Fin 12

$29.00

3

$9.67

$1,450

$483

KA

2

Starfire Fin 12

$29.00

3

$9.67

$1,450

$483

KA

3

Lowe’s A-8

$10.00

2

$5.00

$500

$250

KA

4

LumaVue 38-7.5

$40.00

3

$13.33

$2,000

$667

TD

1

Verbatim A-8

$16.00

5

$3.20

$800

$160

TD

2

Selco 30-8

$30.00

3

$10.00

$1,500

$500

High Ceiling Lighting Issues

Reflectors For High Ceilings

Very Different Considerations

14+’

• • • • • • • • •

Intensity Too Low Bulbs 11’-15’ High Too Few Sockets @20’ OC Baffles Blocking Light May Need: New Wiring Circuits More Sockets Reflectors/PAR Bulbs Higher Wattage-Lm Bulbs Lower Height Bulbs

Reflectors For High Ceiling Houses

Mail Order Frisbee 9” Diameter, 1½” Depth For CCFL/CFL/LED Cost $0.60

“PoultryflectorTM” 20” Diameter, 7” Depth Made For Up To 55W CFL Cost ~ $6.50

Others: 5 Gallon Pail Lids & Painted Pie Pans

Cleaning Lights

1973 Steel Truss Retrofit

Frisbee w/ 8W A19 LED Grow Lights

Poultryflector w/ 23W CFL Broods & Frisbee w/ 8W LED

Total Cost ~ $715 For LED/CFL (40’X400’) In High Ceilings, Reflectors ~ Double fcs @ Floor Get All The Light You’re Paying For!

Improve “Depreciation” By Cleaning Accumulated Debris. Use Sprayer Between Flocks. Lights Off. 1 Part Windex Or Ammonia With 8-10 Parts Water & Jet Stream. Just A Few Seconds Per Bulb & All Debris Boils Off.

Easy Cleaning - Before & After Pics

Disposal

3+ Years

5 Flocks

??% Brighter

• CCFL/CFLs Contain Mercury • Clean Up Areas Around Broken Bulbs, Including Litter. Double Bag & Take To Recycling Center.

35% Brighter 2 Flocks

40 Cooler

LEDs - No Mercury - No Disposal Regs 2 Flocks

16% Brighter

Economics Of Lighting Retrofits Get A Professional Electrical Checkup First! If Existing Wiring Is OK: • ~$800-$2,500+/Hse For LEDs (With No Rebate) • Annual Power Savings: ~ $200+/100’ Of Length (A Watt Is A Watt) • Use LED-Grows & Non-Dim Spiral CFL-Broods • Different Situations; One Size Does NOT Fit All! • Do It Correctly Or Expect Failures! • LEDs Are Great, But Some Issues Still Remain, Especially Cost & Warranty

Questions & Discussion

Lighting Retrofit Summary • Incandescent & HP Sodiums Should Be Replaced With LEDs Or CFLs – Specific Situation Dictates Best Fit • Use Low Wattage LEDs Over Feeders, & Add Higher Wattage Non-Dim CFLs For Brood – Best Bang For The $$ • Clean Bulbs Often – Get The Light You’re Paying For • Don’t Leave $1,000-$1,200/Hse/Yr On The Table • 5 Year Warranties On LEDs Becoming More Common • Simple ROI Paybacks Measured In Flocks, Not Years • Some LEDs Are Cost-Effective, But Some Are Not Yet • If An LED Rebate Program Is Available, Jump All Over It! ***Ultimate Goal Is To Make A Wise Business Decision***