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 campbj1@auburn.edu Gene Simpson 334-844-3514 gsimpson@auburn.edu 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 brothers@auburn.edu 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 donaljo@auburn.edu 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 <$1,700/House • Expect Additional Power Rate Increases • More Farms Facing Demand Metering Surcharge Hen House Lighting Test Results • $1,850/House Electrical Savings Per 44 Week Flock • Power Co. Recently Started Demand Metering (~$0.035) Original 150 Watt HPS Layout • No Loss In Flock Performance (1 Egg/Hen/Yr = $350-$375) • Floor Eggs Cut In Half; Slightly Lower Hen Mortality • No Maintenance & Repair Expense With CFLs • Lighting Amps @ Panel Reduced From ~50A To ~20A • Reduced Power Usage - Saved 54.5 kWH & $6.02 Per Day (16,800 kWH Per 11 Month Flock Cycle) • Demand Metering Delayed ~1½-2 Months ($1.50-$1.75/Day) 23 Watt/1,600 Lumen CFL Layout Tested (<=Optional) • Plan: Replace All Lamps Every 2 Flocks (10-11,000 Hrs) • Savings: Year 1 = $150; Year 2 & Beyond = $1,700 (Plus Any Savings From Demand Metering Delay) Why Change Broiler House Lighting? • LEDs Not Adequate Or Cost-Effective For Hen Houses • Non-Dim CFLs Make Best Economic Sense For Hen Houses Goals Of Broiler House Lighting • Brood - Concentrate Light Over Feeders/Drinkers. • Goals: 1) Extract Full Genetic Potential By Influencing Behavior & 2) Reducing Power Bill • After Turnout, Dim Progressively & Smoothly. • Incandescent Bulbs: >85% Heat; <15% Light • Co. Lighting Programs & Premium Pay Specs Vary. • Incandescent Lights Can Be 25+% Of Power Bill • In General, Target 3-5 fc @ Brood Over Feeders; Then Dim Until End Of Growout. • Reduce Lighting Costs 70-85% By Replacing All Incandescent Lights With Low Wattage LEDs (Typically ~8,000-10,000 kWH/House/Year) • Fill Extreme Dimming Needs Of Catch Crews. • Use Low Wattage Uniform Dim LED Grow Lights • Supplement With Non-Dim CFL Broods At Lowest Wattage Necessary To Reach Target Brood fc. Daily kWH Used – 40’ X 500’ Broiler House 350.00 100w/100w Incandescent 300.00 250.00 250.00 200.00 200.00 KWH KWH 300.00 350.00 150.00 150.00 100.00 100.00 50.00 8w LED/40w CFL 50.00 0.00 0.00 Fans Lights Total Fans Lights Total Documented Lighting Savings By AL Power Co: 10,154 kWH, Worth $1,137/House To The Grower 20,308 kWH @ $0.112 Over 2 years (11 Flocks) Observations In Most Older Houses New Broiler House Lighting Layouts • New Houses Are Easy - Full Flexibility With Specs. • Typical Layout-Past Decade: 2 Circuits Alternating Over Each Feeder – 1 Dim & 1 Non-Dim , 10’ OC. • Use Nickel Plated Brass Sockets. No Oxidation. • Avoid “Jelly Jars” - Causes Heat Buildup. • Issue Is With Retrofitting Older Houses, Not New Brood Off-Brood Lighting Retrofits For Broiler Houses • Corroded/Oxidized Sockets - Wreak Havoc With CCFL/CFL Bulbs, Shortens Life & Affects Dimming • Have Full Elect & Gen Checkup Before Starting On Lights! • Analog Dimmer Curves Designed For Incandescents • Same Lighting Goals As New Houses • Some Digital Dimmers May Still Not Have Smooth Curves For CCFL, CFL & LED Bulbs • Usually Possible To Use Existing Wiring 20’OC Circuits (Avoid $1,400-$1,800 Re-Wiring Cost) • Diff. LED Brands Have Diff. Dimming Components • <25 Ohm Ground A Must For New Digital Dimmers • 24 Hour Burn-In Of CCFL/CFL Bulbs For Long Life • White Down Ceiling Reflects >¼ fc More Than Black • Don’t Dim CCFL/CFLs Below 10% Full Intensity • Difficult & Expensive To Achieve In High Ceiling Houses Without PARs &/Or Reflectors. (Light Shines Up, Too!) • Catch Crews Want It Very Dim, But Too Dim Quickly Damages CCFL/CFLs (Key = Flicker/Strobe). Typical Broiler House Retrofit Lighting Layout • CFLs Over 26W Size Cost Much More & Have Shorter Life One Good Retrofit Solution On 20’ Center Spacing Over Feeders: Use CCFL, Dim CFL, Or LED & Add 40-55 Watt CFLs In Brood Center To Get ~3 fc @ Feeder Brood Off-Brood = 2 Dimmable Grow Light Circuits (60-100 Watt Incand.) Incandescents Replaced With 8 Watt LEDs = 1 Non-Dim Brood Light Circuit (100-150 Watt Incand.) Incandescents Replaced With 23-55 Watt Spiral CFLs No Need To Re-Wire; Use 3 Existing Circuits, 20’ OC LED/CFL - Best Economics & Saves Most Energy Problem: Get ~3+ fc @ Feeder; Center Much Higher (5-9 fc) Consider 2-In-1 Socket Splitter Over Feeders With 1 8W LED & 1 18-26 W Non-Dim CFL With No Center Brood Lights. After Brood, Switch Off All Non-Dim CFL Bulbs & Dim. Good To Match 0K On Bulbs. Use Dim Bulbs Without Splitters In Off-End Result: Get 3-5 fc @ Feeder, Only 2-3 fc In Center Wide Broiler House Lighting Layout Option: Socket Splitter With 4-Way Switch Brood -No Center Line Broods- Off-Brood Use 1 LED & 1 Non-Dim CFL 20’OC. Retail ~ $6.50 4-Way Socket Splitter Lighting Layout Corroded Keyless Sockets Brood Off-Brood Replace With Nickel Plated Brass Retail ~ $1.10 LEDs – Good Tech Solution, But Cost? CCFL/CFL Problems Seen Since 2008 • • • • • • • • • • Bad Quality, High Failures, Breakage & Warranty Issues Significant Lumen Depreciation (~15-25%/Year) New 8W CCFL Only Has 325 Lumens & Loses 60-75+/Year Hard To Clean, Fragile & Discoloring Low-End Dimming Increases Bulb Stress (Shorter Life) Lumen Deprec. Means Dimmer Settings Must Change Often High Post-Washdown Failure Rates Shorted/Corroded Sockets – More Ohms, Heat, Mini-Arcs Lost Flock Performance Over Time Lots Of Frustrations: Grower--Company--Supplier • Higher Mgt Detail Required For CCFL/CFL Success • But Energy Use & Cost Much Lower Than Incandescents LED Demos/Tests – North Alabama Goals: •Test, Demonstrate & Compare Alternative LEDs In Commercial Broiler Housing •Measuring Intensity, Uniformity, LD & Longevity •Grower/Integrator Observations & Feedback Critical •Compare Cost-Effectiveness Of Various Models •Provide Industry With Helpful Information To Make Wise Business Decisions Test House Descriptions, All 8 Farms: All 40’, Drop, Solid Retro, SP>0.17, WS>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***