Energy Efficiency in Poultry House Lighting - 2009.pdf

Page: 1Energy Efficiency in PoultryHouse LightingBy Neil BurrowThe poultry industry has experienced significant scientific gains in thepast 50 years, creating stronger birds, increasing egg production, and as aresult, yielding higher quality final products. With rising energy costsand looming federal mandates, producers are now faced with thechallenge of achieving energy efficiency on their farms whilemaintaining increases in production and quality.The purpose of this paper isto assist electric cooperativesin providing energy efficientlighting options for poultry.This paper will focus on lighting efficiency in poultry houses, provingthrough both quantifiable data and anecdotal evidence that energyefficient lighting systems will lower electrical costs while maintainingprecise poultry lighting standards. The purpose of this paper is to assistelectric cooperatives in providing energy efficient lighting options.These options will both conform to poultry industry demands anddecrease costs and energy usage for their customers.This paper will also address energy regulations put forth by local andfederal governments. It will enumerate cost effective methods, includingrebates, loans, and grants to aid farmers in making these changes. Afterreading this paper, your cooperative will be equipped with the necessaryknowledge to understand lighting in poultry, better address customerneeds, and adapt to our rapidly changing energy environment.Table Of ContentsSection 1: Introduction and Lighting Options, page 2Section 2: Chicken Broiler Houses, page 7Section 3: Chicken Pullet and Laying Houses, page 11Section 4: Turkey House Lighting, page 16Section 5: Lighting Conclusions, page 19Section 6: Financing, page 20Section 7: Appendices, page 24Service Conceptswww.serviceconcepts.coop

Page: 2Introduction and LightingOptions“New housing embodies newtechnology, so slowinginvestment can hinder futureproductivity growth, unlessolder houses can beeffectively retrofited withnewer equipment.”This paper will focus on thebenefits of installing energyefficient lighting in broiler,pullet and laying houses.Introduction to the Poultry Industry: The poultry industry earnedmore than $35 billion in cash receipts in 2008. Although the industry isgrowing, there have been fewer entrants into the market in recent years.In an analysis of the broiler industry, James McDonald states, “Newhousing embodies new technology, so slowing investment can hinderfuture productivity growth, unless older houses can be effectivelyretrofited with newer equipment.” 1 New lighting techniques that increaseenergy efficiency represent a form of this “retrofitting,” allowing existingfarms to offset rising energy costs and grain prices. McDonald alsopoints out that while many poultry companies are using larger contractfarms, over half of broiler production in 2008 came from small farms.These small farms are presented with a large opportunity to save energyand enhance industry competitiveness.Introduction to the Farm Process: The chicken and turkey productionprocess begins in the breeder house. Here, mature hens lay eggs that willeventually form baby pullets (chickens) and poults (turkeys). The eggsare sent to hatcheries where they are incubated and prepared for birth.When the baby chicks hatch, they are immediately transported to housesthat correspond with their purpose. Broilers (birds for meat) aretransported to a broiler house while layers (birds for eggs) are sent to apullet house and then a laying facility. After broiler birds reach theirdesired weight, they are sent to a processing plant to be used for meatproduction. After hatching, laying hens must be developed in a pullethouse until they start their reproductive cycle. They are then transferredto a laying house where they will lay eggs until they are no longerproductive. After the reproductive cycle is complete, laying hens willagain relocate to a processing facility to be used in mature poultryproducts. This paper will focus on the benefits of installing energyefficient lighting in broiler, pullet and laying houses. As you will see,broiler houses have specific lighting plans designed to enhance weightgain, strengthen the skeletal system, and develop a larger, healthier bird.Laying houses, and the pullet houses that hold birds before they enter thelaying facilities, utilize lighting plans throughout the life of the hen tomaximize reproduction rates.Service Concepts1 McDonald, James, “The Economic Organization of U.S. Broiler Production,” USDA EconomicResearch Service, Economic Information Bulletin Number 38, June 2008www.ers.usda.gov/Publications/EIB38/.www.serviceconcepts.coop

Page: 3Lighting Options: In the following section, each type of bulb availableto poultry farmers will be analyzed.Bulbs That Work With Standard Fixtures:Many small-scale farms may be reluctant to switch lighting systemsbecause of high costs to install new lighting fixtures, ballasts, etc. Thefollowing five bulbs use standard light sockets.Incandescent bulbs areinefficient because nearly90% of the power used bythe bulb is released as heatrather than lightIncandescent Bulbs: These bulbs have been the traditional bulb choicein poultry farms. They are inefficient because nearly 90% of the powerused by the bulb is released as heat rather than light. Although this maybe an attractive benefit in the winter, the heat created is inefficient whencompared with other heating options, and the heat produced by thesebulbs will inevitably raise cooling costs in the summer. 2 Incandescentbulbs have a low up-front cost and a consistent light color. They have alifespan of 1,000 hours or approximately two months if lit 16 hours/day.Although inefficient, incandescent bulbs have surprisingly seen anincrease in their usage in poultry because they can be dimmed to a verylow light level.Compact Fluorescent Bulbs (CFLs): The most common household andcommercial replacement for the incandescent bulb is the spiral CFL (seepicture at left). These bulbs have a 10,000 hour lifespan or almost twoyears if lit 16 hours/day. They use 75% less energy than incandescentbulbs according to the EPA. 3 A 23-Watt CFL will emit the equivalentlumens (brightness) of a 100-Watt incandescent bulb. CFLs are currentlyavailable in sufficient wattage for all poultry houses, drop and openceiling. A standard CFL does not have dimming capabilities. Becauseof their spiral design, dust and dirt can accumulate on CFLs in thepoultry environment. CFLs are also more fragile to clean than a standardbulb. CFLs can be purchased as “A-Lamps” with a globe covering thespirals, and wet location coating is available to help ease cleaning of thebulbs. These solutions are not generally employed in poultry because ofheat build-up in A-Lamps and additional costs of coating the bulbs.Most farms find it more profitable to use cheaper spiral CFLs and cleanthem carefully by hand. Because of their design, CFLs spread light moreevenly throughout the poultry house, which prevents birds fromclustering in one area.Service Concepts2 Energy Star, US EPA, http://energystar.custhelp.com/cgibin/energystar.cfg/php/enduser/std_adp.php?p_faqid=3868&p_created=1196785588.3 “Compact Fluorescent Light Bulbs,” Energy Star, US EPA,http://www.energystar.gov/index.cfm?c=cfls.pr_cfls.www.serviceconcepts.coop

Page: 4The US Department ofEnergy states, “Compactfluorescent lamps (CFLs)experience higher lumendepreciation compared tolinear sources, but higherquality models generallylose no more than 20% ofinitial lumens over their10,000 hour life.”Finally, CFLs are often attributed with the negative stigma of lowerperformance late in their lifespan. Although this has some validity, theUS Department of Energy states, “Compact fluorescent lamps (CFLs)experience higher lumen depreciation compared to linear sources, buthigher quality models generally lose no more than 20% of initial lumensover their 10,000 hour life.” 4 In order to best combat this issue, farmersshould buy Energy Star® rated lamps which are guaranteed to perform athigher than 80% of their original lumen output after 4,000 hours 5 and/orbuy lamps with a slightly higher wattage than normally required with anincandescent bulb. Throughout all of the cost analyses below, a slightlyhigher bulb wattage is used in order to more conservatively estimatesavings. This will prove that the performance depreciation of CFLs, evenwhen overstated, is not enough to defray cost effectiveness. At the dateof publication, the CFL is the easiest and most tested method toimmediately lower energy costs in poultry if the farm is not using adimmer.Dimmable CFLs: Dimmable CFLs are on the market, but they arecurrently inconsistent in dimming to extremely low-levels in manyhouses (at or below ½ foot-candle). They are also much more expensivethan traditional CFLs. If dimming is required, farms should use coldcathodesor set up CFLs on separate circuits so that fewer bulbs are usedwhen less intensity is desired.Cold-Cathode Bulbs: Cold-cathodes are a newer technology, a highefficiency fluorescent bulb that lasts approximately 25,000 hours. 6 Coldcathodescome with a globe surrounding their lighting mechanismmaking them similar to incandescent bulbs in terms of cleaning. Theyconsume slightly more energy than spiral CFLs but are still extremelyefficient when compared to incandescent bulbs. An 8-Watt cold-cathodecorresponds to a 40-Watt incandescent bulb. The biggest benefit ofcold-cathodes is that they can dim accurately to meet even the lowestlight intensity requirements in poultry (usually to under ½ foot-candle). Ifa farmer needs more lumens than an 8-Watt cold cathode can provide,they should combine cold-cathodes with another lighting option,generally a CFL.Service Concepts4 “Lumen Depreciation,” US Department of Energy: Energy Efficiency and Renewable Energy,http://www.netl.doe.gov/SSL/usingLeds/general_illumination_life_depreciation.htm.5 “ENERGY STAR® Program Requirements for CFLs,” Energy Star, 10/30/03,http://www.energystar.gov/ia/partners/product_specs/program_reqs/cfls_prog_req.pdf.6 “Cold Cathode Lamp Specifications.” TCP,http://tcpi.com/PDF/1746_1593_02371%20TCP%20CC%20A%20Lamp%20SS%20rev.pdf.www.serviceconcepts.coop

Page: 5Although recently featured insome poultry studies, LEDscannot be recommended as astandard light fixture becausethey do not offer the samepayback period, light colorguarantees, or number oftrials as the other fixturesabove.Light Emitting Diode (LED): LED lights are exceptionally long-lasting(approximately 50,000 hours) and now come in a variety of colors andoptions. Although recently featured in some poultry studies, 7 they cannotbe recommended as a standard light fixture because they do not offer thesame payback period, light color guarantees, or number of trials as theother fixtures above. Some poultry producers are using colored lights tocalm birds or increase reproduction. If houses are using blue or redlights, these lights can be changed to LEDs to save energy costs.Bulbs That Require New Lighting FixturesTube Fluorescent and High Pressure Sodium bulbs show significantpromise in the poultry industry. They are also some of the most energyefficient lighting options on the market today. These options areeconomically viable when compared to incandescent bulbs but theirpayoff period is generally a few years.Tube Fluorescents: Tube Fluorescents are similar in their output toCFLs but achieve even higher energy efficiency. They gained somepopularity in the 1980s and are a popular choice in the Canadian poultryindustry. In the United States, they have failed to achieve a significantmarket share because of high installation and maintenance costs.Because they are installed inside large fixtures, the cleaning of thesebulbs is also an extremely tenuous process. If interested in tubefluorescents, the Ontario Ministry of Agriculture Food & Rural Affairsrecommends the use of T8 Fluorescent bulbs. 8 The following linkprovides good information for interested customers:• www.gtmconf.ca/downloads/presentations/5D4%20-%20Bill%20Revington.pdfHigh Pressure Sodium (HPS) Bulbs: HPS bulbs are extremely efficient(approaching 95 lumens per watt). This efficiency, however, is againoffset by a costly installation and the inability to dim to low light levels.Although extensive testing has not been completed, tests have shown thatbirds do not react negatively to HPS light. 9 HPS bulbs are more popularin laying houses that do not use dimmer switches.Service Concepts7 Van Wicklen, Gary, “More Research Was Needed To Test LED Bulb Effectiveness,” Universityof Delaware, 5/9/2006, http://www.americanfarm.com/Poultry5.09.2006d.html.8 Clark, Steve, “Energy Efficient Poultry Lighting,” Ontario Ministry of Agriculture Food & RuralAffairs, January 2006, http://www.omafra.gov.on.ca/english/engineer/facts/06-009.htm.9 Widowski, Tina & Vandenburg, Carien “Lighting Sources For Broiler Breeders,” University ofGuelph, Poultry Industry Council For Research and Education, Factsheet 139, January 2003,www.poultryindustrycouncil.ca/factsheets/fs_139.pdf.www.serviceconcepts.coop

Page: 6Conclusions: In choosing a lighting plan, all the options outlined abovewill improve energy efficiency and save money when compared toincandescent bulbs. Below is a chart that displays the energy efficiencyof each lighting type. As shown, the energy efficient lights (CFLs, coldcathodesand HPS bulbs) all more than double the efficacy of standardincandescent bulbs. 10At the present time,considering dimmingrequirements, up-front costs,and bulb lifespan, the mostcost effective and easilymanageable option forpoultry houses across thecountry is replacing anolder incandescent systemwith CFLs for standardlighting needs and coldcathodesfor dimming.With a small initial investment (usually $500 or less), most farms canemploy an energy-efficient lighting system. A successful poultrylighting plan will adapt one or more of these energy efficient lights to therequirements of individual farm owners. At the present time,considering dimming requirements, up-front costs, and bulb lifespan, themost cost effective and easily manageable option for poultry housesacross the country is replacing an older incandescent system with CFLsfor standard lighting needs and cold-cathodes for dimming. In thefollowing sections, an appropriate lighting system will be properlymatched with each respective farm type.Service Concepts10 Keefe, T.J., "The Nature of Light," http://www.ccri.edu/physics/keefe/light.htm. TCP,www.tcpi.com.www.serviceconcepts.coop

Page: 7Chicken Broiler House LightingUniversal standards aredifficult to apply to broilerhouses because of differingdimming requirements,strain crosses (breeds), flocklengths, and hours of lightused per day across theindustry.Broilers are extremelyphotosensitive, so properlight levels are absolutelyessential in a broiler housebecause at a low lightintensity, birds will be lessactive but still eat sufficientquantities of food to induceample weight gains.Chicken Broiler Houses: Broiler houses comprise the largest sector ofpoultry sales. 11 A significant economic opportunity exists in broilerhouse lighting because many farms rely on incandescent bulbs.Universal standards are difficult to apply to broiler houses because ofdiffering dimming requirements, strain crosses (breeds), flock lengths,and hours of light used per day across the industry. Despite thesechallenges, this paper will focus on using a combination of CFLs andcold-cathodes in order to achieve optimum lighting performance whileminimizing energy usage and cost in broiler houses.General Lighting Procedures: There are extreme differences in lightingspecifications across the broiler industry. Some broiler houses are solidwalled and must generate all their light from artificial sources. Othershave curtains that can be raised to benefit from natural light on sunnydays. Broilers must receive approximately 3-5 foot-candles of lightduring brooding. This process lasts 10-14 days and helps the chicksacclimate to their new environment (finding food and water sources) andstrengthen their skeletal structure, digestive and circulatory systems, andimmune system. After this initial brooding phase, light intensity islowered (generally to around ½ foot-candle) and alternated with shortperiods of complete darkness for the remainder of growout. 12 Broilersare extremely photosensitive, so proper light levels are absolutelyessential in a broiler house because at a low light intensity, birds will beless active but still eat sufficient quantities of food to induce ampleweight gains. Low light intensity also lowers aggression andcannibalism. 13Cold-cathode / CFL Lighting System: The following data is modeledafter research by Auburn University 14 and the University of ArkansasApplied Broiler Research Farm. 15 The data simulates a 40 feet wide by 500feet long house with 9.5 foot ceilings. CFLs are used in combination withcold-cathodes during brooding. In the brood area, CFLs must be placed ona separate circuit and should be located on a separate feed line and/orService Concepts11 “Poultry Production and Value.” USDA National Agriculture Statistics Service, April 28, 2008,http://usda.mannlib.cornell.edu/usda/current/PoulProdVa/PoulProdVa-04-28-2008.pdf.12 Donald, Jim, “Controlling Light In Broiler Production.” Auburn University Academic PoultryEngineering and Economics Newsletter, July 6, 2000,http://www.aces.edu/dept/poultryventilation/documents/Nwsltr-6.pdf.13 Schwean, Karen, “The Welfare of Poultry: Review of Recent Literature,” Department of Animaland Poultry Science, University of Saskatchewan,http://www.prairieswine.com/porkinsight/welfare_issues/pdf/poultry.pdf.14 Donald, Jim, Auburn University, www.poultryhouse.com.15 Tabler, Tom, University of Arkansas Extension Service, Avian Advice Newsletter,http://www.poultryscience.uark.edu/avianindex.html.www.serviceconcepts.coop

Page: 8Experience in AuburnUniversity testing indicates thattemperature ratings in the 2700to 2900-Kelvin range providepreferable flock behavior, as4000-Kelvin bulbs add moreblue color to the lightspectrum.Incandescent Bulbsalternated every other bulb with cold cathodes. With all the house lights on,a combination of CFLs and cold-cathodes should reach well above 3-5foot-candles of light. After the brooding period, the CFLs are turned offand the cold-cathodes are kept running. With all the cold-cathodesswitched on, light levels should be able to reach at least 1 foot-candle anddim to light levels at or below ½ foot-candle. In comparing CFLs and coldcathodes,cold-cathodes are longer-lasting and have better dimmingcapabilities. Cold-cathodes represent a higher initial cost, but in the longterm are the most cost and energy effective bulbs for dimming in broilerhouses. Cold-cathodes are available in both a “warm-white” 2700-Kelvintemperature rating and “bright” white 4000-Kelvin temperature rating.Experience in Auburn University testing indicates that temperature ratingsin the 2700 to 2900-Kelvin range provide preferable flock behavior, as4000-Kelvin bulbs add more blue color to the light spectrum. These twobulbs have similar prices and identical lumen output. 16Energy Cost Analysis: The following chart is an analysis of the planoutlined above. Sixty 100-Watt incandescent bulbs are replaced by twenty42-Watt CFLs (150-Watt equivalent) and forty 8-Watt cold-cathodes (40-Watt equivalent). More light power is provided during brooding thannormally required in order to offset dust and bulb performance loss (as wellas the associated buyer skepticism). From days 12 to 50, brood lights areswitched 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.# ofBulbsWattsHoursPer Day# ofDaysIntensitykW HoursUsedEnergyCostBrooding Period: Day 1-11 60 100 18 12 100% 1296 $129.60Growout Period: Day 12-50 40 100 18 38 44% 1204 $120.38Combination of CFLs and Cold-Cathodes# ofBulbsWattsHoursper Day# ofDaysCost Per Flock $249.98IntensitykW HoursUsedEnergyCostBrooding Period: CFLs 20 42 18 12 100% 181 $18.14Brooding Period: Cold-Cathodes 40 8 18 12 100% 69 $6.91Growout Period: Cold-Cathodes Only 40 8 18 38 80% 175 $17.51Energy Cost: Incandescent Bulbs $249.98Energy Cost: CFLs and Cold-Cathodes $42.57Cost Savings Per Flock $207.42Cost Per Flock $42.57Notes: kW hour cost = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency waslost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to44%.Service Concepts16 “Cold Cathode Dimmables.” GoodMart,http://www.goodmart.com/products/cold_cathode_dimmable.htm.www.serviceconcepts.coop

Page: 9Bulb Cost Analysis: Despite energy savings of over $200, it is oftenargued that high bulb costs make this switch burdensome for farmowners. While it is true that energy efficient bulbs do represent asignificant initial investment, the following chart proves that the longerlifespan of the bulbs actually makes the purchase of energy-efficientbulbs more cost effective because they are replaced less frequently.Lifespanin HoursHoursUsed PerFlockLifespanin FlocksPer Bulb# ofBulbsUsedCost ofBulbs# of NewBulbs PerFlockCost of NewBulbs PerFlockIncandescent Bulbs 1,000 900 1.11 44.8 $0.60 40.32 $24.19CFLs 10,000 216 46.30 20 $10.00 0.43 $4.32Cold-Cathodes 25,000 900 27.78 40 $12.00 1.44 $17.28Cost of IncandescentBulbs Per Flock $24.19Cost of CFLs and Cold-Cathodes Per Flock $21.60Cost Savings Per Flockof Purchasing New Bulbs $2.59Note: Incandescent bulb usage is scaled back torecognize that only 40 bulbs are lit after brooding period;For calculation purposes, dimming does not lessen bulblifespan.As shown above, farmers will actually save $2.59 per flock over thelifespan of the energy efficient bulbs in addition to direct energy savings.With a lifespan of less than a single flock, incandescent bulbs will alsoneed to be purchased and installed repeatedly, increasing both labor andenergy costs.Total Cost Analysis: This final study is a synthesis of the last twoanalyses. It includes a breakdown of the initial investment and thereturns on that investment, displaying flock and cost data in a yearlyformat. Beyond operating costs, the environmental impact of energysavings is also exhibited.Initial Investment # of Bulbs Bulb Cost Total CostCFLs 20 $10.00 $200.00Cold-Cathodes 40 $12.00 $480.00Total Initial Investment $680.00Operating Costs Per FlockEnergy Savings $207.42Bulb Replacement Savings $2.59Total Cost Savings Per Flock $210.01Flock Data# of Flocks Per Year 6Payback Period (Flocks) 3.24Payback Period (Days) 161.90Service Conceptswww.serviceconcepts.coop

Page: 10Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year 85%Operating Cost Savings, 1 st Year $580.06Annual Return on Investment 185%Annual Operating Cost Savings $1,260.06Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 14,999Annual Energy Efficient Bulb kW Hour Usage 2,554Total Annual kW Hours Saved 12,445% Change in Energy Efficiency 82.97%Over the course of the first year, including the cost of a full lightingreplacement at the outset, savings in operating costs will beapproximately $580. In terms of energy, almost 12,000 kW hours aresaved annually, and the system is 83% more efficient than comparableincandescent bulb energy usage. All bulbs should be changedsimultaneously after testing bulb color and light intensity. This willachieve better and more consistent bulb performance, as incandescentbulbs will not accurately dim alongside cold-cathodes on the samecircuit.Conclusions and Additional Information: All broiler houses canbenefit from an energy efficient lighting system. Cold-cathodes are themost viable bulb choice when dimming is required, and CFLs shouldimmediately replace incandescent bulbs that are not on a dimmer switch.Please contact your local energy cooperative for more detailed costanalyses for large and small broiler birds, as well as comprehensive bulbinformation for poultry. Also, please note that due to the uniqueness ofeach farm, all cost studies will have slightly different results. Thefollowing two links will provide similar studies from the University ofArkansas and James Madison University. The “dimmable CFLs”featured in the 2 nd article are cold-cathodes:• http://www.thepoultrysite.com/articles/1213/energy-efficiencyassociated-with-poultry-house-lighting• http://www.vapoultry.com/assets/Docs/George's%20Handout.pdfService Conceptswww.serviceconcepts.coop

Page: 11Chicken Pullet and Laying HousesMany pullet houses relyexclusively on incandescentbulbs because of dimmingrequirements.“There is no evidence thatone type of lamp is betterthan any other for therearing of growing pullets.”When the pullets begin toage, day lengths areexpanded so that the birdsexpect a long day (simulatedspring) at the beginning oftheir reproductive cycle.Introduction: Layer hens are raised in a pullet house until they beginlaying eggs. Lighting is extremely important in pullet and laying housesbecause 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 layinghouses that can be modified to fit specific farm requirements. It will usea quantitative approach to show the economic viability of energyefficient lights on both types of farms.Pullet Houses: Many pullet houses rely exclusively on incandescentbulbs because of dimming requirements. Some have delayed lightingupgrades because of lower electric bills relative to laying houses.Despite this apparent lack of industry momentum towards a lightingswitch, poultry lighting experts Peter Lewis and Trevor Morris state,“There is no evidence that one type of lamp is better than any other forthe rearing of growing pullets.” 17 Because egg quality and quantity iscomparable regardless of light type, this section will show focus on costbenefits available by replacing incandescent bulbs with cold-cathodes.At the beginning of their life cycle, pullets are exposed to a large amountof light in order to orient themselves in a new environment and find foodand water sources. After this initial brooding period, lighting plansgenerally shorten day lengths, simulating winter. When the pullets beginto age, day lengths are expanded so that the birds expect a long day(simulated spring) at the beginning of their reproductive cycle, generallybetween 14-18 weeks. Because day length and light intensity have adirect impact on reproduction, dimming occurs at different intervalsthroughout the pullet process as long as a noticeable difference existsbetween lights on and lights off. 18Service Concepts17 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom:Northcot, 2006.18 Wineland, Michael J., “Importance of Proper Blackout Housing,” The Poultry Site.Com, NorthCarolina State University, http://www.thepoultrysite.com/articles/851/importance-of-properblackout-housing.www.serviceconcepts.coop

Page: 12Energy Cost Analysis: The following is an energy cost analysis for apullet barn utilizing 300 dimmable bulbs. 8-Watt dimmable coldcathodesaccurately replace 40-Watt incandescent bulbs.Hours # ofkW Hours EnergyIncandescent Bulbs# of Bulbs Per Day Days Watts Intensity Used CostBrooding: First 3 Weeks 300 18 21 40 100% 4,536 $453.60Growout: Week 4-17 300 12 98 40 50% 7,056 $705.60Cost Per Flock $1,159.20Hours # ofkW Hours EnergyCold-Cathodes# of Bulbs Per Day Days Watts Intensity Used CostBrooding: First 3 Weeks 300 18 21 8 100% 907 $90.72Growout: Week 4-17 300 12 98 8 50% 1,411 $141.12Energy Cost: IncandescentBulbs $1,159.20Energy Cost: Cold Cathodes $231.84Cost Per Flock $231.84Cost Savings Per Flock $927.36 Note: kW hour cost = $0.10As displayed above, cold-cathodes will save approximately $927 over a17-week flock.Bulb Cost Analysis: Cold-cathode bulbs last 25 times longer thanincandescent bulbs, thus offsetting their high initial bulb cost.Lifespanin HoursHoursUsed PerFlockLifespanin FlocksPer Bulb# ofBulbsUsedCostofBulbs# of NewBulbs PerFlockCost ofNew BulbsPer FlockIncandescent Bulbs 1,000 1,554 0.64 300 $0.60 466.20 $279.72Cold-Cathodes 25,000 1,554 16.09 300 $12.00 18.65 $223.78Cost of Incandescent Bulbs Per Flock $279.72Cost of Cold-Cathodes Per Flock $223.78Cost Savings by Purchasing New Bulbs $55.94By using cold-cathodes, $55.94 per flock will be saved on bulbpurchases.Service Conceptswww.serviceconcepts.coop

Page: 13Total Cost Analysis: This chart shows that the initial investment in coldcathodesof $3600 will be recouped in slightly over one year due to an80% gain in energy efficiency.Initial Investment # of Bulbs Bulb Cost Total CostCold-Cathodes 300 $12.00 $3,600.00Total Initial Investment $3,600.00Operating Costs Per FlockEnergy Savings $927.36Bulb Replacement Savings $55.94Total Cost Savings Per Flock $983.30Flock Data# of Flocks Per Year 2.61Payback Period (Flocks) 3.66Payback Period (Days) 512.56Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year -29%Operating Cost Savings, 1 st Year -$1,036.39Annual Return on Investment 71%Annual Operating Cost Savings $2,563.61Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 30,222Annual Energy Efficient Bulb kW Hour Usage 6,044Total Annual kW Hours Saved 24,178% Change in Energy Efficiency 80%The scenario above shows a savings of over $2,500 and over 24,000 kWhours of energy annually after the initial investment.Laying House: After 14-18 weeks in a pullet house, hens aretransported to a separate laying facility where they will lay eggs untilthey are approximately 80 weeks old. The laying house is an easierlocation to implement energy efficient lights because the majority oflaying houses are not using dimmable lamps. If dimming is utilized, acold-cathode plan, similar to the one displayed above, can beimplemented. High Pressure Sodium bulbs are a more popular choice inlaying houses in the southern United States; however, they require newballasts and lighting installations making their payoff period muchlonger. Again, different types of light have not been shown to alter ahen’s laying performance. 19Service Concepts19 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom:Northcot, 2006.www.serviceconcepts.coop

Page: 14During the laying period, most houses require approximately 2 footcandlesof light, which, in a high-rise house with lights lowered from theceiling, can be produced by a 60-Watt (or lower) incandescent bulb andreplaced by a 14-Watt (or lower) CFL. Hours per day will be graduallyincreased in a step-up lighting plan; however, this scenario will showaverage costs and hours per day in a typical laying house in order to beeasily applicable across the industry.Energy Cost Analysis: CFLs are used in this scenario because theyrepresent the most cost effective lighting plan, and dimming is notrequired.Incandescent Bulbs # of BulbsHoursPer Day# ofDays WattskW HoursUsedEnergyCostWeek 17 – 80 300 14 441 60 111,132 $11,113.20$11,113.20CFLs# of BulbsIn this barn, over $8,000 can be saved in energy costs between weeks 17-80.Bulb Cost Analysis:HoursPer Day# ofDaysWattskW HoursUsedThe new bulbs will lower bulb costs by almost $300 per flock.EnergyCostWeek 17 – 80 300 14 441 14 25,931 $2,593.08$2,593.08Total Cost –Incandescent $11,113.20Total Cost – CFL $2,593.08Cost Savings Per Flock $8,520.12 Note: kW hour cost = $0.10HoursUsed PerFlockLifespan inFlocks PerBulb# ofBulbsUsedCostofBulbs# of NewBulbs PerFlockCost of NewBulbs PerFlockLifespanin HoursIncandescent Bulbs 1,000 6,174 0.16 300 $0.60 1,852.2 $1,111.32CFLs 10,000 6,174 1.62 300 $4.50 185.2 $833.49Cost of Incandescents Per Flock $1,111.32Cost of CFLs Per Flock $833.49Cost Of Purchasing New Bulbs $277.83Service Conceptswww.serviceconcepts.coop

Page: 15Total Cost Analysis:Initial Investment # of Bulbs Bulb Cost Total CostCFLs 300 $4.50 $1,350.00Total Initial Investment $1,350.00Operating Costs Per FlockEnergy Savings $8,520.12Bulb Replacement Savings $277.83Total Cost Savings Per Flock $8,797.95Flock Data# of Flocks Per Year 0.79Payback Period (Flocks) 0.15Payback Period (Days) 70.89Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year 415%Operating Cost Savings 1 st Year $5,600.76Annual Return on Investment 515%Annual Operating Cost Savings $6,950.76Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 87,799Annual Energy Efficient Bulb kW Hour Usage 20,486Total Annual kW Hours Saved 67,313% Change in Energy Efficiency 76.67%Conclusion: As exhibited above, CFLs can save almost $7000 a yearand almost 67,000 kW hours of energy.Service Conceptswww.serviceconcepts.coop

Page: 16Turkey House LightingIntroduction: This section will serve to identify best lighting practiceswithin the turkey industry. In order to use farm space more effectively,turkey growers normally employ multiple barns for different stages in aturkey's life cycle (up to 3 barns in a turkey’s lifetime). 20 This lessensthe need for dimmer switches in many turkey facilities because eachstage will feature a slightly different lighting plan.Although day lengths varybetween 12 and 23 hours,research has shown that 16hours is the optimal daylength for growing bothmale and female turkeybroilersTurkey Broilers: Also known as growing turkeys, turkey broilers areraised for meat production. Turkey broilers need high light intensitiesduring brooding to find food and water sources and lower light intensitiesfor the rest of the growout period. Turkeys generally brood for 3-5weeks and are then transported to a different house for 11-17 weeks.Turkeys receive at least 5 foot-candles of light during brooding and atleast 1 foot-candle for the rest of the flock. 21 Although day lengths varybetween 12 and 23 hours, research has shown that 16 hours is the optimalday length for growing both male and female turkey broilers. 22Breeding Turkeys: Female breeding turkeys also rotate betweenmultiple barns. They are generally grown in a brooder house until theyreach 29 weeks of age. Brood lights, usually on a different circuit, areutilized during the early portion of this period. After brooding, lightingplans generally use natural light or mimic natural day lengths for 3-4months, employing 11-14 hour days. Day lengths are then lessened toapproximately 6-7 hours a day to simulate winter before the reproductivecycle begins. As the 29-week point approaches, day lengths aregradually extended to around 14 hours per day, simulating springtime atthe beginning of the reproductive cycle. At 29 weeks, the hens areshifted to the laying barn where their production cycle will lastapproximately 26 additional weeks. In the laying barn, light is generallyheld constant at approximately 14 hours per day at a high light intensityto accentuate the birds’ perceptions of lights on and lights off.Male breeder turkeys (toms) are grown in separate barns. Afterbrooding, they are generally grown for 14-hour days at a low-lightintensity (2-3 foot-candles) to prevent aggressive behavior. Althoughcolored light is employed on many farms, research has shown that whitelight is just as effective. 23Service Concepts20 “Poultry Production Phases,” Purdue University,http://cobweb.ecn.purdue.edu/~epados/ag101/src/poultry.htm.21 Winchell, W., “Lighting For Poultry Housing,” The Canada Plan Service, The Poultry Site,http://www.thepoultrysite.com/articles/452/lighting-for-poultry-housing.22 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom:Northcot, 2006.23 Lewis, Peter and Morris, Trevor, Poultry Lighting: The Theory and Practice, United Kingdom:Northcot, 2006.www.serviceconcepts.coop

Page: 17Energy Cost Analysis: The following cost analysis focuses on a genericturkey barn (broiler or laying) featuring sixty incandescent bulbs (100-Watt), which will be replaced by sixty 42-Watt CFLs (150-Wattequivalent). By using a stronger CFL, the study represents aconservative estimate of energy savings, adding more light than generallyrequired to show the substantial cost benefit of switching to spiral CFLs.Turkey barns should use a light meter to determine the lumen output andexact wattage size of CFLs for their barn.As a general plan (discounting external factors such as the season andbarn lighting layout), this analysis displays the value of CFLs overincandescent bulbs for any similar turkey house. The energy savings arepresented in a monthly format so that they can be easily transferable tolarger or smaller barns.# of Hours # ofkW Hours EnergyIncandescent BulbsBulbs Per Day Days Watts Used Cost1 Month Cost Study 60 14 30 100 2,520 $252.00# of Hours # ofkW Hours EnergyCFLsBulbs Per Day Days Watts Used Cost1 Month Cost Study 60 14 30 42 1,058.4 $105.84Energy Cost: Incandescent Bulbs $252.00Energy Cost: CFLs $105.84Cost Savings Per Month $146.16 Note: kW hour cost = $0.10It is shown that savings are $146.16 per month in electricity costs.Bulb Cost Analysis: The following chart shows monthly bulb cost afterthe initial change is made.HoursUsed PerMonthLifespan inMonthsPer Bulb# ofBulbsUsedCostofBulbs# of NewBulbs PerMonthAt $10 per bulb, there will be an additional cost of $10.08 per month fornew bulbs.Cost ofNew BulbsPer MonthLifespanin HoursIncandescent Bulbs 1,000 420 2.38 60 $0.60 25.2 $15.12CFLs 10,000 420 23.81 60 $10.00 2.52 $25.20Cost of Incandescent Bulbs Per Month $15.12Cost of CFLs Per Month $25.20Cost of Purchasing New Bulbs $10.08Service Conceptswww.serviceconcepts.coop

Page: 18Total Cost Analysis: The next chart shows a yearly cost analysis andpayback periods for a full lighting replacement.Initial Investment # of Bulbs Bulb Cost Total CostCFLs 60 $10.00 $600.00Total Initial Investment $600.00Operating Costs Per MonthEnergy Savings $146.16Bulb Replacement Savings -$10.08Total Cost Savings Per Flock $136.08Payback PeriodPayback Period (Days) 136.68Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year 172%Operating Cost Savings 1 st Year $1,032.96Annual Return on Investment 272%Annual Operating Cost Savings $1,632.96Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 30,240Annual Energy Efficient Bulb kW Hour Usage 12,701Total Annual kW Hours Saved 17,539% Change in Energy Efficiency 58%By switching to spiral CFLs, even a small turkey barn accommodatingonly 60 bulbs will save over $1,200 and 20,000 kW hours of energy inthe first year alone. After the first year, savings are increased to $1866per barn.Service Conceptswww.serviceconcepts.coop

Page: 19Lighting ConclusionsThis paper indicates that energy efficient lighting can be used in poultryhouses for a significant gain in energy savings. These general rulesshould be adopted based on circumstances present in poultry farms.• Use cold-cathodes when low-light intensity and dimming isneeded. If cold-cathodes are not able to fulfill the foot-candlerequirements during brooding/growout, combine them with spiralCFLs on a different circuit and/or alternating bulbs to replace theneed for incandescent bulbs.• In houses where dimming is not required, spiral CFLs should beinstalled. They offer more uniform light coverage, more energyefficiency and lower costs than incandescent bulbs. HighPressure Sodiums are not as yet a proven solution because of longpayback periods.• Spiral CFLs should be cleaned by hand, but their long life andenergy cost savings will outweigh any additional labor costs.• Local electricity cooperatives are good sources of informationregarding proper recycling of CFLs.• Despite perceived bulb performance loss, most CFLs will loseless than 20% of their original foot-candles of light, and, asproven above, buying a slightly higher wattage CFL still garnersappreciable financial benefits for the farmer.• Considerable savings are possible even for those with smallerfarms and minimal lighting needs.Service Conceptswww.serviceconcepts.coop

Page: 20FinancingThe initial cost of an energy efficiency transition can be significantlydiminished through a variety of financing and rebate plans. A goodstarting point for most farmers is the USDA energy estimator tool thatfarmers can use to approximate their energy usage:• http://ahat.sc.egov.usda.govGovernmental Requirements and RebatesRenewable Energy Portfolio Standard: Federal and state governmentsare enacting new standards that require energy efficiency. Currently,thirty states sponsor a Renewable Energy Portfolio Standard (RPS orREPS), which mandates efficiency improvements by local cooperatives.Your state’s energy efficiency program can be found at:• http://apps1.eere.energy.gov/states/maps/renewable_portfolio_states.cfmThe 2007 United StatesEnergy Bill announced thatall incandescent bulbs wouldbe banned between 2012and 2014Energy efficient light bulb upgrades can be counted towards REPSrequirements. If current trends continue, mandates similar to REPS willlikely spread throughout the United States. The 2007 United StatesEnergy Bill announced that all incandescent bulbs would be bannedbetween 2012 and 2014. 24 As a result, immediate transition yields notonly economic rewards but represents a preemptive compliance withgovernment standards.Financing through CooperativesIntroduction: Financing for energy efficient measures can be difficultto obtain; however, this paper concludes that energy efficient lightingchanges are financially beneficial in the long term and should beimplemented regardless of whether a rebate plan is available. Energysavings will far outweigh the costs of such measures but a smallcooperative rebate plan can be successful in creating demand andencouraging investment in energy efficiency.Cooperative Rebates: The most common financing plan offered bycoops throughout the nation is a simple $2 rebate for CFL purchases.Other cooperatives offer rebates on fixtures for energy efficientService Concepts24 “U.S. Energy Bill Phases Out Incandescent Light Bulb,” Environmental Leader, December 18,2007. http://www.environmentalleader.com/2007/12/18/us-energy-bill-phases-out-incandescentlight-bulb/.www.serviceconcepts.coop

Page: 21lighting, 25 or plans based on a percentage of money saved by thecustomer. 26PAYS Model – Pay As You Save: 27 At least two energy cooperativesare now offering energy efficiency programs with no up-front cost fortheir members. The programs are SmartSTART by the New HampshireElectric Coop and How$mart by Midwest Energy. They are applicable inall cases where energy savings are greater than the total cost of thestructural improvements:• http://www.nhec.com/business_energysolutions_smartstart.php• http://www.mwenergy.com/howsmart.aspxIn a recent industry report,Mississippi State Universitygave 22 different options forimproving energy efficiencyin poultry housesThe programs require an energy audit (provided free of charge in the caseof How$mart), paying for the improvements with a guarantee of a lowerenergy bill for the customer. For example, if total savings are calculatedas 100% of energy cost reduction, the program fees will amount to 75%of the energy savings (used to fund the improvements and pay thecooperative), and 25% of the savings will be seen in a lower monthly bill.Both programs require that individual farms and business ownerscomplete the energy efficiency upgrades after an energy audit. In arecent industry report, Mississippi State University gave 22 differentoptions for improving energy efficiency in poultry houses. 28 Sincelighting comprised only two of these 22 options, these lighting changescan be combined with other energy efficiency upgrades, and an energyaudit in poultry houses can represent a substantial economic benefit forboth farmers and cooperatives.Financing through GovernmentsResources for Local Financing: The following links are comprehensiveresources for government financing and energy efficiency programs,showing energy efficiency rebates, grants, and loans on a state-by-statedatabase:• http://www.dsireusa.org• http://www.goodtobegreen.com/FinancialIncentives.aspxService Concepts25 “Rebates Offered - Shedding Light on Energy Efficiency,”Jackson Electric Cooperative,http://www.jackelec.com/commercial_industrial/rebates_offered.html.26 “Energy Efficiency Rebates,” Midstate Electric Cooperative,”http://www.midstateelectric.coop/ProductsAndServices/CommercialIndustrial/EnergyEfficiencyPrograms/default.aspx.27 “Pays America,” http://www.paysamerica.org/.28 Smith, Tom W. Jr., “Reducing Energy Costs In Poultry Houses,” Mississippi State University,http://www.msstate.edu/dept/poultry/pubs/is1617.htm.www.serviceconcepts.coop

Page: 22For directories and state resources including local communitydevelopment use:• http://www.agmrc.org/directories__state_resourcesFor resources about sustainable agriculture, please visit:• http://attra.ncat.orgLocal Economic Development Organizations: When looking for helpregarding energy efficiency rebates and programs, customers can bereferred to local or state economic development organization. An onlinedirectory for economic development organizations is under constructionat the following website:• http://www.sitelocationassistance.com/search/regions/usa/default.htm#gaccIn 2008, the federalgovernment gave almost $20million to assist farmers,ranchers and smallbusinesses for renewableenergy systems and energyefficiency improvements.Rural Energy For America Program (REAP): Rural business canqualify for government subsidies based on energy efficient practices. In2008, the federal government gave almost $20 million to assist farmers,ranchers and small businesses for renewable energy systems and energyefficiency improvements. For qualifying energy efficiency projects, theprogram offers a 25% grant (minimum $1500, maximum $250,000) and upto a 75% loan. More information is available online at USDA's website:• http://www.rurdev.usda.gov/rbs/farmbill/index.htmlIf a lighting switch alone does not reach the required amount of savings orcosts for the program, lighting upgrades can be combined with other energyefficiency projects to attain the required eligibility. Two poultry farmers inSouth Carolina received over $25,000 for energy efficiency improvementslast year that included lighting system enhancements. 29Research Grants: If member farms or businesses are interested inconducting research in sustainability and energy efficiency, SustainableAgriculture Research and Education (SARE) offers grants of up to$150,000:• http://www.sare.org/grants/Service Concepts29 “Six S.C. Projects Awarded Grant Funds From USDA,” South Carolina Energy Office,September 20, 2008, http://www.energy.sc.gov/news.aspx?id=94.www.serviceconcepts.coop

Page: 23Conclusions: As energy costs continue to rise, an energy efficient lightingplan is an essential component of a sound long-term business model. Astechnology has improved, opportunities to cut costs while saving energyhave become more readily available. The influx of government assistanceprograms as well as opportunities to save through local cooperative rebateshave made upgrading a farm’s energy profile more feasible and affordablethan ever before. An energy efficient lighting plan is a rapid andmanageable method by which poultry farms can drastically cut costs andremain viable and profitable businesses in the years to come.Contact Information:Neil BurrowService Concepts720 North High School RoadIndianapolis, In 46214877.738.6824317.487.2271 (fax)nburrow@serviceconcepts.coopAbout Service Concepts: Service Concepts sponsored this paper for thepurpose of distribution to electricity cooperatives and farmers across thenation to better address poultry lighting needs. In 1999, 32 rural electricutilities formed Service Concepts to foster innovation and enhance supplierrelationships 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, andmanufacture-direct product relationships to support the adoption of energyefficient lighting. Service Concepts now serves electric utilities and theircustomers in every state in the United States. For more information, pleasevisit www.serviceconcepts.coop.Acknowledgments: The broiler section of this paper was made possiblewith collaboration from the National Poultry Technology Center, AuburnUniversity. Special thanks to Dr. Gene Simpson and Professor Jim Donald.For more information about poultry lighting and energy efficiency inpoultry houses, please visit their website at www.poultryhouse.com.©Service Concepts 2009 - All rights reserved. For permission to copy ordistribute, contact Service Concepts, admin@serviceconcepts.coop.Service Conceptswww.serviceconcepts.coop

Page: 24Appendix 1: Broiler House Cost Analysis, Small Size Chicken (4 lb) witha 37-day flock length and seven total flocks per year.Incandescent Bulbs# ofBulbsWattsHoursPer Day# ofDaysIntensitykW HoursUsedEnergyCostBrooding Period: Day 1-11 60 100 18 12 100% 1296 $129.60Growout Period: Day 12-50 40 100 18 25 44% 792 $79.20Combination of CFLs and ColdCathodes# ofBulbsWattsHoursPer Day# ofDaysCost Per Flock $208.80IntensitykW HoursUsedEnergyCostBrooding Period: CFLs 20 42 18 12 100% 181 $18.14Brooding Period: Cold-Cathodes 40 8 18 12 100% 69 $6.91Growout Period: Cold-Cathodes Only 40 8 18 25 80% 115 $11.52Energy Cost: Incandescent Bulbs $208.80Energy Cost: CFLs and Cold-Cathodes $36.58Cost Savings Per Flock $172.22Cost per Flock $36.58Notes: KW / Hour Cost = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency waslost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to44%.Bulb Cost Analysis:Lifespanin HoursHoursUsed PerFlockLifespanin FlocksPer Bulb# of BulbsUsedCostofBulbs# of NewBulbs PerFlockCost of NewBulbs PerFlockIncandescent Bulbs 1,000 666 1.50 46.48648649 $0.60 30.96 $18.58CFLs 10,000 216 46.30 20 $10.00 0.43 $4.32Cold-Cathodes 25,000 666 37.54 40 $12.00 1.07 $12.79Cost of IncandescentBulbs Per Flock $18.58Cost of CFLs and Cold-Cathodes Per Flock $17.11Cost Savings Per Flock ofPurchasing New Bulbs $1.47Note: Incandescent bulb usage is scaled back to recognize thatonly 40 bulbs are lit after brooding period; For calculationpurposes, dimming does not lessen bulb lifespan.Service Conceptswww.serviceconcepts.coop

Page: 25Total Cost Analysis:Initial Investment # of Bulbs Bulb Cost Total CostCFLs 20 $10.00 $200.00Cold-Cathodes 40 $12.00 $480.00Total Initial Investment $680.00Operating Costs Per FlockEnergy Savings $172.22Bulb Replacement Savings $1.47Total Cost Savings Per Flock $173.69Flock Data# of Flocks Per Year 7Payback Period (Flocks) 3.91Payback Period (Days) 144.85Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year 79%Operating Cost Savings, 1 st Year $535.85Annual Return on Investment 179%Annual Operating Cost Savings $1,215.85Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 14,616Annual Energy Efficient Bulb kW Hour Usage 2,560Total Annual kW Hours Saved 12,056% Change in Energy Efficiency 82.48%Service Conceptswww.serviceconcepts.coop

Page: 26Appendix 2: Broiler House Cost Analysis- Large Size Chicken (7-8 lbs)with a 60-day flock and five total flocks per year.Incandescent Bulbs# ofBulbsWattsHoursper Day# ofDaysIntensitykW HoursUsedEnergyCostBrooding Period: Day 1-11 60 100 18 12 100% 1296.00 $129.60Growout Period: Day 12-50 40 100 18 48 44% 1520.64 $152.06Combination of CFLs and Cold-Cathodes# ofBulbsWattsHoursper Day# ofDaysCost Per Flock $281.66IntensitykW HoursUsedEnergyCostBrooding Period: CFLs 20 42 18 12 100% 181.44 $18.14Brooding Period: Cold-Cathodes 40 8 18 12 100% 69.12 $6.91Growout Period: Cold-Cathodes Only 40 8 18 48 80% 221.18 $22.12Energy Cost: Incandescent Bulbs $281.66Energy Cost: CFLs and Cold-Cathodes $47.17Cost Savings Per Flock $234.49Cost Per Flock $47.17Notes: kW hour Cost = $0.10; When measuring intensity %, it was assumed that 20% of a light's efficiency waslost when using a dimmer, thus a 40-Watt cold-cathode dimmed to 80% = 100-Watt incandescent bulb dimmed to44%.Bulb Cost Analysis:Lifespanin HoursHoursUsed PerFlockLifespanin FlocksPer Bulb# ofBulbsUsedCost ofBulbs# of NewBulbs PerFlockCost of NewBulbs PerFlockIncandescent Bulbs 1,000 1080 0.93 44 $0.60 47.52 $28.51CFLs 10,000 216 46.30 20 $10.00 0.43 $4.32Cold-Cathodes 25,000 1080 23.15 40 $12.00 1.73 $20.74Cost of IncandescentBulbs Per Flock $28.51Cost of CFLs and Cold-Cathodes Per Flock $25.06Cost Savings Per Flock ofPurchasing New Bulbs $3.46Note: Incandescent bulb usage is scaled back torecognize that only 40 bulbs are lit after brooding period;For calculation purposes, dimming does not lessen bulblifespan.Service Conceptswww.serviceconcepts.coop

Page: 27Total Cost Analysis:Initial Investment # of Bulbs Bulb Cost Total CostCFLs 20 $10.00 $200.00Cold-Cathodes 40 $12.00 $480.00Total Initial Investment $680.00Operating Costs Per FlockEnergy Savings $234.49Bulb Replacement Savings $3.46Total Cost Savings Per Flock $237.95Flock Data# of Flocks Per Year 5Payback Period (Flocks) 2.86Payback Period (Days) 171.47Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year 75%Operating Cost Savings, 1 st Year $509.73Annual Return on Investment 175%Annual Operating Cost Savings $1,189.73Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 14,083Annual Energy Efficient Bulb kW Hour Usage 2,359Total Annual kW Hours Saved 11,724% Change in Energy Efficiency 83.25%Service Conceptswww.serviceconcepts.coop

Page: 28Appendix 3: Pullet Barn Cost Analysis with 5-Watt cold-cathodesreplacing 25-Watt incandescent bulbs.# of Hours # ofDimmed kW Hours EnergyIncandescent BulbsBulbs Per Day Days Watts To Used CostBrooding: First 3 Weeks 300 18 21 25 100.00% 2,835 $283.50Growout: Week 4-17 300 12 98 25 50.00% 4,410 $441.00$724.50# of Hours # ofDimmed kW Hours EnergyCold-CathodesBulbs Per Day Days Watts To Used CostBrooding: First 3 Weeks 300 18 21 5 100.00% 567 $56.70Growout: Week 4-17 300 12 98 5 50.00% 882 $88.20Energy Cost: Incandescent Bulbs $724.50Energy Cost: Cold Cathodes $144.90Cost Savings Per Flock $579.60 Note: kW hour cost = $0.10$144.90Bulb Cost Analysis:Lifespanin HoursHoursUsed PerFlockLifespanin FlocksPer Bulb# ofBulbsUsedCostofBulbs# of NewBulbs PerFlockCost ofNew BulbsPer FlockCost of Incandescent Bulbs 1,000 1,554 0.64 300 $0.60 466.2 $279.72Cost of Cold Cathodes 25,000 1,554 16.09 300 $11.00 18.648 $205.13Cost of Incandescent BulbsPer Flock $279.72Cost of Energy Efficient Bulbs Per Flock $205.13Cost Savings by Purchasing New Bulbs $74.59Service Conceptswww.serviceconcepts.coop

Page: 29Total Cost Analysis:Initial Investment # of Bulbs Bulb Cost Total CostCold-Cathodes 300 $11.00 $3,300.00Total Initial Investment $3,300.00Operating Costs Per FlockEnergy Savings $579.60Bulb Replacement Savings $74.59Total Cost Savings Per Flock $654.19Flock Data# of Flocks Per Year 2.61Payback Period (Flocks) 5.04Payback Period (Days) 706.21Return on Investment and Operating Cost SavingsReturn on Initial Investment, 1st Year -48%Operating Cost Loss, 1 st Year -$1,594.43Annual Return on Investment 52%Annual Operating Cost Savings $1,705.57Annual Energy SavingsAnnual Incandescent Bulb kW Hour Usage 18,888.75Annual Energy Efficient Bulb kW Hour Usage 3,777.75Total Annual kW Hours Saved 15,111.00% Change in Energy Efficiency 80%Service Conceptswww.serviceconcepts.coop