BROILERS

Structure

Dimension of house choose:

Length of house = 500ft

Width of house = 40ft

Height of house = 18ft (9ft for each storey)

Capacity: 0.8 ft2 per broiler

Area of layer house:

40ft * 500ft = 20000ft2

So, total number of broiler that can be place in the house:

20000ft2/0.8ft2

= 25000 broilers/storey

For double-storey layer house:

25000 broilers * 2

= 50000 broilers/house

So, for 250000 broilers, no. of layer house needed is:

250000/50000

=5 double-storey layer house

For 5 double-storey broiler house, distance needed between each house is calculated by:

D = 0.4 * H * L0.5

Whereas D = distance between house

H = height of blocking house

L = length of blocking house

So, D = 0.4 * 18 * 5000.5

= 161 ft

Thus, 161 ft of distance between each house is needed for good air circulation

Ventilation System

Ventilation requirements for layers:

1. Weight of layers

2. Waste management system

3. Building construction

4. Outside moisture content

System used: Negative Pressure Ventilation System

How they work: exhaust fans expel air flow from the barn, creating an interior vacuum which draws

fresh air into the building. Air distribution and mixing within the barn is controlled by the air inlet or

baffle system. A well constructed air inlet baffle that can be adjusted to maintain a desired velocity of

800 to 1000ft/min is required. This is achieved by providing 13 ft2 to 16ft2 per 5000cfm. This velocity is

very critical, especially in colder temperature, to ensure good air mixing and to prevent drafts.

Air inlet size:

For air inlet size of 4ft * 3.5ft, they can give a desired velocity of air of 800 to 1000 ft/min

Capacity of air in the house = volume of the house

Length*width*height

500*40*18 ft3

= 360 000 ft3 of air capacity

By using fan with ability of 20000 cfm. No. of fan use are:

360000/20000 = 18 fans

3.5 ft

4.0 ft

So, 9 fans will be put on the first floor and another 9 will be put at the 2nd floor.

For cooling system, cooling pad systems are being used.

Cooling pad is installed within the air inlet. Air entering from the inlet must go through the cooling pad

that is wetted with water. Hot air from outside converts them to water evaporation.

As air go through the cooling pad, they may reduce the air velocity from 800ft/min to 500ft/min.

For 350000cfm of fan capacity, total pad area required is:

Installed fan capacity (cfm)

𝑅𝑒𝑐𝑜𝑚𝑚𝑒𝑛𝑑𝑒𝑑 𝑎𝑖𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑝𝑎𝑑 (𝑓𝑝𝑚)

= 360000 cfm / 500 fpm

= 720 ft2 of cooling pad is required

For 720 ft2 of cooling pad area, we might use the type of 4 inches of thickness, and recirculating.

Feeding and Watering

For a 13 inch diameter of pan feeder, they adequate for 55 broilers.

So, total no. of 13 inch diameter of pan feeder needed for one house (50000 broilers) :

50000 / 55

= 909 pan feeder

So, 909 pan feeders are needed for double-storey house. Each storey needs 455 pan feeders for 25000

broilers.

Waterers are use from the type of nipple drinkers. Drinkers control flow rate by the size of the hole in

the drinker body.

One nipple drinker can support about 6.5 broilers.

So, for 50000 broilers per house,

50000/6.5

= 7692 nipple drinkers are needed for each house

Both feeding and watering facilities need to be arranged so that a bird will not have to travel further

than 10 ft.

Automatic feeders

Automatic waterers

Lighting

Broilers are maintained on fairly high light intensity of 10 to 20 lux (equivalent to 40 to 80 watts per

18m2 of floor area) the first week, so that young chicks will be able to locate feed and water readily.

Then will be followed by low light intensity of 5 lux (15watts per 18 m2) to reduce power costs.

For chicks, 60 watts per 60 ft2 floor area.

So, for 20000 ft2 of house size, watts of light needed is:

(20000 ft2 * 60 watts)/60 ft2

So, amount of light needed is 20000watts.

If we used a bulb of 60 watts each, so we need about 333 bulbs.

For adult broilers, 15 watts per 60 ft2 floor area.

So, for 20000 ft2 of house size, watts of light needed is:

(20000 ft2 * 15 watts)/60 ft2

So, amount of light needed is 5000 watts.

If we used a bulb of 60 watts each, then we need about 83 bulbs.

Light intensity can be controlled by using commercial type rheostats. Rheostats should be disconnected

from the electrical circuit when the building is being washed out.

Incandescent bulbs are considered superior to other light sources. Bright light may contribute to feather

picking, which can lead to cannibalism.

Waste Management

Estimating broiler litter and compost production and storage:

1. Weight of birds produce on the farm each year:

W = 5 * 50000 * 6 * 4.1 = 6.15 tons of birds produced each year

2. Litter produced:

WM = 6.15 tons * 0.5 = 3.075 tons of litter produced each year

Floor operations system used are solid manure system. This system is conducted by using litter of wood

shavings. The waste from the chicken is being mix with the litter, cause them to be solid and produce

less odour. The litter is cleaned after every flock.

The advantage of using wood shavings:

1. They are a very good water absorber, so that can produce less odour within the house.

2. Can mix well with the chicken manure

The thickness of the litter being put on the floor is about 2 to 3.5 inch.

Before the litter being place on the floor, plastics that can withstand air and water being attached to the

floor. This is to make sure the manure doesn’t touch the floor thus make the floor dirty.

The litter with the manure then can be sold for reclamation or horticultural purposes.

Weight of birds

per year

= Number of

houses

Flock

size * * Number of

batches * Pounds weight

market per bird

Weight of manure

per year = Weight of birds

per year * 0.5

Slaughter House

The proposed slaughter house to process the broilers from the farm is taken by the model of that can

process 350birds/hour. Processes that involve in the slaughter house (or poultry processing plants) are:

1. Stunning and slaughter

2. Scalding and defeathering

3. Evisceration

4. Cooling

5. Cutting

6. Packing and grading

7. Refrigeration

One slaughter house can process up to 350birds/hour. The number of birds in the farm is 250000.

For working hour of 7 to 8 hours/day for one slaughter house, we can process

350 * 7 = 2450 birds/day/house

So, we can construct 5 slaughter houses in the farm. Thus, it makes

2450 * 5 = 12250 birds/day

So, for 250000 broilers,

250000birds/12250 birds/day

= 20 days

Thus, it takes about 20 days to process 250000 of broilers.

Stunning and slaughter

Birds are removed carefully from their crates by holding both legs and placed carefully on the overhead

rail. The operator briefly holds the legs or runs his hands down the body to help quieten the bird. The

overhead rail is moving at between 0.6 to 1.4m/minute. As the shackles are at 0.2m intervals, it is

necessary to fill every shackle to ensure maximum production of 350 birds/hour and be able to control

all subsequent operations.

Birds are bled by a method described earlier. They should be allowed to bleed for 1 1/2 to 2 minutes

before dressing starts.

Scalding and defeathering

The overhead rail moves the birds from the stunning/bleeding area and lowers them into a scalding

tank. The speed of the rail ensures the birds are scalded for the right length of time and are sufficiently

agitated in the scald water. A thermostat ensures that the temperature of the water is maintained at

52°C.

After the birds have passed through the scalding tank they are removed from the overhead conveyors

for plucking.

By using a drum plucker, they requires a team of four operators and a drum of 1.5m in length. It

comprises a horizontally mounted stainless drum from which many long rubber fingers extend. The

drum rotates briskly away from the operator. This drum should have a second rotating drum with

rubber fingers positioned above the other so that it is oriented rather like an old fashioned mangle. The

drums should be set to leave about 10mm clearance between rubber fingers with both drums revolving.

The carcase is simply introduced and turned and agitated until all soft feathers are removed.

Evisceration

Birds arrive into the evisceration room through a hole in the dividing wall which separates it from the

plucking room. They should then be eviscerated in the manner of using carousel and evisceration tools.

The carcases should be hung with their backs towards the operators. At the carousel, the first operator cuts the skin down the back of the neck, pulls it out and detaches it from the crop and trachea (windpipe). The crop is removed and dropped into the evisceration tray. A cut is then made round the vent with a sharp knife, taking care not to cut the intestine and making sure the cut is large enough to insert a hand inside the carcase. The next operator inserts a drawing tool through the incision keeping it pressed against the breastbone (which is away from the operator) until it reaches as far as it will go. Holding the carcase horizontally and firmly with the left hand (assuming right-handedness) the tool is pulled down and out so that the offal is drawn outside the bird. The offal is allowed to hang down the back of the bird ready for inspection.

After inspection, the third operator should cut off the liver, heart and gizzard and place them in the appropriate gizzard trays. The inedible offal is then detached allowing it to fall into the evisceration tray. The tray has a waterspray to wash the inedible offal into the offal truck situated underneath. The fourth operator should inspect the carcases and remove any lungs and other unwanted material using the serrated lung removal or other appropriate tool. The head is then cut off and dropped into the evisceration trough and the neck removed with the secateurs. It is then placed in a giblet tray.

The giblet trays holding the edible offal should be moved to the giblet station where the livers, hearts and necks are washed. The gizzards are opened with a sharp knife and then washed. The inside “skin” is removed by knife. This is not easy and, depending on the bird, it may be necessary to scald the gizzard in boiling water first.

After the offal has been cleaned and washed, it is then sorted and placed into small plastic bags and placed on trays in the chill room.

Cooling

The second system involves the use of a chill store.

The birds should be hung with their legs removed, onto a marked cooling rack. Each rack holds about 150 birds and should take about half an hour to fill. They should be allowed to hang in the air for about 15 minutes to dry and then placed directly in a cold store. It is important that the birds are dry before they enter as this will not happen in the cold room where the relative humidity is high.

The chill store will require special management to ensure that the racks already inside are removed in the order in which they entered. In this way each bird will get a constant amount of cooling.

The chill store should be designed to cool four racks, each of 150 birds (say 300 kg) ie a total of 1200kg, from 35°C to 5°C in two hours.

Cutting

The instruments used in preparing chicken portions include cleavers, knives, secateurs and special

machinery, an example of which is shown below. This machine has an arm which points horizontally

towards the operator. It has a groove on the top into which a rotating knife fits. The carcase is pushed

over the arm into the knife and the two pieces fall to the side.

Packing and Grading

Drumsticks, chilled or frozen in a loose plastic bag have little visual appeal whereas the same product neatly arranged on a tray with a clear overwrap has a much better chance of sale.

The packages are placed on a stainless steel tray on a trolley, or into a cardboard carton ready for the chill or freezing cycle.

Refrigeration

Here they are held until frozen before removal and storage in the freezer. There is an area where the

metal trays can be emptied and the product placed in cardboard outer covers. A high degree of

management of product is necessary to ensure that each trolley receives the appropriate time of blast

freezing.