News & Events for Poultry Producers from

E-NEWSLETTER • ISSUE 32 • SUMMER 2015

e-newsWater-cooling is essential to the incubation process in a hatch-

ery. Efficient cooling offers potential energy savings and allows hatcheries to improve the internal environment of its settersor hatchers; thereby improving overall chick quality and hatchability.

All single stage setters and hatchers are equipped with smooth coilsfor cold-water flow to reduce air temperature during the incubationprocess. In recent months, ChickMaster’s engineering team took onthe challenge of improving the cooling effectiveness of our equipmentwith a simple design improvement that has a major impact on coolingperformance. The design change incorporated corrugated cooling coilsto the entire Avida product line and the CVH hatcher. These coolingcoils allow the system to quickly reduce temperature, maintaining theset point more accurately while reducing overall energy usage.

How does the turbulence in the coil improve performance?

The corrugation on the cooling coils is a passive method to improveheat transfer in the fluid. The corrugations, also known as ribs, create

a turbulent flow inside the coil, allowing more fluid contact with thecoil surface. In engineering terms, turbulent water flow reduces theresistance to heat transfer. In layman’s terms, this turbulent water flowincreases the efficiency of the cooling coil and therefore improves theoverall cooling capacity of the incubation system.

When cooling liquid moves through a smooth bore tube (See Figure1), the water near the tube’s wall is doing the majority of the cooling.The water moves in a straight line and the water velocity at the tubewall is nearly zero, limiting heat transfer through the copper wall. Bycomparison, inside a corrugated coil, indentations break the smoothflow and create turbulence on the stream of liquid. The liquid fromthe center of the flow stream moves to the sides and increases the velocity of the water at the tube wall. Now, higher velocity water istouching the wall allowing for more effective heat transfer and fasterair temperature control response times in the setter or hatcher.

Studies on corrugated coils demonstrate that the size of the rib andthe distance between them positively improves heat transfer capacityin proportion to the increased turbulence caused on the fluid (turbulence measured by Reynolds number). We can see in Figures2 and 3 (seen on next page) that coils with ribs ranging from 1.0mmto 1.5mm and separations between 5.08mm and 8.5mm have different heat transfer efficiency and in relationship to the turbulenceon the coil (Reynolds number).

By conducting our own research, we found that a corrugated coil withan incoming temperature of 17°C (62.6°F) had a warm water returnof 26°C to 27°C (78.8°F to 80.6°F), while a smooth coil had a warmwater return of 21°C to 22°C (69.8°F to 71.6°F). That is a 5°C (9°F)difference of efficiency in favor of the corrugated coil with both machines having a water flow of 7-9L/min (4 Gal/min). We alsonoted that in periods of 2 minutes, the cooling liquid will flow for 60to 90 seconds to reach set point and maintain it on a very narrowband of 0.2°C of set point. The smooth coil test machine would take2 minutes to reach set point and maintain it within a 0.4°C band.

Corrugated Cooling CoilsAnother Key Innovation from ChickMaster

Figure 1. Turbulent vs. Laminar flow. Turbulent flow reduces the resistance toheat transfer and increases efficiency of the cooling coil.

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How do these improvements translate to the machine performance?

Customers that are operating machines with these corrugated cooling coilshave reported that the machines reach set point faster and maintain temperature accurately through the cycle. They found a reduction in both

the demand on the cooling system and overall electrical usage with machines equipped with this coil.ChickMaster is constantly bringing practical and efficient innovations to make your operations more profitable. A Hatchery in Harmony is anefficient profitable operation year round. Please contact your ChickMasterrepresentative if you have any questions. •

Corrugated Cooling CoilsCONTINUED FROM PAGE 1

Figure 2. This graph demonstrates how ribs of 1.5mm (orange) show higherheat transfer efficiency than coils with ribs of 1.0mm (red)

Figure 3. This graph demonstrates how ribs of 1.5mm and at different separation ranging from 8.5mm (red) to 5.08mm (orange) show different higher heat transfer efficiency

ChickMaster Parts CornerWelcome to the ChickMaster Parts Corner! We haveadded this section to keep our ChickMaster customers informed of aftermarket activities with Spare Parts, Upgrade Kits and New Product Development. We want tomake sure our customers with either Classic (multi-stage)or Avida (single-stage) systems are aware of the availabilityof Genuine ChickMaster Replacement Parts to keep machines running at their designed performance levels.In addition, as ChickMaster introduces new incubationtechnology to the market, we want to ensure existing cus-tomers are able to take advantage of these advancementswith Upgrades Kits. These kits improve the performanceand efficiencies of ventilation, temperature control, turning, machine controls and management software froma central computer.When improvements are made that allow a setter orhatcher to maintain set points, eliminate hot spots, maintain a consistent environment and reduce alarmconditions, results can be measured by increased hatchability and improved chick quality. The result of consistently maintaining incubation equipment can beseen at the farm by a reduction in mortality numbers andimprovements in feed conversion.Improvements can also be measured in cost savingsthrough reduced electricity consumption, water use and load on HVAC equipment, resulting in reduced maintenance costs. ChickMaster strives to act as your partner, providing partsand service long after the equipment is put into service. •

Announcing the ChickMaster School for Incubation and Energy ManagementAs part of continued efforts to provide our customers withongoing support to improve hatchery performance,ChickMaster is excited to introduce a customer school forsingle stage incubation and energy management. Thisschool will be held in the spring and fall each year, withthe first session on September 29th and 30th, 2015 at ourMedina, Ohio office. This program is generally intendedfor customers who have recently purchased new singlestage incubation systems, however, the program will alsobe available for customers currently operating single stagesystems who would like to train new employees. Addi-tional information will be available on our website soon.Space is limited. Please contact your local ChickMasterSales Representative for additional information. •

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Maestro: A Window into theIncubation ProcessManaging the incubation process is easier with software that gathers

all relevant information and presents it to the hatchery managerwith a single, unified view. Analysis and proactive management decisionsthen become easier. ChickMaster’s Maestro Hatchery Management System offers you such a window into the incubation process.

Maestro offers many advantages to the hatchery, such as:

1 Easy to learn and use: Learning and training others how to use new software can be daunting, but Maestro was designed to be easy to learn

and simple to navigate. With clear and easy-to-interpret graphics, youcan easily navigate through the program. With a couple of clicks of the mouse, you can move from a view of the full hatchery to a specific machine. Each easy-to-read screen displays key information, and visualcues highlight relevant information for easy monitoring.

2 Reach outside the hatchery: Maestro can be accessed remotely by multiple individual users with their own unique password. It is

capable of sending relevant alarms to designated contacts via email ortext message. The OrAlarm system adds an extra level of security byreaching designated users via telephone in the event that Maestro is inoperative or your hatchery lacks communication capability.

3 Easy to read and use graphics: Maestro connects with most ChickMaster controls and gathers relevant data to present clear,

concise information. With easy-to-interpret graphics, you can efficientlymanage the incubation process in the setter and the hatch window in the hatcher. If your hatchery has older incubation systems without connection capabilities, you can easily upgrade them with a GeMeric 2,and connect them to the Maestro for complete hatchery control.

4 Keep track of energy usage and alarms: Maestro tracks electrical consumption of the incubation equipment, important machine

data, and all alarms generated.

5 Manage the ventilation equipment: Going beyond setters and hatchers, the Maestro also connects to our Ventilation Systems via

Zeus Ventilation Controllers. By being able to view, in a single system,how ventilation and incubation equipment interact, you can easily makethe best decisions to operate your hatchery efficiently and economically.

ChickMaster works to constantly evolve and adapt the Maestro HatcheryManagement System to your needs. If you would like to know more aboutMaestro, please contact your ChickMaster representative. •

Keep your Maestroor Advisor SystemUp-to-DateMany of you who receive thisenews are current users of ChickMaster’s Advisor System orMaestro Hatchery ManagementSystem. To receive the latest update to your system’s softwarepackage, please send us an emailto maestro@chickmaster.com and we will be happy to assist you.

Features of the newest softwarepackage (v2015.06.01):

• Multiple user login with password protection

• Sequential alarm notificationwith delays to different users

• Alarm logs communicate failures between the machinecontrol and Maestro

• Historical data retention on version updates

• Alarm acknowledgement allows improved traceability

• Alarm notification in case of PLC fault

MaestroMANAGEMENT SYSTEM

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For Worldwide Customer Service Emergency Support: +44(0)1278 555111

ChickMaster International25 Rockwood Place, Suite 335Englewood, NJ 07631 USAP: +1 (201) 871-8810F: +1 (201) 871-8814

ChickMaster Incubator Co.945 Lafayette Road, P.O. Box 704Medina, OH 44258 USATel: +1 (330) 722-5591

ChickMaster UK Limited1 The LeggarBridgwater SomersetTA6 4AF, UKTel: +44 (0)1278 411000

ChickMaster NewsCheck out industry news at chickmaster.com.Recent articles include:

ChickMaster Avida Expands Operations for golden Foods SiamMay 29, 2015

Şenpiliç Selects ChickMaster forHatchery ExpansionMay 15, 2015

Avesca continues to grow in EcuadorApril 28, 2015

genética Nacional expands hatcherywith Avida Setters April 8, 2015

Jadeed Farms, Pakistan, InauguratesNew grandparent HatcheryMarch 2, 2015

Upcoming EventsAvi Africa 2015Johannesburg, South Africa, June 25-25, 2015

Hatchery in Harmony Seminar SeriesGuayaquil, Ecuador, September 8, 2015

XXIV Congreso de Latinoamericanode AviculturaGuayaquil, Ecuador, September 9-11, 2015

SPACE FranceRennes, France, September 15-18, 2015

IPEX PakistanLahore, Pakistan, Lahore Expo CenterSeptember 24-26, 2015

ChickMaster School for Incubationand Energy ManagementMedina, Ohio, USA, September 29-30, 2015

ANAVIPPanama, November, 2015

Prevent Loss with Hatchery Safety Tools Hatcheries need fail-safe systems in place to safeguard against chick loss as a result of catastrophic failures. Failures can result from an electrical or mechanical breakdown, extreme weather conditions, or human error. To help protect the investment in incubationequipment and production losses, ChickMaster offers several solutions.

The BREAK GLASS SYSTEM is electronic insurance for hatchers with Genesis IV Controls, consisting of a set of redundant circuits that will activate in a high-temperaturealarm condition. In a high-temperature condition, the Break Glass System will override thecontrols and set in motion the following steps until the alarm condition is satisfied: • Open the damper • Turn off the heaters• Open the cooling valves • Turn on the auxiliary blower• Increase fan speed (VFD only) • Sound an audible alarm• Turn on the humidification spraysThese steps will engage automatically once the temperature reaches 101°F for a predeter-mined period of time. The Break Glass System provides time for hatchery managementpersonnel to react and address the cause for the high temperature condition.

As an addition to the Maestro Hatchery Management System, ORALARM has severalfunctions that help hatcheries stay connected during an alarm condition. Equipped withan auto-dialer, the OrAlarm can send a call-out to as many as eight different phone numbersalerting the recipients to an alarm condition at the hatchery. The OrAlarm has the abilityto connect with up to 10 alarm relays from non-incubation eq uipment, including chillers,boilers, and HVAC units. In the event that the Maestro loses communication, the OrAlarmwill use an internal auto-dialer to send out an alarm message and alert hatchery personnel.

ChickMaster recommends adding HI-LITES to your incubation systems. Hi-Lites are designed with 3 LED lights in green, blue and orange, producing a visible status of incuba-tion equipment. With a single glance at the setter or hatcher hall, you can quickly identifythe following conditions:• Solid Green – All Okay • Solid Blue – Humidity is On• Flashing Green – Alarm Condition • Solid Orange – Cooling and Heating are On

Avida Symphony setters and hatchers include a 5 light Hi-Lite system. These systems are effective and very easy to use. Please contact a ChickMaster Sales Representative for any additional information. •

Beginning July 1, Medina, Ohio will be the ChickMaster headquartersfor managing sales, engineering, and incubation equipment. Our factoryin Bridgwater, England is dedicated to ventilation systems and deliveryof Chick Master equipment for the European Common Market. The New Jersey office (100 Union Ave, Suite 200, Creskill, NJ) will be

the President’s office, focusing on supporting sales in Latin America during the transition to Medina, which is taking place in June. Medina’soffice for Latin American sales will be fully operational on July 1. We invite our customers to visit us in Medina to meet the operations andsee how we will assist you to keep your Hatchery in Harmony.

CONSOLIDATION OF OPERATIONS, USA

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