Let’s first look at incubators – we know that they need electricity for turning the fans but there are energy efficiency opportunities to be gained here. At EmTech we use Variable Speed Drives (VSD) as standard on our setters to provide the air flow required at any stage of incubation. They reduce the fan speed down to as low as 75% of full capacity in the first 7 days of incubation – this is during the ‘closed up period’ when the thermal capacity of the air is very high and allows good thermal conductance. VSD’s can also drive the forward and reverse fan direction to effectively minimise temperature bandwidth to no more than 0.6°C and eliminate any potential areas where air pockets can form. However, their most important feature for hatchery sustainability is that by reducing fan speed by 20% it reduces electrical energy consumption by 50%.
Incubator heating is also an area where huge efficiencies can be made. Because EmTech’s highly sealed cabinets have no metal supports (avoiding thermal bridging) they only require power at start-up for up to 8 hours. Once the incubator comes up to temperature heating is not required again until the next eggs are loaded in 18 days.
Now we can look at incubator cooling. Because EmTech employs large capacity cooling coils with a greater surface area than any other system on the market we can run our cooling water at higher temperatures than other systems. This vastly improves the COP (coefficient of performance) of the water chillers which can operate with cooling water of up to 17⁰C for single-stage and up to 22⁰C for the Super Classic multistage with their upgraded 20-row cooling coils.
The EmTech paddle fan design features a full frame, from floor to ceiling. This fully supports the roof making a very strong rigid construction. As a result, vibration is minimal, the machines run much quieter and much more energy efficiently. Most importantly, due to the elimination of vibration, there is no movement in any of the panels, or resonance effects that can, in time, cause a potential breakdown.
Supporting Services is also an area where EmTech also has an enormous breadth of experience. EmTech’s Primary Heat Recovery System gives you the ability to warm the hatchery air, free of charge, either in cold climates or following de-humidification. Our hatchery Heat Recovery systems are designed and calculated on the heat output of the incubators and can be installed in most hatcheries. The core principle of these systems is that we capture the embryonic heat given off by the developing embryos in the chilled water-cooling system and then use this heat, through specially designed coils, to heat the incoming air that the hatchery requires. This system has a huge potential for energy savings and furthermore, reduces the cooling load on the chillers. With these major benefits, coupled with variable flow for both the chilled water and ventilation systems, it can result in a 25-40% annual energy costs.
EnviroTech hatchery ventilation systems are now operating, and supporting ‘The EmTech Effect’, in many hatcheries around the world. This has given EmTech the opportunity to accurately measure actual energy savings from their primary heat recovery systems in a range of climatic conditions.
Based on 1.2 million eggs set per week we have estimated that average savings per annum in Europe will be $245K, in the USA $204K and in Eastern Europe $240K. These are substantial savings with payback that can be measured in only a few years. These figures are comprised from a combination of gas and electrical energy savings when compared to traditional hatchery ventilation systems that do not capture the embryonic heat released from the return lines of the chilled water system to heat the incoming air.
At EmTech we care about the environment at strive to reduce energy wastage throughout the process. Our new high density MAX94 egg systems are now available and operate on the same EmTech Effect/energy efficient principals as for all our incubation systems but with an additional capacity of up to 41% more eggs.
The unmatched egg density of EmTech MAX94 tray systems (insets) not only means that capital costs can be greatly reduced with up to 25% fewer setters and hatchers required for your project, but the resulting smaller hatchery footprint will reduce land, energy and building costs pro-rata.