LED Poultry Lighting: Energy and Production

Efficiency

Michael J. Ostaffe EVP, Once Innovations Inc.

Copyright Notice

This presentation is sole property of Once Innovations, Inc. Data in this presentation is subject to copyright. No portion of this presentation may be reproduced in any manner, or published in

whole or in part without the prior written consent of Once Innovations™, Inc.

Once Innovations makes no representations as to the accuracy, completeness, or fairness of this presentation. So far as is permitted by law, no responsibility or liability whatsoever is

accepted by Once Innovations for the accuracy or sufficiency thereof, or for any errors, omissions, or misstatements relating thereto.

Introduction

• Once Innovations– Plymouth, MN company focused on designing LED

Technology and Lighting Solutions, and manufacturing LED-based lighting products for Agricultural markets

• Mike Ostaffe, EVP– EE, MBA, product leadership experience with GE, Philips,

and Honeywell

What is Light?

• Light is electromagnetic radiation, particularly radiation of a wavelength that is visible to the human eye (about 400–700 nm)

What creates light?

• Incandescent bulb– Heating of a filament by the current flowing through it creates light

through incandescence

• Fluorescent bulb– An electrical arc passing through a mercury vapor creates UV rays

which strike phosphors coating the inside of the glass tube. These phosphors emit photons (fluoresce) in very narrow wavelengths

• Light Emitting Diode (LED) bulb– A solid state device (P-N Junction semiconductor) that converts

electrical energy directly into light through a process called electroluminescence

LED BasicsP-Type matrix with electron hole

N-Type matrix with free electron Free electrons cross the junction to fill the

holes. Energy released during this transition is in the form of light (heat in regular diodes)

So what is so special about LED-based lighting?

• An LED is a solid state device with no filament or high voltage

arcs

• In basic form, LEDs are a highly efficient monochromatic light

source

• Monochromatic LEDs are by far more efficient than any other

available light source (10 to 50 times)

• White LEDs are manufactured by combination of blue or near

UV LEDs with RGB phosphors

• White LEDs are one of the most efficient light sources (800%

greater than incandescent, 30 to 50% greater than CFL)

• Very long life- in excess of 50,000 hours

AC LED Technology has many benefits

• No need for a switch-mode power supply driver• Less complicated design

– Fewer parts– Lower chance of failure– Improved circuit efficiency and lamp efficacy

• Greatly improve power quality– Power Factor >.97– THD < 20%

• Operates at 120Hz, above the range of human/poultry frequency response (approx. 70-80 Hz)

State of the Market

• LEDs continue to gain investment, press, and market share

• Largest Market Opportunities– Street/Area Lighting– Office Lighting– Home and Retail

• PAR30• A19 – 40-100W lamps

LED Developments

• 75-100W Announcements at Lightfair– $45-50 for home LED in 4Q

• Improvements in die-level efficacy

Commercial Lamp Comparison

• 100W Incandescent– 23W CFL– 17W LED (Lightfair Announcement)

• 75W Incandescent– 18W CFL– 13-15W LED

• 60W Incandescent– 9-13W CFL– 10W LED

Additional LED Reading

• http://www.onceinnovations.com/downloads/und_led.pdf

• http://www.onceinnovations.com/perf_diff.html

• http://www.ledsmagazine.com/

• www.linkedin.com has many LED/SSL groups that are very active

Types of Light Sensitivity \ Photoreception: How do we “See”

Humans and Poultry

• Retinal Reception – Photon absorption by photo-pigments rhodopsin (rods), iodopsin (cones) and recently discovered (1998) melanopsin

Poultry

• Retinal Reception – Photon absorption by photo-pigments rhodopsin (rods), iodopsin (cones) and recently discovered (1998) melanopsin

• Pineal Reception - Photon absorption by functional photoreceptors located in pineal gland on the top of the brain

• Hypothalamic Reception - Photon absorption by deep encephalic photoreceptors

Retinal Photoreception - Domestic Fowl retina

rod violet blue green red double

Source: “Avian Cone Photoreceptors Tile the Retina as Five Independent, Self-Organizing Mosaics” Yoseph A. Kram, Stephanie Mantey, Joseph C. Corbo, 2010

Quadchromatic

Transmission of light via avian scull and brain tissue

Source: “Spectral characteristics of visible radiation penetrating into the brain and stimulating extraretinal photo-receptors.” Hartwig, H.G. & van Veen, T

Avian scull, skin and brain tissue create natural light filter. Due to the presence of blood in the tissue, red light penetrates scull with highest transmission efficiencies.

Human Eye Photopic Spectral Sensitivity

Retinal Photoreception - Domestic Fowl Photopic Spectral Sensitivity (Typical)

Data source: “Spectral sensitivity of the domestic fowl (Gallus g. domesticus)” N. B. PRESCOTT AND C. M. (1999)

The effects of artificial light on the performance of chicken

There are three main aspects of the artificial light important to poultry producers

1. Light intensity or the total amount of luminous power produced in the visual (for poultry) part of the light spectrum

2. The photoperiod or number of hours of light and dark in a 24-hour period

3. The spectral composition of the artificial light

Dimming, On/Off, and painted bulbs

Red Color and Hue does matter…

• Increases the growth rate of chickens and turkeys at the beginning of the rearing period

• Increases locomotion that helps minimize leg disorders in the late rearing period

• Stimulates and promotes sexual activity

• Reduces actual feed consumption per egg laid (up to 20%) with no differences in egg size, shell weight, shell thickness, or yolk and albumen weights

• Proliferate cannibalism in broilers

Green and Blue Color and Hue does matter…

• Green light significantly enhances growth rate at an early age by enhancing proliferation of skeletal muscle satellite cells

• Blue light enhances growth at a later age by elevation in plasma androgens

• Green and Blue light promote myofiber growth due to more effective stimulation of testosterone secretion

• Narrow band blue light reduces locomotion

• Narrow band blue light reduce cannibalism rate at late age (broilers)

Why is the spectral composition of artificial lighting important in

agricultural applications?

Because artificial light is quite different compared to natural

daylight.

Plus

Almost all electrical lighting was created for human environments.

Relative Luminous Power - Natural Daylight at noon (D65)

Relative Luminous Power - Daylight at Sunset

Relative Luminous Power - Incandescent Lamp 2800K

Relative Luminous Power - Standard CFL 4000K (typical)

Relative Luminous Power – HPS lamp (typical)

Relative Luminous Power – High End LED 5400K (typical)

Relative Luminous Power - AgriShift™ PLWR5000

Dim To Blue - AgriShift™ PLWB5000 dimmed to 40%

Dim To Red - AgriShift™ PLWR5000 dimmed to 40%

AgriShift® PL

Total power: 12W

Delivered Equivalence: 100W incandescent

Luminous flux: Typ. 590 Lm (Human photopic)

Typ. 750 Lm (Scoptopic)

Harmonic Distortion: < 20%

Power Factor: > 0.97

Dimming: 100 to 1%, smooth transition

Semi linear behavior

Color Temperature: Approx. 5400K with Hue Shift Control

Shade Angle: 90, 120, 160 degrees

NRTL Certifications: UL 1993, CSA 22.2 1993-09

Our Latest PL design

Energy Savings Example

• 56 lamp house– 75W Incandescent Brood and Grow-out– 52 day bird, typical lighting program

• Replace with AgriShift 12W PL lamp– 1:1 screw-in replacement

• Save $1284 per year at $0.10/kWhr rate

Where do I place these?

• Indoors in hot, humid, dusty, damp, ammonia environments– These lamps were designed for poultry, and built for the barn, not

your kitchen. Kitchen lamps were not built for the barn

• In existing sockets in existing layouts that have up to 100W incandescent and/or 26W CFL lamps

• In the same layout you would use in new construction• Dim-to-Blue lamps for Broilers, Hogs• Dim-to-Red lamps for Breeder/Layers

AgriShift® EL

Total power: 3W

Equivalence: 20W incandescent

Luminous flux: Typ. 190 Lm (Human photopic)

Harmonic Distortion: < 20%

Power Factor: > 0.97

Dimming: 100 to 1%, smooth transition

Semi linear behavior

Color Temperature: Approx. 4100K with Hue Shift Control

EL Body Style Options

• Designed to be placed in/on cage systems

• Inside or across aisles• Replace rope lighting, 20W

Incandescent, 9-13W CFL

Decision Time for Poultry Farmers

• Federal Law increases efficacy standards for incandescent lamps by 30%, effectively bans them– 100W – January 1, 2012– 75W – January 1, 2013– 60W, 40W – January 1, 2014

• They will have to make a choice – LED or CFL– CFL lower cost, but underwhelming performance

• Mercury in CFLs can create food safety concerns– Substantial increase in mercury waste

Incandescent Lamps

Benefits

• Lowest Initial Price• Dimmable• Understood by all• No mercury in product

– Mercury released through coal-based generation

Drawbacks

• Least Efficient• High Energy Usage• Highest Total Cost

• Short Lifespan• Susceptible to vibrations

• A ban on standard 100, 75, 60, and 40W lamps begins

phase-in Jan 1, 2012

Compact Fluorescent Lamps

Benefits

• Compared to incandescent– Longer Life– More efficient– Less Energy usage– Uses same socket

• Compared to LED– Lower initial cost

Drawbacks

• 10X-20X Price of incandescent• Contains mercury

• Color Rendering• Color Temperature

• Dimmability• Fragile

• Susceptible to heat and vibration

Cold Cathode similar issues

LEDs

Benefits

• No Mercury• Lowest Total Cost• Low Energy Usage, High Efficacy• Smooth dimming to 1%• Longest life expectancy• Sturdy, no filaments• Instant on, no funny colors during

warm-up• On/Off Cycling and Dimming do not

affect life

Drawbacks

• “New” Technology• Highest initial cost

• Many want to “wait and see”• Many low-end, low-quality

products

Efficacy vs. Efficiency

Efficacy – Lumens/Watt

• Temperature• Phosphors• Light Source

Efficiency - %

• Ballast Losses• Driver Losses

• Control Losses• Wiring Losses

“Benchtop” or die-level data does not tell the entire story

Real world applications

• MN, AL, AR, WI, OK, MO, AB• Broilers, Layers, Turkeys, Ducks

Thank YouPlease visit us at www.onceinnovations.comMike Ostaffe, Executive Vice President – 763-568-4364