ROBOT cage equipment for broiler chicken farming

ROBOT cage equipment for broiler chicken farming

Cage rearing of commercial broiler chicken flocks using high-quality cage equipment and feeds under appropriate labour management system may yield high production output. Modern state-of-art technologies not only allow production of high-quality product but also enable the transformation of the poultry farming process into profitable business.

TEXHA company has designed the dedicated cage equipment for broiler chicken farming that facilitates optimization of the chicken farming process and ensures reliable increase of the production economic performance.

In 2011, the company took out a patent for proprietary technology of fully automated poultry harvesting process and launched it on the market as a new product marketed under the name ‘ROBOT’.

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ROBOT technology successfully passed the tests conducted at TEXHA’s own experimental site, and its advantages are supported by practical evidences collected both during research & development stage and during real-life operation at the facilities of our customers all over the world.


HARVESTING PROCESS

The harvesting process may start from any level as required, since the birds are completely harvested from each cell on the one-at-a-time basis. The cell floor automatically shifts along the battery towards the drive station, and the birds enter the moving litter-removal belt. Using the belt, the birds are transported towards the battery drive station, from where they get to the transverse rod conveyor.

Then, the birds are moved outside the poultry house and enter either the roller conveyor, or the dedicated poultry harvesting table specially designed by TEXHA. Use of the table enables uninterrupted technological process operation.

The process of harvesting poultry from the cage battery is fully automated and may be controlled by a single operator without participation of any additional personnel. In order to finalize the harvesting process, the poultry farm workers will need only to package the birds into boxes for loading into a vehicle.


ADVANTAGES OF ROBOT TECHNOLOGY:

  • Ability to set and modify harvesting capacity;
  • Minimum service personnel requirement;
  • Reduced bird injury rate
  • Lower rate of broiler chicken wings and legs injuries as compared to manual harvesting
  • Reduction of stress experienced by the birds;
  • Higher production output as compared to the broiler chicken floor housing technology;
  • Increased usable area of poultry house;
  • Reliable investments.

WE ENSURE:

  • High quality of the equipment
  • Full or supervised on-site equipment installation
  • Equipment commissioning
  • Warranty and post-warranty service
  • Veterinary and technological support
  • Service maintenance
  • Equipment troubleshooting
  • Poultry farm personnel training
  • Development of customized design and process solution based on the customer’s request

OUT EXPERT TEAM MEMBERS will calculate:

  • Scope of equipment to meet your needs and requirements, depending on the production technology, farm building characteristics or area of construction site allocated for poultry house project, climatic conditions and production capacities.
  • Amount of investments required for the project.

Technological Performance Values for Broiler Chicken Cage Rearing

Rearing Period, daysAverage Weight of 1 Chicken, kgPreservation, %Daily Weight Gain, gFeed ConversionRearing Performance Factor
392,57595,1661,69371,5
382,49096,365,51,67377,9
392,59697,666,71,63398,6
39,52,5809764,51,65384
38,52,50497651,64384,7
39,52,51895,563,51,62375,8
38,52,50397,4651,58400,8
38,52,65496,868,61,63409,4
38,52,58798,367,21,64402,8

Specifications

Number of levels3-4
Number of birds per cage55
Cage width, mm1 200
Cage depth, mm1 608
Distance between levels, mm654
Poultry harvesting opening height, mm190
Facade height, mm408
Door height, mm288
Area per bird, sq. cm350,8
Cell dimensions, mm16*25
Floor mesh wire diameter, mm2
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Projects

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    Poultry Harvesting System

    POULTRY HARVESTING SYSTEMS

    One of the most important and complicated technological processes in broiler chicken farming is the process of poultry harvesting for slaughter. The bird injury rate and the supplied product quality directly depend on how well this process is designed and implemented.

    Cage equipment for broiler chicken farming offered by TEXHA company is available in two different configurations that utilize two distinct poultry harvesting methods described below.

    ROBOT. ROBOTIZED HARVESTING SYSTEM

    This harvesting system is based on TEXHA’s proprietary design unrivaled throughout the world. Before commercialization, the ROBOT system successfully passed a trial at the company’s own experimental site, and the international patent to its design was issued.

    ROBOT technology has made a breakthrough in poultry farming industry by proving that even the seemingly impossible tasks may be successfully accomplished.

    ROBOT harvesting technology uses the special floor opening system, where the cage floors automatically move one-by-one, and the birds enter the moving litter-removal belt. This belt serves as a conveyor for transporting the broiler chicken towards the drive station. Then, the birds are moved outside of the poultry house and loaded into boxes for dispatch to the slaughter shop.

    ROBOT technology facilitates smooth and consistent poultry harvesting flow with reduced injury rate and improved quality of the final product.

    Advantages of robotized poultry harvesting technology

    • Optimization of labor efforts;
    • Removal of human factor influence;
    • Expedited harvesting process and facilitated process management;
    • Enablement of uninterrupted logistic processes;
    • Reduced bird injury rate;
    • Improved quality of poultry meat;
    • Easy maintenance;
    • Long service life of the equipment.

    POULTRY HARVESTING CONVEYOR 

    This conveyor is developed by TEXHA’s own design engineering department and is intended to ensure safe poultry harvesting process. Conveyor design takes into account various considerations, including own experiences, market requirements, reliability and cost effectiveness of the equipment.

    The design is based on the roller conveyor system. A dedicated lifting mechanism moves the conveyor depending on the battery level, from which the chickens are to be harvested. This conveyor acts as a final link of the poultry harvesting process.

    Advantages

    • Safe for birds
    • Energy efficient
    • Easy-to-maintain
    • Minimum service personnel requirement
    • Adjustable speed range
    • Smooth start
    • Active beak feature to reduce a gap between conveyor and poultry harvesting table.

    Conveyor Technical Specifications:

    • Conveyor width – 685 mm
    • Conveyor movement speed – 13,8 m/min (without variable speed drive)
    • Harvesting rate – up to 276 birds per minutes

    SIRIUS POULTRY HARVESTING TABLE

    SIRIUS poultry harvesting table is a proprietary research and development product by TEXHA company intended to improve performance of poultry harvesting from cage batteries for further dispatch to the slaughter shop.

    Shape, dimensions and operational mechanism of SIRIUS table contribute to the poultry harvesting process improvement. The table is a round moveable structure (tabletop) on castor-wheeled legs. Thanks to its mobile design, the table may be easily moved and put away in a warehouse, as and when necessary.   .

    Round structure consists of so called tabletop and perimeter-wise flanges. The tabletop is put in motion by drive gear that actuates its rotation. During harvesting process, the birds enter the table from the conveyor belt and go round in circles until collected by the farm workers. The poultry harvesting may be simultaneously performed by several individuals. Exact number of workers depends on capacity and rate of the harvesting process.

    SIRIUS table surface rotates with the set speed in order to prevent bird injury during collection and ensure comfortable collection rate for personnel involved.

    SIRIUS table has already gained recognition thanks to successful operation at broiler chicken farms all around the world.

    Litter Removal System

    All types of solutions offered by TEXHA, except for the floor poultry management system, use the belt-based litter removal technology, which ensures high-quality litter removal and maintenance of the equipment in clean condition, thus contributing to the improved microclimate in the poultry house.

    This system offers quick and reliable litter removal simultaneously from all levels.

    Dedicated system design allows timely and easy removal of litter, which helps to avoid accumulation of ammonia vapors and has favorable effect on the poultry unit microclimate.

    The litter removal system consists of:

    • Drive and tension station.
    • Polypropylene belt.
    • Transverse and inclined conveyor.

    Polypropylene belts are manufactured at TEXHA’s own factory from high-quality raw materials.

    Litter removal belt characteristics:

    • Durability against aggressive environment
    • Thickness 1-1,2 mm
    • High tensile strength
    • May be used in conveyors operated in the temperature range between 100 to 600С
    • May be used for handling aggressive materials
    • Low surface adhesion
    • Easy cleaning

    The polypropylene belt is located below every level of cells along the battery. When the litter is gradually accumulated, it is carried by the belt along the battery towards the drive station, where the dedicated scrappers move it to the transverse litter unloading conveyor.

    The belt is operated by the drive station, which is also used to adjust its position, where necessary. The tension station serves to maintain the required belt tensioning level. The tension station design uses the auger-type cleaning shaft, which ensures cleansing of the litter removal belt on the inside.

    In the drive station area, the belt surface is cleaned by the dedicated scrappers made of the wear-resistant material. Special mechanism presses the scrappers against the work surface of the belt, which allows efficient cleansing of belt from litter.

    A curtain made from dense wear-resistant material at the end of the battery prevents the litter from scattering during discharge to the transverse conveyor. The curtain is easily removable during maintenance of drive shafts and cleaning of scrappers.

    The transverse conveyor is equipped with the rubber-textile belt for removal of litter from the poultry unit directly to the inclined conveyor, which, in turn, is used for discharge of litter into a vehicle for further disposal. The inclined conveyor also features a dedicated cover made of galvanized steel.

    Advantages:

    • Metal materials with high corrosion resistance
    • Hot dip galvanization of conveyor surface
    • Polypropylene belt
    • In-house production
    • Top-tier raw materials
    • High quality
    • Testing at internal laboratory
    • Quality control
    Feeding System

    The cage equipment for broiler chicken farming supplied by TEXHA company utilizes the intra-cage feeding system.

    The system incorporates:

    • External feed storage bin;
    • Transverse feed supply system;
    • Longitudinal intra-cage feeding system.

    Transverse feeding system comprises of the following:

    • Separator;
    • Inclined and horizontal spring conveyors;
    • Downtakes for supply of feed on longitudinal feeding lines.

    Feed distribution lines have adjustable height.

    Automated feedbox filling system allows programming of the feeding parameters and precise adjustment of feed distribution depending on the utilized poultry cross bread. The replenishment sensor measuring the feed fill-up of entire line is installed in the last cell feedbox.

    • Continuous availability of feed for broiler chickens.
    • Fast feed distribution across all battery levels.
    • Low energy consumption of feed distribution process.
    • Easy and reliable design.
    • Ability to adjust the feed quantity in the feedbox depending on the age of birds.

    KoChiBo FEEDER FOR BROILER CHICKENS

    In cooperation with our Japanese partners, TEXHA has designed multi-purpose feeder intended for use as part of the broiler chicken feeding system regardless of the utilized rearing technology.

    Unique design

    • Low feeder edge allows the chicks to access the feed from the very first day of life.
    • 5-level adjustment of feed supply, feed volume and quantity.
    • Folded flanges and beams of the feeder limit the chicks’ ability to enter inside the feedbox, thus preventing scattering and loss of the feed.
    • Wide diameter of distribution mechanism ensures unhindered spilling and homogenous distribution of feeds.

    Key outstanding feature of KoChiBo feature is preservation of feed and reduction of irrecoverable feed loss!

    Operation

    • Easy installation.
    • Easy and convenient adjustment system.
    • Easy dismantling and washing.
    • Comfortable handling and storage thanks to ability to pile the feeders in stacks on top of each other.

    Perfect quality

    • Use of high-strength elastic material helps to prevent mechanical damage.
    • Robustness against the aggressive environment.
    • Resistance to deformation.
    • Robustness against high-pressure hot washing.
    • Made of food-grade plastic material.

    Cost effectiveness and versatility

    • Compatibility with any feeds.
    • Compatibility with any broiler chicken rearing system.
    • Availability of 8-beam and 16-beam models depending on final broiler weight.
    • Optimal size and shape of the feeder reduce material consumption and cost while maintaining full compliance with feeding standards.

    Adjustment System

    KoChiBo feeder features moveable bottom that enables adjustment of the feeder depth. This features is especially important for chicks during the first days of their life, since it significantly facilitates a search for feedstuff and ensures easy access to feed, thus contributing to the fast growth of the birds.

    With the growth of a chick, the feeding lines may be gradually raised to increase the feeder depth. Therefore, the volume of the feed spilled into the feedbox is also increased thanks to the movement of feeder frame upwards relatively to its bottom. This allows supplying the birds with the higher quantities of feed, while preventing loss of the feed from scattering.

    Drinking Systems

    TEXHA company offers reliable, efficient and easy-to-use drinking system. The purpose of this system is quite simple – to supply the birds with water of proper quality and in sufficient quantity. Furthermore, this system also serves for delivery of necessary medications to the birds.

    The system consists of the following:

    • Water treatment unit;
    • Water distribution system for cage batteries
    • Drinking lines at every level

    The water treatment units comprises of filters, water flow meter, medicator, pressure gauges, valves and fittings. Depending on the technical specifications, water pressure regulators also may be incorporated.

    The filter ensures purification of water from mechanical impurities. Use of 2 filters connected in-parallel through valves and fittings allows uninterrupted water supply to the drinking system without a need for shut-off during maintenance of one of filters.

    Pressure gauges in water supply system control the system pressure and record precise values of filter performance rating.

    Water flow meter allows operational control of the water consumption, which in turn assists in analyzing the flock condition.

    In order to maintain optimal water pressure, the membrane-type pressure regulators are used.

    Water distribution system for cage batteries is made of pipes manufactured from food-grade plastic.

    The nipple drinkers are attached to the plastic square section pipe with the length of 5,98 m. Such design not only reduces the number of connections, but also ensure high-quality assembly and leak-proof connection sealing. .

    The pipe walls feature special bulges in the nipple screwing-in points in order to ensure reliable nipple attachment.

    The drinking line height may be easily adjusted depending on the height of a chick.

    Advantages:

    • Drinking line pipes:
      • Made of top-of-class raw materials;
      • In-house manufacturing
      • High-quality assembly
      • Minimum number of connection points
    • Nipples may move up/down and rotate by 3600
    • Easy access to water even for a day-old chick.
    Microclimate System

    Microclimate in the poultry management is no less important than the quality of poultry housing equipment, and its role can be hardly overestimated.

    Regardless of the cross breed or genetic inheritance of the flock, without proper microclimate conditions the birds cannot maintain good health and yield high-quality product.

    Microclimate inside the poultry house is the combination of such factors as temperature, humidity, air flow rate, atmospheric pressure, noise level, air composition, microbiological contamination level, et cetera.

    The microclimate system represents the production process, the purpose of which is to create and balance the necessary microclimate parameters using the dedicated technical facilities and instruments.

    The poultry farming researchers suggest that the flock productivity depends on microclimate condition by approximately 10-30%. Unfavorable microclimatic conditions result in the reduced disease resistance of the birds. Moreover, the microclimate directly affects the service life of the equipment and even the poultry farm buildings.

    The resulting efficient operation of the microclimate system depends on the correct choice of equipment, its correct installation and proper calculation of the system parameters in general.

    TEXHA excels in design of automated microclimate systems. When choosing the system, a number of specific conditions should be taken into account, including, but not limited to the cross breed and size of flock, geographic location of the poultry far, i.e. climatic zone, et cetera.

    The microclimate system may comprise of the one to four sub-systems in various combinations:

    • Ventilation
    • Heating
    • Humidification / cooling
    • Automation

    HUMIDIFICATION / COOLING

    For hot climatic zones, TEXHA offers cooling units with cellular design (evaporation panels). The cooling panels are designed based on the best and the most innovative developments in the industry, which results in the optimal cooling effect regardless of climatic and operational conditions.

    The evaporation panels are made of dedicated cellulose paper with cellular structure, which contributes to the optimal water-to-air contact conditions. Such cellulose paper is carefully processed with odor-free resin, thanks to which the panels have high water-adsorption coefficient and stable structural shape. The special cellular form of the paper bands crossing angle-wise to the symmetrical air flow allows achievement of high cooling performance, while maintaining minimum pressure drop.

    • Absolute performance
    • Air freshness
    • Long service life
    • Easy maintenance

    HEATING

    Proper temperature regime is essential for productivity of the flock, especially in the early period of life. TEXHA offers highly efficient poultry house heating system with minimum costs. The system uses direct and indirect heating units operated on natural gas, liquefied petroleum gas or diesel fuel, as well as the water-based fan heaters.

    Specific features of direct heating units:

    • Reliability and durability
    • Low noise level
    • High output temperature
    • Quick air heating
    • Performance factor close to 100%

    The company offers to options of heat generators installation in the poultry unit: internal or external.

    The heat generators are equipped with fuses to prevent overheating and the sealed switches for safe and reliable operation. High-quality corrosion-proof components and durable frame ensure long uninterrupted service life even under the most extreme climatic conditions.

    Properties:

    • Minimum carbon oxide, nitrogen and ethylene oxide emissions
    • Frame made of high-quality stainless steel
    • Automated ignition
    • Integration with the automated microclimate control system.
    • Winter / summer switch that allows to use the heaters as air-circulating fans during summer season.
    • Compliance with international standards and quality regulations.

    VENTILATION

    Ventilation system plays an essential role in creation and maintenance of optimum microclimate conditions in the poultry farm unit. Proper air quality has a favorable effect on the health of the birds and significantly improves the flock productivity.  The ventilation system is selected and customized for each specific poultry farm depending on the climatic condition in the region, where it is located.

    Ventilation systems allow maintenance of required temperature, fresh air inflow and air exchange during any season. Such systems use the state-of-art exhaust fans, fresh air valves, temperature control facilities, et cetera.

    TEXHA’s ventilation systems offer:

    • High performance
    • Evergy efficiency
    • Low noise level
    • Durability of equipment
    • Reliability and cost effectiveness
    Lighting Systems

    Well-managed lighting system in the poultry house affects general condition of the birds, their food craving and physiological development, which is directly related to the flock productive performance. Lighting is an essential way to influence state of heath, behavior and productivity of the birds.

    Our equipment uses the state-of-art energy efficient technologies that not only create the favorable lighting conditions, but also reduce the electricity costs.

    TEXHA company offers a wide range of lighting systems for poultry farms regardless of the utilized poultry housing and rearing methods.

    Advantages:

    • Use of LED lamps with energy consumption
      • 10 times lower as compared to the filament lamps
      • 2,5 times lower as compared to the luminescent lamps
    • Lighting intensity adjustment in 0-100% range for sunrise / sunset functions
    • Compliance with the international environmental requirements;
    • High level of protection against external impacts;
    • Supervised installation is included into the lighting system price;
    • Warranty and post-warranty service

    LED Lighting System for Cage Interior of Broiler Chicken Rearing Equipment

    The systems consists of controller, power supply unit and lamp.

    Advantages of P-RLС-1LV-V2  0-10V 230B lighting controller:

    • 99 empty programs available for setting
    • Each program allows setting of the following:
      • Day
      • Time
      • % lighting intensity
      • Switching period in minute until light intensity reaches the set value
    • Lighting intensity may be manually adjusted
    • Ability to switch the lights on / off independently for each individual level

    Power supply unit is included into the scope of LED lighting system and is intended for transformation of input power from 220V / 50 Hz grid into 24V power for LED lights supply, which is safe for both a human and a bird.

    Main features:

    • In-built active function of power factor compensation required in order to ensure even distribution of line power and prevent network overload.
    • Protection from short circuit, overload, high voltage and temperature.
    • Multi-purpose AC input / full range (~88–264 V).

    Characteristics of the LED lamp are as follows:

    • Lamp body made of high-quality polycarbonate
    • High level of protection against external impacts
    • Waterproof (IP67 protection rating)
    • Even light distribution inside every cage as part of cage equipment;
    • Lighting intensity range 0-100%
    • Service life above 50 000 hours (almost 6 years)
    • Sage voltage of 24V
    • Maximum lighting level of 60 LX
    • Color temperature 2 700 – 3 300К
    Automation System

    Modern poultry farm businesses usually seek to implement automation of complete range of involved production processes and works. State-of-art technologies support continuous accumulation and processing of data related to all technological and business processes, careful supervision, immediate response and management of production process for entire poultry farm facility regardless of how large-scale it is.

    TEXHA offers wide range of equipment and varying degree of automation for all essential systems used to support the vital needs of birds. Vast experience and professional expertise of our expert team help to select the most appropriate solution both in terms of its functionality and its cost.

    Our services:

    • Design and development of control system based on input data
    • Installation and commissioning
    • Service support
    • Poultry farm personnel training
    • Warranty and post-warranty service

    TEXHA’s system automation solutions:

    • Microclimate
    • Litter removal
    • Poultry harvesting
    • Egg collection
    • Feed distribution
    • Auxiliary features:
      • Feed weighting at external feed bins
      • Emergency opening of positive pressure ventilation
      • Emergency detection of water level
      • Drinking line flushing

    What does our automation solution do?

    • Eliminates human factor influence
    • Enhances equipment performance
    • Improves finished product quality
    • Saves resources
    • Creates favorable conditions for poultry rearing and management
    • Ensures uninterrupted operational process
    • Provides opportunities for extension of production

    TEXHA also offers remote access system that offers remote data monitoring feature, remote control opportunities, tracking and alarm features for production processes analysis and optimization, as well as the safety unit with critical emergency alert.

    Integrated solutions offered by TEXHA provide an easy way to achieve the following production objectives:

    • Integration of novel technological solutions;
    • Computerization and modernization of poultry farm facility
    • Implementation of data monitoring system

    System features:

    • Remote access with different degree of authorization and access privilege from any place in the work via Web interface using PC, smartphone or tablet.
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