ABB Farm to Fork Poultry business Solutions Guide

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Introduction

Farm to Fork strategies focus on making value chains ethical, healthy and sustainable. The poultry and egg processing industries are facing unprecedented challenges. Energy and raw material prices are increasing, while consumers are demanding ever lower prices. Meanwhile, the global population continues to grow. The need to improve chicken welfare, maintain a sustainable environment and retain profitability is putting increasing pressure on producers to improve productivity while reducing both energy usage and waste. That’s where Farm to Fork strategies can help. The industry requires solutions that can help to make vital improvements within the areas of:

Sustainability – where improvement comes in the form of energy savings, optimized use of water and ventilation, protection of the local environment, and reduction of waste

Re liability – where the need to reduce wear and tear on assets, prolong equipment life, and eliminate the risks of unplanned stoppages are all critical to profitable operation

Safety – where keeping animals, manufacturing, personnel and consumers safe from harm is non-negotiable.

ABB offers application-based solutions for the poultry and egg laying farming sector, food processing sector and logistics across the entire value chain. Our domain expertise, energy efficient motors and variable speed drive (VSD) / variable frequency drive (VFD) technology can help to substantially reduce energy costs, while Programmable Logic Controllers (PLCs) can deliver integrated control systems that help to provide enhanced digital visibility and control over the processes within the poultry farming, food processing and logistics sectors – from Farm to Fork.

Poultry farming

Challenges facing the poultry farming industry

Poultry farms have increased in size, and become more automated in recent decades. However, farmers face significant challenges, while pressure is growing on the industry to become more sustainable and more focused on animal wellbeing.

Achieving optimal conditions for profitability

One of the biggest priorities for poultry farmers is ensuring effective ventilation. Without it, harm could come to animals, increasing costs and generating waste that farmers cannot afford. Ventilation must constantly ensure the right atmospheric conditions, controlling temperature, humidity and oxygen levels to remain within optimal parameters. This typically requires a large number of fans to move air around the facility and ensure adequate cooling, potentially consuming vast amounts of energy. If the barn is not properly ventilated, the risk of fire increases, which is an unacceptable and must be mitigated.

Ensuring reliability and safety for critical processes in poultry farming

High intensity processes, such as hammermilling, may require frequent maintenance that is not always quickly available on-site, particularly in remote areas. The need to ensure personnel safety within the proximity of moving mechanical equipment is paramount.

Solutions across the poultry farming value chain

ABB offers a suite of solutions that can deliver vast benefits for both small and larger farms, as well as the equipment manufacturers that supply them. ABB understands the applications and issues that matter to farmers in a rapidly changing market, and can help them to meet their sustainability, reliability and safety challenges across the poultry farming value chain.

Poultry farming

Challenge

SUSTAINABILITY

My energy costs are rising, while I’m under pressure to operate more sustainably

RELIABILITY

I need to reduce downtime to ensure my animals live in optimal conditions

SAFETY

I need to keep fire hazards to a minimum to prevent risk of mortality and damage

Ventilation

Solution

Drives, high efficiency motors and PLCs from ABB deliver substantial energy and carbon dioxide savings, optimizing the efficiency of your farm while improving performance

Drives ensure ventilation needs are met at all times to create optimal growth conditions, with special ventilation functionality built in

Drives ensure optimal airflow, while Ex-certified motors prevent the build-up of flammable dust and other materials

Poultry farming

Challenge Solution

SUSTAINABILITY

I have to ensure maximum efficiency and effectiveness for scrubbing of exhaust air

Drives and PLCs provide better, more efficient control of the scrubbing process, resulting in cleaner air, lower emissions, and reduced environmental impact

I need to prevent the corrosion of surfaces due to the presence of ammonia

RELIABILITY SAFETY

I need to prevent build-ups of dust and ammonia, and prevent air contamination for the local environment

Air scrubbing

Drives incorporate coated circuit boards (PCBs) to protect against corrosion for increased longevity and lower maintenance requirements

Embedded pump monitoring functions can optimize performance, avoid process disruption, and prevent build-up of harmful gases

Poultry farming

Challenge Solution

SUSTAINABILITY

I want to reduce energy usage, and eliminate waste caused by damage to produce

Drives and PLC provide more efficient control of equipment and better dose control, while mitigating cracked shell damage to eggs and other products

I want to prevent my equipment from being damaged by sudden starts and stops, or by running too fast

RELIABILITY SAFETY

I need to prevent any risk of fire and suffocation of my animals

Conveying

Drives provide smooth operation for various types of conveyor, reducing wear and tear on equipment

Drives in-built functional safety, along with Ex certified motors, that minimize fire risk

Poultry farming

Challenge Solution

SUSTAINABILITY

I need to use the right amount of water in feed production

Drives and high efficiency motors used with PLCs reduces energy use by up to 25% or more in pumps, while ensuring more accurate dose control and mixing

RELIABILITY SAFETY

I have to control the supply of drinking water, while reducing pressure on my pumps and pipes to prevent bursts

I can’t afford to have a pump fail, as my animals rely on them for water

Pumping

Drives ensure pressure is kept at optimal levels, while pump-specific functions extend equipment lifetime

Drives and motors ensure constant supply, with remote monitoring to provide early warning of potential faults

Poultry farming

Challenge Solution

SUSTAINABILITY

I need to reduce the amount of energy and water used, particularly in hot climates and where water is scarce

Drives and motors ensure water and energy is used more efficiently by optimizing processes

I need to ensure optimal running of cooling systems to prevent downtime

RELIABILITY SAFETY

I need to keep my animals healthy by avoiding temperature variations through switching cooling pad pumps on/off

More efficient motor control can be achieved by using a drive, reducing wear on equipment

Cooling

Drives and motors used with compressors and fans ensures the correct temperature is maintained at all times

Poultry farming

Challenge Solution

SUSTAINABILITY

I have to ensure quality of by-products while reducing transportation costs

Drives and PLCs can optimize the speed and load of pellet presses, resulting in a more homogenous end product

The manure layer on my drying belts needs to be optimal, preventing thick or thin layers causing inefficient drying

RELIABILITY SAFETY

I must avoid high concentrations of gases like ammonia to prevent harm to the environment

Manure drying and pelletizing

Drives and PLC ensures optimal conveyor speeds are maintained for the best drying efficiency

By measuring the load of the main motor the supply of raw material can be dosed so overload and overheating of motors is avoided

Poultry farming

Challenge Solution

SUSTAINABILITY

I must reduce waste during both filling of bunkers and emptying of feed

RELIABILITY

My feed kitchen runs 24/7, making maintenance a challenge

SAFETY

I need to ensure that an adequate nutritional mix is provided to animals

Animal feed production (incl. hammermills)

Drives, high efficiency motors and PLCs can optimize the speed and load of hammermills, while ensuring better energy efficiency and less waste through precision control

Use of drives, high efficiency motors and PLCs improves reliability and equipment lifetime, while reducing downtime

PLCs allow precision control of dosing and management of weighing systems

Food processing

Feeding a growing population sustainably In food processing, productivity is key, but it cannot come at the expense of quality and safety. To feed a growing population, facilities must find ways to increase throughput, while also addressing increasing customer demand for transparency and sustainability. With energy prices rising, and the increased overheads upstream adding to raw material costs, the pressure is on food processors to find ways to optimize processes further, while making operations more sustainable. Meanwhile, consumers are increasingly demanding greater visibility over the provenance of their food, requiring poultry processors to track every item for traceability in the event of an issue.

Addressing challenges for poultry producers

Poultry processing requires large volumes of water for the washing and cleaning of produce and equipment, and even small

efficiency gains here can make a significant difference when extrapolated across multiple stations in a facility. In larger facilities, the vast number and scale of the conveyors transporting produce from station to station can present enormous challenges for maintenance engineers, particularly in facilities that operate 24/7. In addition, the safety of human operators is essential around dangerous machinery. Food safety is also a high priority, requiring stringent hygiene measures that can further increase the cost of production.

Ensuring sustainability, reliability and safety for equipment

ABB Motion products are designed to meet the needs of the increasingly sophisticated modern industrial processing facility. From ultra-premium efficiency IE5 SynRM motor and drives packages, to advanced industrial PLCs, ABB is equipped to help poultry producers to improve the sustainability, reliability and safety of their operations.

Food processing

Challenge Solution

SUSTAINABILITY

My energy prices are rising, and I don’t know what I’ll be paying from one month to the next

RELIABILITY

I need to improve productivity in my cutting process, while at the same time reduce costs

SAFETY

Cutting machines can be dangerous – I need to ensure maximum safety while keeping my facility hygienic

Using high efficiency motors and drives substantially reduces motor energy usage and CO2 footprint, while reducing waste

Drives can alter the speed of the cutter if required, while on-board functionality can detect when maintenance is required to the cutter blade

Safe torque off in the drive function allows safety while working on a machine for example when clearing mechanical blockages. Food Safe motors are designed specifically for hygienic environments

Cutting

Food processing

Challenge Solution

SUSTAINABILITY

My facility houses multiple conveyors of different types, with varying speed requirements

Drives ensure smooth start and stop, reducing damage to goods for less waste

Each conveyor can have different maintenance requirements, while longer ones can require numerous gear motors and long cables

RELIABILITY SAFETY

I have a duty to keep my employees safe from dangerous machinery

PLC combined with drives and motor ensures perfect synchronization of multiple conveyors for less wear on equipment and lower maintenance requirements

Conveying

Integrated functional safety in drives reduces risk to personnel

Food processing

Challenge Solution

SUSTAINABILITY

Environmental legislation is increasingly requiring me to lower CO2 levels and minimize waste

RELIABILITY

I have to ensure optimal mixing and smooth operation to prevent wear and tear to machinery

SAFETY

I have to keep my employees safe from machinery, and ensure that contaminants do not enter the food chain

Mixing/Grinding

Drives deliver optimal conveyor speeds for maximum efficiency and minimum waste

Drives provide precise speed and torque control to reduce strain on mechanical equipment

Integrated functional safety within drives reduces personnel risk, while the Food Safe motor is designed to withstand harsh washdowns

Food processing

Challenge Solution

SUSTAINABILITY

Water is a scarce resource, and can be expensive, so I have to minimize its use where possible for cleaning process equipment

Drives can be used to control the flow of water to a set level to optimize usage and reduce energy consumption

High pressure flows and harsh cleaning chemicals can damage my pipes, valves and machinery

RELIABILITY SAFETY

My motors must be regularly cleaned to prevent bacteria build-ups

Pumping

More efficient pumping achieved by drives reduces pressure peaks, while the Food Safe motor features stainless steel chassis for better longevity

ABB’s Food Safe motor is built to withstand frequent harsh washdowns over many years

Food processing

Challenge Solution

SUSTAINABILITY

My facility needs adequate ventilation at all times

Drives ensure ventilation is maintained at required levels while delivering optimum efficiency

RELIABILITY SAFETY

Maintenance is expensive –I need to improve reliability and reduce downtime for my ventilation fans

I have to keep my plant workers safe and comfortable

Ventilation

Remote condition monitoring of assets can detect performance drift to facilitate predictive maintenance before it results in failures

Drives deliver more efficient motor operation, providing improved airflow throughout the facility

Food processing

Challenge Solution

SUSTAINABILITY

Fresh produce has a short shelf-life, so I need to maintain optimal conditions to prevent spoilage

RELIABILITY

I need maximum reliability, as unplanned outages cost money and can result in spoiled goods

SAFETY

Cold chain temperatures must be kept at certain levels without any interruption for maximum shelf-life

Cooling and refrigeration

Drives and PLC ensures food is kept at its correct temperature. ABB ACS580 drives cooling compressor control ensures efficient and effective operation of multiple compressors working in cooperation

Drives and high efficiency motor packages eliminate start-up current peaks for improved reliability of compressors and pumps

Improved reliability through drives use reduces risk of equipment downtime

Logistics

Improving the efficiency and speed of cold chain processes

Once processed, the poultry is transported either in bulk or packaged, to logistics centers for onward distribution to wholesalers and supermarkets. Speed and efficiency is key to ensure that food is kept at optimum freshness at each stage of the process, making reliability, particularly of refrigerators and freezers, the number one concern in poultry distribution.

Manufacturers supplying refrigeration equipment to food manufacturers and logistics centers need to be able to trust in the quality of their components to ensure maximum uptime and reduced maintenance call-outs.

Your trusted partner for motors and motor control in logistics applications ABB offers a wide range of motion solutions designed to address the needs of cold chain logistics operators. High energy efficiency motors can deliver considerable savings while drives and PLCs ensure seamless operation of conveyors and compressors and reduction of wear and tear on components. Data and advisory services can also help to detect potential faults before they turn into failures, keeping downtime to a minimum.

Logistics

Challenge Solution

SUSTAINABILITY

I have to avoid any interruption of the cold chain process

Using drives and high efficiency motors enables optimization of the cooling system to ensure precision control and no drift, while ensuring maximum energy efficiency

I cannot afford for my refrigerators and freezers to fail

RELIABILITY SAFETY

I have to ensure maximum food safety for personnel and customers

Cooling and refrigeration

Drives ensure a soft start of the motor which decreases equipment wear, while remote monitoring can detect issues before they develop in to faults

Drives can control cooling compressors so that they produce according to actual cooling demand, ensuring optimal temperatures are maintained at all times

ABB Motion success stories in poultry farming

Big Dutchman-China enjoys peace of mind with significantly better uptime thanks to ABB

Aiming to raise efficiency on its automated egg farming lines, Big Dutchman-China began using ABB variable speed drives/variable frequency drives (drives) for conveyor and fan operations – providing better uptime, ease of use and peace of mind for both the OEM and their customers.

Located around 30 minutes from Beijing, the company builds modern lines that are installed at egg farms all over China. To improve the lines, they began exploring the market for equipment that offered both better motor control and stronger local service.

More than 200 ABB drives have now been deployed with great success. Operational downtime on egg production lines is estimated to have decreased by 90 percent, while commissioning time is reduced by about 30 percent. In addition, the fans and conveyors can be controlled more accurately, providing a more comfortable environment for the chickens.

ABB helps 13,000-bird flock of chickens to thrive comfortably and sustainably in the Mexican heat

Temperatures near Mexico’s southern border can hover around 38 degrees Celsius, creating a dangerous environment for egg-laying chickens, which do their best work when comfortable. Recently, an ABB customer in southern Mexico was looking to increase the comfort of a nearly 13,000-bird flock while reducing energy consumption at the company’s chicken farms.

ABB helped to configure a solution comprised of Baldor-Reliance® EC Titanium motors and ACS380 drives. EC Titanium motors utilize a highly efficient rotor technology that, when paired with an ABB drive and advanced motor control algorithms, enables higher efficiencies across the full speed load for a sustainable, wirelessly connected solution.

The customer purchased 12 motors with matching drives, and the results were immediate and significant.

• A pproximately 15 percent energy savings at full load operation, and 25 percent or more when drives are used

• 2 5 percent greater airflow inside the chicken houses

• A bility to control the hours of operation and maintenance of each air extractor

• S olar panels situated on the roof, connected to the ACS380 drives, provide free and clean energy during daytime, with no need for a DC/AC converter, reducing dependence on the weak main grid

ABB Motion solutions for poultry producers

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High efficiency motors

• ABB offers a comprehensive range of reliable and high efficiency motors for all poultry applications from farmto-fork

• High efficiency induction motors can significantly reduce energy usage, while meeting and exceeding Minimum Energy Performance Standards (MEPS) around the world

• Ultra-premium efficiency IE5 SynRM motors / NEMA EC

Titanium motors and drives packages can achieve unprecedented energy savings for processing and logistics applications

• IEC and NEMA Food Safe motors contribute to improved hygiene while reducing the impact of harsh chemicals to prolong motor lifetime

Variable speed drives/variable frequency drives

•ABB drives are made with efficiency and performance in mind to empower productivity for poultry farmers and meat producers. They provide flexibility to optimize processes and control across the value chain, while achieving extremely high reliability for less downtime

•Achieves substantial energy savings by delivering precision control to ensure that a motor only uses the energy it needs for a given output

•EnergySave Calculator tool allows you to predict energy performance and savings prior to investing

• Built-in features and functionality tailored to production processes associated with poultry, e.g. cooling compressor control in the ACS580 drive for cooling and refrigeration

• Functional safety built-in

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Programmable Logic Controllers (PLCs) and Human Machine Interfaces (HMIs)

•ABB automation devices deliver solutions with high performance and HMI flexibility to be effectively deployed in applications across the poultry value chain

•Open system architecture for easy integration into existing environments

•ABBs range of PLCs can provide solutions for small, medium and high-end applications and redundancy

• Ideal choice for high availability, condition monitoring, motion control and safety solutions

•Safety PLC specifically designed for safety applications involved in machinery and process automation

• Constantly monitors process variables and instruct motor and drive equipment to adjust operations instantaneously to match requirements in real-time

Our service expertise, your advantage

Keep your operations running profitably, safely and reliably

• Maximize uptime, extend product life c ycle, and enhance the performance and energy efficiency of your assets.

• Enable innovation and success through digitalization by securely connecting and monitoring your motors and drives, increasing reliability and improving efficiency.

• Our domain expertise is stren gthened by a service offering tailored to your needs, enabling you to unlock new possibilities and achieve more sustainable outputs.

ABB Motion OneCare

The modular service agreement tailored to your needs

Recovery services

ABB Motion OneCare

Fast intervention when something goes wrong

The modular service agreement tailored to your needs

Recovery services

Fast intervention when something goes wrong

Planned services

Protect your investment and avoid costly downtime

Reliability

Maximizing uptime Delivering service excellence

Planned services

Protect your investment and avoid costly downtime

Reliability

ABB Motion OneCare

Partnered solutions

The modular service agreement tailored to your needs

Bringing expertise and capabilities together to enhance your business performance

Recovery services

Fast intervention when something goes wrong

MOVING YOUR POULTRY BUSINESS FROM FARM TO FORK SUSTAINABLY, RELIABLY AND SAFELY22 — Planned services

ABB Motion Services

Protect your investment and avoid costly downtime

Maximizing uptime Delivering service excellence

Reliability

Maximizing uptime Delivering service excellence

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ABB Motion OneCare

Partnered solutions

The modular service agreement tailored to your needs

Bringing expertise and capabilities together to enhance your business performance

Recovery services

Fast intervention when something goes wrong

Data and Advisory services

Partnered solutions

Bringing expertise and capabilities together to enhance your business performance

Planned services

Data and Advisory services

Better decision making

ABB Motion Services

Protect your investment and avoid costly downtime

Modernization and Performance improvement services

ABB Motion Services

Optimal performance and lifetime extensions

Reliability

Energy efficiency and Circularity

Reducing carbon emissions and waste Driving the tomorrow

Maximizing uptime Delivering service excellence

Better decision making

Modernization and Performance improvement services

— ABB Motion Services

Optimal performance and lifetime extensions

Energy efficiency and Circularity

Reducing carbon emissions and waste Driving the tomorrow

Digital and Innovation

Delivering digital for success Smart. Secure. Connected.

Digital and Innovation

Digital and Innovation

Life-cycle management

Delivering digital for success Smart. Secure. Connected.

Delivering digital for success Smart. Secure. Connected.

Extending life-cycle Enhancing performance

Life-cycle management

Digital and Innovation

Life-cycle management

Delivering digital for success

Enhancing performance

Smart. Secure. Connected.

Extending life-cycle Enhancing performance

OUR EXPERTISE YOUR ADVANTAGE

OUR EXPERTISE YOUR ADVANTAGE

OUR EXPERTISE YOUR ADVANTAGE

OUR EXPERTISE YOUR ADVANTAGE

ABB Ability™ digital solutions

ABB offers a range of services and digital solutions based around the ABB Ability™ platform, which can help to make better decisions to maximize the potential of your motor-driven applications across the entire powertrain.

ABB Ability™ Mobile Connect for drives I t allows equipment manufacturers to communicate with drives users or service personnel on-site, helping them easily commission and troubleshoot drives remotely. Chats and sharing of images and backups via smartphone makes the technical support process quick and efficient.

enables full transparency on key parameters for drives, motors, and pumps, and can also be used in applications such as compressors, conveyors, mixers and extruder main shafts.

The powertrain is equipped with sensors and cloud connectivity and you can choose yourself what assets you want to monitor.

This increases opportunities to provide online technical support for end customers without complex connectivity infrastructure. This is ideal for facilities in remote locations lacking in modern communications provision.

ABB Ability™ Condition Monitoring for powertrains

ABB Ability™ Condition Monitoring service for powertrains optimizes the performance and efficiency of rotating equipment. It

Data gathered from drives’ inbuilt sensors and loggers together with that collected from ABB Ability™ Smart Sensors fitted to motors and pumps, can be aggregated, stored and further accessed via the cloud. The ability to gather and analyze this data can reveal information on the status and condition of your equipment, so that you can schedule service activities more effectively.

ABB Access and local support

ABB Access – unlocking your drives, motors, and PLCs

With ABB Access, you can unlock all aspects of your drives, motors or PLCs, from one central location: the palm of your hand. Simply scan the QR code on the ABB product to get started.

ABB Access helps you to easily find up-todate product online data. It also provides fast access to documentation and manuals. If you happen to experience issues with your ABB product, this can be quickly and easily reported online to reach expert support from ABB.

Engage ABB support locally

As well as serving the market directly, ABB continuously develops a network of value adding channel partners that enhance ABB’s market reach and proximity around the world. Local expertise, combined with a world leading product and service offering, can help to provide support at every stage of the poultry value chain.

ABB Value Providers are regularly trained in the latest products, techniques and best practices, as well as being periodically assessed on their core competencies to ensure that customer expectations are always fulfilled, 24 hours a day, anywhere in the world.

The ABB Value Provider program ensures that approved third parties deliver authorized sales, support, service and engineering in cooperation with ABB, bringing ABB’s products and services straight to the customer’s front door.

Summary

Across the poultry production value chain, from farming to logistics, key stakeholders face an array of challenges in ensuring maximum efficiency with minimum waste, while attempting to reduce costs wherever possible. Meanwhile the industry is also working hard to improve its environmental footprint.

ABB’s Motion portfolio delivers solutions with tangible benefits for improving the sustainability of operations, and the reliability and safety of poultry production processes, from Farm to Fork.

To find out more about how ABB can help you

ABB Motion

P.O. Box 1

FI-00232

Helsinki, Finland

https://campaign.abb.com/farm-to-fork-poultry

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