Behind the Barn: The ESA Efficiency Master Series
A New Way to Look at Efficiency
For poultry producers, efficiency has always been tied to productivity. Every bird must thrive, every flock must perform, and every resource — from feed to fuel — must be used wisely. But barns themselves often work against these goals. Hidden heat loss, poor ventilation design, and aging equipment quietly drain profits while compromising bird comfort.
The truth is that efficiency is not just an economic issue. It’s also a welfare issue, an environmental issue, and increasingly, a sustainability issue. Inefficient barns burn more energy, cost more to run, and leave birds living in inconsistent, stressful conditions. In today’s market — where margins are tight and consumer expectations are high this is a challenge producers cannot afford to ignore.
The Cost of Lost Heat
Heat inefficiency doesn’t always look dramatic. A fan that leaks air, a curtain that doesn’t seal, or insulation that has thinned with age may seem minor, but together they create constant losses. Research shows barns can lose thousands of dollars annually to preventable heat loss, often hidden in higher feed and energy bills.
For example, if a barn loses heat through unsealed gaps, the heating system works harder to keep birds warm. The increased fuel usage drives costs up, while birds under temperature stress may eat more feed to compensate — reducing feed efficiency and performance. What looks like “normal” variation in costs is often inefficiency in disguise.
Ventilation: The Invisible Factor
Good ventilation does more than exchange air. It regulates oxygen levels, removes excess moisture, reduces ammonia, and distributes heat evenly across the flock. Poor ventilation, on the other hand, allows hot and cold spots to develop, raise stress levels and creates performance inconsistencies.
Producers know the signs: higher mortality in some corners, birds bunching under heaters, wet litter, or unexplained performance gaps between flocks. These are not just management issues; they are often symptoms of poor airflow and heat distribution.
Smarter Barns in Practice
The good news is that efficiency doesn’t always require a complete rebuild. Practical steps can include:
- Regular equipment checks — ensuring fans, heaters, and controls are calibrated and maintained.
- Improved sealing and insulation — closing air leaks and reducing unnecessary drafts.
- Heat recovery systems — capturing wasted energy to pre-warm incoming air.
- Ventilation design adjustments — balancing airflow to reduce stress and improve bird comfort.
Each of these measures contributes to lower input costs, better flock health, and stronger returns. Producers who invest in efficiency upgrades often see payback not just in reduced bills, but in improved performance and easier flock management.
Colin Breukelman is a seasoned broiler producer from Vancouver, British Columbia, Canada. In October of 2022, he decided to invest in three ESA-3000 heat exchangers for his 10,000-square-foot barn. The results were nothing short of remarkable.
With the higher humidity levels experienced on Canada’s west coast, managing litter quality has been a constant challenge for Colin. However, after installing the ESA-3000 heat exchangers, the litter condition in his barn saw immediate and significant improvements. Flock Mortality through 37 days was an impressive 1.5%, outperforming the industry average and Colin’s previous average of 3-4%. The birds thrived under the improved conditions, attaining a healthy average weight of 2.5 kg, and the Feed Conversion Ratio (FCR) improved to an outstanding 1.42.
Not only did the ESA-3000 positively impact the flock’s performance, but it also brought substantial financial benefits. With carcass condemnations at the processing plant reduced to a mere 0.5%, Colin received excellent feedback on the overall bird quality. Additionally, the improved product quality translated to tangible financial gains, as it improved Colin’s performance drastically.
Colin reflected on his decision, saying, “The ESA-3000 exceeded my expectations in every aspect. It not only improved the litter condition and flock performance but also had a direct positive impact on my bottom line. The investment in ESA-3000 heat exchangers was undoubtedly one of the best decisions I’ve made for my poultry production.”
Colin’s success story echoes the sentiment shared by many satisfied users of the ESA-3000. By delivering outstanding results in litter moisture control, flock performance, and financial returns, this innovative technology has proven to be a game-changer for poultry producers seeking to optimize their operations and ensure the well-being of their birds.
Why ESA Is Leading This Conversation
ESA helps poultry producers improve barn efficiency through advanced ventilation and heat-recovery solutions. By combining technology, field expertise, and practical on-farm experience, ESA gives producers tools to cut fuel costs, improve air quality, reduce moisture and ammonia, and create healthier, more productive barns.
Efficiency challenges are complex, and no two barns are the same. That’s why ESA believes education is the first step toward improvement. With field experience, data, and technical insight, ESA is committed to giving producers tools they can apply in real barns — not just abstract ideas.
Smarter barns start here. And over the next year, we’ll uncover together what’s possible.
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