Poultry Case Study - F & H Panton Brothers

In 1949, when Calor and Maywick were developing the heaters and brooders which became the poultry industry standard, gamekeeper Edward Panton bought his first batch of 28 chickens. A humble beginning for a family business - F & H Panton Brothers - which has since expanded to an annual throughput of 3.5 million broilers, as well as mixed farming.

The latest phase in the continuing growth of the mid-Lincolnshire based Panton enterprise is at Willow Wood Farm, East Kirkby, where a 'green field' site has been transformed into a state-of-the-art contract broiler growing operation. The site accommodates 280,000 birds, grown from day-old for G. W. Padley (Poultry) in six identical clear-span all-steel poultry houses constructed by Cold Line of Grimsby.

The correct temperature in each of the 320ft x 71 ft houses is maintained by five Maywick Hired-Hand heaters, fuelled from two 12-tonne Calor propane bulk tanks and controlled by a sophisticated computerised system. The system also embraces ventilation, lighting, feeding, watering and bird weighing, enabling an up to the minute cost base to be calculated as and when required.

The 225,000 Btu/h heaters are installed on an outside wall of each house under a canopy, which forms an integral part of the smooth lines of each building. This removes the need to run gas lines within the houses and eliminates dust contamination from within the building as combustion air is entrained from outside. A quick-action electronic ignition system provides immediate response to any temperature change and the humid warmth provided by propane combustion is a positive aid to good feathering, which in turn contributes to a well-finished product. Depending upon prevailing weather conditions, heating is normally turned off when the birds are between 23 and 33 days old, but as early as 12 days in particularly warm conditions.

The heating installation was carried out by H A T Ltd, a firm of qualified liquefied petroleum gas (LPG) engineers which has fitted a substantial number of Maywick heaters at locations throughout the UK. H A T designed and installed the complete Calor system, which incorporates a metering system linked to a central computer, enabling gas running costs to be monitored accurately 24 hours a day.

The business has been using Calor propane and Maywick brooding systems for well over 30 years. In 1980, the increasing range of brooding equipment and inconsistent standards of service from other manufacturers led to a decision to standardise on Maywick equipment and Calor power - a policy which continues today. "The service provided by both companies is thoroughly reliable and we enjoy excellent relationships with them," commented David Panton, grandson of Edward, who controls the poultry operation with his brother Philip and maintains a patriarchal role within the business.

Although keen advocates of the localised temperature control at bird level afforded by canopy brooders, David and Philip Panton can see other advantages in the whole-house heating method at Willow Wood. As canny businessmen, they continually compare results at all their sites very carefully.

The Panton family is committed to conservation and 'green' issues, and this is evident at Willow Wood Farm. The insulated panels lining each house are manufactured to food standards and have a U-value of 0.21 - considerably better than the insulation performance of most poultry housing. Energy efficiency has also been extended to the lighting, as high frequency fluorescents are regulated by dawn-to-dusk controllers - a system claimed to use up to one third of the energy of conventional dimmable fluorescents.

Panton's 'green' credentials have been emphasised by the conversion of the company's fleet of cars and vans to run on Calor Autogas. The six vehicles, with engines varying between 1.8 and 2.4 litres, have been converted to bi-fuel operation by Brian Parker of Brigg. Prior to conversion. David Panton carried out detailed research and took advice from Calor on the likely cost savings and environmental advantages of running vehicles on Calor Autogas. "We anticipate a saving of around 55% on fuel costs," he commented, "and the environment will benefit from much cleaner emissions."

The on-site Calor Autogas bunkered fuel facility comprises a 2,000 litre surface-mounted tank with an electric dispenser capable of filling at 25 litres/min. The tank is topped up approximately every 4-6 weeks via Calor's computerised delivery system. David Panton forecasts recouping the costs of conversion within nine months, taking into account lower costs for both fuel and vehicle maintenance.

The combination of Maywick and Calor has proved to be a highly successful, cost efficient and reliable formula for F & H Panton Brothers, and the company has every intention of maintaining the partnership into the future.

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