45,000-Bird Broilers Deep Litter System Farm in Kyrgyzstan: Livi Machinery Two-House Renovation Project

Renovating an existing poultry farm is different from designing a broiler house on an empty site. A new building can be designed around the equipment, but an existing house already has fixed dimensions, columns, doors, windows, roof structures and electrical conditions.

This was the starting point for Livi Machinery’s Kyrgyzstan broiler farm project. The customer planned to raise a total of 45,000 broilers using a deep litter production model and already had two poultry houses available for renovation.

The central question was therefore not simply, “Can 45,000 broilers fit inside these houses?” A more useful engineering question was:

How can the two existing buildings be converted into a controllable, automated and energy-conscious broilers deep litter system farm without unnecessary reconstruction?

To answer that question, the project needed to connect the building structure with feeding, drinking, ventilation, heating and environmental management rather than selecting each system independently.

What Did the Kyrgyzstan Customer Need from the Broiler Farm Renovation?

The customer’s objective was not to purchase one isolated machine. The project required a coordinated production system capable of supporting commercial deep litter broiler farming across two existing houses.

This meant the customer needed more than individual equipment. The two houses had to be evaluated as a complete production project, with an automatic poultry farming equipment solution adapted to the actual building conditions.

How Did Livi Machinery Approach the Two Existing Poultry Houses?

One of the most important principles in an existing-house project is to avoid forcing a standard layout into a building that was designed for different operating conditions.

Before finalizing equipment, the relevant house information should include:

• internal house length, width and height;
• usable floor area;
• column positions and structural obstacles;
• roof and wall construction;
• existing doors and windows;
• current fan or ventilation openings;
• floor and drainage conditions;
• space for feed storage and conveying equipment;
• available electrical supply.

Once these conditions are understood, the bird capacity and equipment arrangement can be planned around the buildings.

If the two houses provide approximately equal usable production areas, around 22,500 broilers per house may be used as a preliminary planning reference. However, an equal 50/50 split should not be forced if the two buildings differ significantly in usable space.

How Was Automatic Feeding Planned for 45,000 Broilers?

At a commercial scale of 45,000 birds, feeding is one of the first areas where automation can reduce repetitive manual work and improve daily management consistency.

A typical feeding route for this type of deep litter broiler house can be organized as:

Livi Machinery’s broiler pan feeding system is designed to distribute feed through commercial broiler houses while reducing dependence on manual feed delivery.

For an existing-house project, however, feed-line quantity should not be selected only from the total bird number. House width, line length, pan configuration, structural columns and bird distribution all affect the final layout.

The two houses therefore do not necessarily need identical feed-line configurations. The more practical objective is to provide suitable feed access within the usable area of each building.

Why Were Feeding and Drinking Lines Designed Together?

Feed lines and nipple drinking lines occupy the same production area and influence how birds distribute themselves throughout the house. Designing them independently can create unnecessary congestion or poorly used floor space.

For a broilers deep litter system farm, drinking-system management is also directly connected to litter conditions.

The layout needs to consider:

• drinking-line spacing;
• water pressure regulation;
• line suspension and height adjustment;
• access at different bird ages;
• water leakage control;
• maintenance access.

Excessive water leakage can increase litter moisture, so drinking equipment should be treated as part of environmental management rather than only as a water-delivery system.

How Can a Broiler House in Kyrgyzstan Balance Winter Heating and Ventilation?

This is one of the most important technical considerations in the Kyrgyzstan project.

During colder periods, the farm needs to retain sufficient heat, particularly during brooding. At the same time, the poultry house cannot simply be closed tightly with insufficient fresh-air exchange.

Moisture and undesirable gases still need to be removed from the building. The challenge is therefore to provide the required minimum ventilation without introducing excessive uncontrolled cold air.

How Should Ventilation Be Redesigned in an Existing Broiler House?

Existing windows and openings are not automatically suitable as controlled air inlets.

When exhaust fans remove air from the poultry house, replacement air needs to enter through planned locations. If too many doors, windows or gaps remain uncontrolled, air may follow the easiest path to the exhaust fans instead of being distributed through the intended bird area.

For this reason, each relevant opening in an old poultry house should be evaluated as one of four types:

Fan quantity also cannot be determined reliably from the 45,000-bird capacity alone. Required airflow, house dimensions, selected fan performance, inlet area and building leakage all influence the final ventilation design.

What Determines the Heating Requirement for This Kyrgyzstan Broiler Farm?

Heating is particularly important during brooding, but heater capacity should be calculated from the thermal conditions of the buildings rather than simply from the total number of broilers.

Important factors include:

• house dimensions and internal air volume;
• outdoor design temperature;
• required brooding temperature;
• roof and wall insulation;
• door and window sealing;
• minimum ventilation heat loss;
• uncontrolled air leakage;
• available heating energy source.

In some existing-house projects, improving sealing and insulation can be more effective than simply increasing heater size. This is why Livi Machinery evaluates the house itself together with the heating equipment.

How Can a 45,000-Bird Broilers Deep Litter system Farm Reduce Energy Waste?

Energy efficiency is not determined by one machine. It comes from how the complete farm operates.

What Electrical Capacity Should Be Checked Before the Poultry House Upgrade?

Existing poultry houses may have been built before automatic feeding and modern environmental equipment were planned. Their original electrical systems should therefore not automatically be assumed to support the upgraded farm.

The electrical review should consider loads from:

• automatic feeding motors;
• main feed conveying equipment;
• ventilation fans;
• environmental controllers;
• lighting;
• water-related equipment;
• cooling equipment where required;
• electrical heating equipment where applicable.

Backup power should also be considered for critical equipment. A commercial poultry farm needs a power strategy that reflects the importance of continuous ventilation, drinking water and environmental management.

Was Renovating the Existing Houses Better Than Building New Ones?

The value of renovation depends on the condition of the existing buildings.

Reuse can be practical when:

• the main structure remains suitable;
• there is sufficient usable production area;
• new ventilation openings can be created safely;
• insulation and sealing can be improved;
• feeding and drinking lines can be arranged efficiently;
• electrical capacity can be upgraded where necessary;
• the remaining building life supports the planned investment.

New construction may be more appropriate when an existing house severely limits ventilation, equipment layout, biosecurity management or future expansion.

How Does Livi Machinery Develop a Two-House Broiler Farm Renovation Plan?

A project-specific proposal begins with information about the farm rather than a generic equipment quantity.

Farmers planning a similar project can request a poultry farm design and equipment quotation by providing existing house dimensions, photos or videos, target capacity, local temperature conditions and available electricity.

This information allows Livi Machinery to evaluate how feeding, drinking, heating and ventilation equipment can be integrated into the actual buildings instead of applying a generic layout.

What Can Other Poultry Farmers Learn from This Kyrgyzstan Project?

The main lesson from this 45,000-bird project is that an old poultry house should not be evaluated only by its floor area.

For a successful commercial broiler farm renovation, the building, feeding system, drinking system, heating, ventilation, electrical supply and future management requirements need to work together.

Automatic equipment can reduce repetitive labor, but automation performs best when it is supported by an appropriate house layout and environmental strategy.

For customers with existing buildings, Livi Machinery can evaluate the poultry house conditions first and then configure the automatic broiler feeding equipment and related farm systems according to the actual project.