Multi-tier makes free range unit viable

When it came to converting a redundant agricultural building to a free range laying house, Paul and Kirsty Cooks’ choice of a Jansen multi-tier system meant bird numbers were boosted from a potentially unviable 2,200 to 3,800.

“When planning the unit we were aware it could be a struggle to get a packer to take us on simply because we wouldn’t have enough birds,” explained Paul. “But by installing a multi-tier system it meant that bird numbers were increased to a point where a packer was interested.” The couple were delighted when Noble Foods agreed to take the eggs.

The former cattle shed on the South Devon farm already had a concrete floor and sides built of dungwalling, above which stretched Netlon to aid ventilation. Conversion to a poultry unit involved cladding over the Netlon with solid boarding – but which can be opened if necessary during hot weather – and lining the roof with sheeting, creating a cavity which was filled with insulation material. The ridge was left open to provide good airflow.

Inside the building a Jansen Compact multi-tier system was installed. This consists of two-tier nests sat on top of a raised slatted area on which are positioned chain feeders and nipple drinkers; whilst either side of this running the length of the shed are two raised platforms where the birds can also feed as well as rest on the perches incorporated in the structure. The ground floor consists of litter where the birds can dust bathe.

Underneath the aerial platforms are manure belts which transport the droppings to the end of the shed. Whilst the Cooks have yet to invest in an elevator to load the manure into a trailer, instead using a homemade box on the back of a tractor, Paul estimates that running the belts and taking the manure away still only takes 30 minutes a week.

“We are extremely pleased with the set-up,” he told and it all works very well.” Equally pleasing was the cost, which Paul calculates to be around £14 a bird place, including conversion of the cattle shed. The Hy-Line birds also appear to like their new home, showing their approval with a highly commendable lay rate of 96 per cent at 42 weeks of age.

Floor eggs have not been a problem either, and are currently running at around 40 to 50 a day. Whilst lights are positioned strategically to deter the practice, any that are laid on the raised platforms gently roll forward for ease of collection and the few eggs that are laid on the floor under the structure are gathered using a long-handled lawn rake.

Former broiler grower Paul was full of praise for the fitters from local dealer Jansen UK. “They were very skilled and nothing was too much trouble. Adapting equipment to fit an existing building is never straightforward but the guys from Jansen UK were very accommodating; even making up new profiles so we could incorporate second-hand drinkers out of the broiler sheds.” months into it, the Cooks are enjoying free range egg production, despite describing it as “demanding”.

“There is a lot more to it than growing broilers but the indications are that this will be reflected in better financial returns” says Paul. In fact such is their confidence, Paul and Kirsty are already planning the conversion of a second building on the farm that will boost total bird numbers to around 10,000.