Halaal FarmsHatchery · Kasoa, Ghana
Management

Running a Poultry Farm Through Load-Shedding in Ghana

Halaal Farms hatchery teamOpeikuma, Kasoa · · 9 min read
White chicks resting together

Short answer: Load-shedding hurts a poultry farm through the jobs that get missed in the gaps, more than through the outage itself. Keep an outage log for a month, fill the header tank before the lights go, do the feeding, weighing and egg work in the on-hours, and restart loads in a fixed order. A written plan turns a cut from a crisis into an ordinary part of the day.

Key takeaways

  • Keep an outage log for a month and plan around the pattern it shows.
  • Fill the header tank at the start of each on-window, and measure its cover in hours of use.
  • Put feeding, weighing, egg collection and cleaning inside the hours the power is on.
  • Restart loads in a fixed order, pump first, to avoid a surge that trips the breaker.
  • Write the plan on a card at the switch, and brief every worker on it.

Load-shedding comes on a pattern, so learn the pattern

Ask a farmer which outage hurt most and they will not describe the long one. They describe a short cut at six in the evening, when the pump was half full, the fans were off in a warm house and nobody had checked the drinkers since the afternoon. A long outage is a known disaster, and everyone prepares for it. The short one catches people who think a cut is a nuisance.

Load-shedding, which Ghanaians call dumsor, often runs to a pattern that repeats through the week. Where the utility publishes a schedule for an area, use it. Where it does not, your own log will show the pattern within a few weeks, and that log is more useful than a rumour from the next farm. Plan around the times the power is most likely to go, not the times you hope it stays on.

Keep an outage log for a month before you plan anything

Start the log on the first day of the month and write every cut, however short. Note the time it went off, the time it came back, the length and anything that went wrong. Keep the log by the switch or in a shared phone note that the farm manager can see. A month of entries shows the pattern, the worst hours and the hours when the farm can work safely without the grid.

The rows below are an example of what the log should look like. They are not our own records.

DayOff atBack atLengthWhat was lost or delayed
Monday18:1019:0555 minFans stopped, drinkers checked late
Tuesday07:4008:1535 minNothing, the feed was already out
Wednesday13:2015:00100 minEgg collection late, eggs left in the sun
Thursday22:3023:1040 minPump restarted by hand in the dark

After a month, count the cuts by hour. The hour with the most cuts is the one that decides your task list, and the length of the longest cut sets the minimum water cover you need.

Fill the header tank before the lights go, not after

Water is the load you cannot do without. The pump lifts water into the header tank, and the tank keeps the drinkers full when the mains is off. The rule is to fill the tank at the start of every on-window and let the level climb before you do anything else in the house. A tank that is half full when the power goes gives you hours. A tank that is nearly empty gives you minutes.

Measure the tank in hours of cover, not in litres. Take the usable litres and divide by the house's use in the busiest hour of a hot day, then keep a margin. Layers drink roughly a quarter of a litre a day in mild weather and considerably more in heat, so the hot afternoon is the number to plan for. If the cover is shorter than the longest cut in your log, the storage is too small, and careful scheduling will not fix that. Our water supply guide goes into tank sizing in more detail.

Put the jobs that need power inside the on-hours

Some jobs can wait for the lights and some cannot. A cut does not stop the chicks needing warmth, the eggs needing cooling or the drinkers needing a check, but it makes every job slower and riskier. The table sorts the common jobs into the window where they belong.

JobBest windowWhy
Fill the header tank and check the floatFirst minutes of on-powerThe tank is the buffer for the next cut
Morning feed round and feeder checkOn-power, early morningFeeders are easier to refill with light
First egg collectionEarly morning, on or offCooler hours protect the eggs
Second egg collectionBefore the afternoon heatStops eggs sitting in a hot house
Weigh samples and record countsOn-power, with a torch as backupScales and the sheet need steady light
Vaccine fridge checkAlways on the backup supplyA warm fridge spoils vaccine, so follow our cold chain guide
Washing crates and cleaningDaylight hoursWater is in the tank and light is free
Phone calls and paperworkWhenever the phone has chargeKeep buyers updated in the same message

Decide which loads get power first

When the supply is limited, the farm has to choose. A written priority ladder means the person on duty does not have to decide in the dark. The order below suits a layer or broiler farm on a small supply. Adjust it to your house, but keep the top two lines fixed.

  1. Water pump to the header tank. Without water the rest of the farm does not last long.
  2. Fans or inlet fans in a hot spell. Birds in a closed, hot house go down quickly, so the first fans to run should be the ones that move the most air at bird height.
  3. Brooder heat for chicks. If there are chicks in the house, their heater comes before any lighting.
  4. Vaccine fridge and cold storage. Keep the cold chain running, and check the temperature when the power returns.
  5. Lighting. Lights matter for layers on a set programme, but they come after air, water and warmth.
  6. Incubator, if one is running. Our incubator guide covers the routine for a setting through a cut.

Layers and the light programme that a cut can break

A layer flock works to a light programme. Hens respond to a steady day length, and a sudden dark in the middle of the afternoon is a shock they cannot make sense of. A cut that drops the lights for a long spell can make birds crowd, slow their laying for a day or two and, in a poorly ventilated house, pile up in the corners. A short cut matters less than a long one, but a cut at the wrong hour can do more harm than a long night.

The fix is to keep the programme as steady as the supply allows. On a farm with a generator or solar, run the lights from a set time each day, even when the supply is short, and do not let them come back in a random pattern when the power returns. If the house goes dark for an hour in the middle of the day, do not panic-feed or hand-catch the flock. Check the air, the water and the crowding, and let the birds settle. Our lighting programme guide sets out the schedule.

Eggs during a cut: collect, cool and count

Eggs are the product most exposed to a power cut. A cut that runs through the hot hours leaves eggs sitting in a warm house, and a warm egg loses quality faster than most farmers expect. Collect at least twice a day, and do the second round before the afternoon heat, not after it. Carry eggs in clean trays to a cool room, and keep them out of direct sun while you count.

If you have a cool room on a generator or solar supply, run it first and keep the door shut. If you do not, a shaded, ventilated store is better than a warm room with a door that is always open. Our egg storage guide explains the room options, and the table egg storage guide covers how long eggs keep in each room.

Write the egg count on the sheet at every collection. A drop after a cut can mean the lights were off during the lay peak, the house was too hot or the birds were frightened, and the sheet will show which, if the counts are kept properly.

Restarting in order, so the power does not trip twice

The return of the power is the most dangerous minute of a cut. Every motor and heater comes back at once, the surge trips the breaker, and the farm goes dark again while the water is still low. Restart the loads one at a time, in the same order every time. Start with the pump, let the tank rise, then bring up the fans, then the brooder heat, and the lights last.

Check the breaker and the cables after every restart, and feel the motors for heat once they have run for ten minutes. A breaker that trips twice is telling you something, and the answer is not to bridge it. Call an electrician. Keep a laminated card at the board with the restart order and the electrician's number, so whoever is on duty at night can follow it without thinking.

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Staff, rota and the buyer who calls at noon

A cut is a staffing problem as much as an electrical one. The worker who knows the restart order should be on the farm for the evening cut, and the worker who knows the egg routine should be on the farm for the morning collection. Write a rota that covers the hours the utility is most likely to cut, not only the normal working day.

Tell the buyers too. A buyer waiting for birds or eggs who hears nothing will assume the worst. A short WhatsApp message saying the farm lost power for an hour and the collection is still on keeps the relationship intact. Ask your chick supplier for the same courtesy, and confirm delivery windows in writing so that a cut does not become the excuse for a missed day. Our delivery page explains how chicks reach your region.

A worked example: two cuts on one hot afternoon

Here is an illustrative afternoon, with made-up figures, to show how the sums work on a farm. A 500-bird layer house has a header tank of 1,000 litres. On a hot day the house uses about 225 litres in total, including cleaning, and the busiest hour of the afternoon uses roughly 14 litres. On a hot Thursday the grid drops twice, for 90 minutes at noon and again for 90 minutes at four in the afternoon.

At noon the tank reads 400 litres. At 14 litres an hour in the busiest part of the day, that is about 28 hours of cover, so neither cut is a water crisis. The sheet still gets a note, because the pump has been off for a long stretch and the morning level was already lower than the day before. The real risk comes the next morning, when the pump needs to fill the tank before the six o'clock round and the power may not cooperate.

The lesson is that a tank is measured in hours of cover, not in litres. Write the hours of cover on the sheet at each morning round, and top the tank up whenever the power returns, so the morning level is never lower than the day before. A tank that falls a little every day will reach the wrong number on the wrong morning.

The checks after the power returns that stop a second loss

When the power comes back, the job is not over. Walk the house and check the air first, then the water and the feeders, before you settle into the evening routine. A house that has been closed and dark for an hour can be warm and damp, and birds may have crowded into the corners. Look for birds piled against the walls and spread them out before they suffocate.

  • Air moving at bird height, with the inlets and fans running in the right order.
  • Header tank rising and drinkers full along the line, including the ends.
  • Brooder heat on and the chicks spread out, not piled.
  • Vaccine fridge back in range, with the reading written down.
  • Lights back on the programme time, not at a random hour.
  • Eggs collected and counted, with cracked or dirty eggs set aside.
  • Breaker and cables checked for heat, and the cut logged in the outage log.

Treat generator fuel as a daily budget, not a surprise

If you run a generator through the cuts, measure its fuel the way you measure feed. Write down the litres put in each day, the hours the set ran and the cut it covered. A set that runs all night on a small load is burning fuel the day's cuts did not need, and a set that runs too little can be left with an empty tank on the one night the cut is long.

Plan the generator hours around the priority ladder. Run the pump and the fans, and the brooder if there are chicks, and switch the rest off. Keep a spare can, but store fuel away from the house and the generator, not beside the feed. Our generator guide sets out sizing and fuel choice, so read it before you buy, and use this section to run the set day to day.

Questions farmers ask

How do I find out when load-shedding will hit my area?

Use the utility's published schedule where one exists, and build your own outage log for a month. The log shows the hours your area usually goes off and how long each cut lasts. Plan around that pattern, not around the hope that the power stays on.

What should I switch on first when the power returns?

Restart the pump first so the header tank rises, then the fans, then any brooder heat, and the lights last. Restarting everything at once can trip the breaker and leave the farm dark with the water still low.

How big should the water tank be for load-shedding?

Measure the tank in hours of cover rather than litres. Divide the usable water by the busiest hour of a hot day, and check that the answer covers your longest cut plus a margin. If it does not, add storage before adding more lights.

Do layers lay less when the lights go off?

They can, especially if a cut is long or breaks the day's programme. Keep the lighting on a steady set time when the supply allows, avoid random restarts, and watch the egg count for a few days after a cut.

Can I keep eggs in the house during a cut?

Not for long in the heat. Collect at least twice a day, carry the eggs to a cool, shaded room, and keep them out of the sun while you count. If you have a cool room, run it first on the generator or solar supply.

Is a generator enough to run the whole farm?

It depends on the load list and the fuel budget. A generator that runs only the pump, the fans and the brooder covers most cuts. Size it from your load list, and read the generator guide before you buy.

What do I check first after the power comes back?

Check the air at bird height, the water in the tank and drinkers, the chicks' spread under the brooder and the vaccine fridge. Then check the breaker and cables for heat, and log the cut. Look at the birds before you settle into the evening.

Written by the Halaal Farms hatchery team

We hatch and import day-old chicks in Opeikuma, Kasoa and deliver to farmers in all 16 regions. Questions about this guide? WhatsApp us on +233 24 915 1503.

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