Converting open poultry houses to closed, climate-controlled houses — a planning scenario
Short answer
Converting open-sided houses to closed, tunnel-ventilated houses means sealing and insulating the envelope, installing tunnel fans and inlets, adding cooling and a controller, and upgrading electrical supply and backup power. Whether the existing structure can carry the conversion — span, height, floor and foundations — decides between retrofit and rebuild.
Open-sided, naturally ventilated → Closed, tunnel-ventilated, controller-managed
This is a planning scenario prepared for illustration. It is not a completed HatchMatch project, not a case study and not an engineering design. HatchMatch is not the equipment manufacturer — it is a supplier-neutral platform that helps commercial buyers structure requirements and approach suitable manufacturers.
Is the existing structure worth converting?
Assess before specifying equipment:
- Clear span and sidewall height — a closed house needs a usable tunnel cross-section
- Roof and wall condition, and whether insulation can be applied or panels are needed
- Airtightness potential: a leaky house will not hold static pressure at minimum ventilation
- Floor condition and drainage for washdown
- Foundations and end-wall structure for fan banks and pad frames
What the conversion package contains
Typically: sealed and insulated envelope, tunnel fan bank at the exhaust end, cooling pads and pump at the inlet end, side-wall inlets for minimum ventilation, a climate controller with sensors and alarms, upgraded distribution boards, and a generator sized for minimum ventilation at minimum.
Power and backup are non-negotiable
A closed house without power is a closed box. Standby generation with automatic transfer, plus alarms and a documented failure procedure, moves from optional to mandatory the day the curtains come down.
Operational change, not just equipment
Closed-house operation is managed by static pressure, target temperature and minimum-ventilation logic — a different daily routine. Training and a defined set of controller settings per bird age are part of the scope, not an afterthought.
Retrofit or rebuild
When span, height or foundations do not suit tunnel operation, a new house often costs less over its life than a compromised conversion. Compare retrofit CAPEX plus the performance ceiling of the converted house against new-build CAPEX before committing.
What drives the CAPEX
- Envelope condition and the insulation standard chosen
- House cross-section, which sets fan count and pad area
- Climate: design wet-bulb determines whether pads or fogging apply
- Electrical upgrade and backup generation
- Controller and sensor package
- Downtime: the conversion window between flocks
For indicative bands against your own numbers, use the Growth Planner and the expansion ROI calculator.
What belongs in the RFQ
- House dimensions and current construction, with photographs
- Design temperature, humidity and target air velocity
- Fan airflow at stated static pressure, inlet area and pad area
- Insulation specification and target U-value
- Controller, sensors, alarms and failure logic
- Electrical scope boundary and generator sizing
- Installation window between flocks and commissioning support
- Training package and operating settings per bird age
Scenario FAQ
Next step
Size your own step change, then send the scope to manufacturers on a supplier-neutral basis.