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Ventilation is critical to the health and production of animals in modern farming operations. Livestock producers continuously seek efficient and cost-effective ways to maintain optimal environmental conditions in their barns. Tunnel ventilation systems are designed with air inlets located at one end of the barn and all the exhaust fans located on the opposite end. This configuration pulls fresh air in through the inlets and along the entire length of the barn, generating a tunnel-like airflow.
Tunnel ventilation is a key method of modern barn ventilation because it keeps the air clean, temperatures steady, and animals comfortable. Research from the National Swine Research Center indicates that tunnel ventilation reduces livestock heat stress mortality by up to 15 percent and improves feed efficiency by 10 percent, making it an essential tool for today’s farming operations.
In this article, we will go over the benefits of tunnel ventilation, how it’s used, and some things to consider. By continuously moving fresh air through the barn, this system helps control temperature and reduces moisture, ammonia, and dust, making for a healthier space for livestock and workers.
How tunnel ventilation works
Intakes are strategically placed near the ground on one side of the barn to capture prevailing breezes and bring fresh outside air inside. This air is then pulled through adjustable inlets—such as curtains, louvers, vents, and other mechanisms—ensuring it is evenly distributed throughout the barn.
Powerful exhaust fans are mounted at the opposite end of the barn to create the tunnel effect. The fans exhausting the air out of the barn creates negative pressure in the barn, which draws fresh air in through the inlets. This creates a continuous flow of fresh air from one end of the barn to the other.
Many tunnel ventilation systems use evaporative cooling, where air is cooled by the evaporation of water before entering the barn. The combination of airflow and evaporative cooling keeps the barn comfortable in hot climates while removing excess heat and humidity.
Tunnel ventilation use in different industries
| Industry | Applications | Suitability for use |
|---|---|---|
| Poultry | Broiler chickens, layers, turkeys | Very common due to high air exchange rates needed to manage heat and remove gases. |
| Swine | Nursing and finisher pigs | Common, used to keep pigs comfortable by controlling heat and air quality. |
| Dairy | Milking parlors and barns | Less common, as cross-ventilation and natural ventilation are preferred in most cases. |
| Dairy (hot climates) | Milking parlors and barns | Can be effective in hot climates when properly managed for air distribution. |
| Horticulture | Greenhouses | Rarely used, as other forms of ventilation are typically more suitable for greenhouses. |
Tunnel ventilation is widely used in poultry operations, where high-density housing requires rapid air exchange. Over 80% of commercial broiler operations in the U.S. have adopted this system to manage heat and remove harmful gases effectively (Source: USDA).
Advantages of tunnel ventilation
Low start-up and operating costs
Tunnel ventilation systems are affordable to install and energy-efficient, making them a cost-effective long-term solution.
Temperature stability and climate control
These systems maintain consistent temperatures, preventing heat stress and ensuring a comfortable environment for livestock.
Improved animal health and productivity
A stable, well-ventilated environment keeps animals healthy, leading to better productivity and higher profits for farmers.
Effective cooling
Fast-moving air cools animals, and evaporative cooling can lower air temperature further, especially important in warm climates.
Removal of heat and harmful gases
The system removes excess heat and gases like ammonia, ensuring better air quality inside the barn.
Dry and comfortable bedding
Proper airflow keeps bedding dry, reducing the risk of bacteria and mold growth, which helps keep animals comfortable.
Environmentally friendly
Tunnel ventilation with evaporative cooling is environmentally friendly because it uses water efficiently and produces no wastewater. By optimizing water usage, this system minimizes environmental impact while providing effective cooling in warm climates
Did you know?
Tunnel ventilation can reduce livestock heat stress mortality by up to 15 percent, according to the National Swine Research Center.
Proper maintenance of fans and inlets can lower energy usage by 10 percent annually, based on Purdue University Extension research.
Evaporative cooling systems in tunnel-ventilated barns use up to 80 percent less water than traditional sprinklers (Source: University of California Agriculture and Natural Resources).
Considerations
Tunnel ventilation is effective in warm weather, but adjustments are needed during colder months. Ventilation rates should be reduced in winter to prevent chilling, while still maintaining air exchange to manage moisture and ammonia levels. This helps keep the barn comfortable and safe without overcooling the animals.
Regular maintenance tasks include cleaning fan blades to ensure optimal airflow, checking and tightening drive belts for proper fan operation, and inspecting inlets for wear or damage to maintain effective sealing. These routine checks help prevent uneven airflow and ensure the system operates efficiently year-round.
Conclusion
Tunnel ventilation is an important type of ventilation in modern livestock farming because it uses controlled airflow created by a combination of powerful exhaust fans and intake vents, resulting in a continuous flow of fresh air that cools the barn, removes hazardous gases, and promotes healthy, productive conditions for animals. Its benefits include low startup costs, temperature stability, and increased farmer profits.
Tunnel control solutions from Phason Controls
Phason Controls offers two series of controllers to effectively manage tunnel ventilation systems:
Touch Series includes the Plus Touch and Supra Touch, both equipped with smooth, optimized ventilation control powered by our VentGrid™ merged ventilation. Additionally, Touch Series features secondary modifiers that allow you to use conditions like CO₂, ammonia, humidity, and more to influence ventilation control.
AutoFlex Connect is more than a ventilation controller, it is a precision automation system for your barn. AutoFlex Connect is a modular system — you add what you need — and comes in two sizes. AutoFlex Connect includes all the same features as Touch Series controls, but adds features like remote connectivity and monitoring to give you more control and peace of mind.
