Joe A. Gayle
Poultry House Insulation Retrofit
• Approx. 50,000 poultry houses in the U.S.
• Range of cost: $6,000-$40,000.00
» Tyson Foods: 151.30
» Pilgrim's Pride Corporation: 109.06
» Gold Kist: 61.79
» Perdue Farms Inc.: 51.32
» Sanderson Farms: 30.39
» Wayne Farms LLC: 28.95
» MountaireFarms Inc.: 23.44
» Foster Farms: 16.51
» OK Foods Inc.: 15.80
» PecoFoods Inc.: 15.60
» Total 504.16 MM lbs
FOOTPRINT: 50’ by 500’
WALL AREA: 8800-9600 square feet
CEILING: 20,000-30,000 sq.ft.
Cost Range for complete retrofit:
The Question is:
Can the average farmer do this
himself OR is a professional applicator
We’ve found that most broiler houses that need retrofitting are not constructed with sufficient access to
allow most professional spray foam application rigs to enter the facility.
Therefore, we’ve been actively working on programs for the various sized houses that one could rent,
or buy, the equipment necessary to apply closed cell sprayed polyurethane foam and purchase
refillable & returnable containers of foam product pre-dyed for your poultry needs.
Multiple sizes-Returnable cylinders-Short learning curve-Maximum Results?
(Outside average maximum temperature 91°F/32.8 °C)
House with insulated roof
Interior temperature 92°F/33.3°C
Mortality Rate 0.5%
House with no insulation
Interior temperature 99°F/37.2°C
Mortality Rate 14.3%
• Sunny day metal roofs reach 150°F/66°C
• Ventilation systems cannot handle heat loads from
• Radiant roof heat affects birds before ventilation can
comes into play in many instances
Source: Auburn University in cooperation with U.S. Egg & Poultry
Closed-Cell Foam Insulation
There is no better insulating material that can seal your broiler house
from air and moisture intrusion, save on costly utility bills,
strengthen your house, and protect your poultry investment from
dangerous mold, airborne pollutants, and allergens than Closed Cell
Spray Foam insulation.
Benefits of Closed-Cell Spray Foam Insulation
Stops air and moisture infiltration
Saves on energy costs
Adds strength to the building structure
It is permanent and will not sag
Keeps dust and pollen out
Reduces capacity requirements, maintenance and wear of HVAC
We are extremely proud of our relationship with
Polyfoam Products. With customer service
exceeding exceptional & prompt deliveries, this
arrangement promotes flexibility in product lines,
incidentals, and shipping with locations convenient to
service you better. Furthermore, The Junction Crew
will have an experienced professional in your time
zone to answer questions and guide you through the
Order by the set OR-
Order the 350 gallon set for the big houses.
For clarification, all SPF products are bio-based. However, whether they contain soy-based or sucrose-based
polyols to create the reaction necessary to form the polyurethane foam, a significant portion of the total
formulation in all SPF products on the market today is petroleum-based. Some foam systems even
substitute water as their blowing agent rather than HCF or HCFC gases, giving them an added degree of green
content and renewability.
There is a popular misconception that the bio-containing
foams (whether soy or sugar) are more substantially green,
when, in fact the final polymers are still mostly petroleum
However, the USDA has offered the criteria that if a material is at least 9% renewable content, the claim of being
“bio-based” is valid.
1. Poor quality foam EQUALS an
upset customer which translates
to a technical service nightmare
among other things.
2. Poor yield, or more appropriately,
yielding less than a customer pays
3. The adjacent picture shows 2
examples of a failure to control
the temperature of your foam.
(Top 2 stud cavities.)
4. The Junction Crew focuses on
educating, training, & supporting
the customer on the importance
of temperature & ratio control *see next page for further description.
with a strong focus on safety.
The importance of Temperature
Which of the above appear to have the best quality?
With a few notes of importance.
These photos will be posted inside your rental unit.
• It takes as little as 4 hours for ANY of the available DIY
Kits to cool down to the point where the product performs
• It takes up to 4 days to reheat to optimum temperature.
• A board foot (BFT) is a square foot of foam that is one inch
• Refillable kits are sold according to the board foot (BFT).
• Industry professionals typically charge $.80-1.00 per board
foot to apply closed cell foam for their clients.
• The Junction Crew promotes Returnable Dispensing Kits
include safety equipment & a fresh air system and will cost
.75- .85 per board foot or less on larger applications.
Do it yourself?
The Junction Crew, LLC is one of a growing number of environmental advocates in the
United States that cater to the use of refillable containers. A manufacturer’s
representative for Polyfoam Products, The Junction Crew is your support conduit
devoted to environmentally applying SPF products. Why is this important?
Spray foam insulation is a plural component chemical mixture that is formed when
these two chemicals meet and react at the gun. The result is the inert product that
we know as Sprayed polyurethane foam insulation (SPF).
However, the A-side or Isocyanate, is a particularly nasty product by itself that
vigorously reacts with water and throwing away a container that held, or still most
often holds Isocyanate goes against the very principle of environmental
The Junction Crew promotes the use of refillable tanks through several National
Suppliers of refillable spray foam products and provides training & support.
The Do It Yourself Option
WHAT YOU’LL NEED:
1. 50-150ft. Of Hoses: Either heated or non-
heated depending on your situation.
2. Nitrogen-Pick it up locally
3. Nitrogen Regulator
4. Dispenser Gun
5. Calibration Tips & Calibration scale
6. Dispenser tips of different sizes
7. Noish Approved Fresh Air System
8. Personal Protection package for you and
9. 24/7 Customer Support from the industry’s
best! Quantity of items needed
10. Manual with trouble shooting guide. dependent on the job-
And that’s what you’ll get!
GUARANTEED BUY IT or RENT IT
The choice is yours.
• Back left: System 100-120
12,000 board foot system OR
4000 square feet of an R19.
• Back right: System 60-
6000 board foot system OR
2000 square feet of R19. (wt.
• Front mid: System 17-
1,700 board foot kit OR 567
square feet of R19. (wt.
• Other sizes available
• A 350 gallon set
• Traditional used as a
• Set it on a trailer-connect
the hoses & the Nitrogen
• Spray 35,000 board feet
with a single calibration.
• Very competitively priced
• BIG DEPOSIT/Big Return
OR-Check with your local rental store for-
“Junction Series Rental Units”
• 6x12 Enclosed trailer
• 7,000 gvw
• Spare tire
• Fully insulated box
• Diamond plate floor
• Plywood Walls
• Chemical storage & strapping
• 150 feet of hose
• Nitrogen tank storage & strapping
• Heating sleeves
• Shore powered to plug in overnight. (Keeps the
tanks at optimum temperature.)
• Tool box for storage of pieces & parts
• NOISH APPROVED Fresh air system
• FULL safety package with eye wash kit, ear &
eye protection, respirators, fire extinguishers, &
• Display items-foam wall, brochures, data sheets,
benefits, 6x12 pictured
And if they don’t have it- TELL THEM TO CALL US!
And yet another option-
The Pro-FAMILY consists of professional applicators concentrated in the geographic
locations shown above. There are nearly 250 applicators that we communicate with monthly
in the states shown above-AND, our Supporting Manufacturer GACO WESTERN is there to
provide the dyed product & support that best suits your poultry need.
CALL US TO FIND ONE NEAR YOUR BROILER HOUSE.
What’s your COST?
DIY or PRO
The cost of application is going to range from 0.70-1.00/board foot (sq.ft/inch).
Multiple variables should be considered to calculate your cost.
Call for help in calculating your cost.
Here’s what we’ll need:
1. Area to be sprayed and,
2. The R-Value desired!
Your COST is easily projected thereafter-YOUR SAVINGS AWAITS.