Poultry Scalder Energy Calculator
A 2,000 birds-per-hour scalder line needs about 65 kW of heat, all shift long. On a diesel steam boiler that heat costs about ₱13 per kWh — roughly ₱177,000 a month. On a Karnot heat pump, ₱3 per kWh — about ₱40,600. Around ₱136,000 a month, on the scalder alone.
Put in your own line speed, running hours, fuel and tariff below — every number is editable and the result recalculates as you type. Soft-scald basis 52–55°C per PAES 529.
Your Line & Prices
| Method | ₱ / kWh of Heat | ₱ / Day | ₱ / Month | ₱ / Year | CO₂ / Year |
|---|
The Formulas
Scalder heat load and monthly heat:
Cost per kWh of heat (η = boiler system efficiency; NCV = net calorific value):
Method & Sources
- Scald temperature — soft scalding at 52–55°C per PAES 529 (Philippine Agricultural Engineering Standard, poultry dressing plants). Hard scald runs hotter but is uncommon for PH broiler lines.
- Scalder load — default 32.5 Wh of heat per bird (makeup water, surface and evaporative losses, bird heating), i.e. 65 kW at 2,000 birds/hr. This is a sizing estimate: measured plants vary with tank insulation, makeup rate and bird size, which is why the field is editable.
- Net calorific values — diesel 10.0 kWh/L, LPG 13.6 kWh/kg, bunker/HFO 11.1 kWh/L, with CO₂ factors 2.68, 3.0 and 3.15 kg per unit respectively — the same hub-standard table as our Boiler Converter, aligned with UK Government GHG conversion factor publications. PH grid electricity 0.71 kgCO₂e/kWh.
- Boiler system efficiency — default 65% for a steam boiler feeding the scalder through a distribution loop (flue, blowdown, standby and pipe losses included). A direct-fired hot-water boiler does better: set 80–88% and the comparison recalculates.
- Heat pump — COP 4.0 default for iHEAT R290 at 52–55°C delivery in PH ambient. The heat-recovery row uses an effective COP of 5.9, an estimate for a unit sourcing from immersion-chiller heat rejection instead of ambient air — treat it as the upside case until measured on your plant.
- Honest point — the 82°C steriliser loop is out of scope: R290 stops at 75°C, so that duty takes a CO₂ heat pump. This tool prices the scalder, the largest single heat load in most dressing plants.
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Frequently Asked Questions
How much heat does a poultry scalder need?
A useful first-pass figure is ~32.5 Wh per bird for soft scalding at 52–55°C (PAES 529) — about 65 kW continuous on a 2,000 birds/hr line. Edit the per-bird figure above if you have measured data from your plant.
What does scalder heat cost on diesel versus a heat pump?
At ₱85/L and 65% steam-system efficiency, diesel heat is ~₱13/kWh delivered. A heat pump at COP 4 on a ₱12/kWh tariff delivers it for ~₱3 — around ₱2 with chiller heat recovery. On a 2,000 birds/hr line (8 h × 26 days) that is ~₱177,000 versus ~₱40,600 a month: about ₱136,000 kept in the plant.
Why is boiler efficiency set to 65% and not 85%?
Most plants feed the scalder from a steam boiler through a distribution loop — flue, blowdown, standby and pipe losses put 60–70% overall in the typical range. A direct-fired hot-water boiler does better (80–88%) — the field is editable, and the ranking against the heat pump does not change.
Can the same heat pump run the 82°C steriliser loop?
No — R290 delivers up to 75°C and sterilisers need 82°C. The scalder and washdown run on the R290 unit; the steriliser loop takes a smaller CO₂ heat pump (up to 90°C). This tool prices the scalder only.
Want This Run on Your Real Numbers?
Send a month of fuel receipts and your line speed. We reply with a one-page savings estimate on your plant — free, within two working days, no site visit needed for the first pass.
Get Your Plant's NumbersSpecifying a real system?
Karnot builds R290 and CO₂ heat pumps in the Philippines — 9.5–100 kW, EN 378 design. Free load calculations for consulting engineers and contractors.