Case Study: Huron Poultry's SolarWall Air-Heating Cladding — Cutting Barn Heat Bills in Southwestern Ontario
Huron Poultry is a southwestern-Ontario egg producer whose production barn is clad with a SolarWall solar air-heating system — one of the most-documented Canadian solar-air installations on a livestock operation. The setup uses perforated dark-coloured metal cladding as a passive solar collector, drawing outdoor air through the sun-warmed panel and delivering pre-heated ventilation air into the barn. Egg Farmers of Canada and Canadian Poultry Magazine have documented energy-cost reductions of up to 30% on barn heating. Here's how the technology works, why poultry is one of the strongest fits, and what a comparable retrofit looks like today.
The installation at a glance
| Parameter | Value |
|---|---|
| Location | Southwestern Ontario (Huron County region) |
| Operation type | Commercial egg / poultry producer |
| Solar technology | SolarWall unglazed transpired solar air collector |
| Manufacturer | Conserval Engineering (Ontario) |
| Cladding role | Building envelope AND solar collector — replaces conventional cladding |
| Air heated | Ventilation intake air (delivered pre-heated into barn) |
| Documented savings | Up to 30% barn heating cost reduction |
| Sources | Egg Farmers of Canada, Canadian Poultry Magazine, Conserval Engineering case notes |
SolarWall is a transpired solar-air technology developed by Conserval Engineering, an Ontario-based manufacturer. It's not photovoltaic — it doesn't generate electricity. Instead, dark-coloured perforated metal cladding heats outdoor air as it draws through thousands of tiny perforations, warmed by absorbed solar radiation. A fan draws that pre-heated air through a plenum behind the cladding and delivers it directly into the building's ventilation system.
Why poultry is such a strong solar-air fit
Modern poultry barns require continuous ventilation year-round — not for temperature control primarily, but to remove ammonia, moisture, and CO2 that build up from bird respiration and manure. In Canadian winter, that ventilation air enters the barn at outdoor temperature (often -20°C or colder) and must be warmed to bird-comfortable levels. That heating load is the single biggest utility line on a modern poultry operation.
- The load is HUGE. A commercial barn with 20,000-40,000 birds cycles thousands of cubic feet per minute of ventilation air — every cubic foot at -20°C outside needs to be heated to around 20°C at bird level, running around the clock through winter.
- The load PERFECTLY matches solar-air output. Peak ventilation demand is during daytime bird activity; peak solar-air output is also during daytime. No storage required — heated air goes straight from collector to barn intake.
- The barn already has south-facing wall area waiting to be used. Cladding it in SolarWall costs a modest premium over standard cladding and delivers heating essentially free for 25+ years.
- Poultry operators are chronic fuel-cost sensitive. Barn heating in Ontario often runs on natural gas or propane at commercial rates — same fuel that solar-air is displacing.
What a comparable retrofit costs today
For a mid-scale poultry barn (30-50 metre south wall) retrofitting SolarWall in place of existing cladding at recladding time, 2026 costs typically run:
| Item | Cost range |
|---|---|
| SolarWall cladding (300-500 m² south wall) | $40,000 - $90,000 |
| Plenum framing + air distribution | $15,000 - $30,000 |
| Fan + ductwork + controls | $10,000 - $25,000 |
| Installation labour + electrical | $15,000 - $35,000 |
| Structural / building-envelope integration | $8,000 - $20,000 |
| Total installed cost | $88,000 - $200,000 |
| Federal 30% Clean Tech ITC (Class 43.1) | -$26,000 - -$60,000 |
| AAFC ACT program contribution (typical) | -$10,000 - -$40,000 |
| Net cost after federal + AAFC support | $52,000 - $100,000 |
| Expected payback (barn heating displacement) | 5-9 years typical |
The retrofit math works best when timed with a planned recladding — the SolarWall costs REPLACE the conventional cladding you'd have bought anyway, so only the differential counts against the payback calculation. Building the same system as an addition to existing cladding roughly doubles the marginal cost.
Lessons from the Huron install
- Solar-air heating is under-marketed on Canadian farms. Most producers assume solar means PV; solar-air is often the faster payback path for barn-heating loads.
- Time the install with a planned recladding project. SolarWall integrates cleanly into a new south wall; retrofitting behind existing cladding is more expensive and structurally more complex.
- AAFC ACT program (Agricultural Clean Technology) has funded multiple Canadian SolarWall barn installations. Application timing matters — check ACT program windows before quoting.
- Cladding + fan + controls need to be sized together. An oversized fan wastes electricity; an undersized fan under-utilizes the solar collector. Ask your installer for a load calc based on your barn's actual ventilation flow rate.
- SolarWall works alongside — not instead of — your primary heating system. You still need a boiler / gas heater for early morning, night, and heavily overcast conditions. Solar-air displaces a share of the annual load, not the peak load.
Frequently Asked Questions
Does SolarWall work on poultry barns in cold northern Ontario or the Prairies?
Yes — SolarWall is deployed across cold-climate Canadian applications including Manitoba and Alberta poultry operations. The unglazed transpired technology performs well in cold conditions because it captures diffuse and direct sunlight and delivers moderate temperature rises even on very cold days. Winter yield is roughly 15-25% of annual output; the remaining production comes during shoulder + summer months when heating loads are lower but ventilation air still benefits from pre-warming.
Can dairy or livestock barns use the same technology?
Yes. SolarWall has documented installations on dairy, cattle, and other livestock barns. The math changes with load profile: dairy barns typically have lower ventilation heat load than poultry (cattle heat their own barn), so savings percentages are usually lower but still meaningful. Cold-storage warehouses and industrial operations with high ventilation loads are also strong fits.
What maintenance does SolarWall need?
Very little. The cladding is essentially maintenance-free — no moving parts, no fluid, no glazing to clean. The fan and controls need annual inspection like any HVAC equipment. Manufacturer warranty is typically 20+ years on the cladding.
Does SolarWall qualify for the federal Clean Technology ITC?
Most active solar heating equipment qualifies under CRA Class 43.1, which is a qualifying class for the 30% refundable ITC. SolarWall systems installed for commercial or farm-business use typically qualify. Farm operators structured as sole-proprietorships face different treatment than incorporated operations — confirm eligibility with your accountant.
How does SolarWall compare to putting rooftop PV on the same barn?
Different jobs. Rooftop PV generates electricity that offsets your electricity bill. SolarWall generates warm air that offsets your gas / propane heating bill. On a poultry barn, the heating bill is typically 2-4× the electricity bill — so displacing heating with SolarWall often delivers larger absolute savings than displacing electricity with rooftop PV. Best answer for many farms is both: SolarWall on the south wall + PV on the roof.
Is the Huron Poultry system still operating?
The system has been documented as operational in Egg Farmers of Canada producer case-study coverage and secondary trade press. We haven't independently verified current 2026 operational status. For a live reference call or operational tour, contact Conserval Engineering directly.
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