All Multi Stage Hatcheries I Visit Are Not the Same (Equal) What Makes a Standard Hatchery? Simply Must Have All of the Basics Good Stable Reliable Electricity Good Clean and Dry Compressed air Good Ventilation That Properly Supports the Machines and Embryos Along With Good Management and Maintenance Non - Standard Hatcheries ------Requires------Non - Standard Practices Manipulation Compromise Inferior Results
All Multi Stage Hatcheries I Visit Are Not the Same (Equal) What Makes a Standard Hatchery? Simply Must Have All of the Basics Good Stable Reliable Electricity Good Clean and Dry Compressed air Good Ventilation That Properly Supports the Machines and Embryos Along With Good Management and Maintenance Non - Standard Hatcheries ------Requires------Non - Standard Practices Manipulation Compromise Inferior Results
All Multi Stage Hatcheries I Visit Are Not the Same (Equal) What Makes a Standard Hatchery? Simply Must Have All of the Basics Good Stable Reliable Electricity Good Clean and Dry Compressed air Good Ventilation That Properly Supports the Machines and Embryos Along With Good Management and Maintenance Non - Standard Hatcheries ------Requires------Non - Standard Practices Manipulation Compromise Inferior Results
by: JERRY GARRISON Consultant - Technical Advisor Jamesway Incubator Company Are All Hatcheries Expected to Perform the Same? In Reality Can All Hatcheries Perform the Same? What Is Hatchery Performance Based On? How Is Your Hatchery Performing? Considering the Number One Goal of Any Successful Hatchery --------Being-------- Good Quality Chicks Produced at the Least Cost Is This Still Achievable With the Old Multi Stage Incubation Concept? One Important Fact to Establish and Consider ------is------ All Multi Stage Hatcheries I Visit Are Not the Same (Equal) There Are Many Things to Consider But Simply Only Two Basic Categories Standard OR Non - Standard What Makes a Standard Hatchery? Simply Must Have All of the Basics! Good Stable Reliable Electricity Good Quality Water That Meets the Correct Criteria Good Clean and Dry Compressed Air That Meets the Correct Criteria Good Ventilation That Properly Supports the Machines and Embryos Good Egg Pack That Meets the Correct Criteria Along With Good Management and Maintenance Non - Standard Hatcheries ------Requires------ Non - Standard Practices Manipulation Compromise ------Most Often Causing------ Misunderstanding Confusion Inferior Results To Put This Into Perspective What You Do? What You Have? What You Do With What You Have? What You Should Do? -------------------------------------------------------- Determines Your Success or Failure!!! Multi Stage Incubation Four Things To Consider 1. Recommendation (Specifications - Type, Adjustments and Etc.) 2. Procedures (Egg Handling, Set, Transfer, Pull, Process & Delivery 3. Principle Embryo development requires O2 and creates CO2 As air moves from the old to the fresh eggs it picks up CO 2 and heat Heat and CO 2 is supplied to freshly set eggs, cooling conditions and extra oxygen for the older eggs in the 5th and 6th rack positions Sometime, between 18 and 18 days of incubation eggs are transferred to Hatcher 181/2 days - 12 hour 6th position 18 days - 24 hour 6th position 4. Concept Heat (Majority Supplied by Embryonic Development in the 5th and 6th Positions) Humidity (Two Purposes: 1. Humidification and 2. Cooling) Airflow (Forced Air - Laminar - Negative Pressure) Turning (Two Purposes: 1. Early Embryonic Development and 2. Airflow Balance Monitoring of the Jamesway Multi Stage Incubation System --------------------------------- Jamesway Multi Stage Incubation System Affords You the Opportunity to Monitor and Correct Incubation Concerns Before You Have to See Them Four Tools Available to Monitor The Jamesway Multi Stage Machine 1. Entrance End Temperature 24 Hours After Transfer 2. Internal Infertile Egg Temperature 3. Internal Incubator Pressure 4. Chicks Hatched 12 Hours Prior to Pull Entrance End Temperature 24 Hours After Transfer (100.3 Degrees F. Super J) (100.5 Degrees F. Big J) (Both Right and Left Side) Side to Side Variations Indicates Maintenance or Egg Pack Concerns High or Low Temperatures Indicates Need For Set Time Adjustment Super J Internal Infertile Egg Temperature (5th or 6th Position) 1.Top ------ 98.8 F. 2. Middle -- 98.9 - 99.0 F. (Both Right and Left Sides) 3. Bottom - 98.8 F. Higher Temperature @ Top and Lower @ Bottom Indicates Water Concerns Lower Temperature Top or Middle and Higher @ Bottom Indicates Airflow Concerns Internal Incubator Pressure (.50 - .55 inches w.g. Super J) (.40 - .45 inches w.g. Big J) Indicates Resistance Created by the Egg Pack in Regard to Airflow Chicks Hatched 12 Hours Prior to Pull 1.50 - 60 % With 10% Just Hatched 2. % Hatch of Estimated Hatch Monitors Proper Incubation in Regard to Hatch Window and Evenness The Following Slide Pictorially Illustrates the Hatcherys Role and Responsibility in the Total Success of a Modern Day Poultry Facility When You Consider of the Birds Life the Hatchery Has Control of Almost Half Facts: Embryonic Development Starts at Fertilization First Day of Incubation Occurs in Hen (22 Days Total) Hatchery Assumes Responsibility of Embryo at Pick Up From Breeder Farm Hatchery is Accountable for Chicks Through First Week at Grow Out Facility Hen Produces Egg Hen Produces Egg Egg Goes Into Incubator Egg Goes Into Incubator Embryo Fully Develops in the Incubator Embryo Fully Develops in the Incubator Developed Embryo Goes to Hatcher - Chick Matures and Hatches Developed Embryo Goes to Hatcher - Chick Matures and Hatches Fertile Egg Fertile Egg 18 Day Embryo 18 Day Embryo Late19 - 20 Days Late19 - 20 Days 20thDay 20thDay 504 Hrs. - 21 Days 504 Hrs. - 21 Days Genetic Potential Growth Genetic Potential Growth #1 - Incubation #1 - Incubation #2 - Hatching #2 - Hatching Chicks at Farm Chicks at Farm The Fertile Egg to Chick 22 Days Incubation - 1st Day Occurs in Hen Hen @ 104.5F - Cuticle Applied For Protection Laid By Hen Into A Clean Nest Collected - Graded - Put on the Egg Flat Cooler @Farm 65 - 68F and 75%RH Remains in Farm Cooler 24 - 48 Hours - Incubation is Suspended When Temperature Inside Egg Cools to 72F - Normally in Farm Racks 12 - 24 Hours Transported to Hatchery in Refrigerated Truck @ 65 -68F Hatchery Egg Room @ 65 - 68F - Prepared for Set Egg Set 3 - 5 Days From Time Of Lay Set Into Incubator Properly and Timely - Incubation - Embryonic Development Occurs - All Development Occurs in the Incubator Transferred to the Hatcher Properly and Timely - Maturity Occurs in the Hatcher - Quality Chick Hatches Chicks Are Pulled and Processed Properly and Timely - Ready for Delivery Chicks Are Delivered to Farm - Quality of the Chick Determines Performance Todays Successful Hatchery The Hatcheries That I Deal With That Are Achieving Their Expectation Are Following the Recommendations and Guidelines Set Forward in the Manuals Supplied By The Manufacturer as Well as Applying and Adhering to the Basics and Details in Regard to the Advanced Genetics of Todays Modern Breeds and the Incubation Equipment in Use Recommendations, Procedures, Principles and Concept In Todays Poultry Industry Many Things Have Been Done in Most Areas to Accommodate the High Yield Meat Type Bird Being Produced Feed and Feed Mill Breeder - Feed, Housing and Management Grow Out - Feed, Housing and Management Processing - Basically Anything Wanted Sales and Marketing - Dictates Production Hatchery Seem to Have Been Left Out of the Update TEAMWORK - COMMUNICATION - In the Hatchery as Well as Total Feedmill - Breeder - Hatchery - Broiler - Processing - Sales The High Yield Advanced Genetics of Todays Breeds At Best Presents More Challenges Than Ever In Regard to the Basics and Details of Proper Incubation. The Advanced Genetics With Less Consideration To Hatching and Emphasis Primarily on Growth and White Meat Yield Requires More Attention Than Ever Before. However very good and comparable results in regard to hatching and chick quality are being consistently achieved with these breeds (Even In Some Very Old Facilities). In Order to Accomplish Our Goal at the Hatchery of Good Quality Chicks at Least Cost ----------------------------- Must Start With the Basics ------------------------------ Without the Basics We Are Defeated or To Say the Least Handicapped From the Start Four Basic Inputs That Must Be Provided to the Machines (Influences Outside the Machines) Proper Electricity Proper Water (Quality,Volume and Pressure) Proper Compressed Air Ventilation Also Proper Egg Pack - Very Important Input Proper Design and Layout is a Must Proper Electricity Proper and stable electricity must be supplied due to the controls being microprocessors and the components in the control box being solid state. Improper electricity is a major contributor to improper calibration plus the longevity of the control system will be negatively affected. E/M Controls are less sensitive but can be negatively affected due to control component wear and tear. Heat rod amperage can also be affected. Proper Water Proper water must be supplied in regard to quality, volume and pressure due to its influence of cooling and moisture lost in the eggs. Incorrect water affects evenness of the temperatures in the incubator, higher temperature at the top and lower at the bottom. Although the Jamesway Multi Stage Incubation System is by definition air- cooled the spray also contributes. In reality 70% of the cooling is from the air intake and 30% from the proper spray. Proper Compressed Air Proper compressed air must be supplied in regard to cleanliness and dryness due to each incubator rack turn with its individual air cylinder. Oil and water from the air compressor must be properly handled and eliminated to prevent premature air cylinder failure. ------------------------------------------------------- Proper air pressure @ 65 PSI minimum at the buggies must supplied to allow for proper turning. Improper lines can also create problems. Proper Ventilation The sole purpose and definition of proper ventilation is to replace stale air with fresh air, which is needed by the developing embryos in their varying stages of embryonic development. Multi Stage incubation works on average (average temperature, humidity and damper operating range, O2 CO2 balance) and is non-specific to any particular stage of embryonic development but maintains a proper average for all. Proper ventilation is a basic input in Multi Stage incubation that must be properly sized, designed, controlled, installed and maintained to allow for correct embryonic development as well as proper machine performance and efficiency. Factors to Consider: EGGS FROM FARM TO INCUBATOR Egg Pack Uniformity Egg Handling on the Farm Farm Egg Storage Hatching Egg Transportation Hatchery Egg Storage Egg Storage to the Incubator EGG PACK UNIFORMITY As Observed Now Commonly Accepted As Normal in Todays Industry SIZE - Influences Airflow and Varying Embryonic Heat Based on Chick and Fertility SHAPE - Same plus Impaired Chick Quality SHELL QUALITY - Influences Moisture Lost and More Susceptible to Contamination CLEANLINESS - Garbage in = Garbage Out In Todays Industry a Proper Understanding and Application of the Basics Must Be Considered and Applied in Regard to Embryology and the Incubation Equipment in Use - Considering - The Four Basic Requirements for Incubation (Inside the Machines) a. Heat b.Humidity c.Airflow d. Turning A. Three Controlled Factors in an Incubation System a. Temperature b. Humidity c. Damper B. One Established Factor a. Airflow C. One Programmed Factor a. Turning In General the Four Basic Requirements To Achieve Correct Incubation Heat - Determines Air Temperature That Dictates Speed of Embryonic Development Humidity - Controls Moisture Lost and Afford Some of the Cooling Air Flow - Generated by the Fans Creating the Correct Air Movement Through the Egg Pack (To Obtain, Maintain and Distribute the Correct Air Temperature to Achieve and Control Constant Embryo Temperature) Turning - Keep Embryo in the Correct Position in the Early Stages of Embryonic Development to Avoid Sticking to the Sides as it Develops ALSO Very Important is the Damper - Controls O2 and CO2 Four Basic Requirements That Achieve the Correct Averages for Jamesway Multi Stage Incubation Heat - Air Temperature That Determines Speed of Embryo Development - Damper is the Key - Controlled By The Temperature (Heat) Set Point and Controls O2 and CO2 Balance As Well As Negative and Positive Incubator Pressure Note: Heat Set Point is the Only Controlled Temperature - Lowering the Heat Set Point Will Raise the Egg Pack Temperature - Damper Open (70% of the Cooling is Attributed to the Damper - Air Cooled) Humidity - Supplied by Four Spray Nozzles That Controls Moisture Lost and Afford Approximately One Third of the Cooling in Jamesway Multi Stage (30%Cooling Attributed to Spray) Air Flow - Generated by Six Fans Creating the Correct Air Movement Through the Egg Pack (1. Forced Air - Positive, 2. Laminar - Smooth Steady and 3. Negative - Draws Through Egg Pack) Turning - Compressed Air Supplies Air Pressure to Individual Rack Air Cylinder Turning Egg @ 45 Degree 1. Early Embryonic Development 2. Air Flow Balance Two Types of Incubation in Todays Industry 1. Multi Stage Incubation a. Still by far the most common (varying stages of embryonic development in each incubator) = 80% b. One way system to achieve averages for all c. Interdependent (Each group of embryos supports and are dependant on the other) 2. Single Stage Incubation = 15% a. All in - All out b. Flexibility c. Biosecurity STATEMENT: Industry Trend Is Toward Single Stage Jamesway Has Two Good Incubation Concepts Jamesway Multi Stage Incubator Jamesway Single Stage Incubator PX Hatcher Two Door Hatcher ACI Large Incubator ACI Large Incubator ACI Medium Hatcher ACI Medium Hatcher This Concept Since Early 1960s - Lot of Internal Modifications This Concept Since Early 1960s - Lot of Internal Modifications This Concept Since Late 1980s This Concept Since Late 1980s Always Been Single Stage Always Been Single Stage ACI = Activated Concept Incubation ACI = Activated Concept Incubation Platinum Large incubator Platinum Large incubator Platinum Medium Hatcher Platinum Medium Hatcher This Revised Single Stage Concept (Technology) Introduced in October 2003 This Revised Single Stage Concept (Technology) Introduced in October 2003 With the Challenges of Todays Industry and the Embryo From the Genetically High Yield Breeds Single Stage Incubation is Fast Becoming the System of Chose Over Multi Stage Incubation Due Primarily to the Single Stage System Can Be Profiled to Meet the Specific Needs of the Embryos Whereas Multi Stage Incubation Operates on Averages If You Was Building a New Hatchery Which Incubation Would You Choose?? General Statement of Hatchery Managers with Experience in Both Multi Stage and Single Incubation Systems is: Single Stage Incubation!!! It is Easier!!! WHY??? Multi Stage -vs.- Single Stage Multi Stage Incubation Managing the Needs of Each of the Varying Stages of Embryonic Development Understanding Each Stage Has Its Specific Requirement in Relation to Heat, Humidity,Airflow and Turning Single Stage Incubation Manages the Needs of Each of the Varying Stages of Embryonic Development With the Understanding Each Stage Has Its Specific Requirement in Relation to Heat, Humidity,Airflow and Turning THE PROFILE IS THE KEY!!! Multi Stage -vs.- Single Stage Multi Stage Incubation Managing a Multi - Stage Hatchery in Todays Industry is a Skill That Requires Attention Be Paid to Each of the Details That Affects Embryonic Development as Well as the Performance and Efficiency of the Machines All Considered as They Influence Our Number One Goal (Good Quality At Least Cost) Single Stage Incubation Single - Stage Incubation in Todays Industry Incorporates the Attention to Each of the Details That Affects Embryonic Development as Well as the Quality of the Chick Hatched THE PROFILE IS THE KEY!!! A Very Important Difference That Is More and More Coming To The Forefront In Regard to Single Stage verses Multi Stage ----IS---- A. Multi Stage Incubation Operates on Averages B. Single Stage Incubation Operates On Specifics Todays Embryos Seem to be More Susceptible and Less Viable in Regard to Incubation Simply Will Not Take As Much Temperatures Variations Single Stage Incubation Can Better Meet the Specific Needs Benefits That Can Be Attributed To Single Stage Bio Security Flexibility Specifics Quality BIO-SECURITY Term that the poultry industry is using more and more frequently. As production of poultry becomes more intensive, and genetic selection produces a chicken that is faster growing but possibly more susceptible to disease, all aspects of the production process have to establish procedures to maximize the levels of sanitation and hygiene. Bio Security Warm temperatures and high humidity levels required for incubation also provides an ideal climate for bacteria growth. The Single Stage machines can be thoroughly cleaned and sanitized after each cycle of eggs without any disruption to the incubation process. This high level of cleanliness not only improves chick quality but also reduces field mortality. As well any contamination that does occur is contained within the batch of eggs inside the machine and can be addressed during or after the incubator is emptied. FLEXIBILITY Eggs can be loaded into the setter upon arrival to the hatchery. (Incubator Can Be Used as Egg Storage and Proper Pre - Warming all as per Profile) Not locked into twice per week setting as with multi-stage. Adjust temperature and humidity according to breed, age of eggs, and/or eggs size to maximize hatch results. Programmable profiles and alarms FLEXIBILITY Variable setting handled with ease Program machine for specific needs Separation of eggs Incubator rack can be transported to farm Incubator (Farm) Rack Locking Pin Mechanism Specifics With Your Understanding and Knowing the Variables or Factors in Regard to Your Particular Egg Pack You Can Specifically Profile the Single Stage Incubation System to Meet the Specific Needs and Requirements of Each Group of Eggs You Put Into Incubation Example: 1.Young Flocks (Small Eggs- Less Embryonic Heat ) = 20% 2. Old Flocks (Large Eggs - Low Fertility) = 20% 3. Prime Flocks (Average Size Eggs - High Fertility) = 60% 4. Any Problem Flocks Multi Stage Multi Stage Single Stage Single Stage Quality !!! Single Stage vs Multi Stage Grow Out Results on Prime Flocks (The Best - Easiest) Single-Stage vs Multi-Stage Grow Out 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 1 2 3 4 5 6 7 B-4 Kill Kill Week L b sS-Stage M-Stage 1 2 3 4 5 6 7 B-4 Kill Kill S-Stage 0.3317 0.7700 1.5783 2.4683 3.4125 4.4088 5.6443 6.1720 5.8285 52 days M-Stage 0.3557 0.7384 1.4220 2.2214 3.1517 4.3600 5.2675 5.8775 5.5929 53 days Your Jamesway Hatcheries ----- ARE ----- As Of Now All Multi Stage So Lets Now Focus On ------------- The Jamesway Multi Stage Incubation System What Can Be Done To Improve !!! I Observed Some Improvements (Example: Water Pressure) in the Hatcheries From Previous Visit and I Sincerely Thank You All For The Efforts Put Forth ---------------But------------------ As In Any Hatchery There Are Still Opportunities To Improve (Even in Many Areas Previously Discussed and Reported) Your Results As Observed, Reported and Discussed Still Reveals Many Areas of Opportunities Many Asked: What has been done to improve Multi Stage Incubation?? The fact is: Nothing in regard to Concept. If you will follow and apply the basics and details correctly Multi Stage Incubation even with todays advanced genetic embryos will be quite successful, very efficient in regard to results and cost. -------------------------BUT------------------------ As I observe Multi Stage Incubation worldwide this simply is not being done therefore alternative concepts are being advocated. The Major Concern Impaired Hatch and Chick Quality Objective of this Visit To Again Identify the Causes and Help Set Up a Plan to Alleviate The Number One Concern At Hatcheries I Visit Is Simply Incorrect Incubation Temperature Related To The Four Requirements of Incubation 1. Heat 2. Humidity 3. Airflow 4. Turning The Jamesway Multi Stage Concept The Causes of the Incorrect Incubation Temperatures Are: 1. Improper Procedures 2. Improper Water 3. Improper Ventilation 4. Maintenance Issues Note: All Inclusive - What Else Is It??? THE FOUR WORDS TO CONSIDER THAT DETERMINE PROPER INCUBATION RECOMMENDATION - Requirement - Specs (Supplied By Manufacturer) PROCEDURE - Method Of Doing Things (Directly Under Your Control) PRINCIPLE - Method Of Operation (Established By The Manufacturers Design) CONCEPT - What, Why and How It Works (Created By The Equipment Design) Recommendations Provided by the Manufacturer Provided in the Various Manuals Provides the Proper Specifications Provides the Standards That Makes Each Manufacturer Different Must Be Adhered To - Alterations Will Cause Concerns Procedural Issues Involved in Incubation Eggs (Incubation Hen) Egg Rooms Setting Transfer Pull - Process Hatchery Sanitation Chick Delivery Broiler Farm Each Of These Are Very Important And Are Under The Control Of: YOU !!! Each Of These Are Very Important And Are Under The Control Of: YOU !!! Female Chicken Reproductive System ------------------- First Day Of Incubation Occurs in the Hen ------------------- When Hen Lays Her Egg the Reproductive Tract Is Activated For the Next Cycle ------------------------------------- What About That Fertile Egg Containing The Live Viable But Very Delicate Embryo??? -------------------------------------- Note: This Egg and Embryo Is At Its Best Quality At Lay - What We Do To The Egg Must Be Correct To Maintain Its Quality and Viability The Fertile Egg 22 Days Incubation - 1st Day Occurs in Hen Hen @ 104.5F - Cuticle Applied For Protection Laid By Hen Into A Clean Nest Collected - Graded - Put on the Egg Flat Cooler @Farm 65 - 68F and 75%RH Remains in Farm Cooler 24 - 48 Hours - Incubation Stops When Temperature Inside Egg Cools to 72F - Normally in Farm Racks 12 - 24 Hours Transported to Hatchery in Refrigerated Truck @ 65 -68F Hatchery Egg Room @ 65 - 68F - Prepared for Set Egg Set 3 - 5 Days From Time Of Lay Why Cool the Eggs ??? (Two Main Purposes) 1. Suspends Embryonic Development (All Embryos Put Into Incubation At Same Stage) -------------------------------------------------------------- 2. Thickens The Thick Albumen (Utilized By Embryo During Development) ---------------------------------------------- Note: All Things Done To The Eggs Needs To Be Done In Suspended State (Cooled) Egg Setting Key Operation of Hatchery Breed type Age of Flock Age of Eggs Skipped/Partial Sets Total Incubation Time Transfer of the Eggs From the Incubator to the Hatcher Example: Setting @ 7:00 AM Mon.. - Tues.. - Thurs.. - Fri. - with Average Mix Transfer - Monday - Tuesday @ 7:00 PM & Friday - Saturday @ 7:00 AM Monday - Tuesday = 444 Hrs. 181/2 Days 12 Hrs 6th Position Friday - Saturday = 432 Hrs. 18 Days 24 Hrs. 6th Position Pull @ 7:00 AM = 504 Hrs. Explanation of Correct Transfer Time In Regard to Fertility (Embryonic Heat) Monday - Tuesday: The Embryos That Assume the Sixth are 18 Days Old @ 100.5F = .5 BTU Heat Production - Takes 3/4 Hr. To Reach 98.8F and Damper Start Operating - 4 Hours the Air Temperature at Position 1 (freshly set) Reaches 100.3F - 8,10 to 12 Hours the Temperature Inside the Eggs at #1 Position Reaches 100.3F - Then the 6th Position is Transferred - Finished with Embryonic Heat ----------------------------------------------------------------------------------------------- Thurs. - Fri.: The Embryos That Assume the Sixth are 17 Days Old @ 100.0F = .4 BTU Heat Production - Takes 1 Hr. To Reach 98.8F and Damper Start Operating - 6 Hours the Air Temperature at Position 1 (freshly set) Reaches 100.3F - 20,22 to 24 Hours the Temperature Inside the Eggs at #1 Position Reaches 100.3F - Then the 6th Position is Transferred - Finished with Embryonic Heat Pull Times Process/pull time should be established by set time. Check Hatchers 12 hours Before Planned Process Time (50-60% of Chicks Hatched) Pull entire Hatcher ( do not leave rack in Hatcher) Clean and Sanitize Hatcher Simple Residue Observation Indicating Incubation Normal Normal Normal Normal Over Incubation Over Incubation Over Incubation Over Incubation Chick Holding/Transportation Avoid Unnecessary Rough Handling Monitor Holding Room Conditions Adequately Ventilated Transport Vehicle Minimize Delivery Time ( loading and Unloading) Monitor Conditions in the Broiler House Hatchery Sanitation Egg Storage Incubators/Hatchers Ventilation Equipment Process Equipment Process/Holding Areas Transportation Equipment The Fertilized Egg and Its Importance to the Hatcherys Results -------------- Why All Incubators Should Operate Primarily in the Cooling Mode!!!! ------------------- As Embryo Develops the Heat Produced Requires Cooling to Maintain Correct - Constant Incubation Temperature Fertile Egg Infertile Egg Fertilization A Very Important Factor Associated With Incubation and Embryology Fertility - Translates into Embryonic Heat as Embryo Progresses in Development in the Incubator and Finalization to Hatch in the Hatcher Proper Understanding of this Progress is a Must in Todays Industry The Fertile Egg The Fertile Egg contains a live, very delicate embryo. (Proper Management, Handling and Storage of Hatching Egg Influences Early Embryonic Mortality) Heat and CO2 Required at the Start of Embryonic Development - Where Does it Come From? 1. Heat - Mechanical and Embryos 2. CO2 - Developing Embryos and Control of Fresh and Exhaust Air (Damper) Understanding Why Fertility Is So Important in Todays Industry Is Easy and Simple When Proper Consideration is Given to the Developing Embryo and Embryonic Heat Generation Understanding Why Fertility Is So Important in Todays Industry Is Easy and Simple When Proper Consideration is Given to the Developing Embryo and Embryonic Heat Generation Embryonic Development Embryonic Development is a progressive change in the molecular structure (Metabolism - Growth). The Natural By-Product of Embryonic Development is Heat and CO2 Jamesway Multi Stage Incubation Utilizes and Transfers This Heat and CO2 to Supply Proper Conditions Needed by the Young Embryos Embryonic Heat (Fertility) Utilization and Transfer to Young Embryos 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper 100.5F @ .5 BTU Embryonic Heat @ 18 days 100.5F @ .5 BTU Embryonic Heat @ 18 days 100.0F@ .4 BTU Embryonic Heat @ 17 days 100.0F@ .4 BTU Embryonic Heat @ 17 days 100.3 - 100.8F Air Temperature (Heat - CO2) Transferred From #5 & 6 Position 100.3 - 100.8F Air Temperature (Heat - CO2) Transferred From #5 & 6 Position Heat - CO2 Received - Produced Heat - CO2 Received - Produced Air Flows Negatively Through the Egg Pack (Old to Young) Taking Heat Away From Embryos Producing Heat - CO2 and Transfers to Embryos That Needs the Heat - CO2 Air Flows Negatively Through the Egg Pack (Old to Young) Taking Heat Away From Embryos Producing Heat - CO2 and Transfers to Embryos That Needs the Heat - CO2 Embryonic Development Embryonic Development in the incubators and hatchers requires oxygen. Where does this oxygen come from? Normally, the oxygen is made available through the fresh air introduced by the HVAC (Heating, Ventilation and Air Conditioning) systems and allowed in the incubator through the intake air damper. Jamesway Set Point Temperature is Supplied to the Oldest Embryos and is Established by the Mixing of the Fresh Intake Air with the Air Exiting the Egg Mass into the Mixing Chamber, Then Through the Fans, Over the Top of the Incubator Rack to the Fifth or Sixth Position. Set Point Temperature (Cooling and Oxygen) Supplied to the Oldest Embryos 80F- D.B. 55% - R.H. +.01 Pressure 80F- D.B. 55% - R.H. +.01 Pressure Air Exiting the Through the Egg Pack @ 100.3 - 100.8F (Heat - CO2) Air Exiting the Through the Egg Pack @ 100.3 - 100.8F (Heat - CO2) 98.8F 86.0F 59.9%R.H. 98.8F 86.0F 59.9%R.H. Sensing Point Probes Sensing Point Probes 98.8F- 86.0F 98.8F- 86.0F 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper 250 CFM @ 11/2 Damper Only One Constant Temperature Achieved in Jamesway Multi Incubator??? Constancy Very Important Constancy Very Important Ever Changing in Regard to Embryonic Development and Procedures Ever Changing in Regard to Embryonic Development and Procedures Damper Response and Performance Damper Response and Performance Cooling and Oxygen Cooling and Oxygen All Other Temperatures Are Related and Influenced All Other Temperatures Are Related and Influenced The Fertile Egg The Fertile Egg contains a live, very delicate embryo. Heat and CO2 Required at the Start of Embryonic Development ----------------------------- Cooling and Oxygen Required at the Later Stage of Embryonic Development Understanding Why Ventilation Is So Important in Todays Industry Is Easy and Simple When Proper Consideration is Given to the Developing Embryo Understanding Why Ventilation Is So Important in Todays Industry Is Easy and Simple When Proper Consideration is Given to the Developing Embryo CO 2 & Water Vapor O 2 As Embryonic Development (Heat) Starts and Progresses in the Incubator and Finalizes in the Hatchers the Embryos Requirement for the Proper Heat, Air and Gas Exchange is Ever Present ---------------------------------------- If Not Correct Throughout the Entire Incubation Cycle Will Result in Irreversible Embryonic Damage as Well as Inefficient Machine Performance ----------------------------------------------------- An Insured Means of Provision is Required That Means is Proper Ventilation Ventilation Means Introduction of Fresh Air (the replacement of stale air with fresh air) All Incubators Need Fresh Outside Air (due to embryonic development inside) Air only machines (as Jamesway Multi Stage) uses fresh air for cooling and carbon dioxide control. Heating and/or cooling is required depending on the stage of embryonic development. Air and water machines (as Jamesway Single Stage) use a combination of air and water cooling/heating. Proper Hatchery Ventilation System Ventilation System Must Be: 1. Properly Sized 2. Properly Designed 3. Properly Controlled 4. Properly Installed 5. Properly Maintained For Each Individual Hatchery to Supply the Correct Requirements of Temperature, Humidity and Pressure Needed for the Embryonic Development and the Performance and Efficiency of the Machines How Ventilation Will Affects the Machines 1. Incorrect Room Temperature - Creates Incorrect Air Temperature Mixture Coming Through the Fans Low = Damper Close (Winter) - High = Damper Open (Summer) 2. Incorrect Room Humidity High = Damper Open - Spray Does Not Come On Inside Incubator 90% Air and 10% Spray Ratio Inside Incubator (Summer) Low = Damper Closes Spray On Too Much Inside Incubator 30% Air and 70% Spray Ratio Inside Incubator (Winter) -------- Normally 70% Cooling = Air and 30% = Spray --------- 3. Room Pressure - Negative = Blocks Intake Air ------------------- Too Positive = Deludes Negative Incubator Pressure Ventilation Effects in the Incubator Damper Performance Machine Efficiency and Stability Temperature and Humidity Chick Quality Temperature 98.8 Super J ( Big J 99.0) Humidity 86.0 Hatcher Set Points Temperature 98.5 Super J (Big 98.8) Humidity 86.0 Statement of Observation: Anytime You Adjust The Set Point in a Jamesway Machine It Is To Compensate For Other Concerns That Should Be Addressed Incubator Set Points Altering Set Points Jamesway - Air Cooled - Heat Set Point Controls Damper (Cool) Other Manufacturer - Water Cooled- Cooling Set Point Controls Lowering Temperature Set Point - 98.8F to 98.6F - Senses Too Hot -Opens Damper - More Air Cooling Required - Heat Not On - Negative Pressure Drops - Air Does Not Go Through Egg Pack Properly = Overheating Passed Oldest Embryos Raising Temperature Set Point - 98.8F to 99F - Senses Too Cool - Damper Closes More - Less Air Cooling Required - Heat Is On More - Oxygen and Cooling Reduced to Older Embryos - Overheating Throughout Egg Pack Lowering Humidity Set Point - Opens Damper - Reduces Cooling Attributed to Spray - Raises Mixed Air Temperature Raising Humidity Set Point - Closes Damper - Increases Cooling Attributed to Spray - Lower Mixed Air Temperature Jamesway Multi Stage - Damper Performance is the Key (Air Cooled) MUST Understand the Importance and Achieve the Proper Damper Performance 1. PT-100 - Normal Operating Range of 1-1/4 to 1-3/4 inches with 1-1/2 inches Average Position @ 250 CFM Air Intake 2. E/M - Normal Operating Range of 1 to 1-1/2 inches with 1-1/4 inches Average Position @ 250 CFM Air Intake The Multi Stage Damper Multi Stage = Air Cooled Damper is Controlled by Heat Set Point Damper Controls Temperature and Incubator Pressures Damper Regulates O2 and CO2 Damper = Average Needs of ALL Varying Stages of Embryonic Development Damper is the Key to Correct Multi Stage Incubation General Rule of Thumb in Regard to Proper Incubation 36 Hours Before Pull Hear 1st Chick 30 Hours Before Pull 1st Chick Out 24 Hours Before Pull 5 - 10% Hatched 12 Hours Before Pull 50 - 60% Hatched 4 - 6 Hours Before Pull Last Chick Out At Pull 5 - 10% Still Damp on the Neck Examples of When Ventilation Was Done Right When Proper Ventilation Was Installed Company A / 24-Month Performance 80 85 90 95 Jan-98 Mar-98 May-98 Jul-98 Sep-98 Nov-98 Jan-99 Mar-99 May-99 Jul-99 Sep-99 Nov-99 Company A Fertility Company A H.O.F. Company A Hatch New Ventilation Installed When Proper Ventilation Was Installed Company B / 12-Month Performance 80 85 90 95 100 Jan-99 Feb-99 Mar-99 Apr-99 May-99 Jun-99 Jul-99 Aug-99 Sep-99 Oct-99 Nov-99 Dec-99 Company B Fertility Company B H.O.F. Company B Hatch New Ventilation Installed When Proper Ventilation Was Installed Company C / 24-Month Performance 80 85 90 95 Jan-98 Mar-98 May-98 Jul-98 Sep-98 Nov-98 Jan-99 Mar-99 May-99 Jul-99 Sep-99 Nov-99 Company C Fertility Company C H.O.F. Company C Hatch New Ventilation Installed Typical Cooling/Heating Unit Reheat Reheat Coil Coil Cooling Cooling Coil Coil Room Room Thermostat Thermostat adding reheat improves adding reheat improves humidity control humidity control B B E E D D C C A A Constant-Volume With Reheat Air Conditioning Clinic TRG-TRC001-EN Air Conditioning Clinic TRG-TRC001-EN American Standard Inc. 1999 Establish Proper Maintenance Program as Outlined in Appropriate Manuals A Proper Maintenance Program Should Be: 1. Organized 2. Delegated 3. Responsibility 4. Accountability Maintenance File On Each Incubator and Hatcher as Well as Ventilation Equipment Any Hatchery Regardless Of Its Size, Age or Location Is No Better Than Their Maintenance Program Any Hatchery Regardless Of Its Size, Age or Location Is No Better Than Their Maintenance Program Good Hatchery Managers Use Their Senses Of: Sight Sound Feel Smell Common Hatchery Sense Remember and Consider The Basics Common Hatchery Sense Remember and Consider The Basics Incubation is not Complicated SIMPLY Quality Eggs Quality Incubation Equipment Quality Maintenance Quality Management Quality Chicks BUT: For Every Cause There Is An Effect Simply Input Affects Output Simply: Operate and Maintain Your Equipment as per Jamesway Recommendations (Specifications) Procedure, Principles and Concept Understanding for Every Cause There is an Effect TEAMWORK - COMMUNICATION In the Hatchery as Well as Total Feedmill - Breeder - Hatchery - Broiler - Processing TEAMWORK - COMMUNICATION In the Hatchery as Well as Total Feedmill - Breeder - Hatchery - Broiler - Processing Example of Heat Profile in the Jamesway Multi Stage Incubator 0-3DAYS INCUBATION 3-7DAYS INCUBATION 7-10DAYS INCUBATION 10-14DAYS INCUBATION 14-17DAYS INCUBATION 17-18.5DAYS INCUBATION POSITION No. 1 POSITION No. 2 POSITION No. 3 POSITION No. 4 POSITION No. 5 POSITION No. 6 Endothermic Absorbs Heat Endothermic Endothermic Absorbs Heat Absorbs Heat Exothermic Gives Off Heat Exothermic Exothermic Gives Off Heat Gives Off Heat 98.8F 98.8F 99.1F 99.1F 99.4F 99.4F 99.7F 99.7F 100.0F 100.0F 100.3F 100.3F Air Temp. Air Temp. 99.5F 99.5F 0 0 100.5 - 101F 100.5 - 101F Embryonic Heat Embryonic Heat 100.3 - 101F 100.3 - 101F 98.8F 86.0F 98.8F 86.0F Only One Constant Temperature in Jamesway Multi Incubator??? Only One Constant Temperature in Jamesway Multi Incubator??? Endothermic Endothermic Neutrothermic Neutrothermic Exothermic Exothermic Constant Till Hatch Constant Till Hatch Stages of Transition Stages of Transition 100.3 F 100.3 F 100.0 F 100.0 F 99.7 F 99.4 F 99.7 F 99.4 F 99.1 F 98.8 F 98. 6 F 99.1 F 98.8 F 98. 6 F 98.5 F 97.5 F 98.5 F 97.5 F Air Temp. Required Maintain Air Temp. Required Maintain Embryo Heat Produced BTU/Hr Embryo Heat Produced BTU/Hr Single Stage Specific Air Temp. To Achieve Correct Embryo Temp. Single Stage Specific Air Temp. To Achieve Correct Embryo Temp. Constant Embryo Temp.to Achieve 100.2- 100.3F Constant Embryo Temp.to Achieve 100.2- 100.3F 100.5 F 101.0 F 101.5 F 102.0 F 104.5 F 100.5 F 101.0 F 101.5 F 102.0 F 104.5 F After Hatch Dry After Hatch Dry Setting Proper Mix 0-3DAYS INCUBATION 3-7DAYS INCUBATION 7-10DAYS INCUBATION 10-14DAYS INCUBATION 14-17DAYS INCUBATION 17-18.5DAYS INCUBATION POSITION No.1 POSITION No.2 POSITION No.3 POSITION No.4 POSITION No.5 POSITION No.6 28 wk 28 wk 30 wk 30 wk 60 wk 60 wk 42 wk 42 wk 48 wk 48 wk 45 wk 45 wk Average Age of Breeder Flock - 42 Weeks Average Age of Breeder Flock - 42 Weeks 92 - 94 % Average Fertility as per Broiler Breed 92 - 94 % Average Fertility as per Broiler Breed Visual of Flock Age Differences Which Influence Airflow and Fertility 26 Wk.. 26 Wk.. 32 Wk.. 32 Wk.. 39 Wk.. 39 Wk.. 45 Wk.. 45 Wk.. 52 Wk.. 52 Wk.. 58 wk.. 58 wk.. 3 Way to Manage a Jamesway Hatchery 1. Setting Average Mix of Eggs in Each Incubator 2. Setting Incubators by Age of Flock (young, prime and old) 3. Set Point Point Adjusting and #2 Multi-Stage Incubator Air Flow Must Maintain 5 Positions Per Side For Proper Air Flow Through The Egg Pack (132 Hrs. per wk.) (6 Positions - Only 36 Hrs. per wk.) Entrance End Negative Pressure <-.3 inches W.G.> Entrance End Negative Pressure <-.3 inches W.G.> Exit End Positive Pressure +.2 inches W.G. Exit End Positive Pressure +.2 inches W.G. Internal Incubator Pressure Differential .5 inches W.G. Internal Incubator Pressure Differential .5 inches W.G. Blue Denotes Positive Pressure Influence Blue Denotes Positive Pressure Influence Red Denotes Negative Pressure Influence Red Denotes Negative Pressure Influence Air Temperature That Comes Through at Fans 98.8F and 59 - 60%R.H. Air Temperature That Comes Through at Fans 98.8F and 59 - 60%R.H. Total Pressure Differential - Created By The Egg Mass Input Egg Size Influences Embryonic Heat Fertility Influences Embryonic Heat Manometer - Tube to + Port Manometer - Tube to + Port Internal Incubator Pressure Differential .50 - .55 inches W.G. Internal Incubator Pressure Differential .50 - .55 inches W.G. Entrance End - Negative Pressure Influence Manometer - Tube to < - > Port Manometer - Tube to < - > Port Exit End - Positive Pressure Influence Manometer - Tube to < - > Port Manometer - Tube to < - > Port Mixed Air Over the Incubator Racks Ventilation Influence Temperature @ 80F Humidity @ 50 - 60 % Pressure @ +.005 - .015 Ventilation Influence Temperature @ 80F Humidity @ 50 - 60 % Pressure @ +.005 - .015 Correct Damper Position Correct Damper Position 100.3 - 100.8F Air Mixes with 80F Air = 98.8FThrough Fans 100.3 - 100.8F Air Mixes with 80F Air = 98.8FThrough Fans 250 CFM Intake 250 CFM Intake 250 CFM Exhaust 250 CFM Exhaust Sensing Point Sensing Point Jamesway Air Flows ACI Incubator - Hatcher Air Flow ACI Incubator - Hatcher Air Flow Multi Stage Incubator Air Flow Multi Stage Incubator Air Flow PX Hatcher Air Flow PX Hatcher Air Flow General Observations and Observing the Chicks Hatched Revealed Improper Machine Performance, Dehydration and Heat Related Issues Which Primarily Are Incubation Concerns It Appears Ventilation Issues, Set Time Adjustment, Maintenance and Water Concerns Are Some Main Issues in the Incubators Check of the Incubators for Concerns Problems Are Indicated at the Display If the Concerns are in all Machines (as in your case) Indicates Basic Input Concern If the Concerns are in an Individual Machine Only Indicates Problems in that Particular Machine If the Concerns are in all Machines (as in your case) Indicates Basic Input Concern If the Concerns are in an Individual Machine Only Indicates Problems in that Particular Machine Humidity Set Point @ 86.0F Actual Humidity @ 87.0F Indicates Improper Air Movement in the Incubator Due to Ventilation Concerns Humidity Set Point @ 86.0F Actual Humidity @ 87.0F Indicates Improper Air Movement in the Incubator Due to Ventilation Concerns Damper Fully Open Damper Fully Open Common Alarm Illuminated High Temperature Common Alarm Illuminated High Temperature Placement of Electrotherm Probes For Calibration Curtains Lapped Wrong in the Incubator Incorrect Spacing at the Spacesaver Intakes Air Distribution Duct Proper Adjustment is: 5/8th of an inch - 15 mm Proper Adjustment is: 5/8th of an inch - 15 mm Incorrect Spacing at the Spacesaver Intakes Air Distribution Duct Proper Adjustment is: 5/8th of an inch - 15 mm Proper Adjustment is: 5/8th of an inch - 15 mm Damper (Intake) Fully Open and Air Distribution Adjustment Terrible Incubator Damper Fully Open 11/2 inches - normal 11/4 to 13/4 inches operating range 11/2 inches - normal 11/4 to 13/4 inches operating range 11/4 inches - normal 1 to 11/2 inches operating range 11/4 inches - normal 1 to 11/2 inches operating range PT - 100 PT - 100 Electro Mechanical Electro Mechanical Short Spray Nozzle Laying in the Water Pan - Incorrect Adjustment Correct Positioning of the Spray Nozzles Correct Positioning of the Spray Nozzles Jamesway Spray Nozzle Pattern 60 Degree 360 Circle Solid Cone Spray Pattern 60 Degree 360 Circle Solid Cone Spray Pattern Water Pan Water Pan Ceiling Line Ceiling Line Checking the Spray Nozzles Checking Water Pressure at the Spray Nozzle Checking Water Pressure at the Spray Nozzle Fan Blade Through the Venture (This Affords Another Reference for Proper Fan Blade Adjustment) Should be 1/2 Through the Venture (This is too much!!!) Should be 1/2 Through the Venture (This is too much!!!) Improper Incubator Fan Blade Adjustment (Not Protruding Through the Venture) Example of Improper and Proper Turning Proper Turning Can Be Properly Checked by Measuring the Distance Between the Vertical Turning Bars - Correct @ 4 inches or 10 cm Proper Turning Can Be Properly Checked by Measuring the Distance Between the Vertical Turning Bars - Correct @ 4 inches or 10 cm Correct @ 4 inches Correct @ 4 inches Incorrect - less than 4 inches Incorrect - less than 4 inches Threshold Removed in the Entrance End Due to High Temperature Alarm - Totally Unacceptable - Causes Airflow Problems in the Incubator!!!!! Not to Clean Not to Clean In the Egg Room Need to Leave Space Between Each Stack of Egg and at the Floor to Allow Proper Air Circulation to Obtain and Maintain Correct Egg Temperature in Storage Fresh Unconditioned Air Being Blown Into Incubator Room To No Avail Note: There is no way this air can get to the machine intakes due to the incorrect design of the air intake plenum Completely Closed Air Intake Plenum with Small Very Undersized A/C Supplying All of the Air to the Machine Pressure Taken in all of these plenum was extremely negative meaning Simply the Machines was intaking thus no fresh and conditioned air was going into the Machines - Terrible Terrible Problem Completely Closed Air Intake Plenum with Small Very Undersized A/C Supplying All of the Air to the Machine Pressure Taken in all of these plenum was extremely negative meaning Simply the Machines was intaking thus no fresh and conditioned air was going into the Machines - Terrible Terrible Problem Broken Eggs in Incubator at Transfer Broken Eggs Observed in the Entrance End PX Hatcher Concerns PX Hatcher Side to Side Fan Stand Leveling Proper Positioning and Leveling of PX Hatcher Fan Stand 31/4 inches 31/4 inches Improper Leveled and Positioned PX Hatcher Fan Stand Too Wide at the Top Too Wide at the Top Improper Leveled and Positioned PX Hatcher Fan Stand Too Narrow at the Top Too Narrow at the Top Top Fan Blade Protruding Through the Venture 7/8 inch or 21 mm 7/8 inch or 21 mm Bottom Fan Blade Protruding Through the Venture 7/8 inch or 21 mm 7/8 inch or 21 mm Checking Damper Adjustment in the Fully Closed Position Damper Too Open in Fully Closed Position PX Damper in Fully Closed Must be 1/8 inch PX Damper in Fully Closed Must be 1/8 inch Too Open Too Open Dampers Too Open in Fully Closed Position PX Damper in Fully Closed Must be 1/8 inch PX Damper in Fully Closed Must be 1/8 inch Too Open Too Open Damper Too Open and Bend in Fully Closed Position PX Damper in Fully Closed Must be 1/8 inch and Straight PX Damper in Fully Closed Must be 1/8 inch and Straight Too Open and Bent Too Open and Bent Damper Too Open and Different in Fully Closed Position Both PX Damper in Fully Closed Must be 1/8 inch Both PX Damper in Fully Closed Must be 1/8 inch Too Open and Different Too Open and Different Door Gasket Problems Some Loose Gasket and Missing Gaps in Several Hatchers Some Loose Gasket and Missing Gaps in Several Hatchers Intake - Exhaust Duct Gaskets Also Fan Stand Leveling Separation Gasket Not Sealing at the Wall Separation Gasket Not Sealing at the Wall Fan Stand Not Leveled Fan Stand Not Leveled Intake - Exhaust Duct Gaskets Not Sealing at the Wall Separation Gasket Not Sealing at the Wall Separation Gasket Not Sealing at the Wall Intake - Exhaust Duct Gaskets Separation Gasket Not Sealing at the Wall Separation Gasket Not Sealing at the Wall Cause of Intake - Exhaust Duct Gaskets Not Sealing at the Wall Fasting Clip Loose and Not Tight Against Duct Fasting Clip Loose and Not Tight Against Duct Duct Should Be Flush Duct Should Be Flush Cause of Intake - Exhaust Duct Gaskets Not Sealing at the Wall (Another Hatcher) This Side Is Flush This Side Is Flush This Side Is Not Flush This Side Is Not Flush Fasting Clip Loose and Not Tight Against Duct Some Door Gaskets Was Observed Not Sealing Need to Adjust Door Fastener Catch for a Tight Seal (Gasket to Door Jam) Need to Adjust Door Fastener Catch for a Tight Seal (Gasket to Door Jam) Threshold Gaskets Bad Note: Suggest You Buy Threshold in a Roll and Cut to Length Pre - warm the Roll of Gasket in an Incubator Overnight Before Cutting to Length This Will Help Avoid Excessive Shrink Note: Suggest You Buy Threshold in a Roll and Cut to Length Pre - warm the Roll of Gasket in an Incubator Overnight Before Cutting to Length This Will Help Avoid Excessive Shrink Result of Bad Threshold Gaskets Down Blown Out Into the Hatch Hall Down Blown Out Into the Hatch Hall Hatcher Humidity Calibration Check On Behalf of Thanks for This Opportunity!!!! TO TO From From