Pasreform Hatchery Guide

Publication date: 2015-08-18
Broilers
Incubation Guide
Contents
6.2 Incubation in hatcher: day 19 –
1 About this manual 5 21 61
1.1 Copyright and disclaimer 6.3 Application of disinfectant
notice 6 during hatching period 64
1.2 Audience and scope 7
7 Chick handling 67
1.3 If you need help 8
7.1 Introduction 68
1.4 Version history 9
7.2 Chick take-off 69
2 Introduction 11 7.3 Vaccination of day-old-chicks
71
2.1 Outline of the Incubation
Guide 12 7.4 Sexing of day-old-chicks 75
2.2 Golden rules for a hatchery 7.5 Chick dispatch and transport
14 78
2.3 Quality Management System 7.6 Unloading and brooding
15 chicks at the farm 80
3 Egg handling 17 8 Tools for fine-tuning 83
3.1 Introduction 18 8.1 Introduction 84

3.2 Egg handling at the breeder 8.2 Analysis of hatching egg
farm 20 quality upon arrival 85
3.3 Egg transport to the hatchery 8.3 Analysis of eggshell
24 temperature 89
3.4 Egg receipt 26 8.4 Analysis of egg weight loss
93
3.5 Setting eggs in setter trays and
trolleys 27 8.5 Analysis of clear eggs 95
3.6 Pre-storage incubation 28 8.6 Analysis of unhatched eggs
97
3.7 Storage of hatching eggs
30 8.7 Assessing chick quality:
Pasgar©Score 99
3.8 Disinfecting hatching eggs
32
9 Data analysis for continuous
improvements 101
4 Incubation in setter: day 1-18
35 9.1 Introduction 102
4.1 Introduction 36 9.2 Basics of hatchery specific
database 103
4.2 Single-stage incubation 37
9.3 Construction of a hatchery
4.3 Multi-stage incubation 41
specific database 104
5 Candling and transfer 47 9.4 Evaluation of hatchery results
105
5.1 Introduction 48
9.5 Troubleshooting 106
5.2 10-day candling 49
5.3 Candling and transfer 52 10 Hatchery hygiene 111
5.4 In-ovo vaccination 56 10.1 Introduction 112

10.2 Prevention of pathogens
6 Incubation in hatcher: day 19-21
entering the hatchery 113
59
10.3 Prevention of cross
6.1 Introduction 60
contamination 115
Broilers - Incubation Guide - V 6.0 Contents 3

Contents
10.4 Cleaning and disinfection Recording Form 8A: External
117 hatching egg quality upon
receipt 165
10.5 Hatchery hygiene monitoring
119 Recording Form 8B: Internal
hatching egg quality upon
11 Hatchery maintenance 121 receipt 166
11.1 Introduction 122 Recording Form 8C: Fertility
and embryo quality upon
11.2 Preventive maintenance 123
receipt 167
11.3 Spare parts 125
Recording Form 8D: Eggshell
11.4 Setter and hatcher 126 temperature 168
11.5 Hatchery climate 127 Recording Form 8E: Egg
weight loss 169
11.6 Hatchery automation and
auxiliary equipment 131 Recording Form 8F: Analysis of
clear eggs 170
12 Annexes 133
Recording Form 8G: Analysis of
12.1 Sweating of eggs 134 unhatched eggs 171
12.2 Hatching at high altitudes Recording Form 8H:
140 Pasgar©Score 172
12.3 Adaptive Metabolic Feedback Recording Form 9A: Hatching
(AMF™) 144 results 173
12.4 Energy Saving Module (ESM™) Recording Form 9B: Results
147 egg analysis and Pasgar©Score
174
12.5 Circadian Incubation™ 149
Recording Form 10A:
13 Glossary 151 Registration of visitors 175
Recording Form 10B: Cleaning
14 Recording Forms 155
schedule 176
Recording Form 3A: Egg
Recording Form 10C: Hatchery
transport card 156
microbiological monitoring
Recording Form 3B: Egg 177
receipt form 157
Recording Form 11A: Setter
Recording Form 3C: Hatching maintenance card 178
egg stock list 158
Recording Form 11B: Hatcher
Recording Form 3D: Setter maintenance card 179
trolley card 159
Recording Form 11C: Hatchery
Recording Form 3E: Setter equipment maintenance card
schedule 160 180
Recording Form 3F: Egg Recording Form 11D: Checklist
storage room: climate climate conditions in hatchery
conditions 161 181
Recording form 3G: Egg
disinfection room 162
Recording Form 4A: Incubator
recording form 163
Recording Form 7B: Chick
passport 164
4 Broilers - Incubation Guide - V 6.0 Contents

1 About this manual
In this chapter
Copyright and disclaimer notice 6

Audience and scope 7
If you need help 8
Version history 9
Broilers - Incubation Guide - V 6.0 1 About this manual 5

1.1 Copyright and disclaimer notice
Copyright © 2015 Pas Reform Hatchery Technologies, Zeddam, The Netherlands
All the information and drawings in this manual are the property of Pas Reform
Hatchery Technologies.
No part of this publication may be reproduced, stored in a database, or published in

any form or by any means, electronic, mechanical, photocopying, microfilm or
otherwise, without the prior permission in writing of Pas Reform Hatchery
Technologies.
Please note that all figures in this manual are provided as guidelines only. Pas Reform
Hatchery Technologies cannot be held liable for incorrect interpretation of the
contents of this manual.
We have made every effort to make this manual as accurate and complete as
possible. Should you find errors or omissions, please bring them to our attention so
that we may correct them. In this way we hope to improve our product
documentation. Please send your corrections and comments to our documentation
manager: info@pasreform.com.
This manual is the original English version.
All trademarks stated in this manual are registered trademarks of their suppliers.
6 Broilers - Incubation Guide - V 6.0 1 About this manual

1.2 Audience and scope
The Incubation Guide is a manual for use in daily hatchery practice. It should be used
in conjunction with manuals pertaining SmartSet(Pro)™, SmartHatch(Pro)™,
SmartCenter(Pro)™ and other technical manuals like AMF™ and ESM™.
The chapters 3 to 8 in the Incubation Guide contain practical procedures for the
successful incubation of broiler eggs, from egg handling at the breeder farm up to
placement of the day-old chicks.
In addition to these procedures, a number of general recommendations for hatchery

management are provided. Also included are Recording Forms which support the use
of the procedures.
The procedures contain references to the recording forms, which are numbered to
correspond with the chapters in the instructions.

1.3 If you need help
If you need any assistance, please contact Pas Reform Academy.
If you still have questions after reading this guide, we would encourage you to
contact us. We appreciate all advice, feedback and suggestions from our customers.
Please contact Pas Reform at:
Pas Reform Hatchery Technologies
Address: P.O. Box 2

NL-7038 ZG Zeddam
The Netherlands
Phone: +31 314 659 111
Fax: +31 314 652 575
E-mail: academy@pasreform.com
Internet: www.pasreform.com

1.4 Version history
Every effort has been made to make this manual as accurate and complete as
possible. However, should the user(s) find any errors or omissions, it would be
appreciated if these were brought to the attention of Pas Reform. Please report any
errors or omissions to Pas Reform.
The following table describes the main changes for each document version of this
manual.
Version history
Version Date Changes
V6.0 18-8-2015 New layout, minor modifications and
new chapter Hatchery maintenance

2 Introduction
In this chapter
Outline of the Incubation Guide 12

Golden rules for a hatchery 14
Quality Management System 15
Broilers - Incubation Guide - V 6.0 2 Introduction 11

2.1 Outline of the Incubation Guide
The routing 'from egg to chick' is essential in hatchery management. Hatchery
routing can be divided into five steps:
Five basic steps in hatchery routing

Egg handling
- at the breeder farm
- transport to the hatchery
- receipt and quality control
- setting in setter trays and trolleys
- pre-storage incubation
- storage
- disinfection
Incubation in setter: day 1-18
- single-stage/multi-stage
Egg transfer
- Candling
- Transfer
- In-ovo vaccination
Incubation in hatcher: day 19-21
- Incubation program hatcher
- Application of disinfectants during hatching period
Chick handling
- take-off
- grading
- sexing
- vaccination
- transport
- unloading and brooding at the farm
These five steps constitute the framework of chapters 3 - 7 of this Incubation Guide:
each of these chapters describes all procedures belonging to one of the steps in
hatchery routing.
The procedures are all structured as follows:

- Objective: the aim of the procedure.
- Persons responsible: personnel that usually carry out the procedure.
- Documents: recording forms related to the procedure; these can be found in
Recording Forms (page 155).
- Definitions: descriptions for a number of specific terms used in the procedure; for
definitions of underlined terms, see Glossary (page 151).
- Recommended procedure: a step-by-step guideline on how to carry out the
tasks.
- Additional notes: supplementary advice, precautions etc. For ease of reading, key
words within the additional notes are marked in bold.
In this manual the following signs are used to draw the reader’s attention to
especially important points.
The note sign draws the reader’s attention to additional relevant information.
The caution sign is used for procedures which, if they are not followed, might cause
a decline in hatch results.
12 Broilers - Incubation Guide - V 6.0 2 Introduction

The warning sign is used for certain procedures or actions which, if they are not
performed correctly, could cause physical injury, material damage and/or a decline
in hatch results.
Tools for fine-tuning (page 83) contains all procedures for collecting additional
hatchery data. These data are relevant in the process of analyzing where breeder farm
and hatchery management and incubation programs could be improved.
Data analysis for continuous improvements (page 101) provides general guidelines to
monitor hatchery results using a hatchery specific reference set of data aimed at
continuous improvements and to ensure durable operation of the hatchery. It forms
the basis for fine-tuning incubation programmes and troubleshooting.
Hatchery hygiene (page 111) describes relevant aspects of hatchery hygiene and
includes procedures for cleaning and disinfection as well as for microbiological
monitoring.
Hatchery maintenance (page 121) highlights the importance of hatchery climate and
preventative maintenance.
Annexes (page 133) contains more in-depth information about various aspects of
incubation management which is too lengthy or detailed to include in previous
chapters.
Glossary (page 151) contains a list of definitions of terms used in the procedures; the
terms which are underlined are explained in the glossary.
Recording Forms (page 155) contains all the Recording Forms, the number of the
Recording Form corresponds with the chapter in which they are mentioned.

2.2 Golden rules for a hatchery
The structure of the table below corresponds with the steps in hatchery routing.
'Golden rules for a hatchery' forms the basis of good hatchery management.
Summarizing some crucial key aspects that arise in hatchery practice, this list
provides a useful tool for hatchery managers in daily hatchery routine.
Golden rules for a hatchery

Egg storage room - Do not clean the room and equipment when hatching eggs are present.
- Check temperature and humidity daily and compare with recommendation.
Setter room - Ensure inlet air to setter meets the recommended climate conditions.
- Thoroughly clean and disinfect the floor every week.
- Positive air pressure in relation to other rooms in hatchery.
- Always keep doors closed.
Setters - Check the proper functioning of setter before every new cycle.
- Machine must be dry when eggs are coming in.
- Load incompletely filled setters correctly.
- Check incubation program or set points and adjust if necessary.
Transfer room - Room temperature 21 – 27 °C/69.8 – 80.6 °F; avoid draught directly on eggs.
- Doors closed after passing.
- On transfer day: no more than 2 trolleys out of the machine.
Hatcher room - Ensure inlet air to hatcher meets the recommended climate conditions.
- Dry and clean.
- Doors closed after passing through.
Hatchers - Check the proper functioning of hatcher before every new cycle.
- Machines dry and pre-warmed to set point temperature before loading.
- Load incompletely filled hatchers correctly.
- Check set points and adjust if necessary.
Chick handling room - Room temperature 24 – 27 ºC/75.2 – 80.6 ºF.
- Room relative humidity 40 – 65 %
- On take-off day: do not pull more than two trolleys out of the machine at the
same time.
Chick dispatch room - Room temperature 24 – 27 ºC/75.2 – 80.6 ºF.
- Room relative humidity 55 – 70 %
- Good air supply and circulation; avoid draught.
- Do not put chick boxes directly on the floor.
- Look and listen to behaviour of the chicks.
Chick truck - Check temperature before loading the truck: 24 – 27 ºC/75.2 – 80.6 ºF.
- Truck must be dry and properly cleaned and disinfected.
- Trolleys must be securely tied.
- Avoid delay during transport.

2.3 Quality Management System
The hatchery, as a segment of the food production chain, aims to produce a safe
product of good quality which forms the input for the next segment of the food
production chain: vital chicks that are free of pathogens. All processes in the hatchery
contribute in achieving this goal.
This Incubation Guide is written such that it can be incorporated as part of the total
quality management system for the hatchery. Depending on local legislation or
requirements of the hatchery itself such a quality management system could be
based on ISO-standards (International Organization for Standardization), GMP-
standards (Good Manufacturing Practice), HACCP-system (Hazard Analysis and
Critical Control Point), SQF-program (Safe Quality Food) or on other systems.
This Incubation Guide provides the hatchery manager with guidelines to operate the
hatchery according to clearly described "standard operation procedures = SOP’s",
which could be used also for staff training. The persons responsible for the correct
carrying out of the procedures are specified. Recording forms are useful for tracking
and tracing in case of an uneventful infection of a specific batch of eggs with
pathogens relevant to food safety or national disease control programs. The
recording of relevant data also offers the opportunity for evaluation of the
production process leading to continuous improvements. These aspects are required
items in most quality management systems. Some rewriting of (or parts of) the text
might be needed to fulfill the individual needs of each hatchery, but this Incubation
Guide offers a good starting point.

3 Egg handling
In this chapter
Introduction 18
Egg handling at the breeder farm 20
Egg transport to the hatchery 24
Egg receipt 26
Setting eggs in setter trays and trolleys 27
Pre-storage incubation 28
Storage of hatching eggs 30
Disinfecting hatching eggs 32
Broilers - Incubation Guide - V 6.0 3 Egg handling 17

3.1 Introduction
Egg quality and hatch results can be negatively affected by poor egg handling. Egg
handling starts as soon as the egg is laid and continues until the eggs are placed
inside the setters.
Egg handling at the breeder farm

A healthy, well managed breeder flock, receiving a balanced feed ration, has the
potential to produce good quality hatching eggs. At the moment the egg is laid, it
contains an embryo of 30,000 – 60,000 cells. At that point in time, each cell is already
programmed for its future function. Only with the best of care will the hatching
potential held in this delicate embryonic structure be fully realized.
Egg handling at the breeder farm (page 20) describes how to provide optimum care
for the hatching eggs at the breeder farm until they are transported to the hatchery.
Egg transport to the hatchery

Breeder farms are often situated some distance away from the hatchery. Typically,
deliveries should vary from daily to not less than twice weekly. Egg transport is
generally by truck, although when importing hatching eggs air transport may also be
used.
During transportation from farm to hatchery, mechanical and temperature shocks

should be avoided since these affect potential hatchability. Climate and hygiene have
to be monitored to prevent a deterioration of hatching egg quality before arrival at
the hatchery.
Egg transport to the hatchery (page 24) outlines how to transport hatching eggs in
optimal conditions to the hatchery.
Egg receipt
On arrival of eggs at the hatchery it should be confirmed that the number
corresponds with the number recorded by the breeder farm manager. At this time
hatching eggs should also be separated from non-hatching eggs and a sample for
quality monitoring could be taken.
Egg receipt (page 26) comprises a general inspection of the quantity and quality of
eggs supplied by the breeder farm.
Setting eggs in setter trays and trolleys

Eggs can arrive at the hatchery on paper or small plastic trays in boxes, in egg
containers or on pallets. At some point the eggs need to be set on setter trays. This
offers the opportunity for a complete quality control check and to remove the eggs
unsuitable for hatching.
When eggs arrive in the hatchery already placed on setter trays placed in farm trolleys
they only have to be transferred to setter trolleys.
Setting eggs in setter trays and trolleys (page 27) provides relevant points of attention
for the setting of eggs in setter trays and trolleys.
Pre-storage incubation
Pre-storage incubation is a management tool aiming at making embryo’s more
storage-resistant and can be applied when eggs arrive at the hatchery (up to 3 – 4
days after production date). Pre-storage incubation is only beneficial if the embryos
in the eggs are in a very early stage of development. If embryo development is
already more advanced when eggs arrive in the hatchery pre-storage incubation will
lead to increased early mortality and should be avoided.
18 Broilers - Incubation Guide - V 6.0 3 Egg handling

Pre-storage incubation (page 28) provides guidelines how to establish a suitable pre-
storage incubation protocol in the hatchery.
Storage of hatching eggs

Usually, storage of the eggs prior to incubation is unavoidable. The storage time and
the temperature and relative humidity at which the eggs are stored are very
important for the hatching result.
Recommended procedure (page 28) outlines the optimum climatic conditions for
storage.
Disinfecting hatching eggs

Micro-organisms on the surface of eggshells can have detrimental effects on
hatchability and chick quality. It is therefore essential that the eggs are disinfected
prior to incubation. This could be done already at the breeder farm, but it is more
common to do this just prior to incubation or alternatively at the moment eggs arrive
at the hatchery.
Disinfecting hatching eggs (page 32) outlines how to disinfect hatching eggs in a
special designed disinfection room.

3.2 Egg handling at the breeder farm
3.2.1 Objective
To provide optimum care for the hatching eggs until they are transported to the
hatchery in order to maintain maximum hatching potential.
3.2.2 Persons responsible

Breeder farm manager and personnel assigned to collect, grade and store eggs until
they are transported to the hatchery.
3.2.3 Documents
Recording Form 3A: Egg transport card (page 156)
Recording Form 3B: Egg receipt form (page 157)
Recording Form 3F: Egg storage room: climate conditions (page 161)
3.2.4 Definitions
Refer to glossary for definitions of underlined terms.
3.2.5 Recommended procedure

1. Ensure sufficient, comfortable and easy accessible nest space according to the
specifications in the specific Breeder Management Guide taking local conditions
into consideration. Avoid direct light and draughts into the nests.
2. Keep nests clean at all times. Extra care for nest hygiene should be given at least
1 time per week.
3. Wash and disinfect hands before each egg collection.
4. Collect eggs from the nest at least 4 times per day in case of manual litter nests
and at least 2 times per day from automatic roll away nests under the condition
that temperature on the egg transport belt is 20 – 22 °C/68.0 – 71.6 °F. At lower
and higher temperatures the frequency of egg collection should be increased.
5. Avoid shocks and jolting in handling in order to prevent damage to the fragile
embryonic structure and hairline cracks in the shell.
6. Aim at eggs uniformly cooling down from 41 °C/105.8 °F (the hen’s body
temperature and thus the egg temperature at oviposition) to between 22 and 25
°C/71.6 and 77.0 °F in approximately 6 hours. Too fast and too slow cooling down
should be avoided. Therefore maintain a temperature of 20 – 22 °C/ 68.0 – 71.6 °F
in the egg collection room.
7. Separate non-hatching eggs from hatching eggs. Also keep floor eggs separate.
8. Record the number of hatching eggs and non-hatching eggs (optionally per
category such as double yolks, cracked eggs, floor eggs etc.) into the daily
breeder farm records.
9. Place hatching eggs on well-designed egg trays (paper or plastic) or setter trays
with sharp end down. Avoid the use of floppy trays and do not overstack.
10. Print the farm and house number and country of origin clearly on each egg if this
is required by legislation.
11. Place the egg trays in egg containers or boxes after all the eggs have cooled
down to 22 - 25 °C/71.6 - 77.0 °F. Place setter trays in farm trolleys and allow eggs
to cool down gradually before placement in the egg storage room.
12. Supply each (full) egg container or box or farm trolley with Recording Form 3A:
Egg transport card (page 156) on which egg ID code, production date and egg
numbers are listed.
13. Place the egg containers/boxes/farm trolleys in the egg storage room until they
are collected to be transported to the hatchery.

14. Maintain recommended climate conditions in the egg storage room depending
on the intended duration of storage or as agreed with the hatchery manager (see
table below).
15. Monitor the climate conditions daily and record them on Recording Form 3F: Egg
storage room: climate conditions (page 161).
16. Check proper functioning of any thermometers and hygrometers at regular
intervals by comparing with a calibrated device. Record the date of checking on
Recording Form 3F: Egg storage room: climate conditions (page 161).
17. Complete Recording Form 3B: Egg receipt form (page 157) prior to transport to the
hatchery and sign the form. This recording form contains technical data about
the parent flock and the quantity and quality of the delivered eggs.
Recommended climate conditions during egg storage

Storage duration Temperature Relative humidity* (%) Egg orientation
(°C/°F)
0-3 days 18-21 / 64.4–69.8 75 – 85 Blunt end up
4-7 days 15-17 / 59.0–62.6 75 – 85 Blunt end up
8-10 days 12-14 / 53.6-57.2 80 – 85 Blunt end up
More than 10 days 12-14 / 53.6-57.2 80 – 85 Small end up or
alternatively turning the
eggs every 24 hours
*The recommended relative humidity range for eggs stored on paper trays is 50 – 75%; the risk for dehydration
is much smaller on paper trays and the occurrence of floppy trays due to too high relative humidity should be
avoided.
A good quality hatching egg
Keep floor eggs separate; these form a risk of contamination for the hatchery.
3.2.6 Additional notes

- A healthy, well managed breeder flock, receiving a balanced feed ration has
the potential to produce good quality hatching eggs. At the moment the egg is
laid, it contains an embryo of 30,000 – 60,000 cells. At that point in time, each cell
is already programmed for its future function. Only with the best of care can the
hatching potential held in this delicate embryonic structure be kept at its
maximum potential. This care should already be given at the breeder farm from
the moment the egg is laid. Poor egg handling at the breeder farm cannot be
compensated later on in the hatchery!

- Good breeder farm management includes full attention for the production of
good quality hatching eggs. This does not only include careful egg handling, but
also aspects like feeding and feed quality, housing and climate, health care,
percentage and quality of males, floor egg prevention etc.
- Breeder farm records are useful to monitor the percentage on non-hatching
eggs. In combination with feed-back on egg quality and hatch results from the
hatchery, hatching egg quality can be analysed leading to further improvement.
‘Physiological zero’
Although the exact level of the ‘physiological zero’ is debated by hatchery
specialists and researchers, there is a general consensus that embryonic
development, which starts in the hen’s body, will continue as long as internal egg
temperature is higher than 25 - 27 °C/77.0 – 80.6 °F. To maintain best hatching
potential after egg storage eggs should be cooled down uniformly and gradually
from body temperature to between 18 and 25 °C in approximately 6 hours. Too fast
cooling down results in under-developed embryos and too slow cooling down
results in too much advanced embryos; in both cases embryo survival of stored
eggs is reduced.
Cooling down
The rate at which hatching eggs cool down depends on several factors:
- Nest type in relation to frequency of egg collection plays an important role.
• Manually collected litter nests: Eggs produced in this type of nests cool
down very slowly to environmental temperature, due to the insulation
provided by the surrounding nest litter. Since nest boxes are shared
between 5 - 7 hens, warmth is brought to partially cooled-down eggs
again every time another hen enters the nest. It is only once eggs are
collected that they are able to cool down properly.
• Automatic nests: In this type of nest, the eggs roll away to an egg
transport belt soon after being laid, which exposes all the eggs to a similar
environmental temperature. Cooling down will occur uniformly, but when
there are draughts of cold air over the egg belt there is a risk that eggs
cool down too rapidly.
- The type of egg tray used for egg collection and further storage also plays a
role. Egg temperature at the moment of collection will vary from egg to egg,
with some still holding a temperature of more than 25 °F/77 °F. In this case,
further cooling is required.
• Paper tray: A newly produced egg, with a temperature close to that of the
hen’s body (41 °C/105.8 °F), will take much longer to cool down when
placed at the centre of a paper tray and covered by the next full tray, than
an egg placed at the side of the paper tray. Packing warm eggs on paper
trays directly into egg boxes will certainly lead to high embryonic
mortality!

• Setter tray: Due to the more open character and the fact that filled setter
trays are not stacked directly on top of each other there is an adequate
supply of free circulating air over the trayed eggs. This will greatly assist in
uniform cooling, but if the temperature in the egg collection room is too
low there is the risk that eggs cool down too rapidly, especially when
exposed to a draught of cold air.
• Plastic trays: These are intermediate between paper trays and setter trays,
because plastic is not such a good thermic insulator as paper and allows
some restricted air flow over the eggs.
- Washing of hatching eggs is not included in the above procedure as the risk of
internal contamination of dirty eggs is not eliminated by washing and due to
potential for incorrect washing practices being used the risk might even
increase. Moreover, depending on the detergents used the protective cuticle
could be removed. Rather than focusing on cleaning of dirty eggs the emphasis
should be on preventing eggs from getting dirty in the first place.
- Hatching egg disinfection at the farm is not included in the above procedure. If
done correctly and in agreement with the hatchery it could be implemented
before placement of the eggs in the farm store or alternatively daily in the farm
store itself. However, this only makes sense if eggs are placed on setter trays in
farm trolleys. For details, see Disinfecting hatching eggs (page 32).
- Egg ‘sweating’ must be prevented at all times. When the environmental
temperature of stored eggs suddenly increases, water may condense on the
eggshell: we say the eggs are ‘sweating’. This should be avoided at all times since
sweating eggs provide an ideal environment for the growth of microorganisms
that may penetrate the eggshell. For further explanation, see Sweating of eggs
(page 134).
- The optimal climate settings in the egg storage room should be decided by or
at least coordinated with the hatchery manager in order to avoid sweating
during truck loading and to match with intended storage duration at the
hatchery and climate conditions in the hatchery’s egg storage room. Continued
storage at the hatchery should at least be at equal temperatures and definitely
not higher!

3.3 Egg transport to the hatchery
3.3.1 Objective
To transport the hatching eggs in optimal conditions from the egg storage room at
the breeder farm to the hatchery.

Truck driver assigned to transport eggs.
3.3.3 Documents
3.3.4 Definitions

1. Clean and disinfect the truck and other transport equipment thoroughly prior to
any egg transport to avoid the spread of pathogens. This includes empty return
freight from the hatchery to the breeder farm, such as egg containers, boxes,
farm trolleys, empty egg trays and setter trays.
2. Ensure the temperature in the truck is close to the temperature in the egg
storage room.
3. Keep the relative humidity in the truck low (max. 60 - 70%) to reduce the risk of
‘sweating’. Providing transport time is no longer than 12 – 24 hours the effect of
low relative humidity on the quality of hatching eggs is negligible.
4. Position the egg transport truck with the ‘loading side’ as close as possible to the
exit door of egg storage room at the breeder farm. The best option would be to
connect the truck directly to the egg storage room.
5. Load and unload eggs carefully in order to avoid mechanical shocks from egg
storage room to the truck.
6. Secure the egg containers/boxes/farm trolleys inside the truck well so they
cannot move during transport.
7. Ensure Recording Form 3B: Egg receipt form (page 157) is completely filled out
and check if the number of eggs delivered is recorded correctly. Sign the form if
all is correct.
8. Take the completely filled Recording Form 3B: Egg receipt form (page 157)
together with the batch of eggs to the hatchery.
9. Drive carefully taking the road condition into consideration.
10. Ensure a constant and uniform climate during egg transport. The use of
temperature data loggers during transport is helpful to pinpoint any unwanted
temperature fluctuations.
11. Add the data concerning egg transport conditions toRecording Form 3B: Egg
receipt form (page 157) on arrival at the hatchery. Hand this recording form to
the responsible person at the hatchery.
12. Unload the eggs carefully and place them in the egg reception room.

- Egg transport is generally by truck, although when importing hatching eggs, air
transport may also be used. Also in that case the above procedure applies.
However, it is worth remembering that delays can occur during transfer from
aircraft to truck and while waiting for customs clearance. Ensuring all import
requirements are met and relevant documents are available will help to reduce
any delay.
- Hatching egg transport is actually a period of transition from the farm store to
the hatchery egg store, it is important that climatic conditions are kept optimal
to maintain the hatching potential of the eggs.
Hatching eggs; a precious cargo …

Remind truck drivers regularly, for example by a yearly training session, that
hatching eggs are precious cargo which needs to be handled with great care at all
times. Poor transport conditions during loading, transport and unloading will have
a negative impact on hatchery results. Points of attention are:
- Avoid sudden temperature changes during loading and unloading.
• Consider using buggy bags, especially in situations of high air velocity and
low air temperature. When using buggy bags be aware of unwanted
condensation on the inside of these bags.
• Be aware of direct sunshine as this can rapidly raise the temperature of
the eggs.
- Avoid eggs, paper boxes and paper trays getting wet through rain or due to
sweating during loading and unloading.
• If needed, buggy bags could be of use.
- Avoid shocks and jolts during loading, transport and unloading in order to
prevent damage to the fragile embryonic structure and hair cracks in the shell.
• Shock absorbing trolley wheels, a smooth and even driveway, well-
designed egg trays without sharp edges and trucks with a good
suspension system are only a first step.
• A quality-consciousness mentality is an important second step needed for
careful loading and driving.
- Keep your eyes not only on the road, but also on the temperature and
humidity sensors!
- It is preferred to take non-hatching eggs directly from the breeder farm to e.g.
egg processing industry. If they are first taken to the hatchery these are best
stored in a separate room until delivery.
(page 134).

3.4 Egg receipt
3.4.1 Objective
To verify the numbers of hatching eggs supplied by the breeder farm.

Hatchery manager and personnel assigned to receive the eggs and to check quantity
of the eggs supplied by the breeder farm.
3.4.3 Documents
Recording Form 3C: Hatching egg stock list (page 158)
3.4.4 Definitions

1. On arrival at the hatchery, the egg containers, boxes or farm trolleys are placed in
the egg reception room. Each batch of eggs is accompanied by Recording Form
3B: Egg receipt form (page 157) which contains technical data about the parent
flock and the quantity and quality of the delivered eggs. This form is supplied by
the farm manager. The driver of the delivery truck completes the data on
transport conditions.
2. Ensure each (full) egg container, box or farm trolley is clearly labeled with
Recording Form 3A: Egg transport card (page 156) on which egg ID code,
production date and egg numbers are listed.
3. Check if the number of eggs received corresponds with the information on
Recording Form 3B: Egg receipt form (page 157). If all is correct place sign this
form. Report deviations to the breeder farm manager.
4. Separate non-hatching eggs from hatching eggs and place non-hatching eggs in
a separate room from where they will be taken for disposal as soon as possible.
5. If required, take a representative sample of the batch of hatching eggs received
and perform an analysis of hatching egg quality. For the recommended
procedure, see Analysis of hatching egg quality upon arrival (page 85).
6. Record the number of hatching eggs from each batch received on Recording
Form 3C: Hatching egg stock list (page 158). This list provides the hatchery
manager with actual data on the numbers and background of eggs in stock. The
hatchery manager uses these data to plan the setting of eggs.
7. Place the eggs in either the egg storage room or forward them to the egg
handling room where the eggs will be placed in setter trays and setter trolleys.

- In case floor eggs and/or washed eggs need to be incubated, which is not
recommended, keep these separate from clean nest eggs throughout the entire
incubation process, for example on the lower setter trays inside the setter trolley.
- It is preferred to take non-hatching eggs directly from the breeder farm to e.g.
egg processing industry. If they are first taken to the hatchery these are best
stored in a separate room until disposal.

3.5 Setting eggs in setter trays and trolleys
3.5.1 Objective
To set eggs in setter trays and trolleys.

Hatchery manager and personnel assigned to set eggs in setter trays and trolleys.
3.5.3 Documents
Recording Form 3D: Setter trolley card (page 159)
3.5.4 Definitions

1. If the eggs are placed on paper or plastic egg trays, place the eggs on setter
trays. This could be done manually, semi-automatically by vacuum lifter or fully
automatically. If eggs are already placed in setter trays on farm trolleys this step
is obviously not necessary.
2. Transfer the filled setter trays into setter trolleys.
3. Work carefully to avoid shocks and jolting in handling in order to prevent
damage to the fragile embryonic structure and hairline cracks in the shell.
4. Remove all eggs which do not meet quality criteria for hatching eggs and replace
with good hatching eggs.
5. Check the position of the eggs carefully and correct if necessary: eggs must be
set with the blunt end (= air cell) up – sharp end down.
6. Provide each loaded setter trolley with Recording Form 3D: Setter trolley card
(page 159) on which trolley number, egg ID code and production date are
recorded.
7. Place the loaded setter trolley either in the egg storage room, optionally after
pre-storage egg disinfection and/or pre-storage incubation, or proceed with
incubation.

- The moment of setting of eggs in setter trays and trolleys could be on the day
of arrival in the hatchery and like that be stored until needed for setting.
Alternatively setting of eggs in setter trays and trolleys could be done just prior
to setting. In the latter case eggs are stored until needed for setting on paper or
plastic egg trays in egg containers or boxes or on setter trays in farm trolleys.
- Placing eggs on setter trays is essential before eggs can be effectively
disinfected or be "pre-storage incubated". This is not possible as long as eggs
are tightly packed together on plastic or paper egg trays as there is no "free
space" around each egg.
- The need for removing eggs which do not meet the quality criteria for hatching
eggs during setting of eggs in setter trays and trolleys depends on the accuracy
with which the eggs were selected at the breeder farm.
- Eggs positioned upside-down (= blunt end down) on the setter tray have a
significantly reduced chance to hatch.
- It is NOT recommended to start incubation within 12 hours of arrival at the
hatchery. Immediate setting after transport will increase early embryonic
mortality.

3.6 Pre-storage incubation
3.6.1 Objective
To develop the embryo to a stage of embryonic development that is better able to
survive storage.

Hatchery manager and personnel assigned to decide which batches should be
exposed to pre-storage incubation and to control the pre-storage incubation process.
3.6.3 Documents
No documents.
3.6.4 Definitions

The procedure below describes how to perform small-scale experiments to asses
performance benefits and to establish an effective hatchery and egg type specific
pre-storage procedure. There is no general recommended procedure for pre-storage
incubation, because the performance benefit largely depends on the stage of
embryonic development of the embryos in the eggs at the moment they arrive in the
hatchery.
1. Apply pre-storage incubation as soon as possible after egg receipt at the
hatchery under the conditions that: a) eggs were not produced longer than 3 – 4
days before date of egg receipt at the hatchery and b) eggs are scheduled for at
least 3 – 4 days extra storage at the hatchery.
2. Carry out the experiments with eggs of at least 3 different breeder flocks per
breed and select flocks of different ages.
3. Select for each flock 4 setter trolleys with eggs of the same production date.
4. Place the three experimental trolleys in a running setter at incubation
temperature; the fourth setter trolley is the control trolley and will not be
incubated before further storage.
5. Incubate the experimental eggs for 3, 6 and 9 hours. Every 3 hours 1 trolley
should be removed from the setter.
6. Place the 4 setter trolleys (3 pre-storage incubated and 1 control) for at least
another 3 days in the egg storage room.
7. Incubate both the pre-storage incubated eggs and the control eggs according to
normal practice.
8. Compare hatchability per trolley: pre-storage incubated eggs vs. control eggs.
9. Evaluate results of all experiments and adopt the best pre-storage incubation
procedure as indicated by the results. If no positive results can be achieved, and
especially when early mortality is increased due to pre-storage incubation, it is
an indication that embryos arrived at the hatchery in a developmental stage too
advanced to benefit from pre-storage incubation.

- Pre-storage incubation, i.e. incubating hatching eggs before they are placed in
the storage room, is a new approach to storage management that aims to
develop the embryo to the hypoblast stage: a stage of embryonic development
that is better able to survive storage.
- Pre-storage incubation is also referred to as SPIDES (= Short Periods of
Incubation During Egg Storage).

- Pre-storage incubation is only beneficial if the embryos in the eggs are in an early
stage of development which could be related to too fast cooling down after
oviposition.
- Negative effects of pre-storage incubation could be expected if nest
temperatures are high and the eggs stay in the nest too long. In that case the
embryos may develop beyond the storage resistant stage and pre-storage
incubation will result in increased early embryonic mortality.
- A fresh-egg break out of eggs in the storage room would allow the diameter
and appearance of the embryo to be monitored and this and could be useful to
predict if a performance benefit is to be expected from pre-storage incubation.
For further details, see Analysis of hatching egg quality upon arrival (page 85).
- Eggs scheduled for storage for more than seven days after production benefit
most from pre-storage incubation.
Pre-storage incubation is only possible when eggs are placed on setter trays in setter
trolleys. Only then can a reasonably uniform egg temperature during pre-storage
incubation treatment be ensured. Pre-storage incubation of eggs on paper or plastic
egg trays placed in egg containers or boxes results in uneven egg/embryo
temperatures and high levels of early mortality as a consequence.
- As long as pre-storage incubation is performed in a setter located in the setter

room (‘clean area’), eggs should be disinfected first. Ideally, use a specific
incubator located close to the egg storage room.
- If eggs are to be stored for a long period (for example more than 10 days) there
might be a positive effect to repeat the pre-storage incubation treatment (for
example every 4 or 5 days). The hypothesis is that these regular heat treatments
help prevent embryonic cell death during further storage.
- Contact Pas Reform Academy for further details on the latest research and
SPIDES-specific incubation program (heating and cooling phase).

3.7 Storage of hatching eggs
3.7.1 Objective
To provide optimum conditions for eggs during storage so that losses in potential
hatchability and chick quality are minimised.

Hatchery manager and personnel assigned to store eggs.
3.7.3 Documents
Recording Form 3C: Hatching egg stock list (page 158)
Recording Form 3D: Setter trolley card (page 159)
Recording Form 3E: Setter schedule (page 160)
Recording Form 3F: Egg storage room: climate conditions (page 161)
3.7.4 Definitions

1. Ensure the eggs for further storage at the hatchery are clearly labeled with either
Recording Form 3A: Egg transport card (page 156) or with Recording Form 3D:
Setter trolley card (page 159).
2. Place the eggs in the egg storage room and arrange them to egg ID code and
production date.
3. Keep eggs a little distance away from the wall to allow a little air circulation.
Avoid direct air flow from egg room coolers and/or humidifiers. Keep sufficient
distance from the heating system.
4. Maintain recommended climate conditions in the egg storage room depending
on the intended duration of storage (see table below).
5. Monitor the climate conditions daily and record them on Recording Form 3F: Egg
storage room: climate conditions (page 161).
6. Check proper functioning of thermometers and hygrometers at regular intervals
by comparing them to a calibrated device. Record the date of checking on
Recording Form 3F: Egg storage room: climate conditions (page 161).
7. Remove eggs out of the storage room based on the planned setting date of each
batch of eggs on Recording Form 3E: Setter schedule (page 160). Do this in a
timely fashion in order to allow sufficient time to prepare the eggs for
incubation, such as placing them on setter trays and/or in setter trolleys,
disinfection and pre-warming or pre-heating.
8. Record the number of eggs removed from the storage room for setting on
Recording Form 3C: Hatching egg stock list (page 158) and calculate the remaining
stock.

Recommended climate conditions during egg storage
Storage duration Temperature Relative humidity* (%) Egg orientation
(°C/°F)
0-3 days 18-21 / 64.4–69.8 75 – 85 Blunt end up
4-7 days 15-17 / 59.0–62.6 75 – 85 Blunt end up
8-10 days 12-14 / 53.6-57.2 80 – 85 Blunt end up
More than 10 days 12-14 / 53.6-57.2 80 – 85 Small end up or
alternatively turning the
eggs every 24 hours
*The recommended relative humidity range for eggs stored on paper trays is 50 – 75%; the risk for dehydration
is much smaller on paper trays and the occurrence of floppy trays due to too high relative humidity should be
avoided.

- Eggs can be stored on paper or plastic egg trays in egg containers or boxes or on
setter trays in farm trolleys or setter trolleys.
- Storage starts at day of egg production, which is not necessarily the same as
the date of receipt in the hatchery’s egg storage room. Storage includes the days
the eggs are kept at the breeder farm and the duration of transport.
- If storage time is not constant it is recommended to have two separate egg
storage rooms, each with its own specific climate conditions.
- Optimal hatching results and chick quality can be achieved if eggs are set after
an initial storage period of 1 to 2 days. During this period of adaptation carbon
dioxide is released from the egg, resulting in a pH increase of the albumen to 8.5.
With a virtual constant yolk pH of around 6.5 the embryo, situated on the yolk,
will be exposed to a pH-gradient. This pH-gradient optimizes embryonic
development.
- It is not recommended to start incubation within 12 hours after the eggs arrive in
the hatchery. Immediate setting after transport will increase early embryonic
mortality. Eggs need a period of rest after transport.
- Storage times longer than one week are not recommended: after four days from
production date, every day of storage decreases hatchability by approximately
0.7%-1.0%.
- Stored eggs need about one extra hour of incubation time for every storage day
in excess of three days.
- If hatchery planning is such that eggs need to be stored for more than 10 days, it
is advisable to store them small end up, starting on the first day of storage. If this
is not possible because eggs are stored on setter trays, turn them every 24 hours.
(page 134).

3.8 Disinfecting hatching eggs
3.8.1 Objective
To eliminate micro-organisms on the shells of hatching eggs.

Hatchery manager and personnel assigned to set and incubate eggs.
3.8.3 Documents
Recording form 3G: Egg disinfection room (page 162)
3.8.4 Definitions
3.8.5 Recommended procedure A

Chemical: paraformaldehyde
1. Place the setter trolleys with trayed eggs in the egg disinfection room. Trolleys
should be moved in via the egg receiving/storage room only!
2. Ensure the egg shell surface has a temperature of at least 18 °C / 64.4 °F , but
preferably 20 °C/68.0 °F or higher as formaldehyde is not so effective disinfectant
at lower temperatures than this.
3. Maintain the correct temperature and relative humidity (21 – 25 °C / 69.8 – 77 °F
and 65 - 75%) in the disinfection room.
4. Weigh 7 grams of crystalline paraformaldehyde per m³ of disinfection room and
place in an electric pan.
5. Record date and time of egg disinfection and amount of crystalline
paraformaldehyde on Recording form 3G: Egg disinfection room (page 162).
6. Make sure the fan shaft and the door to the setter room are closed, leave the
disinfection room and close the door behind you.
7. Start the program. The electric pan is heated and the evaporated formaldehyde
gas disinfects the eggs. A recirculation fan should be running continuously
during the entire process.
8. After 30 minutes (including 10 minutes to initiate evaporation) the extraction fan
is switched on automatically and the air inlet valve on the side of the setter room
is opened.
In case the temperature in the disinfection room is higher than 25 °C/77 °F the
extraction should be started 5 – 10 minutes earlier to avoid toxic effects of the
formaldehyde on the embryos.
9. Ventilate for 30 to 60 minutes.
10. Optional: Neutralise the formaldehyde gas with ammonia by using the
"Formaldehyde Neutralisation Unit" according to the procedure of this unit.
11. Open the door at the setter room side and move the trolleys into the setter
room. Leave the door at the egg traying room side closed!
12. Record if any crystalline paraformaldehyde remains used on Recording form 3G:
Egg disinfection room (page 162). If all the paraformaldehyde was not
evaporated, investigate the cause and take corrective actions. If required, expose
the eggs again to the disinfection process.

3.8.6 Recommended procedure B
Chemicals: formalin (37 - 40% formaldehyde in water) and potassium permanganate
1. Place the setter trolleys with trayed eggs in the egg disinfection room. Ideally,
trolleys should be moved in via the egg receiving/storage room only!
2. Ensure the egg shell surface has a temperature of at least 18 °C / 64.4 °F , but
preferably 20 °C/68.0 °F or higher as formaldehyde is not an effective disinfectant
at lower temperatures than this.
3. Maintain the correct temperature and relative humidity (21 – 25 °C /69.8 – 77 °F
and 65 – 75%) in the disinfection room.
4. Make sure the fan shaft and the door to the setter room are closed.
5. First put the potassium permanganate in an enamelled pan (20 grams per m³ of
disinfection room). Then pour the liquid formalin (30 ml per m³ of disinfection
room) over the potassium permanganate. Be aware that the reaction starts
immediately after adding the formalin. Wear a mask with a specific filter; avoid
inhalation!
6. Leave the disinfection room and close the door behind you.
7. Record date and time of egg disinfection and amount of formalin on Recording
form 3G: Egg disinfection room (page 162).
8. After 20 minutes the extraction fan is switched on automatically and the air inlet
valve on the side of the setter room is opened.
In case the temperature in the disinfection room is higher than 25 °C/77 °F the
extraction should be started 5 – 10 minutes earlier to avoid toxic effects of the
formaldehyde on the embryos.
9. Ventilate for 30 to 60 minutes.
10. Optional: Neutralise the formaldehyde gas with ammonia by using the
"Formaldehyde Neutralisation Unit" according to the procedure of this unit.
12. Record if a noticeable of formalin remains in the enamel reaction pan on
Recording form 3G: Egg disinfection room (page 162). If there was formalin left
over, investigate the cause and take corrective actions. If required expose the
eggs again to the disinfection process.
3.8.7 Recommended procedure C

Chemical: Nontox, a liquid disinfectant produced on-site in the Watter system by
Electro Chemical Activation of a saturated sodium chloride solution. Nontox has been
proven to give excellent disinfection results and is user, egg and environmental
friendly.
This procedure is based on Low Volume Misting of Nontox. It requires specially

selected nozzles creating extremely small droplets that keep floating in the air like a
dense fog to ensure a good distribution over all the eggs that are tightly packed on
setter trays loaded in setter trolleys.
Contact Pas Reform for information about the Watter system, the technical
requirements for optimal distribution over all eggs and the recommended amount of
Nontox in relation to duration of fogging for different capacities of egg disinfection
room.
1. Place the setter trolleys with trayed eggs in the egg disinfection room. Trolleys
should be moved in via the egg receiving/storage room only!
2. Maintain a temperature in the egg disinfection room that is intermediate
between storage temperature and setter room temperature and does not result
in eggs ‘sweating’, see Sweating of eggs (page 134). Relative humidity is
preferably not lower than 50 – 55%.
3. Make sure the fan shaft and the door to the setter room are closed, leave the
disinfection room and close the door behind you.

4. Dose the required amount of Nontox 100 %, usually between 5 and 10 liters for
up to 36 setter trolleys.
5. Record date and time of egg disinfection and amount of Nontox on Recording
form 3G: Egg disinfection room (page 162).
6. Start the program. The nozzles are filling the egg disinfection room with a ‘cloud’
of Nontox. Avoid additional air recirculation which is counterproductive.
7. At the end of the fogging time, usually 50 minutes maximum, the extraction fan
is switched on automatically and the air inlet valve on the side of the setter room
is opened.
8. Ventilate for 10 minutes.
10. If any Nontox remains unused record the amount on Recording form 3G: Egg
disinfection room (page 162). Investigate why all the Nontox was not dispersed
and take corrective actions before the next treatment. If required, expose the
eggs again to the disinfection process.

- Legislation in various countries might not allow the use of formaldehyde/
formalin and it can cause unpleasant working conditions.
- Several hatcheries have good experiences with other liquid disinfectants for
hatching egg disinfection. Dosage depends of the disinfectant as well as on the
application method. Application methods vary from Low Volume Misting in a
enclosed room full of loaded setter trolleys (as described under procedure C), to
applying a course spray on individual setter trays before loading into setter
trolleys. Contact your disinfectant supplier or Pas Reform Academy for additional
information.
All eggs should be reached by the disinfectant

Proper egg disinfection using the described procedures is only possible if eggs are
placed on setter trays in setter trolleys (or farm trolleys). Eggs placed on paper or
plastic egg trays are packed too tightly together with the result that the
disinfectant cannot reach all the eggs.
- Disinfect only visually clean eggs. Good disinfection cannot be achieved with
floor eggs and dirty eggs.
- The above described procedures are based on disinfection just prior to setting.
However disinfection of eggs is also possible at the breeder farm or on arrival in
the hatchery.
- When disinfecting eggs at the breeder farm be aware that formalin can diffuse
into the egg during cooling down from the hen’s body temperature. To avoid
early mortality, the eggs need to be cooled down to 20 – 25 °C/68.0 – 77.0 °F
before disinfection. This may take between 4-6 hours, depending on ambient
conditions.
- To avoid re-infection and cross-contamination, disinfected and non-disinfected
eggs should never be placed next to one another.
- If eggs are disinfected on arrival at the hatchery ensure they are not re-infected.
All rooms following the disinfection room should be seen as "clean" areas and
all hygienic instructions should be followed strictly.
- Monitor the efficacy of egg disinfection procedure by taking micro-biological
samples. See Hatchery hygiene monitoring (page 119).

4 Incubation in setter: day 1-18
In this chapter
Introduction 36
Single-stage incubation 37
Multi-stage incubation 41
Broilers - Incubation Guide - V 6.0 4 Incubation in setter: day 1-18 35

4.1 Introduction
Introduction
Procedures for the first 18 days of incubation are described separately for single-
stage and multi-stage incubation.
Single-stage incubation
In single-stage (all in/all out) incubation, the incubator contains only eggs of the
same embryonic age. The advantage of single-stage incubation is that climate
conditions can be adjusted according to the needs of the growing embryo.
Circadian Incubation™ is an advanced method of single-stage incubation aiming at

the production of more robust chicks with a better performance.
Single-stage incubation (page 37) describes the steps involved in single-stage

incubation and provides guidelines for choosing the optimum set points for
temperature, relative humidity, ventilation, frequency and turning for single-stage
incubation.
Multi-stage incubation
In multi-stage incubation the setter contains eggs of different embryonic ages.
Usually 6 or 2 age groups.
Consequently, climate conditions cannot exactly be adjusted according to the needs

of all the growing embryos and a compromise has to be sought to best suit the age
groups present in the setter.
An important aspect of multi-stage incubation is the placement of eggs according to

a repeated setting scheme, such that there is a balance between old "hot" eggs and
new "cold" eggs. Old "hot" eggs are more than 12 days into incubation and contain
heat-producing embryos. New "cold" eggs are less than 7 days into incubation and
contain heat-demanding embryos.
Recommended set points and setting schemes for multi-stage incubation are
described in Multi-stage incubation (page 41).
36 Broilers - Incubation Guide - V 6.0 4 Incubation in setter: day 1-18

4.2 Single-stage incubation
4.2.1 Objective
To incubate hatching eggs in optimum climate conditions according to the all in / all
out principle to achieve maximum hatchability and chick quality.

Hatchery manager and personnel assigned to control the incubators and incubation
programs.
4.2.3 Documents
Recording Form 4A: Incubator recording form (page 163)
Recording Form 10B: Cleaning schedule (page 176)
4.2.4 Definitions

1. Check proper functioning of the empty machine and note this on Recording Form
4A: Incubator recording form (page 163) which should be attached to the door of
the setter. Use the Performance Testing Tool on the SmartDrive™/SmartTouch™.
2. Transfer the setter trolleys filled with trayed eggs from the egg disinfection room
to the setter and place the trolleys according to Recording Form 3E: Setter
schedule (page 160).
3. In case the setter is not completely filled with eggs place full (or at least nearly
full) trolleys on the pulsator/Vortex™ side.
4. Load the remaining eggs on setter trays into incompletely-filled trolleys from the
centre upwards and downwards and leave the top and bottom without setter
trays. Distribute these trolleys evenly on the corridor/mixing zone side by at least
keeping the ‘balance’ within a section (a trolley on both sides of the heart of the
pulsator/Vortex™) as well as in opposing sections (same number of trolleys on
both sides of corridor/mixing zone). Fill the rest of the setter with trolleys
without setter trays.
5. Write the egg ID codes on Recording Form 4A: Incubator recording form (page
163).
6. Ensure the setter trolleys are securely locked in their positions.
7. Start up the setter in order to test the rpm’s of the pulsator/Vortex™ as well as the
turning mechanism of the loaded setter in both directions and record this on
Recording Form 4A: Incubator recording form (page 163).
8. Select the appropriate incubation program manually on SmartDrive™/
SmartTouch™ or send and activate a new incubation program by SmartCenter™.
See general guideline on the next pages for suggested set points for incubation
temperature, relative humidity, ventilation, frequency and turning.
9. Include the pre-heat function in the incubation program as negative time (5-8
hours) at min. 77 – max. 81 °F with trays in horizontal position). Alternatively,
eggs can be pre-warmed in the setter room prior to loading the setter. Eggs
should be pre-warmed for 12 hours when they have been stored up to seven
days and 18 hours in case of longer storage.
10. Fine-tune starting time of incubation based on observations during previous
chick take-off. Adjust the incubation timer aiming at chicks being fully ready for
take-off at the intended time; see Chick take-off (page 69).

11. Record the incubation program and the starting time (0:00 on the incubation
timer) on Recording Form 4A: Incubator recording form (page 163).
12. Start the setter.
13. Record any changes to the incubation program onRecording Form 4A: Incubator
recording form (page 163).
14. Candle eggs on day 10 (see 10-day candling (page 49)) or on the day of transfer
(see Candling and transfer (page 52)) and carry out an analysis of clear eggs if
required, see Analysis of clear eggs (page 95).
15. Transfer eggs to the hatcher baskets approximately 17.5 –18.5 days after the start
of incubation, see Candling and transfer (page 52).
16. On transfer days, all empty setters, setter trays and setter trolleys, the setter room
as well as the transfer room including all equipment must be cleaned and
disinfected followed by thorough drying prior to next use. See Cleaning and
disinfection (page 117) and place signature on Recording Form 10B: Cleaning
Full trolleys on the pulsator/Vortex™ side
Incompletely-filled trolleys loaded from the centre upwards and downwards and leaving
the top and bottom without setter trays evenly distributed on the corridor/mixing zone
side

General guideline SmartSetPro™ with AMF™ and/or ESM™ Broiler
Hatchery at sea level (up to 1200 m)
Moment of Incubation Relative Ventilation (4) Frequency Turning
set point temperature humidity (3) (6)
change (2)
(day.hour) °F % % valve % CO2 AMF (5) % Set point
(positions)
- 0.05/ 0.08 77.0 – 81.0 60 0 – 20 0.40 Off 100 horizontal = 0
0.00 100.4 60 0 0.40 Off 100 2
1.00 100.2 60 0 0.40 Off 100 2
2.00 100.0 60 0 0.40 Off 100 2
3.00 99.9 55 10 0.40 On 75 2
4.00 99.9 55 10 0.40 On 75 2
5.00 99.9 55 10 0.40 On 75 2
6.00 99.9 50 20 0.40 On 75 2
7.00 99.8 50 30 0.40 On 75 2
8.00 99.8 50 40 0.40 On 75 2
9.00 99.5 - 99.7 50 40 0.40 On 75 2
10.00 99.2 - 99.5 50 40 0.40 On 75 2
11.00 99.0 - 99.2 50 50 0.40 On 75 2
12.00 98.6 - 98.8 50 50 0.40 On 75 2
13.00 98.2 - 98.5 48 50 0.40 On 100 2
14.00 97.7 - 98.3 48 60 0.40 On 100 2
15.00 97.5 - 98.0 48 60 0.40 On 100 2
16.00 97.4 - 98.0 45 – 48 60 0.40 On 100 2
17.00 97.2 - 98.0 45 – 48 70 0.40 On 100 2
18.00 97.2 - 98.0 45 – 48 70 0.40 On 100 2
1) The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs. The guidelines in
the table apply to hatcheries at sea level (up to an altitude of approx. 1200 m).
2) The main parameter for the temperature set point is the eggshell temperature measured with the Braun ThermoScan. See
Analysis of eggshell temperature (page 89).
3) The main parameter for relative humidity set point is egg weight loss at the day of transfer. The relative humidity profile can
either be constant (guideline is 50%) or slightly declining from 60 to a minimum of 45 – 48%. See Analysis of egg weight loss
(page 93).
4) If AMF™ is activated, the ventilation (valve position) is controlled such that both relative humidity and the CO2-setpoint do
not exceed their set point. If AMF™ is not activated the valve positions are determined by the programmed valve set points.
5) To make sure the valve does not open during the first days of the incubation period, AMF™ is switched "off" in the
incubation program. Manual switching "off" and "on" of AMF™ is also possible in the "service settings menu" on the setter
itself.
6) The frequency or the rotations per minute of the Vortex™ can be reduced as indicated without affecting hatchability and
chick quality at the same time saving considerably on the energy consumption.

The guidelines in the table apply to hatcheries at sea level (up to an altitude of
approx. 1200 meter). For information on how to adjust these guidelines for higher
altitudes, see Hatching at high altitudes (page 140).
- The set points in the tables should be used as guidelines only. Based on the
extra information in the footnotes 1-6 below the tables, set points might need to
be adjusted.
- To achieve maximum hatchability, uniformity and chick quality it is
recommended to load the incubator with only one type of egg in respect of
breed, maternal age and storage days.
- When different batches of eggs are to be placed in one setter a small benefit
could be obtained by placing eggs with the highest metabolic heat production
on the pulsator/Vortex™ side and eggs with lower expected metabolic heat
production at the corridor/mixing zone side. During the last days in the setter
the egg shell temperature at the pulsator/Vortex™ side is a usually a little lower
compared to corridor/mixing zone side.
- Achieved hatchability, chick quality and results from egg analysis will provide
further information on which set points could be fine-tuned in future cycles.
Ffor further information, see Tools for fine-tuning (page 83).
- To support single-stage incubation, Adaptive Metabolic Feedback (AMF™) and
Energy Saving Module (ESM™) are available options on SmartSet™ and
SmartSetPro™ setters. For further details see Adaptive Metabolic Feedback (AMF™)
(page 144) and Energy Saving Module (ESM™) (page 147) including some typical
climate history graphs.
- Preheating of eggs in an operational setter aims at bringing the eggs to a
uniform INTERNAL temperature of 25 °C/77 °F prior to the onset of incubation.
Due to the air flow generated by the pulsator/Vortex™ this is achieved faster
compared to the situation where trolleys with eggs are pre-warmed in the setter
room. Good preheating or pre-warming facilitates a uniform start of incubation
for all embryos and contributes to a short hatch window. In case eggs are still
wet at start of preheating period due to application of a liquid disinfectant it
makes sense to open air valves for example 20 % during preheating to allow
eggs to dry.
- Pre-heating and pre-warming time has to be longer if eggs have been stored
more than a week because, due to lower storage temperature, it takes more time
to achieve an internal egg temperature of 25 °C/77 °F.
- For successful in-ovo vaccination embryonic development should be as
uniform as possible. Eggs should be transferred as late as possible, but not later
than 19 days. If in-ovo vaccination is carried out too early the vaccine might not
be delivered to the most optimal In-ovo vaccination (page 56).
- Circadian Incubation™ is a new feature in single stage incubation. Circadian
Incubation™ provides the embryos during specific sensitive stages of
development daily with short stimuli of high or low temperatures. For more
details and advice for the development of a hatchery specific Circadian
Incubation™ program, see Circadian Incubation™ (page 149).

4.3 Multi-stage incubation
4.3.1 Objective
To incubate hatching eggs in the optimum climate conditions for multi-stage
incubation to achieve maximum hatchability and best chick quality.

Hatchery manager and personnel assigned to control the incubators and incubation
programs.
4.3.3 Documents
4.3.4 Definitions

1. Check proper functioning of the machine and note this on Recording Form 4A:
Incubator recording form (page 163) which should be attached to the door of the
setter. If you start up an empty setter, use the Performance Testing Tool on the
SmartDrive™/SmartTouch™.
2. Transfer the setter trolleys filled with trayed eggs from the egg disinfection room
to the setter room.
3. Pre-warm the eggs in the setter room prior to loading the setter. Pre-warm for 12
hours if eggs were stored for up to seven days or 18 hours in case of longer
storage.
4. Fine-tune loading time based on observations during previous chick take-off.
Start loading the machine aiming at chicks being fully ready by the intended
time for chick take-off; see Chick take-off (page 69).
5. Place the trolleys according to Recording Form 3E: Setter schedule (page 160). See
recommendations below for possible setting schemes.
6. Ensure the setter trolleys are securely locked in their positions.
7. After loading the setter, test the rpm’s of the pulsator/Vortex™ and test the
turning mechanism in both directions and record that this has been done on
Recording Form 4A: Incubator recording form (page 163).
8. Write the egg ID codes on Recording Form 4A: Incubator recording form (page
163).
9. If necessary, adjust set points of temperature, relative humidity, frequency of the
pulsator and ventilation according to the general guideline in the table below.
Record the starting time and incubator set points on Recording Form 4A:
Incubator recording form (page 163).
10. Candle eggs on day 10 (see 10-day candling (page 49)) or on the day of transfer
(see Candling and transfer (page 52)) and carry out an analysis of clear eggs if
required, see Analysis of clear eggs (page 95).
11. Transfer eggs to the hatcher baskets approximately 17.5 –18.5 days after the start
of incubation, see Candling and transfer (page 52).
12. On transfer days, empty setter trays and setter trolleys, the setter room as well as
the transfer room including all equipment must be cleaned and disinfected
followed by thorough drying prior to next use. See Cleaning and disinfection
(page 117)and place signature on Recording Form 10B: Cleaning schedule (page
176).

General guideline multi-stage incubation with and
without AMF™ and/or ESM™
Broiler; sea level (up to 1200 meter)
Set point 1)
Incubation temperature 99.5 °F 2)
Relative humidity 50 % 3)
Ventilation without AMF™ 50 % valve opening 4)
Ventilation with activated AMF™ 0.4 % CO25)
Frequency Maximal 6)
Turning (positions) 2
1) The machine set points may vary between different breeds, flock ages, storage
times and sizes of eggs. The guidelines in the table apply to hatcheries at sea level (up
to an altitude of approx. 1200 m).
2) The main parameter for the temperature set point is the eggshell temperature. The
temperature set points aims at achieving an average eggshell temperature of 99. 8 –
100.0 °F. See additional notes and Analysis of eggshell temperature (page 89). When
starting an empty machine according to setting scheme as recommended below
single stage temperature set points should be applied initially until day 10-11.
3) The main parameter for relative humidity is egg weight loss. At the day of transfer,
the average egg weight loss should be approximately 10% (young flocks) to 13% (old
flocks). See Analysis of egg weight loss (page 93).
4) The main parameter for ventilation is the CO2-concentration in the incubator.

Without (activated) AMF™ the valve position is determined by its set point. The CO2-
concentration should not exceed 0.4 % and can be measured using a handheld CO2-
meter or an electronic integrated CO2-meter. When starting an empty machine
according to setting scheme as recommended below the valve set point should be
gradually increased from 0% initially to 50% until the machine is fully loaded.
5) If AMF™ is activated, the ventilation (valve position) is controlled such that both
relative humidity and the CO2-setpoint do not exceed their set point. Manual
switching "off" and "on" of AMF™ is possible in the "service settings menu" on the
setter itself.
6) With multi-stage incubation, it is not recommended to reduce the frequency or the

rotations per minute of the pulsator/Vortex™ as this might affect hatchability and
chick quality. If saving on the energy consumption is essential hatchability and chick
quality should closely be monitored.

Recommended setting scheme A (6 embryonic ages in one
setter)
These instructions are only applicable in setters with 6 sections and a central corridor
for loading trolleys.
Rule of thumb: "Newly set eggs should be positioned nearest to the pulsator/
Vortex™"
1. First fill up the positions nearest to the pulsator/Vortex™ in sections 5 and 6
(positions numbered 1; see illustration) with four trolleys containing eggs of the
same embryonic age.
2. After 3-4 days of incubation, place the next four trolleys of eggs in the positions
nearest to the pulsator/Vortex™ in sections 3 and 4 (positions numbered 2; see
illustration).
3. Next setting place four trolleys of eggs in the positions nearest to the pulsator/
Vortex™ in sections 1 and 2 (positions numbered 3; see illustration).
4. The four trolleys of the next setting have to be placed on the positions nearest to
the pulsator/Vortex™ in sections 5 and 6. To enable this, the four trolleys that
were originally placed at positions numbered 1 should be moved to the
positions nearest to the corridor in section 5 and 6 (positions numbered 4; see
illustration).
5. The rule of thumb "Newly set eggs should be positioned nearest to the pulsator/
Vortex™" can be repeated for subsequent settings. When the oldest eggs are
removed from the setter (they are always positioned nearest to the corridor),
four trolleys containing unincubated eggs can be set in the same sections in the
positions nearest the pulsator/Vortex™.
By following setting scheme A strictly, the difference in embryonic age within the
same section is 10 – 11 days.
Setting scheme by positions (see instructions Corresponding embryonic ages with oldest
above) embryo’s being 17 days.

Recommended setting scheme B (2 embryonic ages in one
setter)
These instructions are based on a setter with 2 sections. By simply following the same
routine in other sections this setting scheme B is applicable for all capacities of
SmartSet™ and SmartSetPro™ setters.
Rule of thumb "Newly set eggs should be positioned nearest to the pulsator/
Vortex™".
1. First fill up the positions nearest to the pulsator/Vortex™ in sections 1 and 2
(positions numbered 1; see illustration) with four trolleys containing eggs of the
same embryonic age.
2. After 7 days of incubation, the next four trolleys are placed in the positions
nearest to the pulsator/Vortex™ in both sections. To enable this, the four trolleys
which were originally placed at positions numbered 1 should be moved to the
positions nearest to the corridor (positions numbered 2; see illustration).
3. The rule of thumb "Newly set eggs should be positioned nearest to the pulsator/
Vortex™" can be repeated for subsequent settings. When the oldest eggs are
removed from the setter (they are always positioned nearest to the corridor) four
trolleys containing unincubated eggs can be set in the same section in the
positions nearest to the pulsator/Vortex™.
By following setting scheme B strictly, the difference in embryonic age within the
same section, and thus within the setter, alternates between 7 and 14 days.
Setting scheme by positions (see Corresponding embryonic ages with oldest

instructions above) in a setter with 4 embryo’s being 7 days.
sections.
The guidelines in the table apply to hatcheries at sea level (up to an altitude of
approx. 1200 meter). For information on how to adjust these guidelines for higher
altitudes, see Hatching at high altitudes (page 140).
extra information in the footnotes 1-6 below the tables set points might need to
be adjusted.
- Setting every 3-4 days according to the recommended setting scheme A results
in the most even distribution of "warm" and "cold" eggs throughout the
incubator. Setter scheme B is an acceptable alternative.

- Due to its character it is not possible in multi-stage incubation to achieve the
recommended eggshell temperatures as in single-stage incubation. The
temperature set point is a compromise to achieve recommended egg shell
temperatures as closely as possible. In general the average eggshell temperature
should be 100 - 100.5 °F during the first 12 days of incubation, but could be lower
than that initially. From day 13-18, the average eggshell temperature gradually
increases to temperatures higher than recommended for single-stage
incubation.
- Even though Adaptive Metabolic Feedback (AMF™) was developed to support
single-stage incubation it also is a useful option on Pas Reform SmartSet™ and
SmartSetPro™ setters for multi-stage incubation. For further details, see the user
manual and Adaptive Metabolic Feedback (AMF™) (page 144).
- The use of the Energy Saving Module (ESM™) is not recommended for multi-
stage incubation.
- Correct pre-warming in the setter room preferably at 25 °C/77 °F prior to multi-
stage incubation avoids a too drastic drop of temperature inside the setter when
new eggs are loaded. At the same time it also prevents egg ‘sweating’, which
could easily occur when cold eggs are set in a running and warm setter.
- Pre-warming time has to be longer if eggs were stored more than a week,
because, due to the lower storage temperature, it takes more time to achieve an
internal egg temperature of 25 °C/77 °F.
- A special case which holds the middle between single-stage incubation and
multi-stage incubation is "2-stage semi single-stage incubation" whereby a
setter is filled as described under recommended setting scheme B, but with only
3 days difference between the 2 subsequent settings. Only when the oldest eggs
are removed from the setter is a new cycle started again. This method allows
running the setter on a slightly adapted single-stage program.
- For successful in-ovo vaccination embryonic development should be as
uniform as possible. Eggs should be transferred as late as possible, but not later
than 19 days. If in-ovo vaccination is carried out too early the vaccine might not
be delivered to the most optimal location. See also In-ovo vaccination (page
56).

5 Candling and transfer
In this chapter
Introduction 48
10-day candling 49
Candling and transfer 52
In-ovo vaccination 56
Broilers - Incubation Guide - V 6.0 5 Candling and transfer 47

5.1 Introduction
During the incubation process, eggs can be candled to remove the clear eggs. These
eggs could be infertile or contain early dead embryos. Candling can be done as early
as day 5 - 6 of incubation by an individual candling light, but it is time consuming -
and the risk of candling errors (e.g. accidentally removal of an egg with a normal
living embryo) is evident. The risk of candling errors is reduced if candling is
performed at day 9 or 10 of incubation.
However, in many hatcheries, it is common practice to candle eggs on the day of

transfer to the hatcher, as this is most efficient in terms of time and labour
productivity.
10-day candling
Candling half-way through the setter period could be done on a sample-basis, but
also all eggs could be candled at that time. It offers the opportunity to detect in an
early stage potential problems on breeder farms, during egg handling and early
incubation. Also it allows to adjust the earlier made estimation of expected number
of day-old-chicks in case unexpected problems are unveiled and to anticipate for
future settings.
10-day candling (page 49) describes the 10-day candling procedure for both
sample-basis as well as candling all eggs by means of either an individual candling
light or a ‘candling table’, which illuminates the entire setter tray from beneath.
Candling and transfer

After approximately 17.5 - 18.5 days of incubation, eggs are transferred to the
hatcher. Candling and clear egg removal prior to transferring, especially when the
percentage of clears exceeds 10 - 15 %, has a positive impact on hatchability and
chick quality. In some cases, clears have a market value, whereas take off fees are
incurred for unhatched eggs left behind in the hatcher baskets after chick take-off.
Candling and transfer (page 52) describes the steps of taking out the eggs from the
setter and transferring them from setter trays into hatcher baskets. In these baskets
the chicks will hatch approximately three days later. Guidelines for the loading of the
hatchers are given and procedures for candling are summarized.
In-ovo vaccination
In-ovo vaccination is a technique whereby a suitable vaccine is delivered to the
embryo or its direct environment inside the egg. This replaces the need to vaccinate
day-old-chicks after hatching. This method of vaccination is highly automated and is
incorporated in the transfer procedure.
In-ovo vaccination (page 56) provides some relevant guidelines for correct
application of in-ovo vaccination. For detailed instructions the vaccine-supplier or the
supplier of the in-ovo vaccination technology should be consulted.
48 Broilers - Incubation Guide - V 6.0 5 Candling and transfer

5.2 10-day candling
5.2.1 Objective
To candle 10-day incubated eggs, either on sample basis or all eggs, and to take out
the clears.

Hatchery manager and personnel assigned to carry out the 10-candling procedure.
5.2.3 Documents
Recording Form 9A: Hatching results (page 173)
5.2.4 Definitions
5.2.5 Recommended procedure A: "10-day candling on

sample basis"
1. Select the setter(s) with 10-day (+ or – 1 day) incubated hatching eggs for
candling.
2. Select the egg ID code(s) within the setter(s) for candling and use Recording Form
3E: Setter schedule (page 160) to locate the setter trolleys inside the setter.
3. Turn the setter trays to the horizontal position, switch off the setter and take a
random sample of setter trays out of the selected setter trolleys. Switch on the
setter again.
4. Use an empty setter trolley or a purposely designed carrier to move the selected
setter trays to a climate-controlled room which can be sufficiently darkened in
order to facilitate candling.
5. Candle the eggs with either an individual candling light or a candling table, take
out the clear eggs and place these clears to setter tray on labeled paper or plastic
egg trays. Label with at least the egg ID code, production date, setting date and
setter number.
6. Fill up the empty places on the setter tray by moving the remaining eggs
backwards to create complete rows, leaving the first rows empty.
7. Return the setter trays within preferably 15 – 20 minutes back to setter, whereby
the empty rows are facing away from the pulsator/Vortex™. Ensure the setter is
switched on again.
8. Count the number of clear eggs per egg ID code, calculate the average
percentage of clear eggs per number of eggs set initially and record the
estimated percentage of clear eggs on Recording Form 4A: Incubator recording
form (page 163) and on Recording Form 9A: Hatching results (page 173). Also
calculate and record the estimated number of remaining eggs after this sample
candling.
9. If required, put the labeled paper or plastic egg trays with clear eggs aside for
egg analysis, see Analysis of clear eggs (page 95).

5.2.6 Recommended procedure B: "10-day candling of all
eggs"
Candling of all eggs at this point in time is not very common, but is sometimes
applied in GPS-hatcheries to make a more exact estimate of expected hatchability at
an early stage. The most logical moment for candling of all eggs is on the day of
transfer to the hatcher.
1. Select the setter(s) with 10-day (+ or – 1 day) incubated hatching eggs for
candling.
2. Turn the setter trays to the horizontal position, switch off the setter and take out
a setter trolley. Switch on the setter again.
3. Move the setter trolley to a climate-controlled room which can be sufficiently
darkened in order to facilitate candling. Preferably the candling is done in the
setter room nearby the setter itself.
4. Candle the eggs with either an individual candling light or a candling table, take
out the clear eggs and place these clears per ID code on labeled paper or plastic
egg trays.
5. If required for egg analysis, place clears of random selected setter trays per setter
tray aside on labeled paper or plastic egg trays. Label with at least egg ID code,
production date, setting date and setter number, see Analysis of clear eggs (page
95).
6. Fill up the empty places on the setter tray by moving the remaining eggs
backwards to create complete rows, leaving the first rows empty.
7. Place additional hatching eggs if too many clears are removed during candling;
see for more details under additional notes. In this case, leave the top and
bottom of the setter trolley without setter trays.

8. Return the setter trolley to the setter within preferably 15 – 20 minutes, whereby
the empty rows are facing away from the pulsator/Vortex™. Take out the next
trolley for candling. Ensure the setter is switched on again each time again
between moving subsequent trolleys.
9. Count the number of clear eggs per egg ID code, calculate the average
percentage of clear eggs per number of eggs set initially and record the
percentage of clear eggs on Recording Form 4A: Incubator recording form (page
163) and on Recording Form 9A: Hatching results (page 173). Also calculate and
record the number of remaining eggs after this sample candling.

- Do not candle between 12 and 14 days of incubation, as it interrupts the
movement of the embryo relative to the long axis of the egg.
- The frequency of performing a 10-day candling procedure on a sample basis
could be for every setting, but it is also possible to do this for example on a
monthly basis.
- Random sampling of setter trays for candling (and if required analysis of clear
eggs) entails selecting at least 3 setter trays per ID code from various locations
inside the setter. If the variation between these three trays is higher than
expected or higher than normal then candle three more setter trays. For each
setter tray candled the ID code, production date, setting date and setter number
should be recorded as a minimum.
- Especially when using a candling table there is the risk of candling errors (e.g.
accidentally removal of an egg with a normal living embryo). In case of doubt, a
quick recheck with an individual candling light is a good option.
- The temperature in the egg candling room should be preferably 25 – 27 °C/77.0 –
80.6 °F and no lower than 21 °C/69.8 °F. Draughts directly on the eggs should be
avoided. Eggs should be kept out of the setter for no more than 15 – 20 minutes
in order to avoid the egg temperature decreasing too much.
- Candling of all eggs is preferably done on the day of transfer to the hatcher, see
Candling and transfer (page 52). It is less disturbing for the incubation process
and is also more efficient in terms of time and labour productivity.
- Remove clears when higher than 10 - 15 %. When the percentage of clears is
lower than 10 %, there is no direct need to remove clears prior to transfer.
- If during candling at day of transfer more than 20 % eggs are removed as clears,
add eggs from another tray to ensure each hatcher basket is full. Ideally, eggs
should touch each other while lying in the hatcher basket; it seems the sound
and vibrations caused by first chicks to pip are a trigger for other chicks to start
pipping as well.
'Clears' are eggs which are transparent to candling light. Clear eggs are infertile or contain
embryos which died early in incubation.

5.3 Candling and transfer
5.3.1 Objective
To candle and transfer eggs from the setter to the hatcher.

Hatchery manager and personnel assigned to candle and transfer eggs.
5.3.3 Documents
5.3.4 Definitions

1. Plan transfer of eggs from setter to hatcher between 17.5 and 18.5 days after the
start of incubation. Transferring later than 19 days of incubation should be
avoided.
2. Record on Recording Form 3E: Setter schedule (page 160) for each setter trolley to
which hatcher the eggs will be transferred.
3. Make as many copies of Recording Form 4A: Incubator recording form (page 163)
as the number of hatchers needed to transfer all the eggs from one setter. This
form accompanies the batch of eggs at the transfer from setter to hatcher.
4. Attach a copy of the form next to the door of each hatcher and highlight the
relevant egg ID code on it.
5. Check proper functioning of the required number of empty hatchers and note
this on Recording Form 4A: Incubator recording form (page 163). Use the
Performance Testing Tool on the SmartDrive™/SmartTouch™.
6. Start up the hatcher at least one hour before transfer. Check the set points of
temperature, relative humidity, valve position or CO2.
7. Turn the setter trolleys inside the setter into horizontal position.
8. Switch off the setter, move setter trolleys one-by-one from the setter to the egg
transfer room and ensure each time between moving subsequent trolleys that
the setter is switched on again.
9. If required, candle eggs just prior to transfer by means of an individual candling
light, candling table or fully automatically. Remove the clear eggs. Count the
number of clear eggs to egg ID code, calculate the percentage of clear eggs per
number of eggs set initially and record the percentage of clear eggs on Recording
Form 4A: Incubator recording form (page 163) and on Recording Form 9A: Hatching
results (page 173). Also calculate and record the estimated number of remaining
eggs after this sample candling.
10. Carefully remove potential ‘exploders’ and dispose them in a bucket containing
disinfectant. Clean all equipment with paper towels each time a rotten egg broke
and caused contamination and spray with a suitable disinfectant.
11. Transfer eggs in the egg transfer room manually or (semi-) automatically from
the setter trays into properly cleaned, disinfected and dried hatcher baskets.
12. Place additional hatching eggs in each hatcher basket if too many clears were
removed during candling; see for more details under additional notes.

13. Stack the loaded hatcher baskets onto hatcher dolleys to an equal height
(minimum height is 12 baskets; otherwise put empty hatcher baskets
underneath the loaded baskets). Cover the uppermost hatcher basket with a lid
or an empty basket.
14. Place hatcher dolleys one-by-one into the hatcher until loaded (preferred
minimum number is 4 dolleys; if only 3 dolleys are used place dolleys with empty
hatcher baskets on both outsides). Place dolleys closely together. A small gap (5
cm) is recommended on both sides of the middle dolley in case of 5 dolleys, or a
gap in the middle of approx. 10 cm in case of 4 dolleys.
15. Ensure the hatcher is switched on again between loading subsequent dolleys
and after placement of the last dolley.
16. On transfer days, empty setters, setter trays and setter trolleys, the setter room as
well as the transfer room including all equipment must be cleaned and
A correctly loaded hatcher with 19,200 eggs on 5 hatcher dolleys
A correctly loaded hatcher with 4 hatcher dolleys with a small gap in the middle.
Incorrectly loaded hatcher!
- Stacks of hatcher baskets are not equally high.

- Some stacks lower than a minimum of 12 baskets
- A gap between each stack

Use empty baskets underneath to achieve minimum height of 12 baskets on a hatcher
dolley

- Eggs of different ID codes should be kept in separate hatcher baskets.
- To achieve maximum hatchability, uniformity and chick quality it is very
important to place only one batch of eggs in one hatcher (different types of
eggs can have different hatching times!).
- For optimum uniformity do not mix eggs from corridor/mixing zone side and
eggs from pulsator/Vortex™ side in one hatcher.
- Starting each transfer day with the youngest flocks and ending with the oldest
reduces the risk of cross contamination. Usually the percentage of rotten eggs
is higher in the older flocks.
- The temperature in the egg transfer room should be preferably 25 – 27 °C/77.0 –
80.6 °F and no lower than 21 °C/69.8 °F. Draughts directly on the eggs should be
avoided. Temperatures over 28 – 30 °C/82.4 – 86.0 °F should be avoided because
there is a risk of the eggs overheating due to the absence of air flow.
- Egg transfer and candling should last no more than 30 minutes per setter
trolley; the eggs should not be outside the machines any longer so as to avoid
the egg temperature decreasing or increasing too much.
- Hatcher baskets should be completely dry at transfer.
- If paper is used in the hatcher baskets ensure it does not hamper the horizontal
flow of air.
- Consider performing an egg break-out on a representative sample of clears.
Samples of clears from randomly selected setter trays should be set aside on
labelled paper or plastic trays. Label the trays with at least ID code, production
date, setting date and setter number. See Analysis of clear eggs (page 95).
To candle or not to candle?

- Clear eggs transferred to the hatcher create an unstable climate in the hatcher
baskets because they do not produce metabolic heat. When automatic chick
separators are used, clear eggs are liable to break, causing ‘painted’ chicks.
- When the percentage of ‘clears’ is lower than 10 %, there is no advantage to
removing the clear eggs prior to transfer.
- Remove clears when higher than 10 - 15 % .
- If, during candling, more than 20 % eggs are removed as ‘clears’, add eggs
from another setter tray, such that no more than 3 rows will be empty. This
ensures later on each hatcher basket is full. Ideally, eggs should touch each
other while lying in the hatcher basket; it seems the sound and vibrations
caused by first chicks to pip are a trigger for other chicks to start pipping as
well.

A hatcher basket with normal number of eggs; eggs should touch each other while lying
in the hatcher basket
This hatcher basket does not contain enough eggs

5.4 In-ovo vaccination
5.4.1 Objective
To vaccinate the eggs/embryo’s correctly based on the requirements of the
customers or standard vaccination programme of the hatchery.

Hatchery manager and personnel assigned to carry out in-ovo vaccination.
5.4.3 Documents
Recording Form 7B: Chick passport (page 164)
5.4.4 Definitions
5.4.5 General guidelines "in-ovo vaccination"
These guidelines are based on in-ovo vaccination equipment in general and not on
any specific brand.
1. Read the instructions provided by the vaccine manufacturers and/or supplier of

in-ovo vaccination equipment and follow these carefully, even if these deviate
from below guidelines.
2. Determine which batches of eggs should be in-ovo vaccinated and with which
vaccine.
3. Store vaccines in a correctly working refrigerator kept for this sole purpose until
use. An exception is for Marek’s vaccine, which is stored in liquid nitrogen.
4. Prepare the vaccine according to the vaccine manufactures instructions. Prepare
only the amount of vaccine that can be finished within a maximum of 60
minutes; vaccines for in-ovo vaccination are live vaccines!
5. Prepare the in-ovo vaccination equipment according to the suppliers
instructions.
6. Transfer eggs (see Candling and transfer (page 52)) and include the in-ovo
vaccination as instructed by the supplier of the equipment.
7. Compare the number of doses prepared with the actual amount of eggs
vaccinated. If it deviates more than 5 % contact your supplier of the in-ovo
vaccination equipment to readjust the vaccination equipment.
8. Record the name and batch number of the vaccine used on Recording Form 7B:
Chick passport (page 164).
9. Clean all vaccination equipment thoroughly after every use. Ensure that
absolutely no traces of any chemicals like detergents and disinfectants staying
behind as residues.

- The importance of hygiene before, during and after in-ovo vaccination cannot
be over-emphasized. When the egg shell is dirty, pathogens are pushed inside
the egg by the puncher and or the needle. The hole left behind in the egg shell
during in-ovo vaccination is a breach in the natural protection formed by the
cuticle, egg shell and egg membranes and offers a point of entrance for bacteria
and fungi.

- For good vaccination results the vaccine should be delivered into the amniotic
sac/fluid or into the embryo itself. Timing of vaccination is very important.
Generally, successful in-ovo vaccination requires vaccination not earlier than 17
days and 12 hours and not later than 19 days and 5 hours. However, the
biological age of the embryo and it’s uniformity is more important than the
incubation time itself.
- After diluting live vaccines they have a limited life-span and should therefore be
used within 1 hour. Any traces of chemical left on the equipment after cleaning
can kill the live, attenuated virus and render the vaccine ineffective.
The hole left behind in the shell forms a breach in the natural protection of the egg.
courtesy of Ceva Santé Animale

6 Incubation in hatcher: day 19-21
In this chapter
Introduction 60
Incubation in hatcher: day 19 – 21 61
Application of disinfectant during hatching period 64
Broilers - Incubation Guide - V 6.0 6 Incubation in hatcher: day 19-21 59

6.1 Introduction
The last days of the incubation period take place in the hatcher where the embryos
prepare for hatching followed by the actual hatching process itself. It is a stressful and
critical period, influenced by the physiological condition of the embryos as well as by
climatic conditions in the hatcher.
Incubation in hatcher: day 19 – 21

Optimal climate conditions in the hatcher are of paramount importance for high
hatchability and good chick quality. By avoiding over-ventilation, relative humidity
will rise spontaneously when the first chicks hatch and decrease again when most of
the chicks have hatched and dried. Ventilation can be controlled by the CO2 set point
if hatchers are equipped with Automated Hatching System™ or SmartWatch™;
otherwise valve positions have to be adjusted manually or by incubation program.
Incubation in hatcher: day 19 – 21 (page 61) provides general guidelines for optimal
set points for hatchers with and without Automated Hatching System™ or
SmartWatch™.
Application of disinfectant during hatching period

Disinfecting of eggs directly after transfer helps to counteract the cross
contamination which might have occurred in the setter as a result of exploders or
during transfer.
During the actual hatching process itself a suitable disinfectant can be released
continuously into the hatcher to reduce the risk of chicks getting infected by
pathogenic micro-organisms.
Traditionally formalin has been the disinfectant of choice. Evaporation of

formaldehyde during the hatch results in chicks acquiring a pronounced yellow
colour which is often seen as a sign of healthy chicks by the farm manager. However,
formaldehyde can be unpleasant to staff and there can be negative side effects of
formalin on the trachea of the new-born chicks. For these reasons, alternatives to
formaldehyde are being explored.
Application of disinfectant during hatching period (page 64) explains how

disinfectants can effectively be applied.
60 Broilers - Incubation Guide - V 6.0 6 Incubation in hatcher: day 19-21

6.2 Incubation in hatcher: day 19 – 21
6.2.1 Objective
To hatch the chicks in the optimum climate to achieve maximum hatchability and
best chick quality.

Hatchery manager and personnel assigned to manage the incubation period in the
hatcher.
6.2.3 Documents
6.2.4 Definitions

1. Ensure the hatcher dolleys and hatcher baskets are properly placed inside the
hatcher, see Candling and transfer (page 52). Ensure Recording Form 4A: Incubator
recording form (page 163) is attached to the hatcher and the correct egg ID code
is highlighted on it.
2. Enter the appropriate set points manually on SmartDrive/SmartTouch. If sending
and activating an incubation program by SmartCenter, ensure the incubation
timer is set correctly in accordance with the stage of incubation. See general
guidelines on the next pages for suggested set points for incubation
temperature, relative humidity and ventilation (% CO2 or valve position).
3. Record the set points on Recording Form 4A: Incubator recording form (page 163).
4. Adjust the set points according to the needs of the hatching chicks and record
these adjustments on Recording Form 4A: Incubator recording form (page 163),
including the reason for these adjustments.
5. Transfer dolleys with hatcher baskets to the chick room when 95% of the chicks
are completely dry and 5% of the chicks have down on the neck that is not
completely dry.
6. Take the dolleys out one by one. Do not empty the hatcher completely, but leave
the chicks in the hatcher. Keep the hatcher running while there are chicks inside!.
7. On hatch days, all empty hatchers, hatcher rooms and hatcher baskets must be
cleaned and disinfected followed by thorough drying prior to next use. See
Cleaning and disinfection (page 117) and place signature on Recording Form 10B:
Cleaning schedule (page 176).

General guideline hatcher climate based on CO2-controlled valves (Automated Hatching
System /SmartWatch)
Broiler; hatchery at sea level (up to 1200 m)
Remarks Temperature set point Relative humidity set Ventilation CO2 1) set
°F point point
% %
Transfer 98.0 50 0.50
First chicks: 98.0 50 0.50
The humidity increases spontaneously 2)
10% of chicks: humidity has increased 98.0 50 3) 0.50
spontaneously to 60% 2)
Chicks start to dry: 4) 98.0 - 97.8 - 97.5 5) 50 5) 0.50
1) In case Automated Hatching System or SmartWatch is used, ventilation (valve position) is controlled by the CO2
concentration in the machine. The recommended CO2 concentration may vary slightly depending on breed and the hatchery
altitude.
2) Humidity increases spontaneously during pipping.

3) Ensure the "Relative humidity high alarm" is set to + 30% to avoid unnecessary alarm. Actual relative humidity might go
higher than 78%, but will normally not exceed 83%.
4) Chicks start to dry: This moment can be recognized by the actual relative humidity dropping 6 – 8 % after having achieved
the humidity peak.
5) If chicks have not started to dry, do not lower the temperature, but wait a few hours. Only lower the temperature if chicks
are panting as a sign of being overheated and reduce temperature in two steps if required. Relative humidity could be
increased to 60 % at this moment to minimise dehydration, especially when there is a chance that relative humidity may drop
below 60% before the chicks are pulled.
General guideline hatcher climate (without Automated Hatching System /SmartWatch)

Broiler; hatchery at sea level (up to 1200 m)
Remarks Temperature set Relative humidity Ventilation Reference:
point set point % valve CO2 1)
°F % %
Transfer 98.0 50 40 0.40
First chicks: 98.0 50 40 0.40 - 0.50
The humidity increases
spontaneously 2)
10% of chicks: humidity has 98.0 50 3) 40 0.70 - 0.80
increased spontaneously to 60%
2)
Chicks start to dry: 4) 98.0 - 97.8 - 97.5 5) 50 5) 70 - 80 5) 0.50
1) The CO2 concentration can be used as a reference for the ventilation set point. The CO2 concentration can be measured
using a handheld CO2 meter or can be read from the integrated CO2 meter. When using a handheld CO2 meter do not enter
the machine but keep the door closed (instead, the CO2 concentration can be measured in the exhaust ducts of the hatcher).
The recommended ventilation may vary slightly depending on breed and the hatchery altitude.
2) Humidity increases spontaneously during pipping.
3) Relative humidity will increase spontaneously and in general there is no need to increase the relative humidity set point. If
actual relative humidity remains too low check whether the ventilation can be reduced. If required set the "relative humidity
high alarm" to + 30% .
4) Chicks start to dry: This moment can be recognized by the actual relative humidity dropping 6 – 8 % after having achieved
the humidity peak.
5) If chicks have not started to dry, do not lower the temperature, but wait a few hours. Only lower the temperature if chicks
are panting as a sign of being overheated and reduce temperature in two steps if required. Relative humidity could be

increased to 60 % at this moment to minimise dehydration, especially when there is a chance that relative humidity may drop
below 60% before the chicks are pulled.
The guidelines in the table apply to hatcheries at sea level. For information on how
to adjust these guidelines for higher altitudes, see Hatching at high altitudes (page
140).
extra information in the footnotes 1-6 below the tables, set points might need to
be adjusted.
- Achieved hatchability, chick quality and results from egg analysis will provide
further information based on which set points could be fine-tuned. For further
information, see Tools for fine-tuning (page 83).
- To achieve maximum hatchability, uniformity and chick quality it is very
important to place only one batch of eggs in one hatcher (different types of
eggs can have different hatching times!).
- If desired, apply a disinfectant during the actual hatching of the chicks, see
Application of disinfectant during hatching period (page 64).
- Circadian Incubation™ is a new feature in single stage incubation. In the
hatcher Circadian Incubationprovides the maturing embryos daily with short
stimuli of high or low temperatures. For more details, see Circadian Incubation™
(page 149).
Example of a climate graph of a hatcher with a CO2-controlled valve (Automated

Hatching System™/SmartWatch™)

6.3 Application of disinfectant during
hatching period
6.3.1 Objective
To reduce contamination by pathogenic micro-organisms. In case of formalin
application during the actual hatch also to give the chicks a uniform yellow colour

Hatchery manager and personnel assigned to apply disinfectants during hatching
period.
6.3.3 Documents
Safety instructions provided by the disinfectant manufacturer.
6.3.4 Definitions
6.3.5 Recommended procedure A: "Disinfecting of eggs

directly after transfer"
Chemical: formalin (37 – 40%)
This procedure requires a separate clean air plenum for each hatcher room, and the
hatcher room must be used according to the all in – all out principle.
1. Wear a gas mask with a suitable filter to avoid inhalation of formalin.

2. Dose 100 ml formalin for each hatcher sharing the same hatcher room and clean
air plenum.
3. Make this amount available for the air supported nozzle. This could be a simple
jerry can from where the nozzle sucks itself or a special container from where the
formalin is brought by air pressure to the nozzle.
4. At the end of the day when all eggs are transferred to this specific hatcher room
activate the air supported nozzle which fill the clean air plenum with a dense fog
of formalin. The nozzle should have sufficient capacity to finish the formalin in
approximately 30 minutes (+/- 5 minutes). The hatchers will "inhale" this cloud of
formalin and it will leave the hatchers through the outlet again.
5. On the next morning, ensure the dosed formalin has all been finished.
6.3.6 Recommended procedure B: "Formalin treatment of

eggs and chicks in the hatcher"
Chemical: formalin (37 – 40%)
1. Wear a gas mask with a suitable filter to avoid inhalation of formalin.
2. Place a plate underneath the hatcher dolleys. Ensure that the evaporating
surface of this plate is of the right size: 0.30 x 0.30 m or a diameter of 0.35 m-0.50
m.
3. Fill the plate with 100 – maximum 250 ml of formalin (37 – 40%) before the
chicks have externally pipped.
4. Ensure all formalin is evaporated when chicks are drying (e.g. when relative
humidity starts declining) to avoid excessive irritation to the chicks respiratory
system. Adjust the amount mentioned under step 3 of this procedure if needed.

6.3.7 Recommended procedure C: "Continuous application
of disinfectant during hatching period"
Chemical: "alternatives for formalin"
Some hatcheries have good experiences with applying other liquid disinfectants
during the hatching period. At the moment of writing this Incubation Guide we are
unable to present a detailed step-by-step procedure, including suitable chemicals,
dosage etc.
Contact your disinfectant supplier or Pas Reform Academy for additional information.

- The emphasis should be on good hatchery hygiene procedures including
thorough cleaning and disinfection of hatchers and hatcher baskets rather than
on application of disinfectants during the hatching period.
- It might be beneficial to consider the application of disinfectants after transfer
and/or during the hatching period if a batch of eggs contains many exploders or
is known for its high number of rotten eggs.
- Read the safety instructions provided by the disinfectant manufacturer and
adhere to them! Provide suitable protection to the hatchery staff.
- Avoid overdoses of formaldehyde vapour when chicks are treated with
formalin. Chick quality is adversely affected by high doses of formalin vapour
because it damages the chick's respiratory system.
- Formalin is a toxic chemical. Pas Reform is not responsible for the manner in
which it is used. Legislation in some countries might not allow the use of
formalin.

7 Chick handling
In this chapter
Introduction 68
Chick take-off 69
Vaccination of day-old-chicks 71
Sexing of day-old-chicks 75
Chick dispatch and transport 78
Unloading and brooding chicks at the farm 80
Broilers - Incubation Guide - V 6.0 7 Chick handling 67

7.1 Introduction
After leaving the hatcher the chicks have to undergo several procedures until they
are finally placed in the farm. The post hatch performance will be negatively affected
by sub-optimal chick handling and poor hygiene.
Chick take-off
Accurate timing of removal of the newly hatched chicks from the hatcher is extremely
important. Removing chicks too early as well as too late has negative consequences
for chick quality.
Chick take-off (page 69) describes guidelines for timing chick take-off and preparing
the chick room for subsequent chick handling.
Vaccination of day-old-chicks
Vaccination of day-old-chicks at the hatchery offers the advantage that it occurs
under better controlled conditions compared to the situation in the farm. Also the
larger numbers of birds passing through the hatchery compared to the farm allows
for investing in automated equipment which delivers good results if operated by
skillful hatchery workers.
Vaccination of day-old-chicks (page 71) provides general guidelines for spray

vaccination and for sub-cutaneous/intramuscular vaccination; for more specific
information you should refer to the vaccine manufacturer’s instructions.
Sexing of day-old-chicks
Depending on the market situation there may be a financial benefit to sex day-old
broiler chicks. It allows for separate sex-growing in the broiler farm and males and
females can separately be delivered to the processing plant, each at the most
optimum time and weight.
Sexing of day-old-chicks (page 75) explains 3 different sexing methods.
Chick dispatch and transport

Newly hatched chicks are not yet able to control their body temperature and are
almost fully dependent on climatic conditions. With insufficient attention chicks can
easily get chilled or overheated with long-lasting effects.
Chick dispatch and transport (page 78) provides a guideline for optimising climatic
conditions for temporary storage in the chick dispatch room and during transport.
Unloading and brooding chicks at the farm

Good breeder and hatchery management, together with optimised incubation and
transport conditions is no guarantee of successful post-hatch performance. Of the
many factors that have an impact on this, chick reception and brooding management
are probably the most decisive. It is difficult to recover from a poor start during the
first days, especially when, as is the case for broilers, the production period is short.
Unloading and brooding chicks at the farm (page 80) gives recommendations for this
important period.
68 Broilers - Incubation Guide - V 6.0 7 Chick handling

7.2 Chick take-off
7.2.1 Objective
To take the chicks out of the hatcher at the correct time and prepare them for
transport to the farm.

Hatchery manager and personnel assigned to handle chicks.
7.2.3 Documents
7.2.4 Definitions

1. Prepare the chick room timely for chick handling:
• the temperature should be between 24 – 27 °C/75.2 – 80.6 °F and should be
uniform throughout the chick room; hot/cold spots and draughts directly on
the chicks should be avoided;
• the relative humidity should be 40 – 65%;
• check proper functioning of all machinery (hatcher basket destacker,
transport belts, chick counter, automatic vaccinator, chick box stacker and
destacker).
2. Transfer hatcher dolleys with hatcher baskets to the chick room when 95% of the
chicks are completely dry and 5% of the chicks have down on the neck that is not
yet completely dry.
3. Take the dolleys out one by one. Do not empty the hatcher completely, but leave
the chicks in the hatcher. Keep the hatcher running while there are chicks inside!
4. Ensure strictly separated handling of chicks from different egg ID codes to
minimise mistakes during counting and further chick transportation.
5. Destack the hatcher baskets and take out the chicks. Place the chicks on
transport belts if appropriate.
6. Assess the quality of chicks and separate second grade chicks. Aim at delivering
only vital chicks of good quality. Record a general impression of the chick quality
on Recording Form 7B: Chick passport (page 164).
7. If required, place a random sample of hatcher baskets aside for analysis of
unhatched eggs. See Analysis of unhatched eggs (page 97).
8. If required, evaluate chick quality by determining the Pasgar©Score. See
Assessing chick quality: Pasgar©Score (page 99).
9. If required, sex the chicks. See Sexing of day-old-chicks (page 75).
10. If required, vaccinate the chicks according to the vaccine manufacturer's
instructions. Record vaccination on Recording Form 7B: Chick passport (page 164).
See the general guidelines, Vaccination of day-old-chicks (page 71).
11. Count the chicks, manually or by automatic chick counters, and place the
appropriate number into chick boxes. See Chick dispatch and transport (page
78).
12. Stack the chick boxes and place them correctly into the chick dispatch room until
loading the truck for transport to the farm. See Chick dispatch and transport (page
78).

13. Record number of saleable chicks as well as the number of second grade chicks
on Recording Form 9A: Hatching results (page 173).
14. On hatch days, all empty hatchers, hatcher rooms and hatcher baskets as well as
the chick handling room including all equipment must be cleaned and

- The length of the incubation period, and thus the moment of chick take-off, is
influenced by several factors such as initial speed of heating-up, temperature set
point, flock age, season and duration of egg storage. Therefore it is impossible
to standardise optimal time for chick take-off.
- If chicks are pulled too early, too many chicks will be classified as second grade
because they are not completely dry. Also wet chicks are prone to chilling. There
is also the risk that the navels will not be fully closed, resulting in increased first
week mortality due to omphalitis. Furthermore, insufficient incubation time
might result in an increased percentage of eggs with living chicks inside that did
not finish.
- Thus, chick take-off is preferably not done "on the clock", but should be based
on observations.
- Use the observations during chick take-off to fine-tune future setting times. If
chicks are too wet at the intended chick take-off time similar batches of eggs
should be set earlier in the future. If chicks are too dry and could have been
pulled earlier than initially planned, future settings should be set later.
Pulling chicks at the right time; a matter of observations:

- Signs of too early pulling: too many wet chicks; membranes inside empty egg
shells do not break up when crushing the shell in your hand.
- Signs of too late pulling: nearly all chicks totally dry, extended wing feathers,
dehydrated legs, too much meconium in hatcher basket, membranes inside
empty egg shells break up in many small pieces when crushing the shell in
your hand.
A chick of good quality

7.3 Vaccination of day-old-chicks
7.3.1 Objective
To vaccinate the chicks correctly based on the requirements of the customers or
standard vaccination programme of the hatchery and ultimately the prevention of
diseases.

Hatchery manager, veterinarian and personnel assigned to vaccinate the chicks.
7.3.3 Documents
7.3.4 Definitions
7.3.5 General guidelines "spray vaccination"
These guidelines are based on a spray vaccinator placed over the conveyor line for
chick boxes.
1. Read the vaccine manufacturer’s instructions and follow these carefully, even if
these deviate from the guidelines below.
2. Check the correct working of the spray vaccination equipment before every use.
Adjust the spray vaccinator according to the size of the chick boxes and the
speed of the conveyor belt. Test if the total surface of the chick box is uniformly
covered by spray e.g. by placing absorbent paper inside an empty chick box.
3. Apply coarse spray only. Install a suitable nozzle and adjust pressure to achieve
this.
use.
5. Prepare the vaccine in a clean and dust-free vaccine preparation room. Prepare
only the amount of vaccine that can be finished within a maximum of 60
minutes. Prepare new vaccine timely to avoid delay in chick handling.
6. Dilute the required number of doses vaccine in the correct amount of water
(general guide line 0.15 liter/1000 doses). Ensure the water is of good quality, not
chlorinated and low in mineral content. Use demineralised water if tap water
does not meet these criteria. Use marked buckets or vessels dedicated only to
this purpose.
7. Check regularly that no vaccine is wasted and that all chicks are uniformly
covered by spray or by placing absorbent paper inside an empty chick box. The
addition of special blue dye to the vaccine allows for a better visualization.
8. Compare the number of doses prepared with the actual amount of chicks
vaccinated. If it deviates by more than 10 % either readjust the vaccination
equipment or adjust the amount of water for diluting.

10. Avoid placing wet chicks in a chick dispatch room with a suboptimal
temperature or draughts.
absolutely no traces of any chemicals like detergents and disinfectants stay
behind as residues. Place signature on Recording Form 10B: Cleaning schedule
(page 176).
Testing the "spread" of spray vaccination by absorbent

paper
Before spraying (yellow squares)
After spraying (good "spread", because all squares turned blue)

courtesy of Ceva Santé Animale
7.3.6 General guidelines “sub-cutaneous/intramuscular

vaccination”
These guidelines are based on a semi-automatic pneumatic vaccinator.
1. Read the vaccine manufacturer’s instructions and follow these carefully, even if
these deviate from the guidelines below.
2. Check the correct working of the vaccination equipment before every use. Adjust
the cylinder of the vaccinator for the required amount of milliliters and check its
output by manually triggering the vaccinator at least 10 time and collecting the
vaccine discharged in a calibrated cylinder; readjust if there is a deviation in
volume from expected of larger than 5 %.
3. Select the correct size and gauge of the needle in relation to the vaccine to be
used.
use. An exception is for Marek’s vaccine, which is stored in liquid nitrogen. Take
oil-emulsion vaccines out of the refrigerator up to 8 – 10 hours before use to
allow it to slowly warm up and to reduce its viscosity.

5. Prepare the vaccine according to the vaccine manufacturer’s instructions.
Especially for live vaccines prepare only the amount of vaccine that can be
finished within a maximum of 60 minutes.
6. Vaccinate the chicks sub-cutaneously (in the neck) or intra-muscularly (in the
thigh) by positioning the chick correctly on the vaccinator.
7. Check regularly a few chicks to evaluate the site of injection and the correct
administration of the vaccine without causing trauma to the chick or even dead
chicks. The addition of special blue colouring agent to the vaccine allows for a
better visualization of the injection site.
8. Replace the vaccinator needle after every 5000 chicks or earlier if the needle is
bent or burred.
9. Work carefully and conscientiously in order to avoid injection-trauma to the
chicks or self-injection. If self-injection occurs, especially with oil-emulsion
vaccines, consult a medical doctor immediately and show the doctor the vaccine
bottle on arrival.
10. Compare the number of doses prepared with the actual amount of chicks
vaccinated. If it deviates more than 10 % readjust the vaccination equipment.
absolutely no traces of any chemicals like detergents and disinfectants stay
behind as residues. Place signature on Recording Form 10B: Cleaning schedule
(page 176).
Adding a special blue colouring agent to the vaccine allows for better visualization of the
injection site.
Checking the site of injection

- The general guidelines above can easily be adapted to the use of other
vaccination equipment, such as spray cabinets and manual syringes.
- Never mix different vaccines on your own initiative. If different vaccinations are
required, use only registered combinations formulated by the vaccine
manufacturer and tested for compatibility.

- Vaccines can be either live (in the form of freeze-dried pellets or frozen in Liquid
Nitrogen) or inactivated (in the form of oil-emulsion).
- After diluting live vaccines they have a limited life-span and should therefore be
used within 1 hour. Any residual traces of chemicals such as disinfectants will kill
the live, attenuated virus and render the vaccine ineffective.
- During spray vaccination the water serves as a transport medium for the live
virus to the day-old-chicks. The vaccine will attach to the mucosa cells of the
chicks’ eyes and upper respiratory tract. Preening (where the chick cleans its
feathers with its beak) optimises vaccine uptake. Once in the body, the virus will
multiply inside the mucosal cells, to develop good local immunity in the
respiratory tract.
- When administering vaccines by spray vaccination, it is important that the spray
is ‘coarse’, ie. that droplets are at least 150 microns in diameter. Any smaller and
the vaccine will be inhaled too deeply into the respiratory tract, resulting in an
excessive post-vaccination reaction. This presents as mild disease symptoms in
the flock 3- 5 days after vaccination - and will have a negative effect on
production.
- The quality of sub-cutaneous/intramuscular vaccination depends largely on the
operator. Staff training, motivation, sufficient breaks, good working
environment all contribute to successful vaccination.
- The batch number of the vaccine should always be recorded. If any problems
arise it will help the vaccine manufacturer in tracking and tracing.
- Inform customers which vaccination birds have received at the hatchery. Spray
vaccination that targets the respiratory organs again should be avoided within
14 days of arrival on the farm.

7.4 Sexing of day-old-chicks
7.4.1 Objective
To separate males and females accurately before delivery to the customers.

Hatchery manager and personnel assigned to sex the chicks.
7.4.3 Documents
7.4.4 Definitions

1. Separate the males and females by one of the sexing methods described below.
Ensure the sexing method is applicable to the specific breed or hybrid.
2. Keep males and females strictly separated after sexing and record accurately
onRecording Form 7B: Chick passport (page 164).
3. Monitor regular a sample of sexed chicks for the accuracy of sexing. This could be
a sample from all staff involved in sexing but more samples from individual staff
members may be necessary from time to time – for example, those who are still
in training.
4. Count males and females separately and determine the sex ratio. If this ratio
deviates too much from 50:50 the accuracy of sexing should be checked and
improved.
5. Cull any chicks that are considered to be second class.
3 methods of sexing
There are 3 sexing methods that can be used depending on the breed. Colour sexing
and feather sexing can only be applied in specific breeds and hybrids and whether or
not applicable should be checked with the breeding company. Cloaca or vent sexing
can be used for all breeds and hybrids, but requires specially trained staff.
Colour sexing
Most commonly applied for final product brown feathered layers based on sex-linked
cross of silver/gold genes (see photo below), but also possible with sex-linked cross of
barred/non-barred genes.
The day-old-chicks can be sexed on their external appearance. Breeding companies

supply clear instructions supported by photos to also allow accurate sexing of chicks
where, from their appearance, the sex is not obvious in the first instance.

Sexing based on sex-linked silver/gold genes. The white day-old-chicks are males and the
brown day-old-chicks are females.
Feather sexing
This method of sexing is relatively easy to learn. It is based on the sex-linked gene for
fast-feathering.
Procedure:
1. Spread out the wing like a fan, holding the legs of the chick down-wards.
2. Examine the wing from the top. Feathers in the bottom row are called
"primaries" and those in the top row are called "coverts".
3. Sex the chicks based on observations as explained below.
Female Male (type 1) Male (type II)

The primaries are always Primaries and coverts are the The primaries are always
longer than the coverts same length shorter than the coverts
Female
Male

Cloacal or vent sexing
This method needs specially trained staff, with good eye-sight, good manual
dexterity and the ability to concentrate for a long time. Experience is very important
and it requires a well illuminated work-place.
The procedure involves expelling the faecal material (meconium), turning outward
the vent area and finally looking for the presence or absence of a rudimentary male
sex organ.
Vent sexing; a skill not easily learned!

- If sexing is performed by hired staff that also performs this task in other
hatcheries be very vigilant to ensure they comply with the hygienic procedures
of the hatchery. Provide them with hatchery clothing and shoes. Do not allow
them to bring in their own equipment like lamps and seats.
- Sexing of day-old broiler chicks allows for separate-sex growing in the broiler
farm with the benefit that both sexes can be managed more efficiently with
regard to feeding, lighting and stocking density.
- Males grow faster and achieve a certain delivery weight target earlier than the
females. By delivering the males earlier than the females, the benefit to the
slaughter plant is that all broilers are more uniformly grouped around the target
weight.
- Males are more feed-efficient and have less carcass fat than females at higher
body weights. Therefore it may be cost effective to keep the males longer and
deliver them at a higher body weight.

7.5 Chick dispatch and transport
7.5.1 Objective
To provide optimum conditions for one-day-old chicks during dispatch and transport
from the hatchery to the farm.

The hatchery manager, personnel assigned to prepare chicks for transport and the
truck driver for transport chicks to the farm.
7.5.3 Documents
7.5.4 Definitions

1. Ensure the climate in the chick dispatch room is appropriate for temporary
storage of the chicks (see table below). The optimal temperature depends on
previous experience.
2. Adjust the numbers of chicks per chick box according to the type and size of the
chick box, size of the chicks, expected climate during transport and previous
experience during chick dispatch and transport and communicate this with staff
responsible for chick handling.
3. Place the stacked chick boxes correctly into the chick dispatch room, depending
on the system of ventilation/air circulation. Ensure there is sufficient air flow
around the chick boxes, but be aware of draughts. Avoid placing boxes directly
on the floor or in the direct air stream from blowers.
4. Check the climate in the chick dispatch room regularly; not only by looking to
the display of climate control boxes, but especially by looking and listening to
the chicks behavior. Respond accordingly if there are any deviations from
normal.
5. Load (and unload) the truck quickly and efficiently when no forced ventilation is
present according to the ventilation principle of the truck type. Secure the stacks
of chick boxes well to avoid sliding during transport.
6. At departure, record truck temperature and any disinfectant that has been used
onRecording Form 7B: Chick passport (page 164).
7. Ensure optimal climate inside the truck during transport (see table below). The
optimal temperature depends on previous experience.
8. Avoid unnecessary delay during chick transport (for example, by ensuring that
the fuel tank is filled to capacity prior to loading the truck and by avoiding
getting stuck in traffic jams).
9. On arrival, record truck temperature and housing conditions at placement (floor
temperature, litter quality, water and feed supply) onRecording Form 7B: Chick
passport (page 164).
Recommended climate for chick dispatch room and during transport

Temperature Relative humidity CO2 Air flow
(°C/°F) (%) (ppm)
24 – 27 / 75.2 – 80.6 55 – 70 1500 Sufficient

- Normal rectal temperature for day-old-chicks is 40.0 – 40.5 °C/104.0 – 104.9 °F.
Newly hatched chicks are dependent on external climatic conditions to regulate
their body temperature for the first few days.
- The aim is an air temperature at chick level of 32.0 – 35.0 °C/89.6 – 95.0 °F , thus
INSIDE the chick boxes; the room or truck temperature is secondary.
- An exact optimal dispatch room or truck temperature cannot be provided.
The optimal temperature depends on several factors.The number of chicks per
box and the air velocity through the chick box are perhaps of most influence. For
example, the higher the speed of air through the chick boxes, the higher the
optimal air temperature of the chick dispatch room or truck.
Look and listen to the behaviour of the chicks!

Abnormalities in chick behaviour are related to sub-optimum climate (see table
below). Day-old-chicks kept under ideal climatic conditions breathe quietly
through their nostrils, are evenly spread in the chick boxes, will not make much
noise and will be relatively inactive or even sleeping.
- Occasionally place some chicks on your wrist or against your cheek to sense the
temperature of the feet; when these are "cold to the touch" the chicks’ body
temperature is too low.
- Additionally the vent temperature of a sample of chicks could be measured by a
Braun ThermoScan. Ensure the probe is in direct contact with the bare skin of the
vent. The optimum chick vent temperature is 39.4 – 40.5 °C/103.0 – 105.0 °F.
- Properly placed climate loggers (avoid direct contact between chicks and
sensors) can provide useful information about the conditions during transport.
- The correct loading of the chick dispatch room depends on the method of
ventilation/air circulation.
• Horizontal air flow generated by chick room coolers/heaters or chick room
fans: Position the stacked chick boxes in uninterrupted rows with minimal
30 cm between each row. The fan should blow preconditioned air in
alternate corridors between these rows.
• Ceiling fans: Position each stack of chick boxes such that around each stack
there is minimal 30 cm free space.
Chick's behaviour in relation to climate

Behaviour Probable cause
Chicks are noisy General sign of discomfort (see below)
Chicks huddle together Temperature too low
Chicks produce a lot of meconium Temperature too low
Chicks pant with open beaks Temperature too high
Chicks spread their wings Temperature far too high
Chicks gasp for air and try to stick their Insufficient supply of fresh air (CO2 too
heads out of the chick box high) Temperature too high
Chicks stay in one corner of the chick Draught
box

7.6 Unloading and brooding chicks at the
farm
7.6.1 Objective
To prepare the broiler house for chick reception, to place the chicks and to provide
care and attention during the first 5 – 7 days.

Broiler farm manager and personnel assigned to prepare the broiler house for chick
reception, to place the chicks and to provide care and attention during the first few
days.
7.6.3 Documents
No documents
7.6.4 Definitions

1. Refer to the Broiler Management Guide provided by the breeding company for
more detailed information about brooding management.
2. Clean and disinfect house and equipment, with special attention for the drinking
water system, thoroughly between flocks.
3. Take sufficient time to warm the floor underneath the litter to 28 – 30 °C/ 82.4 –
86.0 °F prior to chick arrival. Depending on floor characteristics and starting
temperature, allow 24–48 hours.
4. Spread the litter evenly prior to chick arrival.
5. Aim for an air temperature of 32 – 35 °C/ 89.6 – 95.0 °F at chick level depending
on the size of the chicks (smaller chicks and particularly those from young
parents require a higher brooding temperature)
6. Take chicks out of boxes immediately on arrival in the house, to avoid them
becoming overheated.
7. Start ventilation in good time to avoid high CO2-concentration, while preventing
draughts, at chick level.
8. Have fresh, clean water and feed easily accessible and well distributed
throughout the entire house. In the first hours, water is more important than
feed, especially if chicks arrive partially dehydrated after a lengthy transport.
9. Ensure minimum light intensity of 20 Lux; 30–40 lux is recommended.
10. Check the climate regularly; not only by looking to the display of climate control
boxes, but especially by looking at and listening to the chicks. Respond
immediately and appropriately if there any deviations in chick behavior from
normal.
11. Use 7-day weight (see performance objectives provided by the breeding
company) and first week mortality (below 1 %) as key indicators for the quality of
chick reception and brooding management.
Recommended climate for brooding chicks at the farm

Temperature Relative humidity CO2 Air flow
(°C/°F) (%)
Air: 32 – 35 / 89.6 – 95.0 50 - 60 Low Negligible
Floor: 28 – 30 / 82.4 – 86.0

- Good breeder and hatchery management, together with an optimised
incubation process and transport conditions, is no guarantee of successful post-
hatch performance. Of the many factors that have an impact on this, chick
reception and brooding management probably have the most influence. It is
difficult to recover from a poor start during the first days, especially when, as is
the case for broilers, the production period is short.
Good floor temperature is essential!

Attention to air and floor temperature in the house is essential, because the chicks’
thermoregulatory systems are not yet fully matured. Their body temperatures
depend largely on environmental temperature but, if attention is paid to the
temperature of the air only, the chicks can still become chilled. For example, if too
much heat is transferred to a cold floor through their legs or body or when exposed
to draughts.
- Once chilling has occurred, the chicks will huddle, lie down and they may
remain inactive instead of seeking water and food. As an consequence they may
get dehydrated and start poorly with increased mortality and gout symptoms
- Making the house too warm is not only costly in most instances, but also leads
to risk of dehydration as a result of panting, especially in combination with low
relative humidity. Again, the chicks will become inactive, resulting in so called
"non-starters" and increased first week mortality.
- Additionally the vent temperature of a sample of chicks could be measured
using a Braun ThermoScan. Ensure the probe is in direct contact with the bare
skin of the vent. The optimum chick vent temperature is 39.4 – 40.5 °C/103.0 –
105.0 °F.
- Getting the chicks to drink and eat as soon as possible after arrival should be
the major target. Attention to detail in preparing the house, such as providing
extra feed close to the drinkers (for example on special chick paper placed under
the drinking nipple lines; the sound of the first chicks walking and picking on it
will attract others to the place where water and feed is available) or extra
drinkers close to the feeders, and adjusting the level and pressure in the water
lines, does pay dividends. In combination with a well-illuminated house, the
chicks will then quickly find food and water.
courtesy of Kanters Special Products

8 Tools for fine-tuning
In this chapter
Introduction 84
Analysis of hatching egg quality upon arrival 85
Analysis of eggshell temperature 89
Analysis of egg weight loss 93
Analysis of clear eggs 95
Analysis of unhatched eggs 97
Assessing chick quality: Pasgar©Score 99
Broilers - Incubation Guide - V 6.0 8 Tools for fine-tuning 83

8.1 Introduction
For evaluating hatchery results it might suffice to just collect basic hatchery data of
each batch of eggs incubated. These basic hatchery data are number of eggs set,
number of eggs removed during candling and number of chicks hatched.
More detailed data are needed to establish a hatchery specific set of data. These data
will be very useful in the process of analyzing where hatching egg quality, hatchery
management and incubation programmes could be improved and is especially
relevant when hatch results are below expectations.
Egg quality determines for a great part the hatch results. Therefore, it is advisable to
regularly monitor egg quality, both externally as well as internally, of a representative
sample of received eggs. A fresh egg break-out also allows to judge the size and
quality of embryo. By doing so problems are detected in an early stage and open
communication with the supplier can be started aiming at improving or at least
maintaining egg quality.
Analysis of hatching egg quality upon arrival (page 85)comprises a general inspection
of the external and internal (including embryo) quality of eggs supplied by the
breeder farm.
Analysis of egg shell temperature

Analysis of eggshell temperature (page 89) describes how to measure eggshell
temperatures during incubation. The eggshell temperature is a good indicator of
embryo temperature and should therefore be the leading parameter for adjusting or
developing incubation programs. If the eggshell temperature deviates too much
from the desired eggshell temperature, the incubator temperature set point should
be adjusted.
Analysis of egg weight loss

Correct egg weight loss is a reflection of the correct relative humidity set point.
Hatchability and chick quality decreases if eggs lose too much or too little weight
during incubation. In the case of suboptimal hatchability and chick quality, it is
recommended to monitor egg weight loss during incubation. Analysis of hatching egg
quality upon arrival (page 85) describes the steps in measuring egg weight loss.
Analysis of clear eggs

Analysis of clear eggs is a practical tool to obtain a hatchery-specific reference for the
percentage of infertile eggs and pattern of embryonic mortality during incubation.
This reference will be useful for analysing causes of high percentages of clear eggs at
transfer (and consequently poor hatchability).
Analysis of clear eggs (page 95) describes the analysis of clear eggs.
Analysis of unhatched eggs

Analysis of unhatched eggs is a practical tool to obtain a hatchery-specific reference
for the pattern of embryonic mortality during incubation. This reference will be useful
for analysing causes of poor hatchability.
Analysis of unhatched eggs (page 97) describes the analysis of unhatched eggs.
Analysis of chick quality: Pasgar©Score

The greatest challenge for the hatchery is to produce uniform chicks of high vitality.
Assessing chick quality: Pasgar©Score (page 99) outlines the use of the Pasgar©Score
method for assessing individual chick quality: a practical, objective evaluation of
chick quality for hatchery managers. The Pasgar©Score also forms a practical tool for
locating problems in the incubation process when chick quality is suboptimal.
84 Broilers - Incubation Guide - V 6.0 8 Tools for fine-tuning

8.2 Analysis of hatching egg quality upon
arrival
8.2.1 Objective
To evaluate the quality of hatching eggs supplied by the breeder farm upon arrival in
the hatchery.

Hatchery manager and personnel assigned to check the quality of the eggs supplied
by the breeder farm.
8.2.3 Documents
Recording Form 8A: External hatching egg quality upon receipt (page 165)
Recording Form 8B: Internal hatching egg quality upon receipt (page 166)
Recording Form 8C: Fertility and embryo quality upon receipt (page 167)
8.2.4 Definitions
8.2.5 Recommended procedure "external egg quality"

1. Measure the core temperature by inserting a digital thermometer into the egg of
5 – 10 eggs throughout the batch of eggs on arrival at the hatchery and record
on Recording Form 8A: External hatching egg quality upon receipt (page 165).
2. Take a random and representative sample (of each) batch of hatching eggs
received. A representative sample consists of at least 180 eggs.
3. Check the quality of each egg carefully and use Recording Form 8A: External
hatching egg quality upon receipt (page 165) to record the number of eggs not
meeting the criteria for good external hatching egg quality as described by each
of the categories listed below:
• dirty – includes manure, conveyor marks, blood, egg contents, dust, etc.
• misshaped – too round, too long, irregular shape (flat-sided eggs)
• upside down – if in doubt use a candling light in a darkened room; the blunt
end (= side with air cell) should be upwards.
• abnormal shell colour – too white (in case of coloured or brown egg layers)
• poor shell quality – includes thin and rough shells, wrinkles, body-checked
eggs
• hairline cracks – use a candling light in a darkened room to recognize
hairline cracks
• obvious cracks – these can easily be seen with the naked eye; egg
membranes could be broken as well.
• too small/too big – there are no international standards, but usually less
than 50 grams and more than 70 grams are out of the normal acceptable
range for hatching eggs.
If an individual egg falls in more than 1 of the categories, then record only the most
prominent ‘defect’. Alternatively, use a recognizable method of recording this egg
for the appropriate categories to avoid counting this egg twice or three times.

4. Communicate openly with your hatching egg supplier if more than 3 % of the
eggs in the sample are recorded under one or more of the mentioned categories,
with the mutual aim of improving quality.
5. If required, continue with the procedures outlined below for assessing "internal
egg quality" and/or "fertility and embryo quality".
8.2.6 Recommended procedure "internal egg quality"

1. Take 10 eggs of good external quality from the sample that was used for
checking external egg quality.
2. Open these eggs one by one onto a plate or petri dish.
3. Check the quality of each egg carefully and use Recording Form 8B: Internal
hatching egg quality upon receipt (page 166)to record the number of eggs not
meeting the criteria for good internal hatching egg quality as described by each
of the categories listed below:
• Air cell depth – more than 2 mm; estimate by looking inside the broken
shell; alternatively before opening the egg a candling light in a darkened
room could be used
• Albumen - thin and watery; white and cloudy
• Yolk – flabby and flat; too pale colour; mottled appearance
• Presence of blood and/or meat spots
If an individual egg falls in more than 1 of the above categories, record only the most
prominent ‘defect’. Alternatively, use a recognizable method of recording this egg
for the appropriate categories to avoid counting this egg twice or three times.
4. Increase sample size to 30 eggs if 1 egg in the sample of 10 eggs is classified as

poor internal quality for one or more of the categories.
5. Communicate openly with your hatching egg supplier if more than 3 eggs in the
sample are recorded as poor internal quality for one or more of the categories,
with the mutual aim of improving quality.
6. If required, continue with the procedure below for assessing "fertility and
embryo quality".
8.2.7 Recommended procedure "fertility and embryo

quality"
1. Take 10 eggs from the sample that was used for checking external egg quality or
internal egg quality.
2. Open these eggs one by one onto a plate or petri dish; take care the yolk does
not break. Alternatively, place the eggs upright on an egg tray and remove the
shell and egg membranes carefully on the blunt end.
3. Look carefully for the white dot on the yolk; this is either the infertile germinal
disc or the embryo.
4. Record on Recording Form 8C: Fertility and embryo quality upon receipt (page
167)for EACH egg which of the following categories is applicable:
• Infertile – compact white spot with ruffled edges
• Fertile, well-developed embryo – doughnut-like opaque ring with
translucent centre; diameter approx. 3.5 – 5 mm
• Fertile, under-developed embryo – embryo too small (≤ 3.5 mm) with white
dots in centre of opaque ring
• Fertile, over-developed embryo – embryo too big (> 5 mm)
• Fertile, abnormal embryo – no translucent center, abnormal colour

5. Increase sample size to 30 eggs if 1 egg in the sample of 10 eggs is classified as
infertile or fertile with under- or over-developed or abnormal embryo.
6. Take action if the number of infertile eggs is higher than normal for a specific
flock age. Take action if more than 3 of the embryos are either under- or over-
developed or abnormal. The action involves first of all to communicate openly
with your hatching egg supplier, with the mutual aim of improving quality.
Description of good hatching egg quality

- External characteristics
• Egg shape
The shape of eggs varies between modern breeds but, generally speaking,
a good quality hatching egg has an oval shape with a blunt side and a
clearly recognizable sharp end.
• Egg shell
High quality hatching egg shells are smooth, without ridges or small
lumps of calcified material (pimples). The colour of eggs, and the
uniformity of shell colour within a batch, should be normal for the specific
breed; white-coloured eggs in case of brown egg producing parent stock
is a sign of poor egg quality.
• Egg size
Depending on the standards of the hatchery, normal egg size is usually
between a minimum of 50/52 grams and maximum of 70 grams. Double
yolks are not suitable for hatching and can be recognized by an abnormal
size compared with the other eggs within a batch. Within a batch,
uniformity of egg size is also an important aspect of good external quality.
- Internal characteristics
• Air cell
The air cell is located at the blunt side of the egg and should be small. The
maximum depth of the air cell should be about 2 mm. A bigger air cell is
an indication of too much water evaporation due to incorrect or too long
egg storage.
• Albumen
Good quality hatching eggs contain a higher proportion of thick viscous
albumen and only a little thin albumen. Good quality albumen is
translucent with a greenish or yellow cast due to the presence of
riboflavin. Meat or blood spots should be absent.
• Yolk
In good quality hatching eggs, the yolk has a uniform colour without any
blood or meat spots. The shape of the yolk is globular or spherical which is
also an indication of a firm yolk membrane.
• Embryo
The embryo floats on top of the yolk. In the unincubated egg, the embryo
is visible as a doughnut-like opaque ring with a translucent centre. A good
quality embryo is 3.5-5 mm in diameter.

- The quality of hatching eggs is one of the major determining factors for the
performance of the hatchery.
- Analysis of hatching eggs on arrival could be done at each egg reception, but it
could also be decided to do this for each breeder flock at regular intervals (for
example every 5 weeks).

- An individual egg might have one or more characteristics of eggs of poor
external and internal quality. Avoid that such an egg is counted twice or three
times by recording this particular egg on the recording from.
- Because the growing embryo fully depends on the nutrients present in the egg,
the albumen and yolk must also be of high quality.
- If the quality of hatching eggs on arrival at the hatchery is not optimal or over
time is deteriorating faster than you expect, communicate openly with your
egg supplier, with the mutual aim of improving and/or maintaining quality.
- Under-developed embryos as described in the procedure above point to eggs
which cooled down too fast after oviposition. These embryos are not storage-
resistant. Pre-storage incubation of batches of eggs with a high number of
under-developed embryos might bring performance benefits, especially if these
eggs are to be stored. See Pre-storage incubation (page 28).

8.3 Analysis of eggshell temperature
8.3.1 Objective
To measure egg shell temperature as a basis for adjusting/optimizing/fine-tuning
temperature set points in the incubation program.

Hatchery manager and personnel assigned to control the incubation process.
8.3.3 Documents
Recording Form 8D: Eggshell temperature (page 168)
8.3.4 Definitions

1. Before starting, the Braun ThermoScan should be warmed in the incubator for 15
minutes (if this is not done, measurements will be inaccurate). Ensure an intact
plastic cover (lens filter) is mounted on the infrared probe.
2. Turn setter trays to the horizontal position; stop the setter (NOT by the
emergency stop!). Open the door and if needed temporarily remove one setter
trolley out of the setter in order to gain access to the inside of the setter. Go
inside.
3. Immediately close the door; switch on the setter; switch on the light. These
actions should be carried out by a second person who stays out of the setter
4. Measure in an operational setter with a closed door.
5. Place the infrared probe on the eggshell just under the air cell (measuring on the
air cell gives a difference of 0.5°F).
6. Measure with the infrared probe placed at a 90° angle on the eggshell to ensure
full contact of the probe with the egg shell (measuring at the wrong angle gives
0.5 - 1.5°F deviation).
7. Measure the egg shell temperature of a minimum of 9 eggs in the centre of the
setter tray. For this the setter tray should be carefully partially pulled out of the
trolley
8. Measure eggs from one setter tray on a minimum of 3 trolleys in each setter.
9. Record the measured values on Recording Form 8D: Eggshell temperature (page
168).
10. Ensure setter trays are properly pushed back in the trolley.

11. Indicate to the person outside the setter when you have finished taking the egg
shell temperatures. The second person should stop the setter and open the door.
Replace the trolley you removed, shut the door and start the setter again.
12. Take the average egg shell temperature of a minimum of 27 eggs, including only
eggs with a living embryo. This is the reference for the eggshell temperature on
that day of incubation.
13. Adjust the incubator temperature set point if the actual average eggshell
temperature deviates too much from the desired eggshell temperature (see
table below). The maximum average egg shell temperature for High Yield heavy
breeds is lower than for High Yield light breeds.

Desired average egg shell temperature (°F)
Incubation timer minimum mean temperature maximum for "High Yield maximum for "High Yield
(days) temperature Light" Heavy"
0 99.9 100.0 100.1
1 99.9 100.0 100.1
2 99.9 100.0
3 99.9 100.0 100.1
4 99.9 100.0 100.1
5 99.9 100.0 100.2
6 99.9 100.0 100.2
7 99.9 100.0 100.2
8 99.9 100.0 100.2
9 99.9 100.0 100.2
10 100.0 100.1 100.3
11 100.0 100.1 100.4
12 100.0 100.2 100.5
13 100.1 100.3 100.7
14 100.1 100.4 100.9
15 100.2 100.6 101.0
16 100.3 100.9 101.3 101.0
17 100.3 101.0 101.4 101.0
18 100.3 101.0 101.5 101.0
19 100.3 101.0 101.5 101.0
Desired average egg shell temperature (°F) for each day of incubation
blue = minimum; green = mean; red = maximum

This procedure should be carried out by qualified personnel only because data must
be collected in an operational machine. For safety, ensure that there are trolleys in
front of each pulstor/Vortex™.
- The procedure is based on measuring with a Braun ThermoScan; using other

devices is not recommended because they might result in different values. The
Braun ThermoScan is accurately calibrated in the narrow temperature range
normal for incubation.
- The Braun ThermoScan is a sensitive device and rough handling might affected
its accuracy. To check the proper working of the Braun ThermoScan measure
some eggs between day 3 and 5; the reading should be 100 °F +/- 0.2 °F with
temperature set points recommended in the guidelines in this Incubation Guide.
- Measurements taken in a machine which is turned off will result in unreliable
data because eggshell temperature changes quickly when the air-flow is nil.
- It is recommended to always measure at the same period of the day, thereby
considering the moment the incubation program will make set point changes.
- Do not measure within 1 hour after a set point change.
- Usually egg shell temperature is only measured at the corridor/mixing zone side.
During the last days of incubation the egg shell temperature at the pulsator/
Vortex™ side is a little lower compared to corridor/mixing zone side. Therefore,
during this period, aim for the higher part of the desired temperature range in
the corridor/mixing zone side.

8.4 Analysis of egg weight loss
8.4.1 Objective
To measure egg weight loss as a basis for adjusting/optimizing/fine-tuning relative
humidity set points in the incubation program.

8.4.3 Documents
Recording Form 8E: Egg weight loss (page 169)
8.4.4 Definitions

1. Mark the empty setter trays (WT) and weigh them. For reliable information
several trays per setter should be marked and weighed.
2. Weigh the marked trays with eggs before incubation starts.
3. Calculate the weight of the eggs only (= weight of loaded tray-weight of empty
tray = W0).
4. Likewise, calculate the weight of the eggs only on, for example, day 10 and 18 of
incubation (W10 … W18).
5. Calculate the weight loss from the start of incubation (see example and
Recording Form 8E: Egg weight loss (page 169)) and plot the result in the graph on
Recording Form 8E: Egg weight loss (page 169).
6. Adjust incubator set points of relative humidity if the weight loss deviates too
much from the recommendation (see table below).
Optimum weight loss depends on flock age

Age breeder flock (weeks) Recommended weight loss (%) at 18
days calculated from fresh egg
weight
25 - 40 10 - 11
40 - 50 11 - 12
50 - 60 12 - 13

- Example: the empty tray weight (WT) is 1,000 g. Before start of incubation weight
of tray containing 150 eggs is 10,300 g. At day 10 of incubation the tray weight is
9677 g, which means a weight loss of ((10,300-1,000) - (9,677- 1,000)) /
(10,300-1,000) x 100 = 6.7% weight loss over 10 days. This figure can be plotted
in the graph on Recording Form 8E: Egg weight loss (page 169); it shows that the
weight loss at 18 days is approximately 12 % if linear weight loss is assumed This
is a good weight loss for medium aged to old flocks. There is no need to adjust
the relative humidity set point.
Example
Before incubation At day 10
Weight of tray with eggs 10,300 g 9,677 g
Weight of empty tray (WT) - 1,000 g - 1,000 g
Weight of eggs only W0 = 9,300 g W10 = 8,677 g
Weight loss over 10 days = ((W0 – W10)/W0)) x 100 % = ((9,300 – 8,677)/9,300) x 100 % = 6.7 %
- The recommendations for optimal egg weight loss are based on fresh egg
weight, whereas in the practice of the hatchery the calculation of weight loss
often is based on egg weight at setting. Depending on storage duration and
storage conditions an addition of 0.5 to 1 % to the calculated weight loss may be
needed.
- The relative humidity profile can either be constant (guideline is 50 %) or
slightly declining from 60 to a minimum of 45 – 48 %.
- At a constant relative humidity throughout the setter period weight loss will be
linear.
- With a gradual declining relative humidity the daily weight loss will show a
gradual increasing tendency, but does not differ so much from linearity. If with
this relative humidity profile the weight loss needs to be increased it is preferred
to lower the initial relative humidity set points rather than reducing the final
relative humidity set points below 45 - 48 % .
- For a correct calculation of the weight loss, do not remove eggs from the marked
trays.
- In case relative humidity is measured by the wet bulb – dry bulb principle:
Ensure that the humidity sensor is well maintained (e.g. the cotton wick is clean
and wet at all time). More information can be found in the setter manual.
- The increasing size of the air cell can also give a useful indication of egg weight
loss.

8.5 Analysis of clear eggs
8.5.1 Objective
To evaluate fertility and the pattern of embryonic mortality during incubation for
establishing a hatchery-specific reference.

8.5.3 Documents
Recording Form 8F: Analysis of clear eggs (page 170)
Recording Form 9B: Results egg analysis and Pasgar©Score (page 174)
8.5.4 Definitions

1. Collect clear eggs from randomly selectedsetter trays from various positions in
the setter. See 10-day candling (page 49) and Candling and transfer (page 52).
2. Ensure all clear eggs are placed on paper or plastic egg trays and label the trays
with, at least the Egg ID code, production data, setting date and setter number.
3. Count the number of clear eggs per setter tray and record on Recording Form 8F:
Analysis of clear eggs (page 170).
4. Open the eggs at the air cell end using forceps. If needed for good observation
pour out the contents onto a plate or petri dish.
5. Classify the eggs according to the categories on Recording Form 8F: Analysis of
clear eggs (page 170) and fill in this form.
6. Calculate the percentages per category based on total eggs set on the sampled
trays.
7. Add this data to Recording Form 9B: Results egg analysis and Pasgar©Score (page
174).

- The examination of clear eggs from just one setter tray is not enough to show
a characteristic pattern in the percentages of death at the various stages of
incubation.
- Random sampling of setter trays for candling and analysis of clear eggs entails
selecting at least 3 setter trays per ID code from various locations inside the
setter. If the variation between these three trays is higher than expected or
higher than normal then candle three more setter trays. For each setter tray
candled the ID code, production date, setting date and setter number should be
recorded as a minimum.
- If on the day of chick take-off an egg analysis on unhatched eggs from the
same setter trays is planned, setter trays and subsequently the hatcher baskets
should be clearly marked. Records of analysis of clear eggs should then also be
made on Recording Form 8G: Analysis of unhatched eggs (page 171); the records
of unhatched eggs collected on the day of chick take-off can then be added to
the same recording form.
- It is often impossible to distinguish between infertile eggs and eggs that
contained an embryo that died early if candling is done at transfer. For a better
estimation of fertility, consider candling on day 10.

- The frequency of performing an analysis of clear eggs could be for every setting,
but it could also be done, for example, on a monthly basis. A regular programme
of analysis of clear eggs allows you to generate ahatchery specific reference.
- In case of disappointing hatchery results, an egg analysis can be performed and
the results can be compared with the obtained reference. For possible causes
of deviation from the reference, see Troubleshooting (page 106).

8.6 Analysis of unhatched eggs
8.6.1 Objective
To evaluate the pattern of embryonic mortality during incubation for the purpose of
establishing a hatchery-specific reference.

8.6.3 Documents
Recording Form 8G: Analysis of unhatched eggs (page 171)
8.6.4 Definitions

1. Take a random sample of hatcher baskets and take out the saleable chicks.
2. Count the number of second class and dead chicks per hatcher basket and
record on Recording Form 8G: Analysis of unhatched eggs (page 171).
3. Place the unhatched eggs per hatcher basket on labeled paper or plastic egg
trays. Label with at least the egg ID code, production data, setting date and
hatcher number.
4. Count the number of unhatched eggs per hatcher basket and record on
Recording Form 8G: Analysis of unhatched eggs (page 171).
5. Open the eggs at the air cell end using forceps.
6. Classify the eggs according to the categories on Recording Form 8G: Analysis of
unhatched eggs (page 171)and fill in this form.
7. Calculate the percentages per category based on the total number of eggs set
originally in the random sample.
174).

- The examination of unhatched eggs from just one hatcher basket is not
enough to show a characteristic pattern in the percentages of death at the
various stages of incubation.
- Random sampling of hatcher baskets for analysis of unhatched eggs entails
selecting at least 3 hatcher baskets per ID code from various locations inside the
hatcher. If the variation between these 3 baskets is higher than expected or
higher than normal then select 3 more baskets. For each hatcher basket sampled
the egg ID code, production date, setting date and hatcher number should be
recorded as a minimum.

- If clear eggs are removed during candling, the number of eggs found at the day
of chick take-off does not represent the total number of unhatched eggs. In case
clear eggs have been removed from a random sample of setter trays for analysis
after candling (see Analysis of clear eggs (page 95)) these setter trays and
consequently the hatcher baskets could be marked for later analysis of
unhatched eggs. Records of analysis of clear eggs should than also be made on
Recording Form 8G: Analysis of unhatched eggs (page 171); the records of
unhatched eggs collected on the day of chick take-off can then be added to the
same recording form. Also consider not removing clear eggs during candling
from a random sample of purposely marked setter trays for later analysis of
unhatched eggs.
- When unhatched eggs are analysed on the day chicks are taken out, it is very
difficult and often impossible to distinguish between infertile eggs and eggs that
contained an embryo that died early. For a better estimation of fertility
consider candling on day 10.
- The frequency of performing an analysis of unhatched eggs could be for every
hatch, but it also possible to do this for example on a monthly basis. Performing
a regular analysis of unhatched eggs allows to generate a hatchery specific
reference.
- In case of disappointing hatchery results, an egg analysis can be performed and
the results can be compared with the obtained reference. For possible causes
of deviation from the reference, see Troubleshooting (page 106).

8.7 Assessing chick quality: Pasgar©Score
8.7.1 Objective
To evaluate and compare chick quality from different batches of eggs.

8.7.3 Documents
Recording Form 8H: Pasgar©Score (page 172)
8.7.4 Definitions

1. Before chicks are graded, take a random sample of 30-50 chicks from the batch
of eggs to be analysed.
2. Score the randomly selected chicks individually for the five parameters and write
each score on Recording Form 8H: Pasgar©Score (page 172).
3. Calculate the Pasgar©Score for each chick separately (see example) by
subtracting each score from 10.
4. Finally, calculate the mean Pasgar©Score for all chicks in one sample.
5. In a good hatch, the average Pasgar©Score should be 9 at minimum.
174).
Criteria used to downgrade chicks
- Vitality (reflex): The 'reflex' of the day-old chick is a general description of the
chick's vitality. The chick is vital if it turns over immediately (within seconds) from
lying on its back to standing on its feet (score=0). If this action takes more than
three seconds, the chick scores one point for reflex (score = 1).
- Navel: The 'navel' of the day-old chick is normal if it is fully closed, which means
that the yolk sac is fully retracted (score = 0). If the navel is open or a black knob
is visible, the navel scores 1.
- Legs: The normal 'legs' of a day-old chick are not swollen and show a normal
colour (score = 0). Legs are scored 1 when they are swollen and/or red.
- Beak: The normal 'beak', including nostrils of a day-old chick is clean (score = 0).
The beak scores 1 if it is dirty and/or has a red dot (score = 1).
- Belly: The thickness of the belly (= volume of the yolk sac) depends on the
volume of the yolk sac before the yolk is withdrawn into the abdomen. The
volume of the yolk sac is mainly determined by humidity and temperature in the
setter. A normal belly feels soft and smooth and these chicks score = 0 for belly. If
the belly feels hard and the skin is tense, the belly scores 1.

Example: bad navel: yolk sac Example: bad beak: red dot Example: red hocks
not fully retracted
Example
Chick number reflex Navel leg beak Belly Pasgar©score
1 0 1 0 0 1 8
2 0 0 0 0 0 10
3 0 1 0 1 0 7
4 0 0 0 0 0 10
5 0 1 0 0 0 9
6 0 1 0 0 0 9
7 1 0 0 0 1 8
Total 1 4 1 1 2 61
The mean Pasgar©Score for this sample of 7 chicks is 61/7 = 8.7
4 out 7 chicks = 57% show navel problems

- The frequency of determining Pasgar©Score could be for every hatch, but it
could also just be done, for example, on a monthly basis. Regular determination
of the Pasgar©Score allows you to generate a hatchery specific reference.
- In case of disappointing hatchery results and chick quality PasgarScore can be
determined and can be compared with the obtained reference. For possible
causes of deviation from the reference, see Troubleshooting (page 106).

9 Data analysis for continuous
improvements
In this chapter
Introduction 102
Basics of hatchery specific database 103
Construction of a hatchery specific database 104
Evaluation of hatchery results 105
Troubleshooting 106
Broilers - Incubation Guide - V 6.0 9 Data analysis for continuous improvements 101
9.1 Introduction
This chapter provides general guidelines for monitoring hatchery results using a
hatchery specific reference set of data aiming at continuous improvements. It
provides general guidelines for:
- the construction of a hatchery specific database of hatchery results;
- the evaluation of hatchery results based on the data collected in the hatchery
specific database in order to create a reference point;
- a procedure for trouble-shooting if hatching results are below the reference
point.
Basics of hatchery specific database

The main management tool for the control and optimisation of hatchery results is a
hatchery-specific reference set of data - namely, a summary of the hatching results
which is continuously updated. In general the hatchery runs the incubation process
on a routine base using incubation set points described in the procedures. However
an adjustment to the routine procedures may be needed under certain
circumstances. For example, changing to a new breed, extended egg storage periods,
new equipment, etc. In other words, any change in the routine which may require a
check as to whether the existing incubation procedures are still appropriate.
Construction of a hatchery specific database

This section provides guidelines on how to collect and use the right data to develop a
hatchery-specific reference set of data which constitutes the basis for continuous
improvements in hatchery performance.
Evaluation of hatchery results

This section describes how the hatchery specific database can be used to calculate
average hatchery results. These can be used as a hatchery specific reference against
which actual hatchery results or results of individual breeder flocks can be evaluated.
Troubleshooting
If hatching results are lower than expected when compared to the reference data set,
a troubleshooting procedure can be initiated. An overview of management tools to
locate sources of suboptimal hatchability or chick quality is described in this section.
102 Broilers - Incubation Guide - V 6.0 9 Data analysis for continuous improvements
9.2 Basics of hatchery specific database
The basis for a hatchery specific database is accurate and consistent record keeping.
Generally, each batch of eggs incubated is specified by a combination of different
variables such as start date of the incubation cycle, egg ID-code and production
date. Other data can be added if required, such as setter and hatcher numbers, egg
weight losses etc.
A hatchery specific database can be designed according to the following two levels:
1. A database of basic hatchery results which are generally easy to collect from
every batch of eggs incubated. See Recording Form 9A: Hatching results (page
173).
2. A more detailed database containing results of:
• Analysis of clear eggs (page 95)
• Analysis of unhatched eggs (page 97)
• Assessing chick quality: Pasgar©Score (page 99)
These results can be summarized on Recording Form 9B: Results egg analysis and
Pasgar©Score (page 174). It is advisable to carry out these procedures for every
batch of eggs incubated. Should this not be feasible, carry out these procedures
for every ID-code at regular intervals (e.g. 4–6 times during the production
period of a breeder flock), in order to establish a reliable reference.
9.3 Construction of a hatchery specific
database
For the construction of a hatchery specific database, hatchery results need to be
collected and organized in a spreadsheet. In this spreadsheet the different variables
are organized in the columns. ‘Flock ID’, ‘egg storage period’, ‘date of egg setting’ or
‘late embryo mortality’ are examples of variables that can be organized in the
columns. The rows of the spreadsheet contain the hatchery results collected during
the different incubation cycles and recorded on appropriate recording forms as
mentioned above.
Using a spreadsheet table to organize the hatchery data makes it possible to select
and analyze interactions between the different variables. The table below shows an
example of a suitable spreadsheet. The headers of the columns contain the names of
different variables. In a spreadsheet, the number of variables that can be organized in
the columns are unlimited (just add more columns to the right).
Egg-ID Breed Setting Production Flock age Storage No. of eggs Total no. of Total Saleable
date date days set chicks hatchability (first class)
% chicks (%)
9.4 Evaluation of hatchery results
The main advantage of data collected in spreadsheets is the possibility of extracting
averages or other types of summarized data in a simple way. The summarized data
can then be used to prepare a hatchery specific reference. An example of a hatchery
specific reference based on overall averages is shown in the figure: the blue line
comprises the average of hatchabilities from all eggs delivered to the hatchery. The
red lines are the results from one specific flock.
Eggs produced by flock 2 show hatchabilities higher than the overall average even
when the flock is ageing. From this it can be concluded that breeder and/or
incubation management is optimum for eggs produced by flock 2. Evaluation of
hatching results could then be done less intensively compared to the attention
needed for eggs produced by flock 1.
Since hatching results (=hatchabilities) are influenced by many variables it is

advisable to consult a professional statistician if a detailed and more reliable analysis
is needed. A professional statistician can unravel and separate, for example, the
possible influences of the location of a specific setter on hatchabilities from the
influence of breeder flock management. Without the help of a professional we can
often reach conclusions which might be completely wrong - for example, because
the number of data are too low to make a significant conclusion. The help of a
professional statistician will prevent mistakes and wrong conclusions.
Examples of production graphs of 2 different parent flocks

blue = average of hatchabilities from all eggs delivered to the hatchery
red = actual hatchability of parent flock 1 or 2
9.5 Troubleshooting
In case of suboptimal results, first the problem has to be specified. By comparing the
achieved results with the hatchery specific reference set of data it is possible to
accurately define what is suboptimal about hatchability or chick quality. For example,
hatch results of eggs produced by flock no. 1 (figure 1a) drops below the overall
hatchery average when the flock age is more than 37 weeks.
In order to improve hatch results the need might arise to collect additional data on
the batch in question or at least on the next batch with the same egg ID-code by
carrying out:
• Analysis of clear eggs (page 95)
• Assessing chick quality: Pasgar©Score (page 99)
The troubleshooting table in this section can be used to find possible causes for the
defined suboptimal results. It will be possible to exclude some potential causes based
the available file of continuous records, whereas other potential causes for the
suboptimal results will require further investigation.
When the cause of the suboptimal results is found, formulate a corrective action and
communicate it to the person responsible for the specific procedure. Obviously, it is
important to follow up the effect of the corrective action. If it does not lead to an
improvement in the results then another cause was probably responsible for the
suboptimal results and a different corrective action should be formulated.
9.5.1 Adjusting incubation programs

If analysis of the troubleshooting table at the end of this section leads to the
conclusion that the incubation program may need adjustment, then records of the
incubation conditions before and after the adjustment should be made:
- Analysis of eggshell temperature (page 89)
- Analysis of egg weight loss (page 93)
- CO2 concentration:
• Single-stage incubation (page 37)
• Multi-stage incubation (page 41)
• Incubation in hatcher: day 19 – 21 (page 61)
9.5.2 To bear in mind when troubleshooting

In many cases, the source for suboptimal hatching results or chick quality may be
found in factors other than incubation conditions.
When seeking the cause of suboptimal results, bear the following aspects in mind:
- Maternal age: young flocks produce small eggs and small chicks.
- % of second class eggs: thin shells require adjustments of relative humidity,
contaminated eggs can greatly reduce hatching results and chick quality.
- Egg handling at the breeder farm: factors playing a role are egg hygiene,
frequency of egg collection, climate etc.
- Egg transport: long transport times at sub-optimal conditions (temperature,
hygiene, bad driving and road conditions) can depress hatching results.
- Storage duration: each day of storage (in excess of three days from production)
reduces the hatchability by 0.7%- 1.0%! Stored eggs need about one extra hour
of incubation time for every storage day in excess of three days; taking off the
chicks too early will result in high percentages of unhatched eggs.
- Egg storage conditions: compare storage duration and recommended climate
conditions.
- Fumigation with formalin: was the duration and temperature correct during
fumigation? If not, disinfection may have been ineffective or detrimental.
- Disinfection with other disinfectants: did these block the cuticle or pores in the
egg shell and with that hamper gas exchange and weight loss by reducing
evaporation of water?
- Egg transfer and candling: evaluate the transfer time; eggs should not be kept
outside the incubator for more than 30 minutes.
- Hatching process: a high level of unhatched chicks may indicate a problem in the
hatching phase. Also compare incubation duration with pre-incubation storage
times.
- Parent flock: before concluding that the hatchability was too low, first compare
the results with the history of the parent flock. There may be a fertility, nutritional
or health problem in the breeder flock.
- Egg analysis: opening clear and unhatched eggs may reveal causes of bad
hatching results. See:
• Analysis of unhatched eggs (page 97),
• Recording Form 9B: Results egg analysis and Pasgar©Score (page 174).
- Chick quality: compare chick quality based on Assessing chick quality:
Pasgar©Score (page 99) with incubation conditions and Recording Form 9B:
Results egg analysis and Pasgar©Score (page 174).
- Chick boxing and dispatch: in hot weather, reduce the numbers of chicks in the
chick boxes. Also, carefully monitor climate conditions during chick dispatch.
- Day-old-chick transport: long transport times in sub-optimal conditions
(temperature, hygiene and road conditions) can lead to a deterioration in chick
quality and may cause chick losses before arrival at the farm. First-week mortality
may also be increased.
- Placement conditions: litter must be dry and clean, the floor must be at the right
temperature (28 - 30 °C/82.4 – 86.0 °F) on chick arrival, and feed and water must
be provided at the right height (e.g. lowered for small chicks from young flocks).
This troubleshooting table aims to assist the hatchery manager in finding probable
causes for suboptimal hatchery results; however Pas Reform Academy does not
pretend that this troubleshooting list is complete and applicable to all situations.
Troubleshooting table
Problem Probable cause
Infertility - Males sterile or badly selected.
- Too many or insufficient males.
- Old males.
- Excessive weight gain, both males and females.
- Inadequate feed and water space allowances.
- Seasonal effect (e.g. high breeder-house temperature).
- Disease.
- Wet litter leading to foot problems.
- Leg or joint infections in males.
Died at "membrane stage" - Poor and rough egg handling.
(day 1–2) - High nest temperature in combination with low frequency of egg collection.
- Broodiness.
- Prolonged or improper egg storage.
- Incorrect egg disinfection.
Died at "blood ring stage" - Chilled or overheated hatching eggs.
(day 3–4) - Incorrect incubation temperature.
- Incorrect egg disinfection.
- High numbers of floor eggs, cracked eggs and contaminated eggs.
- Disease.
- Nutritional causes.
- Turning failure.
- Broodiness.
- Feed contamination.
Died at "eye stage" - Incorrect incubation temperature.
(day 5–7) - Turning failure.
- Disease.
Died from "egg tooth stage" until start - Incorrect incubation temperature.
yolk sac absorption - Eggs too long out of the setter during candling if done between 7–10 days.
(day 8–17) - Poor ventilation of setter and/or setter room.
- Incorrect humidity in incubator.
- Turning failure.
- Disease.
Death of chicks before internal pipping - Insufficient turning.
- Incorrect incubator temperature or humidity.
- Eggs incubated upside down.
- Air cell in the wrong place.
- High humidity in setter.
- High humidity in hatcher before 10% of chicks have hatched.
Death of chicks after external pipping - Low humidity in hatcher.
- Temperature too high or too low for a short period.
- Poor ventilation in hatcher.
Delayed hatch - Low humidity and temperature 1–19 days.
- Low hatcher temperature.
- Hot and cold spots during incubation.
- Improper egg collection.
- Prolonged egg storage.
- Excessively large eggs.
Premature hatch - High temperature in setter.
- Small eggs.
Sticky chicks - Low temperature 20–21 days.
- High humidity 20–21 days.
- Poor or inadequate air circulation in hatcher.
- Turning failure.
- Prolonged egg storage.
Dry chicks - Eggs dehydrated.
- Low humidity at hatching.
- High temperature 20–21 days.
Unhealed navels - Low temperature.
Protruding navels - High temperature in setter.
- Temperature fluctuations.
- High humidity in hatcher.
Chicks too small - Small eggs.
- Low humidity in setter.
- High temperature in setter.
- Thin porous shells.
Large and flabby chicks (poor reflex) - Low temperature in hatcher.
- High humidity in setter.
- Poor ventilation in hatcher.
- Omphalitis (inflamed navels).
- Large eggs.
Weak chicks - High temperature in hatcher.
- Inadequate ventilation in hatcher.
Crossed beak - Heredity.
- Virus infection.
Missing eyes - High temperature during first days in setter.
- Rough egg handling.
Twisted neck, stargazers - Possibly nutrition.
Crooked toes - Incorrect incubation temperature during last days in setter and in hatcher.
Straddled legs - Smooth hatching trays.
Head above right wing - High temperature in setter.
10 Hatchery hygiene
In this chapter
Introduction 112
Prevention of pathogens entering the hatchery 113
Prevention of cross contamination 115
Cleaning and disinfection 117
Hatchery hygiene monitoring 119
Broilers - Incubation Guide - V 6.0 10 Hatchery hygiene 111

10.1 Introduction
Poor hatchery hygiene may result in reduced hatchability and chick quality and
consequently considerable economic losses. Additionally, hatchery hygiene plays an
essential role in the efficiency and safety of the poultry production chain.
Without proper control, pathogens will multiply and spread within the hatchery,
potentially putting many if not all customers at risk, especially where contamination
presents a health hazard for the consumer by food-borne infections, such as
Salmonella and Campylobacter.
More common bacteria, like E. coli spp can cause increased seven-day mortality, with
suboptimal production and the need for the increased use of antibiotics. Ultimately,
the hatchery’s reputation may be jeopardized - and restoring the customer’s
confidence is much harder than maintaining it.
The hatchery should have a hygiene programme designed to minimise the level of
micro-organisms in the hatchery.
Optimised hygiene in the hatchery is dependent on three key areas:

1. preventing pathogens from entering the hatchery, i.e. maintaining biosecurity
2. avoiding cross-contamination or the transfer of pathogens within the hatchery,
and
3. inhibiting further pathogenic development in the hatchery i.e. cleaning and
disinfection
Prevention of pathogens entering the hatchery

This section summarises recommendations to prevent the introduction of pathogens
into the hatchery by applying strict biosecurity rules.
Prevention of cross contamination

This section summarises recommendations to minimise the risk of spreading
pathogens between hatchery rooms.
Cleaning and desinfection

Advice is given on cleaning and disinfection methods and frequencies for the various
hatchery rooms.
Hatchery hygiene monitoring

This section summarises recommendations for microbiological monitoring of the
hatchery's hygienic status.
112 Broilers - Incubation Guide - V 6.0 10 Hatchery hygiene

10.2 Prevention of pathogens entering the
hatchery
Good hatchery hygiene begins with preventing the introduction of pathogens into
the hatchery. Pathogens can be carried into the hatchery by various vectors. Several
of those vectors are described and recommendations are given on how to prevent
the introduction of pathogens through those vectors.
10.2.1 Hatching eggs including transport equipment

One of the most obvious vectors for the introduction of pathogens are the hatching
eggs and egg trays. Floor eggs and dirty eggs should not be considered as hatching
eggs and therefore should stay out of the hatchery, particularly because they are
potential exploders. It is important that hatching eggs are well supported during
transport in order to avoid hairline cracks, which provide unchecked entry points for
bacteria and fungi to get inside the egg. Once the shell - a critical defence mechanism
- is breached, the result is not only loss, but also a serious breach in hatchery
biosecurity. Purpose designed setter trays for on-farm traying are a perfect alternative
to the single use of pulp trays. In any case, only new pulp trays should be used – and
setter trays and farm trolleys should be cleaned and disinfected between each use.
Hatching eggs should be disinfected before entering the clean area of the hatchery;
for the recommended procedure, see Disinfecting hatching eggs (page 32).
Vertical transmission, from breeder hen to day-old-chick by egg yolk contamination,

of specific pathogens like Salmonella enteritidis and Mycoplasma gallisepticum can
only be prevented by strict monitoring of the breeder flock. Monitoring for
Salmonella spp. includes taking fluff samples from the hatcher from every specific
batch of eggs. Yet still we should accept that chicks will hatch between the onset of a
breeder flock being infected and the identification of this infection, so continuous
measures do need to be in place to prevent cross contamination, see Prevention of
cross contamination (page 115).
10.2.2 People (hatchery staff and visitors)

To avoid people acting as vectors and bringing pathogens into the hatchery a well-
designed entrance facility is essential. The following facilities should be present:
- a wardrobe for clothing and shoes worn outside the hatchery;
- a wash-basin (soap, disposable paper towels, hot and cold water tap) or even
better - a shower;
- a clear separation between the "clean" and the "dirty" area;
- a wardrobe with clean, disinfected clothing and footwear to be worn inside the
hatchery.
Any area accessed prior to the changing rooms and showers in a hatchery should be
regarded as a ‘dirty area’, with the ‘clean area’ of the hatchery incorporating the setter
room, candling and transfer room, hatcher rooms and chick handling and dispatch
rooms at minimum.
Technical areas, for example electrical installations or the boiler room, should be
located at the outside of the building, so that engineers have no cause to enter the
clean area of the hatchery. Similarly, offices for administrative personnel, canteens for
truck drivers and meeting rooms for customers should be clearly and effectively
separated from clean areas of operation.
Only necessary visitors should be allowed into the hatchery. Visitors should sign in
their name, company, date of last contact with live poultry and purpose of the visit on
the appropriate form on entering the hatchery, see Recording Form 10A: Registration
of visitors (page 175), and should follow the same hygiene instructions applying to
hatchery personnel. Pay particular notice to items visitors want to bring inside like
tools, mobile phones, etc. and inform them about the policy of the hatchery
pertaining to these items.

A regular check of the Salmonella status of hatchery staff and an up-to-date
Salmonella test for visitors might also be part of the hygiene policy of the hatchery.
10.2.3 Air
Prevention begins when designing a new hatchery project. The location should be
carefully chosen, taking the position of other poultry farms and public roads in
relation to prevailing wind direction into consideration. Air filters in the air handling
unit(s) minimize the introduction of pathogens, often attached to dust particles, into
the hatchery. Biofilters are recommended if a higher level of protection is required.
10.2.4 Rodents
Strict rodent control, based on prevention and continuous monitoring, is also
essential to keep these unwelcome visitors out of the hatchery. Prevention includes
keeping the surroundings of the hatchery neat and tidy, avoiding the attraction of
rodents by food such a hatchery waste and making the hatchery vermin-proof.
Monitoring should not only be based on seeing rodents themselves, but much more
on observing the signs of their presence - for example, foot prints and droppings.
Out-sourcing of rodent control to a specialized company might be considered to
ensure this aspect of hatchery hygiene continues to get full attention. Also such a
company has the knowledge and experience of rodenticides in relation to the build
up of resistance to specific rodenticides in the local rodent population.
10.2.5 Other vectors

Pathogens could enter the hatchery in or on other vectors, such as water, birds,
beetles, pet animals, contaminated paper chick boxes (e.g. Aspergillus) or dirty chick
boxes after a previous chick delivery. One should be alert for each of these vectors
and take adequate action if required.

10.3 Prevention of cross contamination
For good hatchery hygiene it is equally vital to prevent contamination spreading
from one room to another. To prevent cross-contamination, it is important to clearly
demarcate the different hygienic zones in the hatchery:
- egg arrival area; setter room;
- candling/transfer room;
- hatcher room;
- chick handling and dispatch room.
10.3.1 Uni-directional flow

The processes in the hatchery should be carried out according to a one-way traffic
system in line with the egg flow through the hatchery. The hatchery manager who
first takes a look in the chick handling room and moves from there straight, without
changing, to the setter room acts as a transport medium for micro-organisms.
Likewise, the hatchery maintenance engineers, constantly moving through the
hatchery are a risk factor for cross contamination.
Different coloured hatchery clothing and shoes, as well as tools such as floor
scrubbers, greatly help to enforce hygiene-responsible behaviour by hatchery
personnel.
10.3.2 "Clean should never meet dirty"

A well designed hatchery makes practical implementation of the rule "clean should
never meet dirty" easily achievable. For example, eggs being transferred to the
hatcher do not cross the path of chicks just being pulled out of hatchers. After being
washed and disinfected, hatcher baskets do not pass through the chick room, or any
area where processing takes place, on their way to the transfer room.
10.3.3 Controlling air movement

Chick down is another potential contaminant - and easily becomes airborne. Its
movement must therefore be controlled to prevent cross-contamination. The
frequency of opening doors should be minimised to prevent air moving from one
room to another. Doors, including one-way doors, help stop cross contamination
between rooms. The setter room should be maintained as the cleanest room in the
hatchery and is therefore maintained at a higher pressure compared to the hatcher
rooms. The accumulation of down in air ducts is to be avoided because this forms
breeding grounds for moulds like Aspergillus.. Air leaving the hatcher, and preferably
also the setter, should be brought directly into exhaust plenums which can be easily
cleaned and disinfected. The use of air ducts should be restricted for clean air only.
10.3.4 Dealing with exploders

Exploders, often caused by Pseudomonas spp, are an important source of cross-
contamination between batches within the same setter. To reduce this risk, batches
with an increased incidence of exploders should be transferred to the hatcher last.
Potential exploders are often recognized by a foamy substance oozing from the pores
in the shell; carefully try to remove them prior to transfer and dispose of them in a
bucket containing a disinfectant solution. Clean up the debris thoroughly and
immediately every time an egg explodes.
10.3.5 Optimal size of hatcher rooms

Strictly applying the "One batch per hatcher" rule, enabled by limiting the capacity of
the hatchers, greatly prevents the risk of cross contamination, for example from older
to younger batches.
In a well-designed hatchery the number of hatchers per hatcher room is based on the
daily production of chicks. This avoids recontamination after cleaning and

disinfection, and thus minimizes the risk of contaminating the next days hatch. If a
specific batch is known to be infected with Salmonella, the decision, often enforced
by legislation, is either to destroy the eggs before they hatch or to pull the infected
chicks at the end of the hatch day.

10.4 Cleaning and disinfection
It will be impossible to have a hatchery completely free of micro-organisms, even
when the most strict biosecurity rules are implemented. Regular cleaning and
disinfection controls the multiplication of micro-organisms effectively.
10.4.1 Procedure
It is essential to clean prior to disinfection since organic material inhibits the chemical
action of disinfectants. Good cleaning also removes up to 85 per cent of micro-
organisms. Instructions for cleaning and disinfecting every hatchery room or any
hatchery equipment should be formulated and clearly displayed in the relevant area;
see Recording Form 10B: Cleaning schedule (page 176). For specific procedures of
cleaning and disinfecting hatchery equipment see the relevant manuals.
The following general routine is recommended:

1. Remove all loose debris such as fluff and eggshells.
2. Cover the entire area with soap and soak for about 15 minutes.
3. Remove soap together with suspended 'dirt'.
4. Allow to dry properly as any remaining water will over-dilute the disinfectant.
5. Apply the disinfectant according to the manufacturer's instructions. Read the
label carefully!
The table at the end of this section provides guidelines for the frequency with which
the hatchery rooms and equipment should be cleaned and disinfected.
10.4.2 Products: soap and disinfectant

Consider at least the following points when choosing chemicals for cleaning and
disinfection and discuss these with your supplier:
- pH-values: alkaline soaps remove organic dirt (protein, fat) – acid soaps remove
mineral deposits (such as calcium). Depending on water hardness, the occasional
use of acid soap will help maintain smooth surfaces.
- Foam or non-foaming: In washing machines non-foaming soaps should be used.
To increase the contact-time between soap and dirt, a foaming soap should be
used for hatchery rooms and equipment; it allows for excellent cleaning results
with relative low water pressure.
- Compatibility: check that the soap does not render the disinfectant ineffective.
- Range: broad-spectrum disinfectants provide efficacy against a variety of micro-
organisms and are preferred over narrow- range disinfectants, unless these are
needed to remove specific pathogens such as Aspergillus.
- Residual activity: to help avoid recontamination.
- Method of application: for example, room disinfection requires gas or fog, while
setter disinfection is best achieved with a spray.
- Corrosiveness: some chemicals used for cleaning and disinfection are very
corrosive to certain materials. Check which materials are used in the hatchery
equipment (see technical specifications in user manuals!) and ensure the
chemicals are safe to use with these materials.
- Safety for hatchery staff and environment: provide protective clothing and masks
for the cleaning staff.
- Pricing: cheaper is not necessarily better. Also consider the concentration
required when comparing products.
Commercial disinfectants often contain more than one active ingredient which
complement each other in the fight against a wide variety of pathogens - together
with buffering agents, wetting agents, sequestering agents etc. in order to ensure
their efficacy in contact with organic matter, in cold water, in low and high pH and to
increase the shelf life.

Every cleaning and disinfection should be recorded; see Recording Form 10B: Cleaning
schedule (page 176); review the cleaning schedule regularly and especially when your
microbial monitoring indicates any deterioration in hygiene status.
Recommended cleaning and disinfection frequency hatchery rooms and

equipment
Room Cleaning frequency Room and equipment Cleaning frequency
Egg receiving room Once every week Hatcher room Once every week
Egg storage Once every week Hatchers After each hatch
Egg setting room Once every week Chick handling room After each handling
Setter room Once every week 1) Chick dispatch room After each handling
Setters After each incubation Racks, egg trays, hatcher After each use
cycle baskets, chick boxes
Egg transfer room After each handling Egg and chick trucks After each egg/chick
delivery
1) Never fumigate the setter room with formalin when eggs younger than four days of incubation are inside the
setters.

10.5 Hatchery hygiene monitoring
Hatchery hygiene monitoring is an essential element of any hatchery quality
assurance programme for the evaluation of cleaning and disinfection procedures. It is
crucial to conduct the monitoring programme on a routine basis, for example once
every two weeks. To avoid dissuade hatchery personnel from just devoting extra
attention to cleaning and disinfection prior to a scheduled hatchery hygiene
monitoring, it is advisable to monitor occasionally at unscheduled times.
The following 3 levels of hatchery hygiene monitoring can be recognized:

- Visual inspection;
- Agar-cultures for non-specific bacteria and fungi;
- Specific bacterial and fungal monitoring.
10.5.1 Visual inspection

Once visual dirt is present one can rest assured there will also be a high number of
micro-organisms. During inspection attention should not only be paid to the surfaces
that can easily be reached, but especially to the hard-to-reach surfaces, such as the
undersides of doors, the back of cooling coils and the outlet pipe of hatchers.
10.5.2 Agar-cultures for non-specific bacteria and fungi

Here, guidelines are restricted to the routine programme which involves the
sampling of air and surfaces in rooms used for hatchery practiceThe purpose of
sampling is to evaluate the effectiveness of a sanitation programmeand should be
performed only after a clean-up has occurred. For microbial monitoring, use is often
made of solidified agar in Petri dishes containing nutrients matching the metabolic
needs of bacteria and fungi. If bacteria and fungi are present they will grow on this
media when incubated.They will multiply and become visible as colonies. The
number of these colonies is an indication of the hygienic state of the surface
sampled.
For inspecting flat surfaces (walls, ceilings), one of the following methods may be
used:
- Swab and streak procedure: rub a sterile swab which has been moistened in a
sterile solution or a manufactured sterile culturette, over a predefined area (2.5
cm-5.0 cm) of sample surface. Then gently streak over the surface of an agar
plate several times in a zig-zag fashion.
- Rodac plate procedure: "RODAC" stands for Replicate Organism Detection And
Counting. Rodac plates are plastic plates where the base is filled with agar gel.
This agar layer is slightly higher than the edge of the plate so that direct contact
is made with the surface to be sampled. Remove the cover of the plate, press the
agar gently on the surface to be monitored (do not move while contact is made).
The cover should be replaced after the impression is made, taking care not to
touch the agar.
The Rodac plate can be used for monitoring air. Expose the Petri dish with the
selected media, by carefully placing the plate media-half on the bottom, on a flat
surface within the environment to be monitored. Gently remove the cover. Leave the
media exposed to the air for the specified time. For relatively clean areas, a 10-minute
sampling time is sufficient.
The agar plates which are being evaluated for bacterial contamination should be
incubated for 48 hours at 37 - 37.5°C/98.6 – 99.5°F in a microbiological incubator or a
setter (place the plates in a plastic bag and set where they will not be disturbed).
Plates are incubated upside down so that drops of condensation will not fall onto the
inoculated surface. After incubation, the colonies on the agar media can be counted
and recorded.
Evaluating and monitoring hygiene conditions should be based on the hatchery's

own criteria. In general, an excessive number of colonies indicate poor sanitation
procedures or a hatching egg production problem. For detailed advice on sampling,

reading and evaluating agar plates, see instructions and advice from the agar media
manufacturers.
It is advisable to maintain records of all results so that changes occurring over time
can be observed in the various areas being monitored. See Recording Form 10C:
Hatchery microbiological monitoring (page 177). The results should also be carefully
correlated with hatchability and liveability data.
10.5.3 Specific bacterial and fungal monitoring

A more intense monitoring program requires bacterial and fungal identification.
Samples could involve swabs, Rodac plates, fluff, paper from chick boxes, unhatched
eggs and even day-old-chicks. Samples have to be properly taken, packed and sent to
specialised laboratories according to their instructions. Results are forwarded to the
hatchery after the tests have been conducted.

11 Hatchery maintenance
In this chapter
Introduction 122
Preventive maintenance 123
Spare parts 125
Setter and hatcher 126
Hatchery climate 127
Hatchery automation and auxiliary equipment 131
Broilers - Incubation Guide - V 6.0 11 Hatchery maintenance 121

11.1 Introduction
Modern hatcheries are capital intensive and production orientated companies. The
down time of equipment and machinery is prohibitively expensive and affects the
financial results of the hatchery. To achieve maximum results the hatchery
equipment should be kept in top condition by a well-organized preventive
maintenance program. This is more efficient than waiting for equipment break-down
followed by repair. Key ingredients for the success of a preventive maintenance
program are using original spare parts and a having a skilled and dedicated technical
staff.
Preventive maintenance
This section explains the importance of a well-organized preventive maintenance
program. Relevant aspects of such a program includes defining who is responsible for
preventive maintenance, scheduling the maintenance activities, recording what was
done and which parts were replaced and analyzing history records of preventive
maintenance in order to fine-tune the interval and instructions for preventive
maintenance.
Spare parts
This section asks attention for the importance of having a certain minimum level of
essential parts on stock and gives advice on how to organize the technical workshop.
Setter and hatcher

This section indicates special point of interest concerning the preventive
maintenance for setters and hatchers. An important aspect is to check the proper
functioning of the incubators before every new cycle.
Hatchery climate
This section summarizes the importance of a good internal hatchery climate and
advices to check climate conditions in all relevant rooms on a regular basis. Where
there are deviations from the recommended climate conditions, the cause should be
identified and actions should be taken to rectify the situation. Preventive
maintenance of climate related equipment is essential.
Hatchery automation and auxiliary equipment

This section asks attention for preventive maintenance of all other hatchery
equipment. A failure of hatchery automation should be avoided, because it may lead
to a discontinuation of the production process. Also the relevance of keeping
auxiliary hatchery equipment, such as trucks and stand-by generator, in good
working-order should not be underestimated.
122 Broilers - Incubation Guide - V 6.0 11 Hatchery maintenance

11.2 Preventive maintenance
Hatcheries are capital intensive companies and their success depends on the
uninterrupted operation of all relevant equipment. This does not only apply to setters
and hatchers but also to stand-by generator, the climate control system incl. chiller,
alarm system, hatchery automation, waste system, trucks etc.
Waiting for equipment break-down is the opposite of a well-organized preventive

maintenance program. Equipment break-down and malfunctioning equipment
should be avoided, because:
- It always comes unexpected and at inappropriate moments, such as half way an
incubation cycle or in the middle of the night or during a festive season.
- The technical engineer of the hatchery is not available or does not know exactly
how to repair or solve an urgent problem
- Relevant spare-parts might not be on stock and it will at least take a few days
before receiving urgently ordered spare parts.
- During the period of equipment break-down followed by the required repair,
costs are being made, for example because hatchery staff are idle for some hours
until they can commence their activities again.
- Depending on the time of the break-down or malfunctioning of equipment it
almost surely has a negative effect on hatchery results.
Equipment break-down and malfunctioning equipment can be avoided by

implementing a well-organized preventive maintenance program.
Preventive maintenance includes:

- regular checking of the proper functioning of all hatchery equipment;
- carrying out relevant activities to extend the lifetime of essential parts;
- replacing parts before their technical life time is over.
When during a regular check problems are detected there is still ample time to plan
the replacement of the relevant part before it actually breaks down and an
interruption of the incubation process can be avoided.
There are different types of preventive maintenance that can be used in the hatchery:
- Time based (examples: lubricate every week; check the proper functioning of the
setter prior to each new incubation cycle)
- Recommended maintenance advice from the Original Equipment Manufacturer
(OEM) (example: replace V-belt after … running hours)
- Condition based by visual checks, sounds etc. (example: replace bearing because
an abnormal sound is heard)
Structure and planning is important for the success of the preventive maintenance
program:
1. List all hatchery equipment which requires preventive maintenance.
2. Define who is responsible for preventive maintenance of each item of hatchery
equipment.
3. Schedule the frequency of preventive maintenance for each item of hatchery
equipment.
4. Describe what should be done at which interval. Make a distinction between
activities which should be done daily, weekly, before each incubation cycle and
less frequent for example every 6 months.
5. Record all preventive maintenance activities and also include what corrective
actions were performed or which parts were repaired or replaced.
6. Analyze the maintenance records on a regular basis to fine-tune the optimal
frequency of preventive maintenance.
The recommended maintenance intervals and the instructions from the Original
Equipment Manufacturers should be followed initially. The accurate recording of
maintenance activities will generate a useful maintenance history of the equipment.
By analyzing this data over a longer time period, the frequency of preventive
maintenance as well as specific instructions for maintenance activities can be

adjusted. When making these kind of modifications to the preventive maintenance
plan keep in mind that the purpose is to avoid or reduce the number of break-downs
of hatchery equipment. By this kind of systematic approach of preventive
maintenance hatchery equipment will always be in top condition.
To make sure that all preventive maintenance activities are done and nothing is
accidentally forgotten a detailed checklist for each item of hatchery equipment is a
useful tool. The responsible employee who carries out the preventive maintenance
ticks off all activities on this checklist. Final records should be made on the individual
maintenance card belonging to each item of hatchery equipment and his signature
should be placed as a proof that maintenance was actually carried out.
The Maintenance Module within SmartCenter™ is a useful tool for scheduling and
recording the preventive maintenance program for all listed equipment. Important
management information about the maintenance history of the equipment is
available. Alternatively the recording forms as available in this Incubation Guide
could be used.

11.3 Spare parts
The spare parts stock and the technical workshop in the hatchery should be well
organized. Important is that the most essential spare parts are on stock at any time. A
list of essential spare parts and the recommended number related to the size of the
hatchery is provided by the Original Equipment Manufacturers. It is highly
recommended to only use spare parts from the Original Equipment Manufacturer, as
these are designed for the use in hatchery equipment and have been specifically
tested for durability in a typical hatchery environment, energy use and safety.
Don’t store broken parts in or near the spare parts stock. If the broken part is not
repairable treat it as scrap. For example if a temperature sensor is broken, cut the
cable from the sensor to make sure that nobody will try to use it again. If the part can
be repaired store it on a defined location and mark it clearly as broken.
Tools for maintenance and service should be in toolboxes and stored at defined
locations, such that they can always be easily found when needed.

11.4 Setter and hatcher
At least twice daily monitoring the performance of setters and hatchers is essential.
Temperature, relative humidity, ventilation, CO2 and turning, are crucial factors for
hatchability and chick quality. The integrated alarm system is monitoring these
factors 24/7 and generates an alarm if the difference between set points and actual
values is too high to draw the attention from the responsible hatchery staff. After a
power failure setters and hatchers start-up automatically as soon as power is back. In
the meantime the alarm system will warn hatchery staff.
An important aspect of preventive maintenance is to check the proper functioning of

setters and hatchers before every new cycle. The "Performance Testing Tool" on the
SmartDrive™ and SmartTouch™ is developed especially for this purpose. Records of
this check should be made on Recording Form 4A: Incubator recording form (page
163).
By listening (for example strange noise in bearing of main- or turning motor) and
looking (for example excessive cooling activity on machine display in one of the
sections) to the machines it is possible to notice failures before they lead to
breakdowns or incubation problems. If these kind of failures are noticed at an early
stage there is no need to interrupt the hatching process. There is then still ample time
to organize the required parts and the repair can be planned for the next down time
between incubation cycles. By doing so the repair does not interrupt a running
incubation cycle and thus there is no negative influence on hatchability chick quality.
V-Belts for example are typically wear and tear parts in setters and hatchers which
should be replaced preventatively on a time based schedule according to the
maintenance instructions in the machine manuals. These are very essential in relation
to hatchability and chick quality, so must be in top condition. Always replace spare
parts per machine, as the operational hours of all sections is equal. The same applies
to electronic humidity and CO2-sensors; to guarantee their accuracy, needed for a
correct working controller of the incubator, replacement on a time-based interval,
according to the maintenance instructions in the machine manuals, is advised.
All maintenance activities including corrective actions and replacements or repair of

parts should be recorded. This could be either in the Maintenance Module in
SmartCenter™ or alternatively on Recording Form 11A: Setter maintenance card (page
178)and Recording Form 11B: Hatcher maintenance card (page 179).

11.5 Hatchery climate
In a hatchery, climate conditions should be optimum for the development of the
embryo and for chick quality. Also egg quality deterioration prior to incubation must
be minimized. In this respect, not only do conditions inside the incubators have to be
optimal, but climate conditions also have to be monitored closely during egg
storage, egg handling, transfer and chick handling and dispatch.
In the tables below recommendations are listed for climate conditions for the main
hatchery rooms. Actual (= measured) values should be within the mentioned ranges.
It is important to mention that the values in the tables are not necessarily be the
same as the set points for the climate control system!
Recommended climate conditions for the main hatchery rooms (°C)

Room Temperature Humidity CO2
°C RH dew point maximum
% °C % / ppm
egg handling 19 – 25 50 – 65 - 0.12 / 1200
egg store: 1) 0.50 / 5000
0 – 3 days 18 – 21 75 – 85 -
4 – 7 days 15 – 17 75 – 85 -
≥ 7 days 12 – 14 80 – 85 -
air inlet setter 2) 21 – 27 ≤ 70 11 – 19 0.09 / 900
transfer 3) 21 – 27 40 - 65 - 0.12 / 1200
air inlet hatcher 2) 21 – 27 ≤ 70 11 – 19 0.09 / 900
chick handling 4) 24 – 27 40 – 65 - 0.12 / 1200
chick dispatch 4) 24 – 27 55 – 70 - 0.15 / 1500
1) Egg ‘sweating’ must be prevented when moving eggs from a cold room to a warmer room; see Sweating of eggs (page
134).
2) Optimal temperature and humidity for setter and hatcher inlet air depends also on external climate conditions and energy
costs needed to condition the inlet air. Contact Pas Reform for a customized advice for optimal climate conditions
3) Avoid draughts directly on eggs and limit the time egg stay in the transfer room to 15 – 20 minutes.
4) Room climate is secondary and depends on air velocity as well. The climate AT CHICK LEVEL should be ideal; see Chick
dispatch and transport (page 78).

Recommended climate conditions for the main hatchery rooms (°F)
Room Temperature Humidity CO2
°F RH dew point maximum
% °F % / ppm
egg handling 66.2 – 77.0 50 – 65 - 0.12 / 1200
egg store: 1)
64.4 – 69.8 75 – 85 - 0.50 / 5000
0 – 3 days 59.0 – 62.6 75 – 85 -
4 – 7 days 53.6 – 57.2 80 – 85 -
≥ 7 days
air inlet setter 2) 69.8 – 80.6 ≤ 70 51.8 – 66.2 0.09 / 900
transfer 3) 69.8 – 80.6 40 - 65 - 0.12 / 1200
air inlet hatcher 2) 69.8 – 80.6 ≤ 70 51.8 – 66.2 0.09 / 900
chick handling 4) 75.2 – 80.6 40 – 65 - 0.12 / 1200
chick dispatch 4) 75.2 – 80.6 55 – 70 - 0.15 / 1500
1) Egg ‘sweating’ must be prevented when moving eggs from a cold room to a warmer room; see Sweating of eggs (page
134).
2) Optimal temperature and humidity for setter and hatcher inlet air depends also on external climate conditions and energy
costs needed to condition the inlet air. Contact Pas Reform for a customized advice for optimal climate conditions
3) Avoid draughts directly on eggs and limit the time egg stay in the transfer room to 15 – 20 minutes.
4) Room climate is secondary and depends on air velocity as well. The climate AT CHICK LEVEL should be ideal; see Chick
dispatch and transport (page 78).
The acceptable range for humidity of inlet air for setters and hatchers is indicated as
dew point. With both conversions tables below it is easy to check if a certain
combination of relative humidity and temperature is within the acceptable (= high-
lighted) dew point range of 11 – 19 °C / 51.8 – 66.2 °F.
Example
Measured air inlet setter / hatcher Acceptable?
Temperature Relative humidity

(°C/°F) (%)
26 / 79 65 Yes, 65 % RH is within the
range.
26 / 79 70 No, 70 % RH is too high.

Conversion table Dewpoint (°C)
T°C \ RH% 35 % 40 % 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 %
15 °C -0.4 1.5 3.2 4.7 6.0 7.3 8.5 9.6 10.6 11.6 12.5 13.4 14.2
16 °C 0.5 2.4 4.1 5.6 7.0 8.2 9.4 10.5 11.6 12.5 13.5 14.4 15.2
17 °C 1.4 3.3 5.0 6.5 7.9 9.2 10.4 11.5 12.5 13.5 14.5 15.3 16.2
18 °C 2.3 4.2 5.9 7.4 8.8 10.1 11.3 12.4 13.5 14.5 15.4 16.3 17.2
19 °C 3.2 5.1 6.8 8.3 9.7 11.1 12.3 13.4 14.5 15.5 16.4 17.3 18.2
20 °C 4.1 6.0 7.7 9.3 10.7 12.0 13.2 14.4 15.4 16.4 17.4 18.3 19.2
21 °C 4.9 6.9 8.6 10.2 11.6 12.9 14.2 15.3 16.4 17.4 18.4 19.3 20.2
22 °C 5.8 7.8 9.5 11.1 12.5 13.9 15.1 16.3 17.4 18.4 19.4 20.3 21.2
23 °C 6.7 8.7 10.4 12.0 13.5 14.8 16.1 17.2 18.3 19.4 20.3 21.3 22.2
24 °C 7.6 9.6 11.3 12.9 14.4 15.8 17.0 18.2 19.3 20.3 21.3 22.3 23.1
25 °C 8.5 10.5 12.2 13.9 15.3 16.7 18.0 19.1 20.3 21.3 22.3 23.2 24.1
26 °C 9.3 11.4 13.1 14.8 16.3 17.6 18.9 20.1 21.2 22.3 23.3 24.2 25.1
27 °C 10.2 12.2 14.1 15.7 17.2 18.6 19.9 21.1 22.2 23.3 24.3 25.2 26.1
28 °C 11.1 13.1 15.0 16.6 18.1 19.5 20.8 22.0 23.2 24.2 25.2 26.2 27.1
29 °C 12.0 14.0 15.9 17.5 19.0 20.4 21.8 23.0 24.1 25.2 26.2 27.2 28.1
30 °C 12.9 14.9 16.8 18.4 20.0 21.4 22.7 23.9 25.1 26.2 27.2 28.2 29.1
Conversion table dew point (°F)

T°F \ RH% 35 % 40 % 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 %
59 °F 31.4 34.7 37.7 40.4 42.8 45.1 47.2 49.2 51.1 52.8 54.5 56.1 57.6
61 °F 33.1 36.5 39.5 42.2 44.7 47.0 49.1 51.1 53.0 54.8 56.5 58.0 59.6
63 °F 34.9 38.3 41.3 44.1 46.6 48.9 51.0 53.1 54.9 56.7 58.4 60.0 61.5
65 °F 36.7 40.1 43.1 45.9 48.4 50.8 52.9 55.0 56.9 58.7 60.4 62.0 63.5
67 °F 38.4 41.9 44.9 47.7 50.3 52.7 54.8 56.9 58.8 60.6 62.3 64.0 65.5
69 °F 40.2 43.7 46.8 49.6 52.2 54.5 56.7 58.8 60.7 62.6 64.3 65.9 67.5
71 °F 42.0 45.5 48.6 51.4 54.0 56.4 58.6 60.7 62.7 64.5 66.3 67.9 69.5
73 °F 43.7 47.2 50.4 53.3 55.9 58.3 60.5 62.6 64.6 66.5 68.2 69.9 71.5
75 °F 45.5 49.0 52.2 55.1 57.7 60.2 62.4 64.5 66.5 68.4 70.2 71.9 73.5
77 °F 47.2 50.8 54.0 56.9 59.6 62.0 64.3 66.5 68.5 70.4 72.1 73.8 75.5
79 °F 49.0 52.6 55.8 58.8 61.5 63.9 66.2 68.4 70.4 72.3 74.1 75.8 77.4
81 °F 50.8 54.4 57.7 60.6 63.3 65.8 68.1 70.3 72.3 74.2 76.1 77.8 79.4
83 °F 52.5 56.2 59.5 62.4 65.2 67.7 70.0 72.2 74.3 76.2 78.0 79.8 81.4
85 °F 54.3 58.0 61.3 64.3 67.0 69.6 71.9 74.1 76.2 78.1 80.0 81.7 83.4
87 °F 56.0 59.8 63.1 66.1 68.9 71.4 73.8 76.0 78.1 80.1 81.9 83.7 85.4
89 °F 57.8 61.5 64.9 67.9 70.7 73.3 75.7 77.9 80.0 82.0 83.9 85.7 87.4
The characteristics of the air that enters the setter or hatcher has an effect on the
incubators behavior. When setter inlet air is (both) cold and(/or) dry the humidifier
inside the setter might be activated too much. This leads to a local cold-spot close to
the humidifier and should thus be avoided. Another example is when hatcher inlet air
is (both) warm and(/or) humid. This might lead to excessive condensation on the cold
walls of the hatcher and eventually to water on the floor; this situation should also be
avoided.
The level of CO2 in inlet air of setters and hatchers should also be measured since this
is a good indicator of the quality of air entering the incubators.

It is advisable to take weekly readings of the climate conditions of every room in the
hatchery where steps of the incubation process occur and to record these on
Recording Form 11D: Checklist climate conditions in hatchery (page 181). Use good
quality handheld thermometers, hygrometers and CO2-meters and get these
calibrated and certified at least once per year. The accuracy of these handheld
instruments should be at least similar as the accuracy of the sensors used for climate
control.
Compare the readings of the handheld instruments with the actual set points and the
acceptable range of deviation from the set point. When the actual readings, after
several times repeating the measurement, deviate too much from the set points, the
cause should be identified and actions should be taken to rectify the situation.
Too high CO2 concentrations in the clean air plenum may indicate that the filters of
the air handling unit need to be replaced. Modern air handling units (AHU) are
engineered with a "blocked filter’’ sensor. The AHU will give an alarm when the filter
is dirty and should be replaced. When these replacement intervals are recorded on
Recording Form 11C: Hatchery equipment maintenance card (page 180) it is possible to
plan changing the filters preventive on a time based interval.
Check and clean air fans, ventilation grill, clean or replace protection filters of sensors.
Include these activities in the preventive maintenance program.
Paying attention to air pressures in the various pressure-controlled rooms and

comparing those with set points is important for correct air flow (‘from clean to dirty’)
in the hatchery and for optimal performance of the incubators. Instruct all employees
in the hatchery to close the doors when they are leaving a room; open doors disturb
the room air pressures and temperatures. This will have not only a negative effect on
the hatchability but will also lead to increase of the energy costs.

11.6 Hatchery automation and auxiliary
equipment
Equipment such as trolley loaders and unloaders, washing machines, vaccinators,
chick counters, candling and transfer machines, vacuum waste system etc. are some
examples of equipment of the wide range of hatchery automation.
Even when there is a problem in the automation line the production should continue.
Therefore it is important to make ‘escape plans’ so that it is clear what to do when
critical equipment stops working.
For example: When there are problems in automation of egg transfer and the
engineers are working to solve the problem, eggs can be transferred with simple
semi-automatic equipment.
Also auxiliary equipment such as the stand-by power generators, the trucks for egg
and chick transport, fork lifters, water supply, snow plough and the truck wash
installation need preventive maintenance.
For example: The preventive maintenance for the stand-by generator should be on a
time based schedule. It should be started up every week to check its functioning and
the level of gasoil should be checked at the same moment. A power failure from the
public supplier is only a disaster if the standby generator fails due to neglected
preventive maintenance!
Because of the number and variety of parts for all of this auxiliary equipment it is
important to identify the most critical and/or common parts and keep them on stock
in the hatchery. Often controllers, transmissions, belts, pumps, nozzles are special
designed for this application and ordering and delivering can take some time.
The maintenance intervals of the Original Equipment Manufacturer should be

followed as a minimum. Some of this specialized equipment requires service checks
by specialists from the manufacturer. Integrate these visits in the preventive
maintenance schedule and make sure that the visit is organized when it is required.
For every equipment listed under hatchery automation use Recording Form 11C:
Hatchery equipment maintenance card (page 180).
Finally, even though the hatchery building itself is not defined as ‘equipment’ it also
requires maintenance at a regular interval to keep it looking good and extend its
lifetime.

12 Annexes
In this chapter
Sweating of eggs 134

Hatching at high altitudes 140
Adaptive Metabolic Feedback (AMF™) 144
Energy Saving Module (ESM™) 147
Circadian Incubation™ 149
Broilers - Incubation Guide - V 6.0 12 Annexes 133

12.1 Sweating of eggs
'Sweating' of eggs refers to the phenomenon of condensed water sitting on the egg
shell surface. This occurs when cold eggs are suddenly exposed to a higher
environmental temperature. The warm air with a certain moisture content cools
down rapidly directly around the colder eggs. Since cold air can contain less water
than warm air, relative humidity will increase until the air is saturated. And at that
moment, condensation will take place on the cool egg surface.
The term 'sweating' is, if taken literally, misleading, because the water on the shell
does not in fact come from within the egg. The same physical process is seen when a
bottle of water is removed from a refrigerator on a warm summer day.
Sweating of eggs should be avoided because moisture on the shell surface weakens
the egg's natural defence mechanisms, providing as it does an ideal environment for
the growth of micro-organisms, and further facilitating their penetration through the
shell pores.
Once inside the pores, micro-organisms are protected from most routine egg
sanitising operations, therefore presenting a potential risk for contamination. Bacteria
and fungi which manage to pass through the shell membranes will multiply at a rapid
rate when they are exposed to incubation temperature, because the defence
mechanism in the albumen is no longer able to protect the growing embryo.
This of course will lead to increased embryonic mortality, 'exploders' and infected
day-old-chicks (increased first week mortality).
Clearly moisture on egg shells should be prevented. Egg sweating is prevented when
the difference in temperature between the egg storage room and 'the outside' (e.g.
loading platform of the truck, egg traying room, setter) is small and the 'outside'
humidity is low.
The table below can be used to predict whether sweating will occur if no additional
measures are taken. For a wider range of temperatures and humidities, a 'Mollier'
diagram or psychrometric chart provides a useful tool and is explained below.
There is also a risk of eggs sweating if they are set too cold in a setter that is already
running to temperature, as is the case in multi-stage incubation practice.
Eggs will 'sweat' if the relative humidity (% RH) in the egg traying room is higher than:
Temperature of Temperature egg traying room:
storage room 1)
15 °C/59.0 °F 18 °C / 64.4 °F 21 °C / 69.8 °F 24 °C / 75.2 °F
21 °C / 69.8 °F - - - ≥ 85 % RH
18 °C / 64.4 °F - - ≥ 83 % RH ≥ 71 % RH
16 °C / 60.8 °F - ≥ 89 % RH ≥ 74 % RH ≥ 60 % RH
11 °C / 51.8 °F ≥ 74 % RH ≥ 64 % RH ≥ 53 % RH ≥ 44 % RH
1) It is assumed that the temperature of the eggs equals the temperature of the egg storage room.
12.1.1 Advice
- If the risk of sweating is high, pre-warm eggs gradually at least six hours prior to
removing them from the egg storage room. This can be achieved by first
bringing the eggs to a room with an intermediate temperature (for example
from the colder egg storage room for long stored eggs to the warmer egg
storage room for short stored eggs) prior to moving them to the warmest room
(for example the setter room). It is important to realize that not all eggs warm up
at the same, uniform speed, especially with low air circulation and if stored on
paper trays and stacked closely together.
- Store at a higher temperature, combined with a shorter storage period.
134 Broilers - Incubation Guide - V 6.0 12 Annexes

- Connect the truck picking up the hatching eggs directly with the storage room
to minimise any temperature differences from the outside environment.
- Ensure that the climate in the truck is the same as in the egg store.
- Maintain humidity below the levels indicated in the table.
- Prior to placement in the setter, place the filled setter trolleys at a room
temperature of 25 ˚C with good air circulation for several hours. This pre-
warming of the eggs before setting is particularly important when using multi-
stage incubation.

12.1.2 ‘Sweating’ of eggs explained by Mollier diagram (°C)
The Mollier diagram describes the relation between temperature, moisture and
energy in air. It forms the basis for the calculations needed for designing hatchery
climate control, but it can also be used to predict when sweating of eggs will occur.
To predict if sweating will occur, it is necessary to know only the meaning the
following 2 lines of the diagram:
1. The horizontal lines, which represent the temperature of the air; the values are
indicated in degrees Centigrade on the vertical axis on the left.
2. The curved lines in the diagram represent the relative humidity of the air; the
values are indicated as %RH on the curved lines themselves.
In the worked example below, it is assumed that the temperature in the setter room
is 25 °C. The coloured circles in the diagram represent three possible levels of relative
humidity in the setter room: 50 % (green circle), 60 % (blue circle) and 70 % (red
circle).
If eggs are brought into this setter room from the egg store the air directly
surrounding these eggs will cool down from 25 °C to approximately egg temperature.
This is indicated by the vertical coloured lines. As we move down these lines, they
cross through several curved relative humidity lines. In other words, the relative
humidity of the air directly surrounding the eggs is increasing. Once the relative
humidity of the air directly surrounding the eggs reaches 100 %, the air can no longer
hold the water in vapour form (the air becomes saturated because a relative humidity
higher than 100 % does not exist) and the excess moisture will condense onto the
egg shell.
From the Mollier diagram below, considering a setter room with a temperature of 25
°C, it is possible to state that:
- With a humidity of 50 % in the setter room, sweating will occur if eggs are lower
in temperature than 14 °C (indicated by green square and horizontal green line
intersecting the 100%RH curved line).
in temperature than 17 °C (indicated by blue square and horizontal blue line).
in temperature than 19 °C (indicated by red square and horizontal red line).
Practically this means that there is a higher risk for sweating if relative humidity in the
setter room is high. This could be the case immediately after cleaning the setter
room, but also in hot and humid countries. In those situations eggs should be
gradually warmed up prior to bringing them into the setter room. Alternatively
attempts could be made to lower the relative humidity in the setter room.
For every situation, the Mollier diagram can be used to determine if there is a risk for
sweating and what can be done to prevent it happening.

12.1.3 ‘Sweating’ of eggs explained by a psychrometric
chart (°F)
A psychometric chart contains the same information as the Mollier diagram; however
the lines run a bit different.
To predict if sweating will occur, it is necessary to know only the meaning the
following 2 lines of the diagram:
1. The vertical lines, which represent the temperature of the air; the values are
indicated in degrees Fahrenheit on the horizontal axis.
2. The curved lines in the diagram represent the relative humidity of the air; the
values are indicated as %RH on the curved lines themselves.
In the example below, it is assumed that the temperature in the setter room is 77 °F.
The coloured circles in the diagram represent three possible levels of relative
humidity in the setter room: 50 % (green circle), 60 % (blue circle) and 70 % (red
circle).
If eggs are brought into this setter room from the egg store the air directly
surrounding these eggs will cool down from 77 °F to approximately egg temperature.
This is indicated by the horizontal coloured lines. As we move these lines towards the
left, they cross through several curved relative humidity lines. In other words, the
relative humidity of the air directly surrounding the eggs is increasing. Once the
relative humidity of the air directly surrounding the eggs reaches 100 %, the air can
no longer hold the water in vapour form (the air becomes saturated because a
relative humidity higher than 100 % does not exist) and the excess moisture will
condense onto the egg shell.
From the psychrometric chart below, considering a setter room with a temperature of
77 °F, it is possible to state that:
in temperature than approx. 57 °F (indicated by green square and vertical green
line intersecting the 100%RH curved line).
in temperature than approx. 62 °F (indicated by blue square and vertical blue
line).
in temperature than approx. 66.5 °F (indicated by red square and vertical red
line).

12.2 Hatching at high altitudes
The effects of high altitude on hatchability and chick quality depends largely on the
altitude at which the hatching eggs are produced - and how the hatchery manager
adjusts the incubation programme.
Barometric pressure declines with altitude, as does the partial pressure of oxygen and
absolute humidity. Because at lower density molecules can move more freely the
overall diffusion through the pores of the egg shell of oxygen, carbon dioxide and
water is increased. Moreover, at altitude fresh ventilating air will tend to be colder
and drier than at sea level.
12.2.1 Oxygen availability

The oxygen content of air is always 21%, but the reduced partial pressure at altitude
provides less oxygen from a given volume of air. The resulting reduced oxygen
supply to the embryo is only partially compensated by the increased rate of diffusion
of oxygen through the egg shell and by the embryo’s higher capacity for binding
oxygen to the blood haemoglobin. At altitudes above 2000 meters, it can help to
inject oxygen into the setter and the hatcher, to raise the oxygen level from 21% to
23 - 25%. The main drawbacks of using oxygen are cost and safety. Its use may,
therefore, be limited to hatching parent stock.
12.2.2 Water loss

It is reasonable to assume that the increased rate of diffusion in combination with the
drier air at altitude will result in increased moisture loss from the eggs. However,
there is evidence that breeder flocks may adapt to altitude by producing eggs with a
lower effective pore area similar to the adaptation of wild birds to altitude. This
compensates for increased diffusion and therefore water vapour loss through the egg
shell at any altitude may remain the same as at sea level. When choosing the relative
humidity set point for incubation this potential adaptation of shell conductance to
altitude should be taken into consideration. Confirmation if the optimal relative
humidity set point has been chosen can only be obtained by checking that the actual
egg weight loss is correct.
12.2.3 Three ‘altitude’ scenarios
1 Eggs produced at sea level: hatchery at altitude (1000 - 2000

meters)
Of the three scenarios, this is the least desirable because it will definitely result in
reduced hatchability. Eggs produced at sea level have a relatively large effective pore
area and setters and hatchers should be operated at a higher relative humidity to
avoid excessive weight loss. However, this poses difficulties as air at altitude is drier
and at the same time requires the addition of more water compared to sea level to
reach the required relative humidity. Also the need for increased ventilation rate to
accommodate for the reduced oxygen level makes it an even bigger challenge to
control relative humidity. Pre-conditioning the inlet air to a relative humidity of 75%,
with a temperature of 24 - 28 °C (optimum) will assist the incubators in achieving its
required relative humidity set point.
For this situation an incubation program is suggested below.
2 Eggs produced at same altitude as hatchery (1000 - 2000

meters)
In general this will give good results. Relative humidity set points could probably be
kept similar to sea level, because the increased rate of diffusion may be compensated
by the lower effective pore area of the egg shell. Ventilation rates should be higher
than normal for sea level, such that the embryo is provided with sufficient oxygen.
During humid external conditions, increase ventilation, as humidity reduces oxygen

levels in the air still further. This higher ventilation rate may cause reduced humidity
in the setters and hatchers and thus constantly activated humidifiers. Especially
during the last days in the setter it is therefore beneficial to reduce relative humidity
set point even further and to even accept the resulting higher than optimal weight
loss (eg. 13 – 14 %).
3 Eggs produced at altitude: hatchery at sea level
Generally, this will give good results. The set points for relative humidity may need to
be reduced to achieve optimum weight loss as the eggs will probably have a reduced
effective pore area compared to eggs laid at sea level.
12.2.4 Advice
- Fine-tune relative humidity set points by weighing trays of eggs before setting
and again at transfer at 18 - 18.5 days. Exact set points for relative humidity are
dependent on altitude of hatchery and egg shell conductivity (age flock,
nutrition, genetics, altitude of breeder flock). Optimum weight loss for good
hatchability and chick quality is indicated in Analysis of egg weight loss (page 93).
- Judge the size of the air cell as an indicator of weight loss.
- Be aware of signs that indicate insufficient weight loss and/or a shortage of
oxygen during an egg break-out. These signs are: too many wet, fully developed
embryos that fail to pip. If this is observed, reduce set points for relative humidity
and/or increase ventilation rate.
- Ensure that humidity and CO2 sensors are calibrated for altitude or alternatively
find the correct set point to be used (see table under additional notes).

General guideline SmartSetPro™ with AMF™ and/or ESM™ Broiler;
hatchery altitude > 1500 m (eggs produced at sea level)
Moment of Incubation Relative Ventilation (4) Frequency Turning
set point temperature humidity (3) (6)
change (2)
(day.hour) °F % % valve % CO2 AMF (5) % Set point
(positions)
- 0.05/ 0.08 77.0 – 81.0 70 0 - 20 0.30 Off 100 horizontal = 0
0.00 100.4 70 0 0.30 Off 100 2
1.00 100.2 70 0 0.30 Off 100 2
2.00 100.0 70 0 0.30 Off 100 2
3.00 99.9 70 0 0.30 On 75 2
4.00 99.9 65 10 0.30 On 75 2
5.00 99.9 65 10 0.30 On 75 2
6.00 99.9 65 10 0.30 On 75 2
7.00 99.8 65 10 0.30 On 75 2
8.00 99.8 60 20 0.30 On 75 2
9.00 99.5 - 99.7 60 20 0.30 On 75 – 100 2
10.00 99.2 - 99.5 55 30 0.30 On 75 – 100 2
11.00 99.0 - 99.2 55 40 0.30 On 75 – 100 2
12.00 98.6 - 98.8 55 50 0.30 On 75 - 100 2
13.00 98.2 - 98.5 40 60 0.30 On 100 2
14.00 97.7 - 98.3 40 70 0.30 On 100 2
15.00 97.5 - 98.0 40 80 0.30 On 100 2
16.00 97.4 - 98.0 40 80 0.30 On 100 2
17.00 97.2 - 98.0 40 90 0.30 On 100 2
18.00 97.2 - 98.0 40 90 0.30 On 100 2
1) The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs. The guidelines in
the table apply to hatcheries at an altitude of approx. 1500 – 2000 m.
2) The main parameter for the temperature set point is the eggshell temperature measured with the Braun ThermoScan. See
Analysis of eggshell temperature (page 89).
3)The main parameter for relative humidity set point is egg weight loss at the day of transfer. See Analysis of egg weight loss
(page 93).
4) If AMF™ is activated, the ventilation (valve position) is controlled such that both relative humidity and the CO2-setpoint do
not exceed their set point. If AMF™ is not activated the valve positions are determined by the programmed valve set points.
5) To ensure valve does not open during the first days of incubation period AMF™ is switched "off" in the incubation program.
Manual switching "off" and "on" of AMF™ is also possible in the "service settings menu" on the setter itself.
6) The frequency or the rotations per minute of the Vortex™ can be reduced as indicated without affecting hatchability and
chick quality at the same time saving considerably on the energy consumption.
The set points in the table should be used as guidelines only. Based on the extra
information in the footnotes 1-6, set points might need to be adjusted.

The CO2 set point should be adjusted for altitude, because the CO2-sensor is
calibrated for sea level. The set points in the table below are corrected for the
different altitudes and are similar to the recommended set points for hatcheries at
sea level. If a higher ventilation rate at altitude is required to accommodate for the
reduced oxygen level from 1000 m onwards the CO2-set points in the table could be
reduced by 0.05 – 0.1 %.
CO2 set point adjusted for altitude

Altitude Setter Hatcher
(m above sea level)
0 – 500 0.40 0.50
500 – 750 0.40 0.45
750 – 1000 0.35 0.40
1000 – 1500 0.35 0.40
1500 – 2000 0.30 0.40
2000 0.30 0.35

12.3 Adaptive Metabolic Feedback (AMF™)
AMF™ has been developed to ensure that the incubation environment meets the
metabolic needs of the growing embryo. AMF™ controls the ventilation (=valve
position) such that both relative humidity (RH) and carbon dioxide (CO2) do not
exceed their set points. Ventilation and (as a consequence) humidifying is kept at a
minimum contributing to an even more uniform temperature distribution.
Typically during the first part of incubation, AMF™ uses the measured RH as the
leading parameter for the valve position. The higher the RH set point, the lower the
valve position and vice versa. Only when the measured valve position is 0 % may the
humidifiers be activated in order to maintain RH at its set point. To ensure the valve
remains closed during, for example the first 3 days of incubation, AMF™ can be
switched "off" in the incubation program; together with a programmed valve set
point of 0 % the valve will then be closed.
When embryonic metabolism increases, typically during the second half of

incubation, there is a seamless transfer to CO2 as the leading parameter for the valve
position. Generally this means that the valve will open progressively. To keep RH at its
set point additional humidification will be needed.
A relative humidity below the set point will be corrected by activation of the
humidifiers and a CO2 level below set point is disregarded by design as it has no
negative effect on the embryo.
When AMF™ is activated:

- manual adjustment of the valve set point is not possible anymore;
- the valve set points as defined in the SmartCenter™ incubation programs are
overruled.
AMF™ is active only during incubation and is inactive:

- during timer mode with negative incubation time;
- during pre-heating mode;
- when the AMF™ set point in the incubation program is "off";
- when AMF™ is switched "off" in the "service settings menu" on the setter itself.

12.3.1 Example of AMF™ in practice
In the climate history graph of a SmartSetPro™ with 6 sections which is shown below,
the following 3 periods can be recognized:
1. First 3 days of incubation: The ventilation valves are closed during this period,
because the AMF™ set point in the incubation program is "off". The valve set
point of 0 % in the incubation program is leading. Relative humidity is above its
set point of 60 % thus humidifiers are not activated.
2. Day 3 to day 11 - 12 of incubation: During this period the valve position is
fluctuating between 10 and 20 %. The measured relative humidity is the leading
parameter for AMF™ and valve position is continuously controlled such that
relative humidity does not exceed its set point. During this period the
humidifiers are not activated. Meanwhile the CO2 level is gradually increasing
towards the set point of 0.4 % as a result of the increasing embryonic
metabolism.
Fluctuations of valve position during this period are normal and can be explained by
a variation of relative humidity of the inlet air, for example a day-night rhythm or a
sudden increase due to wet-cleaning of the setter room.
3. From day 11 - 12 of incubation onwards: The CO2 level has reached its set point
of 0.4 % by day 11 – 12 of incubation and CO2 becomes the leading parameter
for the valve position. The valve opens now progressively such that CO2 does not
exceed its set point. Most likely with these increased valve openings the
humidifiers are activated in order to keep the relative humidity as its set point.
The recommended CO2 set point for hatcheries at an altitude up to 1200 m is 0.4 %.
However, it is also possible to reduce the set point for example to 0.3 %. The effect is
that CO2 level will reach its set point earlier and thus valves will start to open
progressively earlier. Also at a lower CO2 set point the ventilation valves will open
further during this period.

Single-stage incubation program activated on machine S34 (see climate history graph
above);
only the setpoints that are relevant for AMF™ are indicated
Moment of set Incubation Relative Ventilation Frequency Turning
point change temperature humidity
(day.hour) °F % (%) Set point
% valve % CO2 AMF
(positions)
- 0.05/ 0.08 60 0 0.40 Off
0.00 60 0 0.40 Off
1.00 60 0 0.40 Off
2.00 60 0 0.40 Off
3.00 55 10 0.40 On
4.00 55 10 0.40 On
5.00 55 10 0.40 On
6.00 55 20 0.40 On
7.00 55 30 0.40 On
8.00 50 40 0.40 On
9.00 50 40 0.40 On
10.00 50 40 0.40 On
11.00 50 50 0.40 On
12.00 50 50 0.40 On
13.00 45 50 0.40 On
14.00 45 60 0.40 On
15.00 45 60 0.40 On
16.00 45 60 0.40 On
17.00 45 70 0.40 On
18.00 45 70 0.40 On

12.4 Energy Saving Module (ESM™)
ESM™ allows a reduction in the energy consumption of the setters when there is no
need for maximum air flow over the eggs.
The module reduces the energy consumption by means of an AC variable Frequency

Drive. The frequency set points of these drives are defined in the SmartCenter™
incubation program and in the set point menu of the SmartDrive/SmartTouch
To ensure maximum air flow the set point of the frequency ("freq" column) is set at 95
% (SmartSet™) or 100% (SmartSetPro™). Maximum air flow is necessary during
preheating, the first and last days in the setter. During the intervening days less heat
needs to be transferred allowing a lower frequency set point.
At a lower frequency set point:

- the air flow over the eggs is reduced;
- at similar valve positions, less fresh air enters the setter.
12.4.1 Example of ESM™ in practice

In the climate history graph of a SmartSetPro™ with 6 sections shown below, the
following 3 periods can be recognized:
1. Incubation time 0.00 to 3.00 days: The frequency set point is 100 %.
2. Incubation time 3.00 to 13.00 days: The frequency set point is reduced to 75 %.
The main purpose is energy saving.
3. Incubation time 13.00 onwards: The frequency set point is returned to 100 %
again. At a higher frequency more air enters the setter if valve position remains
unchanged.
In this example the setter is equipped with Adaptive Metabolic Feedback (AMF™). At
the same moment the frequency is returned to 100 % there is an approx. 10 %
reduction in valve position. AMF™reduces valve position to a level that ensures CO2
does not exceed its set point.
The frequency set points in the above example are as in Pas Reform’s general
guideline for hatcheries at an altitude up to 1200 meter. Further reductions might be
possible (e.g. day 1.00 till 3.00 at 75%); day 3.00 till 12.00 at 65%; day 12.00 till 14.00
at 75%), but the effect on hatchability and chick quality should be closely monitored.

12.5 Circadian Incubation™
12.5.1 Summary
Circadian Incubation™ is a new feature of single stage incubation.
Circadian Incubation™ means applying short, daily stimuli of high or low temperature
to the embryos during specific phases of embryonic development. It aims to produce
long-lasting effects by training the embryo’s thermoregulatory system, leading to the
production of more robust day-old-chicks with better performance due to their lower
metabolic needs.
Results seemed to be interfered by breeder flock management and thus hatching

egg quality. For this reason the hatchery manager needs to develop a flock specific
circadian single stage incubation program.
The procedure for Circadian Incubation™ is largely the same as for Single-stage
incubation (page 37). It only requires a modification to the incubation program (as
shown in the example below) and setters (and hatchers) which are able to cool down
all eggs fast and uniformly at the end of each temperature stimulus.
Some important points to consider:

- It is recommended to only apply Circadian Incubation™ if good/excellent
hatching results are normally achieved with straight-forward single-stage
incubation.
- Evaluate the results of Circadian Incubation™ in the hatchery and on the farm for
each batch of eggs separately.
- Find the optimum timing and length of temperature stimulation by undertaking
trials on different batches of eggs of differing quality.
12.5.2 Further details

Today the design and application of a single stage incubation program is based on
the idea that the embryo should develop under constant environmental conditions
without any fluctuation in either climate parameter. However from scientific research
it becomes clear that fluctuations in incubation temperature (also called thermal-
conditioning) induces long-term embryonic adaptations with positive effects on
post-hatch thermoregulation and performance. At thermal-conditioning the embryo
receives hot or cold stimuli at specific time-points during embryonic development.
Thermal conditioning in the practice of a commercial hatchery is defined as ‘Circadian

Incubation™’. The final result of Circadian Incubation™ depends on the time window
of thermal stimulation since each stage of embryonic development will respond
specifically for that stage (Tzschentke, 2008). For example, the number of muscle cells
is increased in turkey embryos thermal conditioned during the early phases (days 5-8)
of muscle cell differentiation (Maltby et al, 2004). In broilers the metabolic rate of
embryos and chicks was lowered after thermal conditioning (12 h/day at 39.5 °C/
103.1 °F) of embryos 14-18 days of age in the time period when the physiological
controller for metabolism (= hypothalamus-hypophyse-thyroid axis) develops and
matures (Piestun et al., 2009, 2013). Thermal conditioning during the maturation
phase (from day 16) of embryonic development induces in the brain of chicks a shift
of neurons involved in thermoregulation and metabolism (Tzschentke, 2007).
In recent years more and more research groups have shown that thermal stimulation
or Circadian Incubation™ improves hatchability and feed conversion rates. Circadian
Incubation™ in practice of the hatchery means that the embryos receive daily short
periods of heat or cold stimuli of 1 to 2 °C (1.8 to 3.6 °F) during the second or third
week of incubation. Circadian Incubation™ provides the hatchery manager with an
extra tool to produce high numbers of robust day old chicks which can cope with
different environmental conditions and fully benefit from their genetic potential.
Circadian Incubation™ has been applied at the commercial scale in several broiler
hatcheries in Europe and Brazil. In all these commercial hatcheries the setters and
hatchers were equipped with accurate climate controllers and sufficient cooling

capacity. Short term thermal-conditioning improved hatching results in most
incubation trials with 1-2%, increased final body weight and feed conversion rates
improved 1 to 2 points. Results were predictable and good in most cases, although
hatchery managers need to fine tune incubation programs with respect to timing and
intensity of thermal conditioning. In addition results seemed to be interfered by
breeder flock management and thus hatching egg quality. For this reason the
hatchery manager needs to develop a flock specific circadian single stage incubation
program. An example of an incubation program for Circadian Incubation™ is given
below.
12.5.3 Advice
- Optimize hatchery results using Circadian Incubation™ if single stage stage
incubation practice is routine in your hatchery.
- Ensure accurate climate control in setters (and hatchers), to promote optimised
temperature uniformity and sufficient cooling capacity so that the incubation
temperature can be reduced quickly and uniformly at the end of each
temperature stimulus.
- Evaluate the results of Circadian Incubation™ in the hatchery and on the farm for
each batch of eggs separately.
- Find the optimum timing and length of temperature stimulation by undertaking
trials on different batches of eggs of differing quality. See an example of an
incubation program for Circadian Incubation™ below.
- Evaluate hatchability, chick quality and farm results after each trial of Circadian
Incubation™.
- Contact Pas Reform Academy if you consider to undertake trials with Circadian
Incubation in your hatchery for latest results and support.
Example of Circadian Incubation program

Moment of Incubation Relative Ventilation Frequency Turning
set point temperature humidity
change
(day.hour) °F % % valve % CO2 AMF % Set point
(positions)
< 16.00 Single-stage incubation program

16.00 98.0 45 60 0.40 On 100 2
16.12 100.0 45 60 0.40 On 100 2
16.14* 98.0 45 100 0.40 Off 100 2
16.15 98.0 45 60 0.40 On 100 2
17.12 100.0 45 70 0.40 On 100 2
17.13* 98.0 45 100 0.40 Off 100 2
17.14 98.0 45 70 0.40 On 100 2
18.12 100.0 45 70 0.40 On 100 2
18.13* 98.0 45 100 0.40 Off 100 2
18.14 98.0 45 70 0.40 On 100 2
> 18.15 Transfer eggs to hatcher only after they have cooled down to normal level and no later than 19.00
*Directly at end of temperature stimulus, the valves are fully opened for 1 hour to facilitate fast and uniform egg cooling.

13 Glossary
Batch of eggs: a clearly-defined group of eggs from one breeder flock and preferably
one production house and produced on the same day (or more practically with no
more than 3 -5 days difference in production date.
Batch of chicks: a clearly-defined group of chicks originating from a specific batch of

eggs and set and incubated together.
Braun ThermoScan: thermometer based on infrared radiation and specifically

designed and calibrated to measure human body temperatures of 37 - 40°C (accuracy
0.1°C).
Chick dispatch room: room used to bring together chicks in boxes that are destined
for one chick farm. From this room the chick boxes are loaded into trucks.
Candling/candle: the selection and removal of infertile eggs and eggs containing
dead embryos by exposing trays of eggs to candling light.
Clear eggs: eggs which are transparent to candling light. Clear eggs are infertile or
contain embryos which died early in incubation.
Crystalline paraformaldehyde: a disinfecting powder that evaporates when it is

heated electrically.
Draughts: a flow of air of lower temperature into a room of higher temperature;

often a draught is experienced as unpleasant and creates discomfort.
Egg container: trolley for transporting stacked paper or plastic trays with eggs.
Egg disinfection room: a room specially designed for disinfecting eggs. Located at
breeder farm, at entrance for eggs to the hatchery or between egg handling room
and setter room.
Egg ID code: each batch of eggs should be given a label with a batch-specific
identification (ID) code, e.g. a combination of a farm and house number and egg
production date.
Eggshell temperature: temperature of the surface of the egg, which is used as a

reference for embryo temperature. The eggshell temperature is measured by placing
the probeof a Braun ThermoScan halfway down the side of the egg in order to avoid
the air cell.
Eggshell temperature on a specific day of incubation: the average eggshell

temperature of a minimum of 27 eggs per setter (3 setter trays; 9 eggs/setter tray)
containing living embryos.
Egg storage room: area in breeder farm and in the hatchery with equipment to
maintain a stable temperature and relative humidity for the storage of hatching eggs
under optimal conditions.
Egg tray: 30-egg capacity stackable paper or plastic tray designed for holding eggs
with sharp end down.
Egg traying room: area for traying eggs. The egg traying room might be the same
area as the egg receiving room.
Electric pan: an electric pan connected to a programming unit used for the
evaporation of crystalline formaldehyde.
Embryonic age: age of the embryo expressed as the time the egg has spent in the
incubator.
Exploder: gas producing bacteria inside the egg can cause the egg to explode
spontaneously of when triggered by for example egg transfer.
External pipping: when the chick’s beak has cracked the eggshell we say the chick
has pipped externally.
Farm trolley: trolley for transporting setter trays with eggs from farm to hatchery.
Broilers - Incubation Guide - V 6.0 Glossary 151

Floor eggs: eggs laid outside the nest. Floor eggs are heavily contaminated with
micro-organisms and should never be sent to the hatchery. But, if floor eggs are sent
to the hatchery, they should be treated and incubated separately.
Hairline cracks: eggs with fine cracks in the shell that may only be detectable by
candling.
Hatcher: incubator cabinet designed to incubate hatching eggs at the appropriate

temperature, humidity and air composition during the last three days of embryonic
development, hatching and drying of chicks. A hatcher is loaded with eggs from the
same section in the setter.
Hatcher basket: carrier for hatching eggs during the last three days of embryonic
development and during hatching.
Hatcher dolley: cart designed to stack hatcher baskets onto to be placed in a

hatcher.
Hatching eggs: eggs from breeder farms with clean, smooth and intact shells and
with oval shape and within required size range.
Incubation program: the incubation program defines per day the incubator set
points for temperature, humidity, valve or carbon dioxide, turning and the frequency
of pulsator or Vortex™.
Infertile eggs: eggs that were never fertilised by sperm. The unfertilised oocyte can
be recognised as a white dot in the centre of the yolk.
Internal pipping: when the chick’s beak has penetrated the inner shell membrane
and thus reached the air cell we say the chick has pipped internally; from this
moment onwards the chicks inside the eggs can make sound and can be heard.
Meconium: The first manure of greenish colour produced by the hatched chicks and
visible on empty egg shells and chick paper/
Misshapen eggs: eggs with shells that have ridges, spiral grooves or a flat wrinkled
side.
Multi-stage incubation: an incubator containing eggs with embryos of different

ages.
Non-hatching eggs: these include floor eggs and poor-quality eggs (dirty eggs,
hairline and cracked eggs, misshapen eggs, eggs with poor shell quality and eggs out
of the required size range).
Oviposition: the actual laying of the egg.
Pasgar©Score: an objective method for evaluating the quality of day-old chicks.
Pre-heating: heating of eggs in an operational setter to a uniform temperature of 77

– 81 °F prior to the onset of incubation.
Pre-storage incubation: incubating hatching eggs for some hours before further
storage at the hatchery aiming at bringing the embryo to a storage-resistant stage of
development.
Pre-warming: the gradual warming-up of eggs by placing filled setter trays in a room
with a higher temperature.
Random sample/random selection: setter trays, hatcher baskets, eggs or chicks

should be collected without any preference of the person taking the sample.
Rectal temperature: Body temperature of the day-old-chick taken by inserting a

digital medical thermometer inside the cloaca.
Representative sample: the number of setter trays, hatcher baskets, eggs or chicks
should be large enough to avoid incorrect conclusion due to individual variation.
Second-class chicks: chicks of suboptimal quality which are not suitable for selling.
Setter: incubator cabinet designed to incubate hatching eggs at the appropriate

temperature, humidity and air composition during the first days of embryonic
development.
152 Broilers - Incubation Guide - V 6.0 Glossary

Setter tray: carrier for hatching eggs to be placed in a setter.
Setter trolley: cart designed to hold setter trays in a setter. The trolley is equipped
with a turning device.
Single-stage incubation: an incubator which is filled with eggs on one day. The
incubator is emptied completely at transfer.
Stacker and destacker: equipment that takes hatcher baskets or (empty) chick boxes
from stacks automatically.
Sweating: the condensation of water droplets on the egg surface when cold eggs are
moved into a warm, humid environment.
Truck: a conditioned truck, at least for temperature, designed for hatching egg or
chick transport. In case of chick transport fresh air supply should be controlled based
on CO2-concentration.
Unhatched eggs: eggs which remain in the hatcher basket after hatched chicks are
removed.
Vacuum egg lifter: manual or automatic equipment for transferring eggs from paper
or plastic trays to setter trays.
Vent temperature: Body temperature of the day-old-chick taken by placing the

probe of a Braun Thermoscan on the bare skin of the cloaca.
Weight loss: average loss of weight of eggs from start of incubation expressed as a
percentage of initial egg weight.
Broilers - Incubation Guide - V 6.0 Glossary 153

154 Broilers - Incubation Guide - V 6.0 Glossary
14 Recording Forms
In this chapter
Recording Form 3A: Egg transport card 156

Recording Form 3B: Egg receipt form 157
Recording Form 3C: Hatching egg stock list 158
Recording Form 3D: Setter trolley card 159
Recording Form 3E: Setter schedule 160
Recording Form 3F: Egg storage room: climate conditions 161
Recording form 3G: Egg disinfection room 162
Recording Form 4A: Incubator recording form 163
Recording Form 7B: Chick passport 164
Recording Form 8A: External hatching egg quality upon receipt
165
Recording Form 8B: Internal hatching egg quality upon receipt
166
Recording Form 8C: Fertility and embryo quality upon receipt 167
Recording Form 8D: Eggshell temperature 168
Recording Form 8E: Egg weight loss 169
Recording Form 8F: Analysis of clear eggs 170
Recording Form 8G: Analysis of unhatched eggs 171
Recording Form 8H: Pasgar©Score 172
Recording Form 9A: Hatching results 173
Recording Form 9B: Results egg analysis and Pasgar©Score 174
Recording Form 10A: Registration of visitors 175
Recording Form 10B: Cleaning schedule 176
Recording Form 10C: Hatchery microbiological monitoring 177
Recording Form 11A: Setter maintenance card 178
Recording Form 11B: Hatcher maintenance card 179
Recording Form 11C: Hatchery equipment maintenance card 180
Recording Form 11D: Checklist climate conditions in hatchery 181
Broilers - Incubation Guide - V 6.0 14 Recording Forms 155

Recording Form 3A: Egg transport card
Supplier
Name
Address
Postal code
Telephone
Egg ID-code
Breed
Maternal age
No. of hatching eggs normal size
No. of hatching eggs small
No. of washed eggs
No. of floor eggs
No. of other non-hatching eggs
Pas Reform Hatchery Technologies, P.O. Box 2, NL-7038 ZG Zeddam, The Netherlands
phone +31 314 659 111, fax +31 314 652 575, E-mail info@pasreform.com
156 Broilers - Incubation Guide - V 6.0 14 Recording Forms

Recording Form 3B: Egg receipt form
Date Number of receipt
Supplier Recipient
Name Name
Address Address
Postal code Postal code
Telephone Telephone
Flock data
Breed Laying % last week
Maternal age Diseases
Medication
Delivered
Egg ID-code Production Hatching eggs Non-hatching eggs
date Normal size Small Washed eggs Floor eggs Others
TOTAL DELIVERED
TOTAL RECEIVED
Climate storage room at breeder farm

Temperature Humidity %
Transport conditions
Departure time Arrival time
Truck temperature Truck temperature
Truck disinfectant
Signatures
Name supplier Name driver
Signature supplier Signature driver
Name recipient
Signature recipient

Recording Form 3C: Hatching egg stock list
Egg ID-code Production date Date of receipt Number of Number of eggs Stock Remarks
hatching eggs set

Recording Form 3D: Setter trolley card
Trolley number
Egg ID-code
Production date

Recording Form 3E: Setter schedule
Trolley. no. Trolley no. Trolley no. Trolley no.
Egg ID code Egg ID code Egg ID code Egg ID code
Prod. Date Prod. Date Prod. Date Prod. Date
Setting date Setting date Setting date Setting date
Hatcher no. Hatcher no. Hatcher no. Hatcher no.
Trolley no. Trolley no. Trolley no. Trolley no.

Recording Form 3F: Egg storage room: climate conditions
Recommended climate condition during egg storage
Storage duration Temperature Relative humidity (%) Egg orientation
(°C/ °F)
0-3 days 18-21 / 64.4–69.8 75 – 85 Blunt end up
4-7 days 15-17 / 59.0–62.6 75 – 85 Blunt end up
8-10 days 12-14 / 53.6-57.2 80 – 85 Blunt end up
More than 10 days 12-14 / 53.6-57.2 80 – 85 Small end up or alternatively
turning the eggs every 24
hours
Date Temperature Humidity Remarks Date Temperature Humidity Remarks

(°C/ °F) (%) (°C/ °F) (%)
Calibration date thermometer
Calibration date hygrometer

Recording form 3G: Egg disinfection room
Date Time No. of trolleys in Disinfectant Amount Remaining Remarks
disinfection room disinfectant

Recording Form 4A: Incubator recording form
Setter number Hatcher number
Setting date Hatching date
Starting time Starting time
Incubation program
Set points multi-stage incubation

Temperature RH% Ventilation
Check setter o V-belt and bearing Check hatcher o V-belt and bearing
o Heating o Heating
o Cooling o Cooling
o Humidifier o Humidifier
o Sensors o Sensors
o RPM’s o RPM’s
o Turning
Transfer date and time
Egg ID-code Production date Trolley numbers Number of eggs set (Estimated) Clears (Estimated) number
(%) of eggs after
(sample) candling
Total
Adjustments to set points setter and hatcher

Date Time Display time Adjustments to set points Reason
(day.hour)

Recording Form 7B: Chick passport
Setting date Setter number
Hatching date
Egg ID-code Number of chicks Quality of chicks Treatments Person carrying out the
(♂ male / ♀ female) treatments
Transport conditions
Departure time Arrival time
Truck temperature Truck temperature
Truck disinfectant
At the farm
Floor temperature Number of chicks
Litter quality Chick quality
Feed & water supply
Signatures
Name truck driver Name customer
Signature truck driver Signature customer

Recording Form 8A: External hatching egg quality upon
receipt
Egg ID-code Breed
Production date Maternal age
Date of receipt Date of quality control
Core temperature
(5 – 10 eggs)
Sample size
Category Number of eggs % of sample
Dirty
Misshaped
Upside down
Abnormal shell colour
Poor shell quality
Hairline cracks
Big cracks
Too small
Too big
Total

Recording Form 8B: Internal hatching egg quality upon
receipt
Egg ID-code Breed
Category Number of eggs within ...
Sample of 10 eggs Additional 20 eggs
Air cell depth > 2 mm
Albumen thin and watery
Yolk
- Flabby and flat
- Very pale colour
- Mottled
Blood- or meat spots
Total

Recording Form 8C: Fertility and embryo quality upon
receipt
Egg ID-code Breed
Category Number of eggs within ...
Sample of 10 eggs Additional 20 eggs
Infertile
Fertile, diameter approx. 3.5– 5 mm;

doughnut-like opaque ring with translucent centre
Fertile, embryo too small (≤ 3.5 mm);
white dots in centre of opaque ring
Fertile, embryo too big (> 5 mm)
Fertile, abnormal embryo
Total

Recording Form 8D: Eggshell temperature
Setter number
Start date of incubation cycle
Name of incubation program
Set point Display
Date of measuring Temperature
Incubation time Relative humidity
Ventilation
Trolley
Tray
Egg ID-code
Production date
Breed
Maternal age
Storage days
Egg no. 1
Egg no. 2
Egg no. 3
Egg no. 4
Egg no. 5
Egg no. 6
Egg no. 7
Egg no. 8
Egg no. 9
Egg no. 10
Egg no. 11
Egg no. 12
Average
Average of all

Recording Form 8E: Egg weight loss
Setter number
Name of incubation program
Trolley
Tray
Egg ID-code
Production date
Breed
Maternal age
Storage days
Incubation time: 0 days 0 0 0 0 0 0
Weight empty tray = WT
Weight tray + eggs
Weight eggs only = W0
Incubation time: A days A= A= A= A= A= A=
Weight tray + eggs
Weight eggs only = WA
Weight loss =
((W0 - WA )/ W0 )x 100%
Incubation time: B days B= B= B= B= B= B=
Weight tray + eggs
Weight eggs only = WB
Weight loss =
((W0 – WB )/ W0 )x 100%
14
10% weight
12 loss
weight loss
11% weight
10 loss
8 12% weight
loss
6 13% weight
loss
4
6 8 10 12 14 16 18
incubation time

Recording Form 8F: Analysis of clear eggs
Egg ID-code Breed

Setter number Storage days
Hatcher number
Trolley
Basket
Total unhatched eggs
Category Number of eggs Total % of

eggs on trays
No. Description
1 Gaseous eggs / rots
2 Cracks before/during setting
3 Cracks during transfer
4 Thin/porous egg shell

(dehydrated)
5 Not fertilised
(irregular white spot)
6 Died day 1 – 2
(membrane)
7 Died day 3 – 4
(blood ring)
8 Died day 5 – 7
(eye)
9 Died day 8 – 10 (egg tooth)
17 Abnormalities

Recording Form 8G: Analysis of unhatched eggs
Egg ID-code Breed

Hatcher number
Trolley
Basket
Total unhatched eggs
Category Number of eggs Total % of

eggs on trays
No. Description
1 Gaseous eggs / rots
2 Cracks before/during setting
3 Cracks during transfer
4 Thin/porous egg shell
(dehydrated)
5 Not fertilised
(irregular white spot)
6 Died day 1 – 2
(membrane)
7 Died day 3 – 4
(blood ring)
8 Died day 5 – 7
(eye)
9 Died day 8 – 10 (egg tooth)
10 Died day 11 – 14
(feathers, embryo
"floats/rests" on yolk)
11 Died day 15 – 17
(embryo turned to length axis of
egg)
12 Died after 17 days
(embryo dry; start yolk sac
absorption)
13 Internally pipped
14 Externally pipped
15 Dead chicks in tray
16 2nd class chicks
17 Abnormalities

Recording Form 8H: Pasgar©Score
Egg ID-code Breed
Hatcher number
Trolley (optional)
Basket (optional)
Chick no. Reflex Navel Leg Beak Belly Pasgar©Score Chick no. Reflex Navel Leg Beak Belly Pasgar©Score
1 26
2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50
Subtotal Total
Average
Pasgar©Score

Recording Form 9A: Hatching results
cycle
incubation
Start date
code
Egg ID
date
Production
Breed
Maternal age Storage days % clears
eggs set
chicks of
% saleable
eggs
transferred
chicks of
% saleable
chicks
% 2nd class
mortality
1st week

Recording Form 9B: Results egg analysis and Pasgar©Score
n cycle
incubatio Egg ID
Start date
date code
Production
age Breed
Maternal Storage
1 days
egg analysis (7F and 7G)

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
core (7H)
Pasgar©S

Recording Form 10A: Registration of visitors
Hatchery name
"The undersigned persons agree to follow all hygiene instructions strictly as applying in this hatchery"
Date Name Company How many days ago in Purpose of visit
contact with live
poultry?

Recording Form 10B: Cleaning schedule
Room/equipment
Instructions
Detergent
Disinfectant
Frequency
Date Name Signature Date Name Signature

Recording Form 10C: Hatchery microbiological monitoring
No. of sample Room Description of objects Number of colonies Score

Recording Form 11A: Setter maintenance card
Setter number
Date P/C* Description Action Signature
* P = preventive maintenance; C = corrective maintenance

Recording Form 11B: Hatcher maintenance card
Hatcher number

Recording Form 11C: Hatchery equipment maintenance card
Name hatchery equipment

Recording Form 11D: Checklist climate conditions in
hatchery
Date
Room Temperature Relative humidity CO2

(°C / °F) (%) (% / ppm)
set point actual set point actual actual
Egg handling
Egg store:
Store 1: 1-3 days
Store 2: 4-7 days
Store 3: over 7 days
Air inlet setter
Transfer
Air inlet hatcher
Chick handling
Chick dispatch
Pressure-controlled rooms Air pressure

(Pa / inch H2O)
set point average
clean air plenum setter
dirty air plenum setter
clean air plenum hatcher
dirty air plenum hatcher
air preparation room
Calibration date thermometer
Calibration date hygrometer
Calibration date CO2 -meter
Calibration date pressure sensors


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3 Egg handling 17 8 Tools for fine-tuning 83

3.1 Introduction 18 8.1 Introduction 84

5.4 In-ovo vaccination 56 10.1 Introduction 112

Broilers - Incubation Guide - V 6.0 Contents 3

4 Broilers - Incubation Guide - V 6.0 Contents

Copyright and disclaimer notice 6

Broilers - Incubation Guide - V 6.0 1 About this manual 5

No part of this publication may be reproduced, stored in a database, or published in

This manual is the original English version.

6 Broilers - Incubation Guide - V 6.0 1 About this manual

In addition to these procedures, a number of general recommendations for hatchery

Broilers - Incubation Guide - V 6.0 1 About this manual 7

Pas Reform Hatchery Technologies

Address: P.O. Box 2

Phone: +31 314 659 111

Fax: +31 314 652 575

8 Broilers - Incubation Guide - V 6.0 1 About this manual

Broilers - Incubation Guide - V 6.0 1 About this manual 9

Outline of the Incubation Guide 12

Broilers - Incubation Guide - V 6.0 2 Introduction 11

Five basic steps in hatchery routing

The procedures are all structured as follows:

12 Broilers - Incubation Guide - V 6.0 2 Introduction

Broilers - Incubation Guide - V 6.0 2 Introduction 13

Golden rules for a hatchery

14 Broilers - Incubation Guide - V 6.0 2 Introduction

Broilers - Incubation Guide - V 6.0 2 Introduction 15

Broilers - Incubation Guide - V 6.0 3 Egg handling 17

Egg handling at the breeder farm

Egg transport to the hatchery

During transportation from farm to hatchery, mechanical and temperature shocks

Setting eggs in setter trays and trolleys

18 Broilers - Incubation Guide - V 6.0 3 Egg handling

Storage of hatching eggs

Disinfecting hatching eggs

Broilers - Incubation Guide - V 6.0 3 Egg handling 19

3.2.2 Persons responsible

Recording Form 3B: Egg receipt form (page 157)

3.2.5 Recommended procedure

20 Broilers - Incubation Guide - V 6.0 3 Egg handling

Recommended climate conditions during egg storage

A good quality hatching egg

3.2.6 Additional notes

Broilers - Incubation Guide - V 6.0 3 Egg handling 21

22 Broilers - Incubation Guide - V 6.0 3 Egg handling

Broilers - Incubation Guide - V 6.0 3 Egg handling 23

3.3.2 Persons responsible

3.3.5 Recommended procedure

24 Broilers - Incubation Guide - V 6.0 3 Egg handling

Hatching eggs; a precious cargo …

Broilers - Incubation Guide - V 6.0 3 Egg handling 25

3.4.2 Persons responsible

Recording Form 3B: Egg receipt form (page 157)

Recording Form 3C: Hatching egg stock list (page 158)

3.4.5 Recommended procedure

3.4.6 Additional notes

26 Broilers - Incubation Guide - V 6.0 3 Egg handling

3.5.2 Persons responsible

3.5.5 Recommended procedure

3.5.6 Additional notes

Broilers - Incubation Guide - V 6.0 3 Egg handling 27

3.6.2 Persons responsible