2010-01-12 Incubation Guide Broiler V1

Incubation Guide
Broiler
Practical guidelines
Version 4.0
Publication date: 12-1-2010
Contents
Practical guidelines............................................................................................1
1. Introduction .........................................................................3
1.1 About this manual.....................................................................................4
1.2 Outline of the Incubation Guide ............................................................5
1.3 HACCP........................................................................................................7
2. Egg handling .......................................................................9

2.1 Introduction..............................................................................................10
2.2 Egg receipt...............................................................................................12
2.3 Storage of hatching eggs......................................................................14
2.4 Setting eggs in setter trays and trolleys ...............................................16
2.5 Disinfecting hatching eggs....................................................................18
3. Incubation of broiler eggs: day 1-18 ..............................21

3.1 Introduction..............................................................................................22
3.2 Single-stage incubation program ........................................................24
3.3 Multi-stage incubation settings.............................................................28
3.4 Analysis of eggshell temperature .........................................................32
3.5 Relative humidity and egg weight loss................................................34
4. Candling and transfer ......................................................37

4.1 Introduction..............................................................................................38
4.2 Candling and transfer ............................................................................39
4.3 Analysis of clear eggs.............................................................................41
5. Hatching of broiler eggs: day 19-21 ...............................43

5.1 Introduction..............................................................................................44
5.2 Incubation program hatcher ................................................................45
5.3 Formaldehyde treatment of chicks in hatcher ..................................48
5.4 Analysis of unhatched eggs..................................................................50
6. Chick handling .................................................................53

6.1 Introduction..............................................................................................54
6.2 Chick take-off ..........................................................................................55
6.3 Assessing chick quality: Pasgar©Score ................................................57
6.4 Chick despatch and transport .............................................................59
7. Hatchery management ...................................................61

7.1 Introduction..............................................................................................62
7.2 Continuous improvements ....................................................................64
7.3 Hatchery hygiene ...................................................................................71
7.4 Hatchery maintenance .........................................................................75
8. Appendices.......................................................................77
8.1 Introduction..............................................................................................78
8.2 Appendix 1...............................................................................................79
8.3 Appendix 2...............................................................................................81
8.4 Appendix 3...............................................................................................83
Incubation Guide - Broiler - Version: 4.0 i

8.5 Appendix 4...............................................................................................85
8.6 Appendix 5...............................................................................................87
9. Recording Forms ...............................................................89

Recording Form 1A: Golden rules for a hatchery ........................................90
Recording Form 2A: Egg receipt form ...........................................................91
Recording Form 2B: Egg container card.......................................................92
Recording Form 2C: Hatching egg quality upon receipt...........................93
Recording Form 2D: Hatching egg stock list.................................................94
Recording Form 2E: Setter schedule ..............................................................95
Recording Form 2F: Egg storage room: climate conditions .......................96
Recording Form 3A: Incubator recording form ............................................97
Recording Form 3B: Eggshell temperature....................................................98
Recording Form 3C: Egg weight loss..............................................................99
Recording Form 4A: Analysis of clear eggs.................................................100
Recording Form 5A: Analysis of unhatched eggs......................................101
Recording Form 6A: Pasgar©Score ..............................................................102
Recording Form 6B: Chick passport .............................................................103
Recording Form 7A: Hatching results ...........................................................104
Recording Form 7B: Results egg analysis and Pasgar©Score ..................105
Recording Form 7C: Cleaning schedule .....................................................106
Recording Form 7D: Registration of visitors .................................................107
Recording Form 7E: Checklist climate conditions in hatchery.................108
Recording Form 7F: Setter maintenance card...........................................109
Recording Form 7G: Hatcher maintenance card .....................................110
Recording Form 7H: Hatchery equipment maintenance card ...............111
Index ........................................................................................113
ii Incubation Guide - Broiler - Version: 4.0

1. Introduction
In This Chapter
About this manual .................................................4
Outline of the Incubation Guide ..............................5
HACCP .................................................................7
Incubation Guide - Broiler - Version: 4.0 3

1.1 About this manual
The Incubation Guide is a manual for use in daily hatchery
practice.
Every chapter in the Incubation Guide contains a practical
procedure needed for the successful incubation of broiler eggs,
from the arrival and quality control of the hatching eggs 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.
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: info@pasreform.com
Internet: www.pasreform.com
Please note that all figures in this manual are provided as
guidelines only. Pas Reform cannot be held liable for incorrect
interpretation of the contents of this manual.
Pas Reform reserves the right to make changes and
improvements without prior notice. 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.
© Copyright 2010 Pas Reform B.V., Zeddam,
The Netherlands.
All rights reserved.
Version 4.0
Pas Reform Academy
4 Incubation Guide - Broiler - Version: 4.0

1.2 Outline of the Incubation Guide
Routing
The routing 'from egg to chick' is essential in hatchery
management. Basically, hatchery routing can be divided into
five steps: egg handling, incubation, transfer, hatching and
chick handling.
Egg handling
- receipt and quality control
- storage
- setting in setter trays
- storage
Incubation of eggs: day 1-18

- single-stage/multi-stage
Egg transfer
Hatching of eggs: day 19-21
Chick handling
- take-off
- chick grading
- tansport

These five steps constitute the framework of this Incubation
Guide: each chapter describes one of the steps in hatchery
routing. The chapters all begin with a short introduction which
generally describes the procedures to be executed in that
routing step. The procedures are all structured as follows:
• Objective: the aim of the procedure

• Persons responsible: personnel that usually carry out the
tasks described
• Documents: documents related to the procedure, such as
other procedures and recording forms
• Definitions: descriptions for a number of specific terms used
in the procedure
• Recommended procedure: a step-by-step guideline on how
to carry out the tasks
• Additional notes: supplementary advice, precautions etc.
The final chapter (see "Hatchery management" page 61)
summarises general recommendations to optimise results and
ensure durable operation of your hatchery. These
recommendations should be interpreted as general guidelines
only.
Golden rules for a hatchery

The structure of Recording Form 1A: Golden rules for a hatchery
(page 90) corresponds with the steps in hatchery routing.
'Golden rules for a hatchery' forms the basis of good hatchery
management. Summarising some crucial key aspects that arise
in hatchery practice, this list provides a useful tool for hatchery
managers in daily hatchery routine.

1.3 HACCP
This Incubation Guide provides the hatchery manager with
guidelines to operate the hatchery to HACCP (Hazard Analysis
and Critical Control Point System) standards. HACCP is a
systematic approach to the identification, evaluation and control
of hazards in food production. The key element of the HACCP
system is its preventive nature, meaning that potential food
safety hazards are controlled throughout the process. The
advantage of using the HACCP system lies in the control it
provides over food safety in the processing plant at all times,
from receiving raw materials to shipping final product, or in
hatchery terminology from reception of hatching eggs until
delivery of chicks.
The hatchery, as a segment of the food production chain, aims
to produce a safe product which again forms the input for the
next segment of the food production chain: vital chicks that are
free of pathogens. The hatchery processes will be structured
around critical control points (CCPs). CCPs are designed to
control potential hazards that are biological, chemical or
physical in nature and that may pose a risk to food safety. For
the purpose of this Incubation Guide the scope of these CCPs is
widened to control the production process in the hatchery,
aiming for good results.
Seven HACCP principles

The HACCP approach is based on seven principles aimed at
identifying hazards in food production, controlling hazards at
critical control points in the process and verifying that the
system is working properly.
The seven basic HACCP principles are:

1 Identify the hazards and list preventive measures to control
them.
2 Determine the critical control points.
3 Establish limits at each critical control point.
4 Establish procedures to monitor the critical control points.
5 Establish corrective actions to be taken in case of a
deviation.
6 Establish procedures to verify that the systems are working
correctly.
7 Establish effective record-keeping.
This Incubation Guide supports the operation of a hatchery to
HACCP standards. The use of recording forms is especially
useful in the implementation of step 7.

2. Egg handling
In This Chapter
Introduction ....................................................... 10
Egg receipt......................................................... 12
Storage of hatching eggs ..................................... 14
Setting eggs in setter trays and trolleys ................. 16
Disinfecting hatching eggs.................................... 18

2.1 Introduction
Egg handling involves receipt, quality control and also usually
the storage of hatching eggs. Prior to incubation, eggs are set
on setter trays and disinfected.
Egg receipt
At the breeder farm, eggs can be stored in boxes, egg
containers or on setter trays placed in farm trolleys. During
transportation from farm to hatchery, temperature shocks
should be avoided since these affect potential hatchability. Truck
climate and hygiene have to be monitored to prevent a
deterioration of hatching egg quality before arrival at the
hatchery.
The procedure (see "Egg receipt" page 12) comprises a general
inspection of the quantity and quality of eggs supplied by the
breeder farm. Quality control involves the removal of eggs
unsuitable for hatching and usually takes place during or after
placing the eggs on setter trays.
Storage of hatching eggs

At the hatchery, eggs are set in setter trays before or after
storage. Usually, storage of the eggs prior to incubation is
unavoidable. The storage time and, above all, the temperature
and relative humidity at which the eggs are stored are very
important for the hatching result.
The procedure (see "Storage of hatching eggs" page 14)

outlines the optimum climatic conditions for storage.
Setting eggs in setter trays and trolleys

Batches of eggs leave the storage room only when they have to
be prepared for incubation. According to the setting schedule
which is composed by the hatchery manager, the eggs are
moved from the storage room to the egg traying room.
The procedure (see "Setting eggs in setter trays and trolleys"
page 16) describes the steps involved in preparing the hatching
eggs for incubation.

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 just prior to
incubation.
The procedure (see "Disinfecting hatching eggs" page 18)
outlines how to fumigate hatching eggs in a separate fumigation
room.

2.2 Egg receipt
Objective
To verify the numbers and inspect the quality of hatching eggs
supplied by the farmer.
Persons responsible
Hatchery manager and personnel assigned to receive, handle
and store eggs.
Documents
Recording Form 2A: Egg receipt form (page 91).
Recording Form 2B: Egg container card (page 92)
Recording Form 2C: Hatching egg quality upon receipt (page 93).
Recording Form 2D: Hatching egg stock list (page 94).
Recording Form 2E: Setter schedule (page 95).
Definitions
Egg container: trolley for transporting stacked pulp or plastic
trays with eggs.
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 number and egg production date.
Farm trolley: trolley for transporting setter trays with eggs from
farm to hatchery.
Floor eggs: eggs laid outside the nest. Floor eggs are heavily
contaminated with micro-organisms and should never reach the
hatchery at all. But if floor eggs are sent to the hatchery they
should be treated and incubated separately.
Hairline and cracked eggs: eggs with fine (hairline) cracks or
large cracks.
Hatching eggs: eggs from breeder farms with clean, smooth and
intact shells and with oval shape and within required size range.
Misshapen eggs: eggs with shells that have ridges, spiral
grooves or a sandpaper-like surface.
Setter tray: carrier for hatching eggs to be placed in an incubator.

Recommended procedure
1 On arrival at the hatchery, the egg containers or farm
trolleys are placed in the receipt room. Each batch of eggs is
accompanied by Recording Form 2A: Egg receipt form (page
91) 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 When the eggs are received, check the egg ID code and
number of eggs and compare this with information on
Recording Form 2A: Egg receipt form (page 91). Report
deviations to the farm manager.
3 Separate non-hatching eggs from hatching eggs. Non-
hatching eggs 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).
4 Supply each egg container or farm trolley containing
hatching eggs with Recording Form 2B: Egg container card
(page 92) on which production date and egg numbers are
listed.
5 Take a representative sample of each batch of hatching eggs
received and record a summary of the quality of each batch
of eggs on Recording Form 2C: Hatching egg quality upon
receipt (page 93).
6 Record the number of hatching eggs from each batch
received on Recording Form 2D: Hatching egg stock list (page
94). This list provides the hatchery manager with actual data
on the numbers and background of eggs in stock. The
hatchery manager uses this data to plan the setting of eggs
which is noted on Recording Form 2E: Setter schedule (page
95).
Additional notes
• In case floor eggs and/or washed eggs are to be incubated,
which is not recommended, keep these separated throughout
the entire incubation process.
• Non-hatching eggs can also be taken 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.

2.3 Storage of hatching eggs
Objective
To provide optimum conditions for eggs during storage so that
losses in potential hatchability and chick quality are minimised.
Persons responsible
Hatchery manager and personnel assigned to receive, handle
and store eggs.
Documents
Recording Form 2B: Egg container card (page 92)
Recording Form 2F: Egg storage room: climate conditions (page
96).
Definitions
Egg container: trolley for transporting stacked pulp or plastic
trays with eggs.
Egg storage room: area in hatchery located near the egg
receiving room. The egg storage room has equipment for
conditioning the climate for the optimal storage of hatching
eggs.
Farm trolley: trolley for transporting setter trays with eggs from
farm to hatchery.
Pre-warming: the gradual warming-up of eggs by placing filled
setter trays in a room with a higher temperature.
''Sweating': the condensation of water in droplets on the egg
surface when cold eggs are brought into a warm, humid room.
1 After registration on Recording Form 2D: Hatching egg stock
list (page 94) move the egg containers or farm trolleys with
attached to it the Recording Form 2B: Egg container card
(page 92) to the storage room and arrange them according
to the egg ID code.
2 Record the expected setting date of each batch of eggs on

3 The optimum climate settings in the storage room depend on
the number of days the eggs are to be stored (see table
below). Monitor the climate conditions daily and record them
on Recording Form 2F: Egg storage room: climate conditions
(page 96).
4 Check proper functioning of thermometer and hygrometer at
regular intervals by comparing with a calibrated device.
Record the date of checking on Recording Form 2F: Egg
storage room: climate conditions (page 96).
Recommended climate conditions during egg storage

Storage duration Temperature (°C / °F) Relative humidity (%) Egg orientation
0-3 days 18-21 / 64.4–69.8 75 Blunt end up
4-7 days 15-17 / 59.0–62.6 75 Blunt end up
8-10 days 10-12 / 50.0-53.6 80 - 88 Blunt end up
More than 10 days 10-12 / 50.0-53.6 80 - 88 Small end up or
alternatively turning the
eggs every 24 hours
Additional notes
• 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.
• If storage time is not constant it is recommended to have
two separate storage rooms, each with its specific climate
conditions.
• Storage times longer than one week are not recommended:
after three 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.
• Eggs stored for this longer period should be prewarmed for
18 hours at 23 °C / 73.4 °F and 50% relative humidity
before being set.
• 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.

2.4 Setting eggs in setter trays and trolleys
Objective
To set eggs in setter trays and prepare eggs for incubation.
Persons responsible
Hatchery manager and personnel assigned to set and incubate
eggs.
Documents
Egg receipt (page 12).
Definitions
Egg traying room: area for traying eggs. The egg traying room
might be the same area as the egg receiving room.
Fumigation room: a room specially designed for disinfecting
eggs. Ideally, it should be located between the egg traying room
and the incubator room. This room functions as a sluice valve.
No one should pass through! The fumigation room is separate
from the setters.
Hatching eggs: eggs from breeder farms with clean, smooth and
intact shells and with oval shape and within required size range.
Setter trolley: cart designed to set setter trays in a setter. The
trolley is equipped with a turning device.
'Sweating': the condensation of water in droplets on the egg
surface when cold eggs are brought into a warm, humid room.
Vacuum egg lifter: manual or automatic equipment for
transferring eggs from pulp or plastic trays to setter trays.
1 Place the eggs on setter trays in setter trolleys according to
the plan previously made on Recording Form 2E: Setter
schedule (page 95).
2 If the eggs were stored on pulp or plastic trays, use a
vacuum egg lifter to place the eggs on setter trays.
3 Remove all eggs which do not meet quality criteria for
hatching eggs and replace with good hatching eggs.
4 Check the position of the eggs carefully: eggs must be set
with the blunt end (= air cell) up.
5 Provide the setter trolleys with an egg ID code.

6 Record the numbers of eggs removed from the storage room
to be set on Recording Form 2D: Hatching egg stock list (page
94).
7 Place the loaded setter trolleys in the fumigation room.
Eggs will 'sweat' if the relative humidity (% RH) in the egg traying room is higher than:
Temperature of Temperature egg traying room:
1)
storage room 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.
Additional notes
• 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.
• The table shows the relationship between temperature and
humidity in the egg storage room and the egg traying room
and the risk of egg sweating. Egg sweating is prevented
when the temperature difference between the egg storage
and egg traying rooms is small and humidity in the egg
traying room is low.

2.5 Disinfecting hatching eggs
Objective
To eliminate micro-organisms on the shells of hatching eggs.
Persons responsible
Hatchery manager and personnel assigned to set and incubate
eggs.
Documents
Storage of hatching eggs (page 14).
Definitions
Crystalline paraformaldehyde: a disinfecting powder that
evaporates when it is heated electrically. The formaldehyde gas
penetrates the eggshell.
Electric pan: an electric pan connected to a programming unit
used for the evaporation of crystalline formaldehyde.
Fumigation room: a room specially designed for disinfecting
eggs. Ideally, it should be located between the egg traying room
and the incubator room. This room functions as a sluice valve.
No one should pass through! The fumigation room is separate
from the setters.
Setter trolley: cart designed to set setter trays in a setter. The
trolley is equipped with a turning device.
Recommended procedure A
Chemical: paraformaldehyde.
1 Place the setter trolleys with trayed eggs in the fumigation

room. Trolleys should be moved in via the egg
receiving/storage room only!
2 Maintain the correct temperature and humidity (21-25 °C /
69.8-77 °F and 65%-75% RH) in the fumigation room.
3 Weigh 7 grams of crystalline paraformaldehyde per m³ of
fumigation room and place in an electric pan.
4 Make sure the fan shaft and the door to the setter room are
closed, leave the fumigation room and close the door behind
you.
5 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.

6 After 30 minutes (including 10 minutes to initiate
evaporation) the extraction fan is switched on automatically,
while the air inlet valve on the side of the setter room is
opened.
7 Ventilate for 30 to 60 minutes.
8 Optional: Neutralise the formaldehyde gas with ammonia by
using the “Formaldehyde Neutralisation Unit” according to
the procedure of this unit.
9 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!
Recommended procedure B
Chemical: formalin (37%-40%) and potassium permanganate;
(formalin is paraformaldehyde dissolved in water).
1 Place the setter trolleys with trayed eggs in the fumigation

room. Ideally, trolleys should be moved in via the egg
receiving/storage room only!
2 Maintain the correct temperature and humidity (21 - 25 °C /
69.8 – 77 °F and 65%-75% RH) in the fumigation room.
3 Make sure the fan shaft and the door to the setter room are
closed.
4 First put the potassium permanganate in an enamelled pan
at the rate of 20 grams per m³ of fumigation room. Then add
the liquid formalin at the rate of 30 ml per m³ of fumigation
room. Be aware that the reaction starts immediately after
adding the formalin. Wear a mask with a specific filter; avoid
inhalation!
5 Leave the fumigation room and close the door behind you.
6 After 20 minutes the extraction fan is switched on
automatically, while the air inlet valve on the side of the
setter room is opened.
7 Ventilate for 30 to 60 minutes.
8 Optional: neutralise the formaldehyde gas with ammonia by
using the “Formaldehyde Neutralisation Unit” according to
the procedure of this unit.
9 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!
Recommended procedure C
Chemical: alternative for paraformaldehyde.
Legislation in various countries might not allow the use of
formalin, because of its negative impact on human health and
the environment. Contact Pas Reform Academy for details of
alternative methods of hatching egg disinfection.

Additional notes
• If the eggs were stored below 15 °C, pre-warm them for 12
hours in an egg traying room at 18°C and 60%-70% relative
humidity prior to disinfection.
• In case the temperature in the fumigation room is higher
than 25 °C the extraction should start earlier than 20
minutes.
• To avoid re-infection and cross-contamination, fumigated
and non-fumigated eggs should never be placed next to one
another.

3. Incubation of broiler eggs: day 1-18
In This Chapter
Introduction ....................................................... 22
Single-stage incubation program........................... 24
Multi-stage incubation settings ............................. 28
Analysis of eggshell temperature .......................... 32
Relative humidity and egg weight loss ................... 34

3.1 Introduction
After disinfection, the hatching eggs are prepared for incubation.
Procedures for the first 18 days of incubation are described
separately for single-stage and multi-stage incubation. A
number of procedures are also outlined that should be carried
out to control and monitor the incubation process.
Single-stage incubation program

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. The procedure in
this chapter is helpful in choosing the optimum set points for
temperature, relative humidity, ventilation and turning for single
stage incubation.
Multi-stage incubation settings

In multi-stage incubation, eggs of different ages are incubated
at the same time in one machine.
Consequently, set points for temperature, relative humidity,

ventilation and turning are similar during the entire setting
period. Eggs are placed in the multi-stage incubator according
to a repeated three-day setting schedule. Recommended set
points for multi-stage incubation are described in the procedure
in this chapter.
Systematic analysis of eggshell temperature

The procedure in this chapter 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.

Relative humidity and 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. The
procedure in this chapter describes the steps in measuring egg
weight loss.

3.2 Single-stage incubation program
To incubate hatching eggs in optimum climate conditions
according to the all in / all out principle to achieve maximum
hatchability and chick quality.
Persons responsible
Hatchery manager and personnel assigned to control the
incubators and incubation programs.
Documents
Systematic analysis of eggshell temperature (see "Analysis of
eggshell temperature" page 32).
Relative humidity and egg weight loss (page 34).
Analysis of clear eggs (page 41).
Recording Form 3A: Incubator recording form (page 97).
Definitions
Handheld CO2 meter: portable equipment designed to measure
carbon dioxide levels in the 0.05%-2.00% range (500 ppm-
20,000 ppm).
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. The
hatcher basket design allows air to pass freely over the eggs.
Incubation program: the incubation program defines per day the
incubator set points for temperature, humidity, valve or carbon
dioxide and turning.
Integrated CO2 meter: CO2 equipment and software integrated
into the Pas Reform incubator’s SmartDrive™ or Navigator
controller.
Pre-heating: heating of eggs in an operational setter to a uniform
temperature of 77 – 81 °F prior to the onset of incubation.

Setter: incubator cabinet designed to incubate hatching eggs at
the appropriate temperature, humidity and air composition
during the first days of embryonic development.
Single-stage: one incubator is loaded in one go with one type of
egg. The incubator is empty after transfer.
1 Check proper functioning of the machine and note this on
Recording Form 3A: Incubator recording form (page 97) which
is attached to the door of the setter. Use the Performance
Testing Tool on the SmartDrive™.
2 Transfer the trolleys filled with trayed eggs from the
fumigation room to the setter and place the trolleys
according to Recording Form 2E: Setter schedule (page 95).
3 In case the setter is not completely filled with eggs place
equal number of eggs left and right from the corridor with at
least trolleys in front of the pulsator. Fill the rest of the
setter with empty trolleys. Load incompletely-filled trolleys
from the centre upwards and downwards and leave the top
and bottom without setter trays.
4 Write the egg ID codes on Recording Form 3A: Incubator
recording form (page 97).
5 Define the appropriate incubation program manually or
select the program in the SmartCenter™ or Observer
software (see the next Incubation program setter table and
the appendices for recommended set points).
6 Include the preheat-function in the incubation program (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 for 12 hours in case eggs
were stored up to seven days or 18 hours in case of longer
storage.
7 Note the incubation program on Recording Form 3A:
Incubator recording form (page 97).
8 Start the incubation timer.
9 Candle eggs on day 10 or on the day of transfer and carry
out an analysis of clear eggs if required; see Analysis of clear
eggs (page 41).
10 Transfer eggs to the hatcher baskets approximately 17.5 –
18.5 days after the start of incubation.

General guideline
General guideline single-stage incubation program for broiler eggs 1)
Moment of set Incubation temperature Relative Ventilation Turning

point change humidity
(day.hour) Set point Eggshell Set point Set point Set point
2) temp 3) 4) (positions)
(°F) (%) (% valve)
2)
(°F)
- 0.05 - - 0.08 77.0 – 81.0 - 53 0 horizontal = 0
0.00 See 100.0 53 0 2
"Appendix 1"
1.00 100.0 53 0 2
, on page 79
2.00 until 100.0 53 0 2
3.00 "Appendix 4" 100.0 53 10 2
, on page 85.
4.00 100.0 53 10 2
5.00 100.0 53 10 2
6.00 100.0 53 20 2
7.00 100.0 53 30 2
8.00 100.0 53 40 2
9.00 100.0 53 40 2
10.00 100.0 53 40 2
11.00 100.0 53 50 2
12.00 100.0 53 50 2
13.00 See 53 50 2
"Appendix 1"
14.00 53 60 2 or 3
, on page 79
15.00 until 53 60 2 or 3
16.00 "Appendix 4" 53 60 2 or 3
, on page 85.
17.00 53 70 2 or 3
18.00 53 70 2 or 3
Transfer 17.5 - 18.5 days after the start of incubation.
1) The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs.
The hatchery's altitude should also be considered. See the appendices for some examples.
2) The eggshell temperature is the main parameter for the temperature set point. If the eggshell
temperature deviates too much from the desired eggshell temperature, the incubator temperature set point
should be adjusted. For measuring the average eggshell temperature see Systematic analysis of eggshell
temperature (see "Analysis of eggshell temperature" page 32).
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 Relative humidity and egg
weight loss (page 34).
4) The main parameter for ventilation is the CO2 concentration in the incubator. The CO2 level may increase
from about 0.06% at the start of incubation to 0.40% at transfer. The level of CO2 can be measured using a
handheld CO2 meter or an electronic integrated CO2 meter.

Additional notes
• To achieve maximum hatchability and chick quality it is
recommended to load the incubator with one type of eggs
with respect to breed, maternal age and storage days.
• The set points in the table should be used as guidelines only.
2) 3) 4)
Based on the main parameters , and set points might
need to be adjusted.
• When the incubator is not completely filled up with eggs, use
the egg shell temperature as a reference for the temperature
set point.

3.3 Multi-stage incubation settings
Objective
To incubate hatching eggs in the optimum climate conditions for
multi-stage incubation to achieve maximum hatchability and
best chick quality.
Persons responsible
Documents
eggshell temperature" page 32).
Analysis of clear eggs (page 41).
Definitions
Embryonic age: age of the embryo expressed in time the egg
has spent in the incubator.
20,000 ppm).
controller.
Multi-stage incubation: eggs with embryos of different ages are
set in one incubator.

1 Check proper functioning of the machine and note this on
Recording Form 3A: Incubator recording form (page 97) which
is attached to the door of the setter.
2 Transfer the setter trolleys to the setter room. Pre-warm the
eggs in the setter room prior to loading the setter for 12
hours in case eggs were stored up to seven days or 18 hours
in case of longer storage.
3 Place the trolleys according to Recording Form 2E: Setter
schedule (page 95). See recommendations below for the
setting scheme.
4 Write the egg ID codes on Recording Form 3A: Incubator
5 Record the settings of the incubator on Recording Form 3A:
Incubator recording form (page 97) and adjust set points of
temperature, humidity and ventilation according to the table
below if necessary.
6 Candle eggs on day 10 or on the day of transfer and carry
out an analysis of clear eggs if required; see Analysis of clear
eggs (page 41).
7 Transfer eggs to the hatcher baskets approximately 17.5-
18.5 days after the start of incubation.
Recommended multi-stage incubation settings for broiler eggs

1)
Set points Reference
Incubation temperature 99.5 °F 2)
Eggshell temperature : 100.0 °F
Relative humidity 50% 3)
Egg weight loss : 10%-13%
Ventilation (% valve) 50% 4)
CO2 concentration : 0.25%-0.30%
Turning (positions) 2 -
1) The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs. The hatchery's
altitude should also be considered; further information can be found in Appendix 5.
2) The eggshell temperature is the main parameter for the temperature set point. See Systematic analysis of eggshell
3) The main parameter for relative humidity is egg weight loss. At transfer, the average egg weight loss should be
approximately 10% (young flocks) to 13% (old flocks). See Relative humidity and egg weight loss (page 34).
4) The main parameter for ventilation is the CO2 concentration in the incubator. In a multi-stage incubator, the average
CO2 concentration should be approximately 0.25%-0.30%. The level of CO2 can be measured using a handheld CO2
meter or an electronic integrated CO2 meter.

Recommended setting scheme 115-capacity setter
1 First fill up the hindmost half of sections 5 and 6 (trolleys
number 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 hindmost half of sections 3 and 4 (trolleys
number 2).
3 Next, fill up the hindmost half of sections 1 and 2 (trolleys
number 3).
4 Subsequently, fill up the remaining halves of the sections
(follow up the trolley numbers, see illustration).
5 When the oldest eggs are removed from the incubator, fill up
the empty sections with trolleys containing unincubated
eggs.

Additional notes
• Other setting schedules are possible. Contact the Pas Reform
Academy for advice on setting schedules and set points that
are appropriate for your hatchery.
• Setting every 3-4 days according to the recommended
setting scheme results in the most even distribution of
“warm” and “cold” eggs throughout the incubator.
• Aim at setting every 3-4 days when filling up succeeding
sections, so that different egg ages are evenly distributed
throughout the incubator when it is completely filled.
• If setters with smaller capacity are used, follow the setting
schedule of the 115-capacity setter at a smaller scale.
• Due to its character it is not possible in multistage
incubation to achieve 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. From day 13-18 the average
eggshell temperature gradually increases to temperatures
higher than recommended for single-stage incubation.
• The CO2 concentration is an indication of air replenishment in
the incubator. If the levels of CO2 deviate from the
recommended levels in the table below, adjust the
ventilation set points by opening the valves (when CO2 levels
are too high) or closing the valves (when CO2 levels are too
low).

3.4 Analysis of eggshell temperature
Objective
To adjust incubation temperature based on eggshell
temperature.
Persons responsible
incubation process.
Documents
Single-stage incubation program for broiler eggs (see "Single-
stage incubation program" page 24).
Recording Form 3B: Eggshell temperature (page 98).
Definitions
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).
Eggshell temperature: temperature of the surface of the egg,
which is used as a reference for embryo temperature. The
eggshell temperature is measured by a Braun ThermoScan
placed on the eggshell under the air cell.
Eggshell temperature on a specific day of incubation: the average
eggshell temperature of a minimum of 30-50 eggs per setter
containing living embryos.
Embryo temperature: the body temperature of the growing
embryo.
1 Before starting, the Braun ThermoScan should be warmed in
the incubator for 15 minutes (if this is not done,
measurements will be inaccurate).
2 Measure in an operational setter with a closed door. A
second person is needed to switch on the machine as soon
as the person who has entered for measuring has closed the
door.
3 Place the infrared probe on the eggshell just under the air
chamber (measuring on the air chamber gives a difference of
0.5°F).
4 Measure with the infrared probe placed at a 90° angle on the
eggshell (measuring at the wrong angle gives 0.5 - 1.5°F
deviation; see illustration).
5 Measure the eggshell temperature of 10-15 eggs in the
centre of different trays from different trolleys in different
sections.

6 Write the measured values on Recording Form 3B: Eggshell
temperature (page 98).
7 Take the average of a minimum of 30-50 eggs.
8 Use the average temperature of eggs with living embryos as
a reference for the eggshell temperature on that day of
incubation.
9 Adjust the incubator temperature set point if the actual
eggshell temperature deviates too much from the desired
eggshell temperature.
Measure the egg shell temperature with the probe placed at a

90° angle on the eggshell.
Additional notes
• Warning: this procedure should be carried out by qualified
personnel only because data must be collected in an
operational machine with every section fully loaded with four
trolleys of eggs.
• Measurements taken in a machine which is turned off will
result in unreliable data because eggshell temperature
changes immediately when the air-flow is nil.
• Make sure the plastic cover (lens filter) is on the infrared
probe (the Braun ThermoScan will not function properly
without this filter).
• During the first 12 days of incubation a deviation of + 0.2°F
from recommended eggshell temperature is acceptable.
During the last days of incubation the recommended egg
shell temperatures should not be exceeded, but a deviation –
0.3 after 15 days of incubation is acceptable.

3.5 Relative humidity and egg weight loss
Objective
To check whether the humidity set point is correct for optimum
embryo development. Egg weight loss is a reflection of the
relative humidity set point.
Persons responsible
incubation process.
Documents
Recording Form 3C: Egg weight loss (page 99).
Definitions
Initial egg weight (W0): weight of eggs when incubation starts.
Marked tray: tray with eggs assigned to be weighed on different
days during the incubation cycle. These trays are tagged with a
label.
Weight loss: average loss of weight of eggs from start of
incubation expressed as a percentage of initial egg weight.
1 Mark the empty trays (WT) and weigh them. For reliable
information several trays per setter should be marked.
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 e.g. day
10 and 18 (W10 … W18).

5 Calculate the weight loss from start of incubation (see
example and recording form 3C: 'Egg weight loss') and plot
the result in the graph on Recording Form 3C: Egg weight loss
(page 99).
6 Adjust incubator set points of relative humidity if the weight
loss deviates too much from the recommendation.
Example:
W0 W10
weight of tray with eggs 10,300 g 9,854 g
weight of empty tray 1,000 g - 1,000 g -
weight of eggs on day 0 = W0 9,300 g
weight of eggs on day 10 = W10 8,854 g
weight loss over 10 days = ( W0- W10) / W0 =
(9,300-8,854) / 9,300 x 100 = 4.8%
Additional notes
• 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 9677g,
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. i.e. 0.67% per day of incubation. This is a good weight
loss for medium to old aged flocks. There is no need to
adjust the relative humidity set point.
• Optimum weight loss depends on flock age. At egg transfer,
the egg weight loss should be between approximately 10%-
11% (young flocks) to 12%-13% (old flocks). The weight
loss is assumed to be approximately linear: over 18 days the
daily weight loss should be 0.55%-0.61% (young flocks) to
0.67%-0.72% (old flocks) of the initial egg weight.
Optimum weight loss depends on flock age

Age breeder Recommended weight loss (%)
flock (weeks) At transfer Daily
25–40 10–11 0.55–0.61
40–50 11–12 0.61–0.67
50–60 12–13 0.67–0.72

• For a correct calculation of the weight loss, do not remove
eggs from the marked trays.
• Actual relative humidity (as seen on the display) will follow a
natural pattern as a result of gradually increased ventilation.
Actual relative humidity will be higher than set point during
the first days of incubation (up to 65%) due to fact that the
valves are closed. During the last days in the setter actual
relative humidity might drop below set point depending on
valve position and climatic conditions in the setter room.
• Ensure that relative humidity is measured by a well-
maintained humidity sensor (e.g. clean cotton wick); more
information can be found in the setter manual.
• Alternatively the size of the air cell provides an indicator of
weight loss.

4. Candling and transfer
In This Chapter
Introduction ....................................................... 38
Candling and transfer .......................................... 39
Analysis of clear eggs .......................................... 41

4.1 Introduction
After approximately 17.5-18.5 days of incubation, eggs are
transferred to the hatcher. Often, before transferring the eggs
to the hatcher cabinets, eggs are candled to remove infertile
eggs and eggs containing dead embryos.
In the case of unexpectedly high percentages of clear eggs, an
analysis of clear eggs can help to locate problems of low
hatchability or bad chick quality.
Candling and transfer

The procedure (see "Candling and transfer" page 39) 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 summarised.
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).
The procedure (see "Analysis of clear eggs" page 41) describes
the step for the analysis of clear eggs.

4.2 Candling and transfer
Objective
To candle and transfer eggs from the setter to the hatcher.
Persons responsible
Hatchery manager and personnel assigned to control egg
candling and transfer.
Documents
Definitions
Candling: 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.
Infertile eggs: eggs that contain a degenerated oocyte which was
not fertilised by sperm. The unfertilised oocyte can be
recognised as a white dot in the centre of the yolk. Infertile eggs
are transparent to candling light.
1 See Recording Form 2E: Setter schedule (page 95) for
planning the transfer of eggs.
2 Recording Form 3A: Incubator recording form (page 97)
accompanies the batch of eggs at the transfer from setter to
hatcher. Therefore, make copies of this form depending on
the number of hatchers across which the eggs of one setter
are divided. Attach a copy of the form next to the door of
each hatcher and highlight the relevant egg ID-code on it.

3 Start up the hatcher at least one hour before transfer. Check
the set points of temperature and relative humidity and
record proper functioning of the machine on Recording Form
3A: Incubator recording form (page 97). Use the Performance
Testing Tool on the SmartDrive™.
4 Transfer the trolleys from the setter to the egg transfer
room. Here, eggs are (semi-) automatically removed by a
transfer/candling machine from the setter trays and placed
into hatcher baskets.
5 When eggs are candled during egg transfer, remove clear
eggs and transfer them to special containers. Record the
percentage of clear eggs on Recording Form 3A: Incubator
6 Transfer all eggs from one setter tray to one hatcher basket.
When from a 150-egg capacity setter tray more than 30
eggs are removed during candling, refill empty places up to
130 eggs.
7 Preferably fill the hatcher completely to ensure proper air
circulation. Fill up empty positions on the hatcher trolleys
with empty hatcher baskets. Cover the uppermost hatcher
basket with a lid or an empty basket.
Additional notes
• Eggs of different ID codes should be kept in separate
hatcher baskets.
• The nominal capacity of a hatcher is 19,200 hen eggs.
Contact Pas Reform Academy for advice how to load
hatchers which are not filled to capacity.
• For maximum hatchability 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!).
• The temperature in the egg transfer room should be at least
25°C.
• Egg transfer and candling should last no more than 30
minutes; the eggs should not be outside the machines any
longer to avoid the egg temperature dropping too much.
• Hatcher baskets should be completely dry before transfer.
• If paper is used in the hatcher baskets ensure it does not
hamper the horizontal flow of air.

4.3 Analysis of clear eggs
Objective
To evaluate fertility and the pattern of embryonic mortality
during incubation for establishing a hatchery-specific reference.
Persons responsible
incubation process.
Documents
Recording Form 4A: Analysis of clear eggs (page 100).
Recording Form 7B: Results egg analysis and Pasgar©Score (page
105).
Definitions
incubation.
Infertile eggs: eggs that contain a degenerated oocyte which was
not fertilised by sperm. The unfertilised oocyte can be
recognised as a white dot in the centre of the yolk. Infertile eggs
are transparent to candling light.
Pulp tray: 30-egg capacity paper tray. Pulp trays with eggs can
be stacked. Egg trays may also be made of plastic.
1 Collect clear eggs of trays from various positions in the
setter.
2 Place the eggs on a pulp or plastic tray.
3 Open the eggs at the air cell end using forceps.
4 Classify the eggs according to the categories on Recording
Form 4A: Analysis of clear eggs (page 100) and fill in this
form.
5 Calculate the percentages per category based on total eggs
set on sampled trays.
6 Add this data to your reference table; see Continuous
improvements (page 64).

Additional notes
• It is often impossible to distinguish between unfertilised
oocytes and eggs that contain an embryo that died early if
candling is done at transfer. For a better estimation of
fertility consider candling on day 10.
• The examination of a single clear egg or 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.
• A representative sample from one trolley consists of clear
eggs collected from the upper, the middle and the lower
setter tray.
• More reliable information will be obtained if more than 1
trolley per setter is sampled.
• In case of disappointing hatchery results an egg analysis can
be performed and the results can be compared with the
obtained reference. Refer to Continuous improvements (page
64) for possible causes of deviation from the reference.

5. Hatching of broiler eggs: day 19-21
In This Chapter
Introduction ....................................................... 44
Incubation program hatcher ................................. 45
Formaldehyde treatment of chicks in hatcher.......... 48
Analysis of unhatched eggs .................................. 50

5.1 Introduction
After transferring the eggs to the hatcher, the hatching program
is started, lasting approximately three days. In the case of
unexpectedly low hatching percentages or poor quality chicks,
an analysis of unhatched eggs can help to locate problems.
Incubation program hatcher

It is important to realise that hatching times may vary between
batches of eggs depending on the age of the parent flock,
incubation temperature and pre-incubation storage time.
The procedure (see "Incubation program hatcher" page 45)
provides guidelines for hatching program set points and for
timing the correct moment for taking out the chicks.
Formaldehyde treatment of chicks in hatcher

Often, during the hatching process, liquid formalin is placed in
the hatcher for evaporation to give the hatching chicks a yellow
colour.
The procedure (see "Formaldehyde treatment of chicks in
hatcher" page 48) is described in this chapter.
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.
This procedure (see "Analysis of unhatched eggs" page 50)
describes the analysis of unhatched eggs.

5.2 Incubation program hatcher
Objective
To hatch the chicks in the optimum climate to achieve maximum
hatchability and best chick quality.
Persons responsible
Documents
Formaldehyde treatment of chicks in hatcher (page 48).
Definitions
External pipping: when the chick’s beak has cracked the eggshell
we say the chick has pipped externally.
20,000 ppm).
Incubation program: the incubation program defines per day the
incubator set points for temperature, humidity, valve or carbon
dioxide and turning.
controller.
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.
1 Check that the hatcher trolleys and hatcher baskets are
properly placed in the hatcher. Ensure the correct egg ID-
code is highlighted on Recording Form 3A: Incubator recording
form (page 97) which is attached next to the hatcher door.
2 Start the hatching program.

3 Make daily records of the settings of the hatcher on
Recording Form 3A: Incubator recording form (page 97) and
adjust temperature, humidity and ventilation set points
according to the needs of the hatching chicks (see next
tables for the recommended set points).
4 If desired, start the treatment of newly hatched chicks with
formaldehyde when 10% of the chicks have pipped. Follow
the procedure in section Formaldehyde treatment of chicks in
hatcher (page 48).
5 Transfer trolleys 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.
Recommended hatcher program for broiler eggs based on CO2-controlled valves

(Automated Hatching System)
Remarks Temperature Relative Ventilation
1)
set point humidity set CO2 (%) set
point point
Transfer 98.0°F 53% 0.50%
First chicks: 98.0°F 53% 0.50%
2)
The humidity increases spontaneously
10% of chicks: humidity has increased 98.0°F 3) 0.50%
53%
2)
spontaneously to 60%
4) 98.0 - 97.8 - 5) 0.50%
Hatching complete : 60%
5)
If hatching is not yet complete, do not lower 97.5°F
temperature and only do this if chicks are panting
as a sign of being overheated.
1) In case Automated Hatching System is used, ventilation 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) Hatching is complete when 95% of the chicks are dry and 5% of the chicks are almost dry (have wet down on
the neck). Hatching time depends on flock age, storage time and incubation temperature in the setter.
5) If hatching is not yet complete, 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.
Avoid relative humidity falling below 60% by adjusting the set point to minimise dehydration.

Recommended hatcher program for broiler eggs
(without Automated Hatching System)
Remarks Temperature Relative Ventilation
set point humidity % valve Reference:
set point 1)
CO2 (%)
Transfer 98.0°F 53% 40% 0.40%
First chicks: 98.0°F 53% 40% 0.40%–
The humidity increases spontaneously 0.50%
2)
3)
10% of chicks: humidity has increased 98.0°F 53% 40% 0.70%–
2)
spontaneously to 60% 0.80%
Hatching complete: 98.0 - 97.8 - 5) 70%–80% 0.50%

60%
5) 5)
If hatching is not yet complete, do not 97.5°F
lower temperature and do not
increase ventilation, but wait a few
4)
hours
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) Hatching is complete when 95% of the chicks are dry and 5% of the chicks are almost dry (have wet down on
the neck). The hatching time depends on flock age, storage time and incubation temperature in the setter.
5) If hatching is not yet complete, do not lower the temperature and do not increase ventilation, 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. Avoid relative humidity falling below 60% by adjusting the set point to minimise
dehydration.
Additional notes
• For maximum hatchability and chick quality it is very
important to place only one batch of eggs from one section
in the setter in one hatcher (different types of eggs can have
different hatching times!). See Recording Form 2E: Setter
schedule (page 95) for the location of the eggs in the setter
and hatchers.
• Take the trolleys out one by one. Do not empty the hatcher
completely, but leave the chicks in the hatcher. Keep the
hatcher running while the chicks are inside!

5.3 Formaldehyde treatment of chicks in
hatcher
Objective
To give the chicks a uniform yellow colour and reduce
contamination by pathogenic micro-organisms.
Persons responsible
Documents
Safety instructions provided by the disinfectant manufacturer.
Definitions
1 When using chemicals always read and follow the
manufacturer's instructions. Avoid inhalation by personnel.
2 When a fumigation plate is used in a hatcher, make sure
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 this plate with 100 – maximum 250 ml of 37%-40%
formaldehyde when 10% of the chicks have externally
pipped.

Additional notes
• Read the safety instructions provided by the disinfectant
manufacturer!
• Avoid overdoses of formaldehyde vapour when chicks are
treated with formaldehyde. Chick quality is adversely
affected by high doses of formaldehyde vapour because it
damages the chick's windpipe (trachea).
• Formaldehyde is a toxic chemical. Pas Reform is not
responsible for the manner in which it is used. Legislation in
various countries might not allow the use of formalin.

5.4 Analysis of unhatched eggs
Objective
To evaluate the pattern of embryonic mortality during
incubation for the purpose of establishing a hatchery-specific
reference.
Persons responsible
incubation process.
Documents
Recording Form 5A: Analysis of unhatched eggs (page 101).
105).
Definitions
incubation.
Pulp tray: 30-egg capacity paper tray. Pulp trays with eggs can
be stacked. Egg trays may also be made of plastic.
Second-class chicks: chicks of suboptimal quality which are not
suitable for selling.
Unhatched eggs: eggs which remain in the hatcher basket after
hatched chicks are removed.

1 Take out the chicks and take three hatcher baskets with
unhatched eggs and second-class chicks from a hatcher
trolley.
2 Count the number of second-class chicks and the number of
unhatched eggs.
3 Place the unhatched eggs on a pulp or plastic tray and open
the eggs at the air cell end with forceps.
4 Classify the eggs according to the categories on Recording
Form 5A: Analysis of unhatched eggs (page 101) and fill in this
form.
5 Calculate the percentages per category based on the total
number of eggs set in representative sample.
6 Add this data to your reference table; see Continuous
improvements (page 64).
Additional notes
• 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. These clear eggs can be
analysed separately (see Recommended procedure: analysis
of clear eggs (page 41) or consider not removing clear eggs
during candling from those setter trays marked 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 unfertilised oocytes and eggs that
contain an embryo that died early. For a better estimation of
fertility consider candling on day 10.
• The examination of a single unhatched egg or 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.
• A representative sample from one trolley consists of
unhatched eggs collected from the upper, the middle and the
lower hatcher basket.
• More reliable information will be obtained if more than one
trolley per hatcher is sampled.
• In case of disappointing hatchery results an egg analysis can
be performed and the results can be compared with the
obtained reference. Refer to Continuous improvements (page
64) for possible causes of deviation from the reference.

6. Chick handling
In This Chapter
Introduction ....................................................... 54
Chick take-off ..................................................... 55
Assessing chick quality: Pasgar©Score .................. 57
Chick despatch and transport ............................... 59

6.1 Introduction
The first hours of a chick's life are very important for its ability
to live and performance during the growing period. After
hatching, climate conditions may seriously affect the vitality of
the chick since it is unable to regulate its body temperature
during the first three or four days of life.
Chick take-off
Accurate timing of removal of the newly hatched chicks from the
hatcher is extremely important. When chicks are taken off too
early, insufficient incubation time will result in high percentages
of unhatched eggs. But chicks that remain in the hatcher too
long will suffer excess dehydration.
The procedure (see "Chick take-off" page 55) describes
guidelines for timing chick take-off and preparing the chick room
for subsequent chick handling.
©
Assessing chick quality: Pasgar Score
The greatest challenge for the hatchery is to produce uniform
chicks of high vitality. For assessing individual chick quality, the
procedure (see "Assessing chick quality: Pasgar©Score" page
©
57) outlines use of the Pasgar Score method: 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.
Chick despatch and transport

Conditions and duration of chick transport can greatly affect
performance and growth of chicks at the farm. The procedure
(see "Chick despatch and transport" page 59) provides a
guideline for optimising conditions for chicks during transport to
minimise losses due to inefficient sanitation, dehydration,
starvation and cold or heat stress. Delays during transport and
placement may cause poorer performance throughout flock life
and should therefore be avoided.

6.2 Chick take-off
Objective
To take the chicks out of the hatcher at the correct time and
prepare them for transport to the farm.
Persons responsible
Hatchery manager and personnel assigned to handle chicks.
Documents
Assessing chick quality: Pasgar©Score (page 58).
Recording Form 6B: Chick passport (page 103).
Definitions
Automatic vaccinator: equipment to vaccinate day-old chicks
automatically.
Chick counting and boxing system: equipment that automatically
counts day old-chicks and places them in chick boxes.
Stacker and destacker: equipment that takes hatcher baskets or
(empty) chick boxes from stacks automatically.
1 Prepare the chick room for chick handling:
the temperature should be between 22 - 28°C/71.6 –
82.4°F and should be uniform throughout the chick room;
hot/cold spots and air draughts should be avoided;
the relative humidity should be 50%-60%;
check proper functioning of all machinery (hatcher
baskets destacker, transport belts, chick counter,
automatic vaccinator, chick box stacker and destacker).
2 Transfer trolleys 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.
3 Take the trolleys 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 ID
codes to minimise mistakes during counting and further
chick transportation.
5 Hatcher baskets are destacked and the chicks are placed on
transport belts.
6 Assess the quality of chicks and remove second grade
chicks. Only vital chicks of good quality should be delivered
to the farmer. Record a general impression of the chick
quality on Recording Form 6B: Chick passport (page 103).
7 Consider evaluating chick quality by determining the
Pasgar©Score. See section Assessing chick quality:
Pasgar©Score (page 58).
8 If required, vaccinate the chicks according to the vaccine
manufacturer's instructions. Record vaccination on Recording
Form 6B: Chick passport (page 103).
9 Chicks are usually counted by automatic chick counters and
subsequently placed into chick boxes.
10 A maximum of 100 chicks is placed into one chick box.
During hot weather, lower the numbers of chicks per box to
avoid suffocation during subsequent chick waiting and
transport.
11 On hatch days, all equipment and rooms used must be
cleaned and disinfected after use.

6.3 Assessing chick quality: Pasgar©Score
Objective
To evaluate and compare chick quality from different batches of
eggs.
Persons responsible
incubation process.
Documents
Recording Form 6A: Pasgar©Score (page 102).
105).
Definitions
Batch of chicks: a clearly-defined group of chicks from one flock,
incubated in one setter and hatched in one hatcher.
Pasgar©Score: an objective method for evaluating the quality of
day-old chicks.
Random sampling of chicks: chicks from the same batch,
randomly taken from several hatcher baskets.
Representative sample: a number (30-50) of chicks collected at
random from a batch of chicks.
Criteria used to downgrade chicks (see examples):
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
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 smooth and these chicks score = 0 for belly.
If the belly feels hard and the skin is tense, the belly scores 1.

1 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 6A:
Pasgar©Score (page 102).
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.
Example: bad navel: Example: bad beak: red Example: red hocks
extruded yolk sac dot
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 1 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 2 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% shows navel problems
Additional notes
• When the quality of the chicks is suboptimal, use the
troubleshooting table in Continuous improvements (page 64)
to locate the problem and decide on the action to be taken.

6.4 Chick despatch and transport
Objective
To provide optimum conditions for one-day-old chicks during
transport from the hatchery to the farm.
Persons responsible
The truck driver, hatchery manager and personnel assigned to
prepare chicks for transport.
Documents
Recording Form 6B: Chick passport (page 103).
Definitions
Chick despatch 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.
1 After placement of the chicks into chick boxes, these are
stored briefly in the chick despatch room prior to transport.
The temperature in the chick despatch room should be 22 -
28°C/71.6 -82.4°F. Levels of relative humidity should be
55%-60%.
2 There should be sufficient ventilation (CO2 max. 500 ppm–
600 ppm) in the room and trough the chick boxes; allow
space between rows of chick boxes.
3 Hygiene during transport: the hatchery agrees with every
truck driver on a sanitation procedure for both truck and
driver, with regard to:
Cleaning and disinfection procedures of the truck
(method, frequency).
Washing/disinfection of hands and change of clothing
prior to handling chicks.
Inspection protocols.
4 Keep chick transport as short as possible (for example,
prevent any delays in chick delivery by ensuring that the fuel
tank is filled to capacity prior to loading the truck).
5 When loading the chick boxes make sure there is sufficient
room between the truck walls and the boxes. Avoid sliding of
the boxes.
6 At chick loading, the truck driver fills in the truck
temperature and hygienic conditions on Recording Form 6B:
Chick passport (page 103).

7 On arrival, the truck driver records truck temperature and
housing conditions at placement (floor temperature, litter
quality, water and feed supply) on Recording Form 6B: Chick
passport (page 103).
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 pant with open Temperature too high
beaks
Chicks spread their Temperature far too high
wings
Chicks gasp for air and Ventilation insufficient (CO2 too high)
try to stick their heads Temperature too high
out of the chick box
Chicks stay in one Draught
corner of the chick box
Additional notes
• Look and listen to the behaviour of the chicks; abnormalities
in their behaviour is related to sub-optimum climate (see
table). Day-old-chicks kept under ideal climatic conditions
breath quietly through their nostrils, are evenly spread in the
chick boxes, will not make much noise and are relatively
inactive.
• Delays during transport and placement may affect
performance throughout flock life and should therefore be
avoided. On arrival on the farm, unbox the chicks without
any delay.
• On placement of the chicks, the floor temperature of the
housing facilities should be approximately 28 - 30°C / 82.4 –
86.0°F.
• On placement, water and feed should be available to the
chicks.
• The litter should be dry and clean.
• The environment should be quiet.

7. Hatchery management
In This Chapter
Introduction ....................................................... 62
Continuous improvements.................................... 64
Hatchery hygiene ................................................ 71
Hatchery maintenance ......................................... 75

7.1 Introduction
General guidelines are presented in the following chapters,
supporting proper and durable operation of the hatchery. Advice
is also provided on how to exploit the information acquired
during the hatchery processes, to optimise results and to solve
problems. These guidelines should be considered as general
suggestions.
Continuous improvements
The main management tool for the control and optimisation of
hatchery results is a hatchery-specific reference set of data: 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: change to a new breed,
extended storage conditions, new equipment etc. In other
words, any change in the routine might require a check as to
whether the incubation procedures are appropriate. This chapter
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 hatching results
improvement. Also, if hatching results are lower than expected
from 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 here (see
"Continuous improvements" page 64).
Hatchery hygiene
Hatchery hygiene plays an essential role in poultry breeding. In
the first place, hatchery hygiene involves the prevention of
pathogens entering the hatchery, to minimise risks of food-
borne illness. Secondly, poor hatchery hygiene may result in
reduced hatchability and chick quality and consequently
considerable economic losses.

The hatchery should have a hygiene programme designed to
minimise the level of micro-organisms inside the hatchery.
General recommendations are presented for preventing
pathogens from entering and spreading through the hatchery.
Advice is also given on cleaning and disinfection methods and
frequencies for the various hatchery rooms.
Finally some recommendations for microbiological monitoring of
the hatchery's hygienic state are summarized (see "Hatchery
hygiene" page 71).
Hatchery maintenance
In a hatchery, conditions should be optimum for the
development of the embryo and for chick quality, but at the
same time bacterial growth and egg quality deterioration prior
to incubation must be minimised. 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,
handling, transfer and chick handling and despatch. The
optimum climate conditions and monitoring guidelines for every
room in the hatchery are summarized (see "Hatchery hygiene"
page 71).
For durable operation of the hatchery, it also equally important
that the equipment is in good condition. Records should be kept
from the maintenance and calibration of hatchery equipment so
that actual records of the state of the machines are available at
all times. This documentation provides tools to detect repetition
of a particular defect and to locate a possible structural problem.

7.2 Continuous improvements
This chapter provides the hatchery manager with tools to
monitor and optimise hatchery results using a hatchery-specific
reference set of data.
Optimise results
The main management tool for optimising results is a hatchery-
specific reference set of data. This hatchery-specific data set is a
summary of the hatchery results which is continuously updated.
On one hand it is therefore a tool for continuous improvement.
On the other, if hatchery results are lower than expected from
the reference data set a troubleshooting procedure can be
initiated.
Hatchery-specific reference set of data

The basis for such database is formed by accurate and
consistent record keeping, whereby the following three levels
can be recognised:
1 A database of basic hatchery results which are generally

easy to collect from every batch of eggs incubated. See
Recording Form 7A: Hatching results (page 104).
2 A database of results of Analysis of clear eggs (page 41),
Analysis of unhatched eggs (page 50) and Assessing chick
quality: Pasgar©Score (page 57). See Recording Form 7B:
Results egg analysis and Pasgar©Score (page 105). 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.
3 A file of continuous records made on the various recording
forms available in this manual. These provide important data
on the background of every batch of eggs (breeder flock
data, egg quality) and conditions during storage and
incubation.
Every batch of eggs incubated is specified by a combination of
start date incubation cycle, egg ID-code and production date.
Other data can be added if required such as setter and hatcher
number, achieved weight loss etc.
For ease of interpretation and analysis it is suggested that data
from Recording Form 7A: Hatching results (page 104) and
105) be entered in a computer thus producing an electronic
database.

Here both recording forms might be integrated into one
database. Ideally use database software for this instead of a
simpler spreadsheet program. The Track and Trace Module
within SmartCenter™ is a useful tool for making such a
database and analysing the results. An electronic database
offers the possibility of using a “filter”, thus showing only the
results of a specified maternal age group or storage days. Easy-
to-read production graphs can be constructed.
Examples of production graphs of two different parent flocks.

——Hatchability according to the norm (provided by breeder
companies)
——Actual hatchability

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. If not
performed yet 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 41),
Analysis of unhatched eggs (page 50),
Assessing chick quality: Pasgar©Score (page 57).
The troubleshooting table in this chapter can be used to find
possible causes for the defined suboptimal results. Some of the
possible causes can be excluded based the available file of
continuous records, whereas others 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.
Pas Reform Academy has developed the 'Consultant module' to
offer support to hatchery managers in analysing and solving
hatchery problems. This 'Consultant module' is available
exclusively to Pas Reform customers through SmartPortal™ . If
the cause of the problem cannot be located, please do not
hesitate to contact the Pas Reform Academy.
Adjusting incubation programs

If analysis of the troubleshooting table at the end of this chapter
leads to the conclusion that the incubation program may need
adjustment, than records of the incubation conditions before
and after the adjustment should be made:
• Eggshell temperature
eggshell temperature" page 32);
• Egg weight loss
Relative humidity and egg weight loss (page 34);
• CO2 concentration
Single-stage incubation program for broiler eggs (see "Single-
stage incubation program" page 24),
Multi-stage incubation settings for broiler eggs (see "Multi-
stage incubation settings" page 28),
Incubation program hatcher (page 44).
To bear in mind when troubleshooting

In many cases, the source for suboptimal hatching results or
chick quality is to 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 transport: long transport times at sub-optimal
conditions (temperature, hygiene, 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.
• Storage conditions: compare storage duration and
recommended climate conditions.
• Fumigation: was the duration and temperature correct
during fumigation? If not, disinfection may have been
ineffective or detrimental.
• 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. Use Analysis of clear eggs
(page 41) and Analysis of unhatched eggs (page 50) and
Recording Form 7B: Results egg analysis and Pasgar©Score
(page 105).
• Chick quality: compare chick quality based on Assessing chick
quality: Pasgar©Score (page 57) with incubation conditions
and Recording Form 7B: Results egg analysis and Pasgar©Score
(page 105).
• Chick boxing and despatch: in hot weather, lower the
numbers of chicks in the chick boxes. Also carefully monitor
climate conditions during chick despatch.
• Day-old-chick transport: long transport times in sub-optimal
circumstances (temperature, hygiene and road conditions)
can lead to a deterioration in chick quality and may cause
chick losses. 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).

Trouble Shooting Table
Troubleshooting table
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.
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 fumigation.
Died at “blood ring stage” • Chilled or overheated hatching eggs.
(day 3–4)
• Incorrect incubation temperature.
• Incorrect fumigation.
• 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” • Incorrect incubation temperature.
until start yolk sac
• Eggs too long out of the setter during candling if done between 7–10 days.
absorption (day 8–17)
• Poor ventilation of setter and/or setter room.
• Incorrect humidity in incubator.
• Disease.
Death of chicks before • Insufficient turning.
internal pipping

• 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 • Low humidity in hatcher.
external pipping
• 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.
• 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 • Low temperature in hatcher.
(poor reflex)
• 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.

7.3 Hatchery hygiene
This section summarises guidelines to prevent the introduction
of contamination into the hatchery and to minimise the risk of it
spreading between hatchery rooms. Beside general basic
hygiene recommendations for all personnel and visitors are
provided, along with advice for cleaning and disinfection and for
monitoring.
General hygiene
Good hatchery hygiene begins with preventing the introduction
of contamination into the hatchery. Sources of contamination
are: eggs, air, water, people, rodents, birds and equipment. For
good personal hygiene the entrance for both personnel and
visitors should contain a wardrobe for clothing and shoes worn
outside the hatchery, a wash-basin (soap, disposable paper
towels, hot and cold water tap) or a shower, a barrier (a clear
separation between the “clean” and the “dirty” area) and a
wardrobe with clean, disinfected clothing and footwear to be
worn inside the hatchery. Personnel must wear clean clothes
and shoes on entering the hatchery and must wash or sanitise
hands before commencing work and after lunch breaks etc.
Visitors: 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
7D: Registration of visitors (page 107), and should follow the
hygiene instructions applying to personnel.
Next, it is equally vital to prevent contamination spreading from
one room to the next. So work according to a one-way traffic
system in line with the egg flow through the hatchery (see
hatchery workflow plan). The frequency of opening doors should
be minimised to prevent air drawing from one room to another.
In critical areas of the hatchery, air is maintained at a positive
pressure, so contamination cannot be drawn in through an open
door. Doors, including one-way doors, help stop cross-
contamination between rooms.
Cleaning and disinfection

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 should be
formulated and pinned up in that particular room; see Recording
Form 7C: Cleaning schedule (page 106).
The following 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 closely!
The table at the end of this chapter provides guidelines for the
frequency with which the hatchery rooms and equipment should
be cleaned and disinfected.
Consider at least the following points when choosing chemicals
for cleaning and disinfection and discuss these with your
supplier:
• pH-values: alkaline soap removes organic dirt (protein, fat)

– acid soap removes mineral deposits (such as calcium).
Depending on water hardness, the occasional use of acid
soap use will help maintain smooth surfaces.
• 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 needed to remove specific
pathogens such as Aspergillus.
• Residual activity: to 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, to complement each other in the fight against a wide
variety of pathogens, together with buffering agents, wetting
agents,
sequestering agents etc. 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 7C: Cleaning schedule (page 106); allowing a
review over time and comparison with the results of microbial
monitoring.

Hatchery microbiological monitoring
Microbiological 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 having hatchery personnel devoting
extra attention to cleaning and disinfection prior to
microbiological monitoring, it is advisable to monitor
occasionally at unscheduled moments.
Here, guidelines are restricted to the routine programme and
involve merely the sampling of air and surfaces in rooms used
for hatchery practice. A more intense monitoring programme
should be used to solve a specific problem and would include
egg washes, chick sampling and bacterial identification.
To evaluate the effectiveness of a sanitation programme,
assessing cleanliness and sanitation 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. Bacteria
and fungi grow on this media when put in an incubation cabinet.
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 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 and let
the plate rest. 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 on 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, excessive 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
monitored. The results should also be carefully compared with
hatchability and liveability data.
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 1) Chick despatch room After each handling
Once every week
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.

7.4 Hatchery maintenance
This chapter offers recommendations for providing the optimum
climate conditions for the processes that take place in various
rooms of the hatchery. Naturally the equipment must also be in
an optimum technical state. Recommendations for maintaining
and monitoring equipment conditions at all times are provided.
Climate conditions
It is advisable to take weekly readings of the temperature and
relative humidity of every room in the hatchery where steps of
the incubation process occur. In hatcher and setter rooms, the
level of CO2 should also be measured since this is a good
indicator of the levels inside the incubation machines. A
handheld CO2 meter may be used for this. Measurements should
be recorded and monitored; see Recording Form 7E: Checklist
climate conditions in hatchery (page 108) for evaluating the
conditions to which eggs and chicks were subjected.
On Recording Form 7E: Checklist climate conditions in hatchery
(page 108), recommendations are listed for optimum climate
conditions for the main hatchery rooms. Where there are
deviations from these recommendations, the cause should be
located and set points may need to be adjusted. Divergent CO2
concentrations in setter and hatcher rooms may indicate that air
filters need to be replaced. For recommendations on monitoring
air pressure in various rooms, see instructions on the hatchery
ventilation system.
Equipment maintenance
A distinction should be made between preventive and corrective
maintenance. Preventive maintenance helps to extend the
lifetime of all hatchery equipment and ensures proper
functioning of the equipment during its use, thereby ensuring an
uninterrupted incubation process. 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™ is helpful with this. Records
of this check should be made on Recording Form 3A: Incubator
recording form (page 97). Some parts of the hatchery
equipment need to be replaced or lubricated at regular intervals
to prevent future problems. To avoid this being forgotten it is
suggested that this preventive maintenance scheduled on a
calendar or by computer. The Maintenance Module within
SmartCenter™ is a useful tool for scheduling maintenance.
Details on preventive maintenance can be found in the manuals
of the various hatchery equipment. Records should be made on:
Recording Form 7F: Setter maintenance card (page 109),
Recording Form 7G: Hatcher maintenance card (page 110),
Recording Form 7H: Hatchery equipment maintenance card (page
111).

Corrective maintenance is carried out after a technical failure.
Every technical failure of a setter, a hatcher or another hatchery
device and the action which was taken to correct it should be
recorded; see Recording Form 7F: Setter maintenance card (page
109)', Recording Form 7G: Hatcher maintenance card (page 110)
and Recording Form 7H: Hatchery equipment maintenance card
(page 111); so that the actual state of the equipment is known
at all times. It is advised to check the maintenance cards
regularly: when a particular defect occurs more frequently there
may be a structural problem.

8. Appendices
In This Chapter
Introduction ....................................................... 78
Appendix 1......................................................... 79
Appendix 2......................................................... 81
Appendix 3......................................................... 83
Appendix 4......................................................... 85
Appendix 5......................................................... 87

8.1 Introduction
Appendix 1:
1)
HY -light, age PS up to 40 – 45 weeks, eggs stored maximum
3 days.
1) HY = High Yield
Appendix 2:
HY-light, age PS up to 40 – 45 weeks, eggs stored 4 days and
more.
Appendix 3:
HY-heavy, age PS up to 40 – 45 weeks of age, eggs stored
maximum 3 days.
Appendix 4:
HY-light, age PS over 40 – 45 weeks with less than 20% clears,
eggs stored maximum 3 days.
Appendix 5:
Hatching at altitudes.
Important !
The set points in the appendices should only be used as
guidelines. Based on the main parameters as explained in the
1) 2) 3) 4)
footnotes , , and set points might need to be adjusted.
1)
The guidelines in the table apply to hatcheries at an altitude
of a maximum 800 – 1200 metres above sea level, with eggs
produced at the same altitude. Information how to adjust these
guidelines for higher altitudes can be found in Appendix 5 (page
87).
2)
The eggshell temperature is the main parameter for the
temperature set point. If the eggshell temperature deviates too
much from the desired eggshell temperature, the incubator
temperature set point should be adjusted. For measuring the
average eggshell temperature see Systematic analysis of eggshell
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
4)
The main parameter for ventilation is the CO2 concentration in
the incubator. The CO2 level may increase from about 0.06% at
the start of incubation to 0.40% at transfer. The level of CO2 can
be measured using a handheld CO2 meter or an electronic
integrated CO2 meter.

Appendix 1
HY-light broiler eggs, age PS up to 40 - 45 weeks, eggs stored

maximum 3 days 1)
Moment of Incubation temperature Relative Ventilation Turning
setpoint change humidity
(day.hour) Set point
2)
Eggshell temp
2)
Set point
3)
Set point
4) Set point
(°F) (°F) (%) (% valve) (positions)
- 0.05 - - 0.08 77.0 – 81.0 - 53 0 horizontal = 0
0.00 100.4 100.0 53 0 2
1.00 100.2 100.0 53 0 2
2.00 100.0 100.0 53 0 2
3.00 99.9 100.0 53 10 2
4.00 99.9 100.0 53 10 2
5.00 99.9 100.0 53 10 2
6.00 99.9 100.0 53 20 2
7.00 99.8 100.0 53 30 2
8.00 99.8 100.0 53 40 2
9.00 99.8 100.0 53 40 2
10.00 99.7 100.0 53 40 2
11.00 99.5 100.0 53 50 2
12.00 99.2 100.0 53 50 2
13.00 98.8 100.1 53 50 2
14.00 98.5 100.5 53 60 2 or 3
15.00 98.3 101.0 53 60 2 or 3
16.00 98.0 101.3 53 60 2 or 3
17.00 98.0 101.5 53 70 2 or 3
18.00 98.0 101.5 53 70 2 or 3
1) The guidelines in the table apply to hatcheries at an altitude of a maximum 800 – 1200 metres above sea
level, with eggs produced at the same altitude. Information how to adjust these guidelines for higher
altitudes can be found in Appendix 5 (page 87).
2) The eggshell temperature is the main parameter for the temperature set point. If the eggshell temperature
deviates too much from the desired eggshell temperature, the incubator temperature set point should be
adjusted. For measuring the average eggshell temperature see Systematic analysis of eggshell temperature
(see "Analysis of eggshell temperature" page 32),
weight loss should be approximately 10% (young flocks) to 13% (old flocks); see Relative humidity and egg
weight loss (Jump Template) (see "Relative humidity and egg weight loss" page 34).

Additional notes:
recommended to load the incubator with one type of eggs in
terms of breed, maternal age and storage days.
• The set points in the table should only be used as guidelines.
2) 3) 4)
• When the incubator is not completely filled with eggs, use
the eggshell temperature as a reference for the temperature
set point.

8.2 Appendix 2
HY-light broiler eggs, age PS up to 40 - 45 weeks, eggs stored 4

days and more 1)
Moment of Incubation temperature Relative Ventilation
2)
Eggshell temp
2)
Set point
3)
Set point
4) Set point
- 0.05 - - 0.08 77.0 – 81.0 - 53 0 horizontal = 0
Start 1 hour 100.4 100 53 0 2
earlier per extra
day of storage
0.00 100.4 100.0 53 0 2
1.00 100.2 100.0 53 0 2
2.00 100.0 100.0 53 0 2
3.00 99.9 100.0 53 10 2
4.00 99.9 100.0 53 10 2
5.00 99.9 100.0 53 10 2
6.00 99.9 100.0 53 20 2
7.00 99.8 100.0 53 30 2
8.00 99.8 100.0 53 40 2
9.00 99.8 100.0 53 40 2
10.00 99.7 100.0 53 40 2
11.00 99.5 100.0 53 50 2
12.00 99.2 100.0 53 50 2
13.00 98.8 100.1 53 50 2
14.00 98.5 100.5 53 60 2 or 3
15.00 98.3 101.0 53 60 2 or 3
16.00 98.0 101.3 53 60 2 or 3
17.00 98.0 101.5 53 70 2 or 3
18.00 98.0 101.5 53 70 2 or 3
(see "Analysis of eggshell temperature" page 32).
4) The main parameter for ventilation is the CO2 concentration in the incubator. The CO2 level may increase from
about 0.06% at the start of incubation to 0.40% at transfer. The level of CO2 can be measured using a handheld
CO2 meter or an electronic integrated CO2 meter.

Additional notes:
2) 3) 4)
set point.

8.3 Appendix 3
HY-heavy broiler eggs, age PS up to 40 - 45 weeks, eggs stored

maximum 3 days 1)
2)
Eggshell temp
2)
Set point
3)
Set point
4) Set point
- 0.08 77.0 – 81.0 - 53 0 horizontal = 0
0.00 100.4 100.0 53 0 2
1.00 100.2 100.0 53 0 2
2.00 100.0 100.0 53 0 2
3.00 99.9 100.0 53 10 2
4.00 99.9 100.0 53 10 2
5.00 99.9 100.0 53 10 2
6.00 99.9 100.0 53 20 2
7.00 99.8 100.0 53 30 2
8.00 99.8 100.0 53 40 2
9.00 99.5 100.0 53 40 2
10.00 99.2 100.0 53 40 2
11.00 99.0 100.0 53 50 2
12.00 98.8 100.0 53 50 2
13.00 98.4 100.2 53 50 2
14.00 98.2 100.5 53 60 2 or 3
15.00 98.0 100.8 53 60 2 or 3
16.00 97.8 101.0 53 60 2 or 3
17.00 97.5 101.0 53 70 2 or 3
18.00 97.5 101.0 53 70 2 or 3
(see "Analysis of eggshell temperature" page 32).

Additional notes:
2) 3) 4)
set point.

8.4 Appendix 4
HY-light broiler eggs, age PS over 40 - 45 weeks (less than 20%

clears), eggs stored maximum 3 days 1)
2)
Eggshell temp
2)
Set point
3)
Set point
4) Set point
- 0.05 - - 0.08 77.0 – 81.0 - 53 0 horizontal = 0
0.00 100.4 100.0 53 0 2
1.00 100.2 100.0 53 0 2
2.00 100.0 100.0 53 0 2
3.00 99.9 100.0 53 10 2
4.00 99.9 100.0 53 10 2
5.00 99.9 100.0 53 10 2
6.00 99.9 100.0 53 20 2
7.00 99.8 100.0 53 30 2
8.00 99.8 100.0 53 40 2
9.00 99.7 100.0 53 40 2
10.00 99.6 100.0 53 40 2
11.00 99.4 100.0 53 50 2
12.00 99.0 100.0 53 50 2
13.00 98.6 100.1 53 50 2
14.00 98.3 100.5 53 60 2 or 3
15.00 98.1 101.0 53 60 2 or 3
16.00 97.8 101.3 53 60 2 or 3
17.00 97.8 101.5 53 70 2 or 3
18.00 97.8 101.5 53 70 2 or 3
1) The guidelines in the table apply to hatcheries at an altitude of a maximum 800 – 1200 metres above sea level,
with eggs produced at the same altitude. Information how to adjust these guidelines for higher altitudes can be
found in Appendix 5 (page 87).
adjusted. For measuring the average eggshell temperature see Systematic analysis of eggshell temperature (see
"Analysis of eggshell temperature" page 32).
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 Relative humidity and egg weight loss (page
34).
4) The main parameter for ventilation is the CO2 concentration in the incubator. The CO2 level may increase from
about 0.06% at the start of incubation to 0.40% at transfer. The level of CO2 can be measured using a handheld
CO2 meter or an electronic integrated CO2 meter.

Additional notes:
2) 3) 4)
set point.

8.5 Appendix 5
Hatching at high altitudes
Background
The effects of hatching at high altitude on hatchability and chick
quality depend 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. Fresh ventilating air
will tend to be colder and drier than at sea level.
Oxygen availability
The oxygen content of air is always 21 %, but reduced partial
pressure at altitude provides less oxygen from a given volume
of air. This pressure reduction results in lower levels of oxygen
for the embryo, which is partially compensated by the embryo's
higher capacity for binding oxygen to blood. 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.
Water loss
It is reasonable to assume that the drier air at altitude will result
in increased moisture loss from the eggs. However, it is
important to realize that breeder flocks adapt to altitude by
producing eggs with a lower effective pore area. This offsets
increased diffusion and therefore water vapour loss through the
egg shell at any altitude remains the same as at sea level.
Conclusions
The following three scenarios are considered:
Eggs produced at sea level: hatchery at altitude (1.000 to 2.000
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 will
therefore lose more water at higher altitudes. To compensate,
setters and hatchers should be operated at a higher relative
humidity. This is best achieved by pre-conditioning the inlet air
to a relative humidity of 75 %, with a temperature of 24 - 28°C
(optimum). At the same time, increase the ventilation rate from
normal for sea level, to accommodate the reduced oxygen
levels.

Eggs produced at same altitude as hatchery (1.000 to 2.000
meters)
In general this will give good results. Ventilation rates should be
higher than normal for sea level. During humid external
conditions, increase ventilation even more, as humidity reduces
oxygen levels in the air still further. This higher ventilation rate
may cause reduced humidity in the setters and hatchers. To
avoid constant humidifying, humidity set points should be
lowered and the resulting more than optimal weight loss (eg. 14
- 15%) is preferred in this case.
Eggs produced at altitude; hatchery at sea level
Generally, this will give good results. The set points for relative
humidity need to be reduced to achieve optimum weight loss as
the eggs have a reduced effective pore area.
Advice
Exact set points for relative humidity are dependent on a.o.
altitude and egg shell conductivity (age flock, nutrition,
genetics). It is therefore recommended that relative humidity
set points are fine-tuned by weighing trays of eggs before
setting and again at transfer at 18, 18.5 days.
Optimum weight loss for good hatchability and chick quality is
indicated in the table.
Age breeder flock Optimum weight loss (%)

Young flocks 10-11
Medium flocks 11-12
Old flocks 12-13
Optimum weight loss for good hatchability and chick quality based on
experience
Alternatively the size of the aircell provides an indicator of
weight loss. If during an egg-breakout too many wet, fully
developed embryo's that fail to pip are observed, this indicates
insufficient weight loss and/or a shortage of oxygen. In this
case, set points for relative humidity should be reduced and/or
ventilation rate should be increased.
For further information or advice, please contact the Pas Reform
Academy.

9. Recording Forms

Recording Form 1A: Golden rules for a hatchery
Egg storage - Do not clean the room and equipment when hatching eggs are present.
room - Check daily temperature and humidity and compare with recommendation.
Setter room - Room temPerature 25 – 27ºC/77.0 – 80.6ºF.

- Room relative humidity 50%–55%.
- Thoroughly clean and dry the floor every week.
- Positive air pressure in relation to other rooms in hatchery.
- Always keep doors closed.
Setters - Check before start of every cycle:

o V-belt (cracks);
o heating and cooling system;
o humidifying system (water level, rotation);
o humidity sensor (water level, clean wick);
o turning system with the trolleys placed in the machine;
o CO2-sensor (remove protection cap).
- Machine must be dry when eggs are coming in.
- Check incubation program or set points and adjust if necessary.
Transfer room - Room temperature 25ºC/77.0ºF.

- Doors closed after passing.
- On transfer day: no more than 2 trolleys out of the machine.
Hatcher room - Room temperature 25ºC/77.0ºF.

- Dry and clean.
- Doors closed after passing.
Hatchers - Check before start of every cycle:

o V-belt (cracks);
o heating and cooling system;
o humidifying system (water level, rotation);
o humidity sensor (water level, clean wick);
o CO2-sensor (remove protection cap).
- Machines dry and pre-warmed to set point temperature before loading.
- Check set points and adjust if necessary.
Chick handling - Room temperature 22 – 28ºC/71.6 – 82.4ºF.

room - Room relative humidity 55%–60%.
- On take-off day: do not pull more than two trolleys out of the machine.
Chick - Room temperature 22 – 28ºC/71.6 – 82.4ºF.

despatch room - Room relative humidity 55%–60%.
- 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: 25ºC/77.0ºF.

- Truck must be dry and properly cleaned and disinfected.
- Trolleys must be securely tied.
- Avoid delay during transport.
Pas Reform Hatchery Technologies, P.O. Box 2, 7038 ZG, Zeddam, The Netherlands, telephone +31 314 659 111, fax +31 314 652 575,
E-mail info@pasreform.com

Recording Form 2A: 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- Production Hatching eggs Non-hatching eggs

code date Washed
Normal size Small Floor eggs Others
eggs
TOTAL DELIVERED
TOTAL RECEIVED
Climate storage room at breeder farm
Temperature Humidity %
Transport conditions
Departure time Arrival time

Truck temperature Truck temperature
Truck disinfectant
Name supplier
Signature supplier Signature on behalf of
hatchery

Recording Form 2B: Egg container card
Supplier
Name
Address
Postal code
Telep hone
Egg ID-code
Production date
Date of receipt
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

Recording Form 2C: Hatching egg quality upon receipt
Egg Date of Egg Number Number of eggs Remarks

ID- receipt temperature of eggs Poor Cracks Dirty Upside-
code sampled shell down
quality

Recording Form 2D: Hatching egg stock list
Egg ID- Production Date of Number of Number of Stock Remarks

code date receipt hatching eggs set
eggs

Recording Form 2E: Setter schedule
Setter number
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.




Prod. Date Prod. Date Prod. Date Prod. Date

Prod. Date Prod. Date Prod. Date Prod. Date

Recording Form 2F: Egg storage room: climate conditions
Recommended climate conditions during egg storage

Storage duration Temperature (°C/°F) Relative humidity (%) Egg orientation
0 - 3 day s 18 - 21 / 64.4 - 69.8 75 Blunt end up
4 - 7 days 15 - 17 / 59.0 - 62.6 75 Blunt end up
8 - 10 days 10 - 12 / 50.0 - 53.6 80 - 88 Blunt end up
More than 10 days 10 - 12 / 50.0 - 53.6 80 - 88 Small end up or
alternatively turning the
eggs every 24 hours
Date Te mperature Humidity Remarks Date Te mperature Humidity Remarks

% %
Date of accuracy check thermometer
Date of accuracy check hygrometer

Recording Form 3A: Incubator recording form
Setter number Hatcher number

Setting date Hatching date
Starting time Starting time
Check setter V-belt Check hatcher V-belt
Heating Heating
Cooling Cooling
Humidifier and sensor Humidifier and sensor
CO2-sensor CO2-sensor
Turning
Transfer date and time
Egg ID- Production Trolley numbers Number of eggs Number of eggs after
code date candling
Total
Name incubation program
Display Te mperature Relative Ventilation Display Te mperature Relative Ventilation

time (°F) Humidity (%) time (°F) Humidity (%)
(day.hour) (%) (day.hour) (%)
0.00 17
1 18
2 19
3 20
4 21
5 22
6 23
7 24
8 25
9 26
10 27
11 28
12 29
13 30
14 31
15 32
16 33

Recording Form 3B: Eggshell temperature
Setter number Name incubation program
Set point Display

Date of measuring Temp erature
Start date of Relative humidity
incubation cycle
Incubation time 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
Egg no. 13
Egg no. 14
Egg no. 15
Average
Average of all

Recording Form 3C: Egg weight loss
Setter number
Start date of
incubation cycle
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

Recording Form 4A: Analysis of clear eggs
Start date of incubation

cycle
Egg ID-code Breed

Production date Maternal age
Setter number Storage days
Trolley
Tray
To tal clears
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)
17 Abnormalities

Recording Form 5A: Analysis of unhatched eggs

cycle
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 6A: Pasgar©Score

cycle
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 Tota l
Average Pasgar©Score

Recording Form 6B: Chick passport
Setting date Setter number

Hatching date Country of destination
Egg ID-code Number of chicks Quality of chicks Treatments Person carrying

out the 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
Signature truck driver Signature customer

Recording Form 7A: Hatching results
Start date
incubation cycle
Egg ID-code
Production date
Breed
Maternal age
Storage days
% clears
% saleable chicks
of eggs set
% saleable chicks
of transferred eggs
% 2nd class chicks
1st week mortality

Recording Form 7B: Results egg analysis and Pasgar©Score
Start date
incubation cycle
Egg ID-code
Production date
Breed
Maternal age
Storage days
Pasgar©Score
(6A)
Egg analysis
(4A and 5A)
Category 1
Category 2
Category 3
Category 4
Category 5
Category 6
Category 7
Category 8
Category 9
Category 10
Category 11
Category 12
Category 13
Category 14
Category 15
Category 16
Category 17

Recording Form 7C: Cleaning schedule
Room/equipment
Instructions
Detergent
Disinfectant
Frequency
Date Name Signature Date Name Signature

Recording Form 7D: 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 7E: Checklist climate conditions in hatchery
Date
Temp erature (°C/°F) Relative humidity (%) CO2 (ppm)1

Room
recommended actual recommended actual recommended actual
Egg store
Room 1: 1 – 3 days 18 – 21 64.4 – 69.8 75
Room 2: 4 – 7 days 15 - 17 59.0 – 62.6 75
Room 3: over 1 week 10 - 12 50.0 – 53.6 80 – 88
Fumigation room 21 - 25 69.8 – 77.0 65 – 75
Setter room 25 – 27 77.0 -80.6 50 – 55 500 – 600
Candling/transfer room 25 – 27 77.0 -80.6 50
Hatcher room 25 77.0 50 – 55 500 – 600
Chick handling room 22 – 28 71.6 – 82.4 50 – 60 500 – 600
Chick despatch room 22 – 28 71.6 – 82.4 55 – 60 500 – 600
1
500 – 600 ppm = 0.05 - 0.06 % CO2
Date of accuracy check thermometer
Date of accuracy check hygrometer
Date of accuracy check CO2 -meter

Recording Form 7F: Setter maintenance card
Setter number
Dat e P/ C* Descrip t ion Act ion Signat ure
* P = preventive maintenance; C = corrective maintenance

Recording Form 7G: Hatcher maintenance card
Hatcher number

Recording Form 7H: Hatchery equipment maintenance card
Name hatchery equipment

Index eggshell temperature • 22,
25, 32
A F
About this manual • 4 Floor eggs • 12
Analysis of clear eggs • 24, Formaldehyde treatment of
25, 28, 29, 38, 41, 64, 66, chicks in hatcher • 44, 45,
67 46, 48
Analysis of eggshell fumigation • 25
temperature • 24, 26, 28,
Fumigation • 18, 19
29, 32, 66, 78, 79, 81, 83,
85 H
Analysis of unhatched eggs
• 44, 50, 64, 66, 67 HACCP • 7
Appendices • 77 Hatchery hygiene • 63, 71
Appendix 1 • 26, 79 Hatchery maintenance • 75
Appendix 2 • 81 Hatchery management • 6,

61
Appendix 3 • 83
Hatching of broiler eggs
Appendix 4 • 26, 85
day 19-21 • 43
Appendix 5 • 78, 79, 81, 83,
85, 87 hygiene • 10
Assessing chick quality I

Pasgar©Score • 54, 57,
Incubation of broiler eggs
64, 66, 67
day 1-18 • 21
C Incubation program • 25
Candling and transfer • 37, Incubation program hatcher
38, 39 • 44, 45
Chick despatch and Introduction • 3, 10, 22, 38,
transport • 54, 59 44, 54, 62, 78
Chick handling • 53
M
chick quality • 11, 14, 23,
24, 25, 28, 32 Multi-stage incubation
settings • 22, 28, 66
Chick take-off • 54, 55
CO2 concentration • 25 O
Continuous improvements • Outline of the Incubation
41, 42, 51, 58, 62, 64 Guide • 5
D R
Disinfecting hatching eggs • Recording Form 1A
11, 18
Golden rules for a
E hatchery • 6, 90
Recording Form 2A
Egg handling • 9
Egg receipt form • 12,
Egg quality • 12
13, 91
Egg receipt • 10, 12, 16, 89
Recording Form 2B
egg weight loss • 23, 25, 34

Egg container card • 12, Cleaning schedule • 71,
13, 14, 92 72, 106
Recording Form 2C Recording Form 7D
Hatching egg quality Registration of visitors •
upon receipt • 12, 13, 71, 107
93 Recording Form 7E
Recording Form 2D Checklist climate
Hatching egg stock list • conditions in hatchery
12, 13, 14, 16, 17, 94 • 75, 108
Recording Form 2E Recording Form 7F
Setter schedule • 12, 13, Setter maintenance card
14, 16, 24, 25, 28, 29, • 75, 76, 109
39, 45, 47, 95 Recording Form 7G
Recording Form 2F Hatcher maintenance
Egg storage room card • 75, 76, 110
climate conditions • 14, 15, Recording Form 7H
96 Hatchery equipment
Recording Form 3A maintenance card •
Incubator recording form 75, 76, 111
• 24, 25, 28, 29, 39, Recording Forms • 89
40, 45, 46, 75, 97 Relative humidity • 23, 25
Recording Form 3B Relative humidity and egg
Eggshell temperature • weight loss • 24, 26, 28, 29,
32, 33, 98 34, 66, 78, 79, 81, 83, 85
Recording Form 3C
S
Egg weight loss • 34, 35,
99 Setting eggs • 10, 16
Recording Form 4A Setting eggs in setter trays
and trolleys • 10, 16
Analysis of clear eggs •
41, 100 Single-stage incubation
program • 22, 24, 32, 66
Recording Form 5A
Storage of hatching eggs •
Analysis of unhatched
10, 14, 18
eggs • 50, 51, 101
Recording Form 6A V
Pasgar©Score • 57, 58, Ventilation • 25
102
Recording Form 6B
Chick passport • 55, 56,
59, 60, 103
Recording Form 7A
Hatching results • 64,
104
Recording Form 7B
Results egg analysis and
Pasgar©Score • 41,
50, 57, 64, 67, 105
Recording Form 7C

2010-01-12 Incubation Guide Broiler V1

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Incubation Guide

2. Egg handling .......................................................................9

3. Incubation of broiler eggs: day 1-18 ..............................21

4. Candling and transfer ......................................................37

5. Hatching of broiler eggs: day 19-21 ...............................43

6. Chick handling .................................................................53

7. Hatchery management ...................................................61

Incubation Guide - Broiler - Version: 4.0 i

9. Recording Forms ...............................................................89

ii Incubation Guide - Broiler - Version: 4.0

Incubation Guide - Broiler - Version: 4.0 3

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Incubation of eggs: day 1-18

Hatching of eggs: day 19-21

Incubation Guide - Broiler - Version: 4.0 5

• Objective: the aim of the procedure

Golden rules for a hatchery

6 Incubation Guide - Broiler - Version: 4.0

Seven HACCP principles

The seven basic HACCP principles are:

Incubation Guide - Broiler - Version: 4.0 7

Incubation Guide - Broiler - Version: 4.0 9

Storage of hatching eggs

The procedure (see "Storage of hatching eggs" page 14)

Setting eggs in setter trays and trolleys

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Recommended climate conditions during egg storage

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1 Place the setter trolleys with trayed eggs in the fumigation

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1 Place the setter trolleys with trayed eggs in the fumigation

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Single-stage incubation program

Multi-stage incubation settings

Consequently, set points for temperature, relative humidity,

Systematic analysis of eggshell temperature

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General guideline single-stage incubation program for broiler eggs 1)

Moment of set Incubation temperature Relative Ventilation Turning

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Recommended multi-stage incubation settings for broiler eggs

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Measure the egg shell temperature with the probe placed at a

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Optimum weight loss depends on flock age

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