Hatchery Incubation Guide English L9180-2

Hatchery
Management
Guide
Hatchery Management Guide - Version L9180-2 1
Contents
1 Introduction 5
1.1 Outline of the Incubation Guide 7
1.2 Golden rules for a hatchery 9
1.3 Quality Management System 10

2 Egg handling 11
2.1 Introduction 12
2.2 Egg handling at the breeder farm 13
2.3 Egg transport to the hatchery 17
2.4 Egg receipt 19
2.5 Setting eggs in setter trays and trolleys 20
2.6 Pre-storage incubation 21
2.7 Storage of hatching eggs 23
2.8 Disinfecting hatching eggs 26

3 Incubation in setter: day 1 – 18 28
3.1 Introduction 29
3.2 Single-stage incubation 30
3.3 Multi-stage incubation 33

4 Candling and transfer 35
4.1 Introduction 36
4.2 10-day candling 37
4.3 Candling and transfer 39

5 Incubation in hatcher: day 19 – 21 41
5.1 Introduction 42
5.2 Incubation in hatcher: day 19 - 21 43
5.3 Application of disinfectant during hatching 46

6 Chick handling 48
6.1 Introduction 49
6.2 Chick take-off 50
6.3 Vaccination day-old-chicks 52
6.4 Sexing day-old-chicks 55
6.5 Chick dispatch and transport 59
6.6 Unloading and brooding chicks at the farm 61
2 Hatchery Management Guide - Version L9180-2

7 Tools for fine-tuning 62
7.1 Introduction 63
7.2 Analysis of hatching egg quality upon arrival 64
7.3 Analysis of shell temperature 68
7.4 Analysis of egg weight loss 70
7.5 Analysis of clear eggs 72
7.6 Analysis of unhatched eggs 73
7.7 Analysis of chick quality: Chick Score 74

8 Data analysis for continuous improvements 76
8.1 Introduction 77
8.2 Basics of hatchery specific database 78
8.3 Construction of a hatchery specific database 79
8.4 Evaluation of hatchery results 80
8.5 Trouble shooting 81

9 Hatchery hygiene 85
9.1 Introduction 86
9.2 Prevention of pathogens entering the hatchery 87
9.3 Prevention of cross-contamination 89
9.4 Cleaning and disinfection 90
9.5 Hatchery hygiene monitoring 92

10 Hatchery maintenance 94
10.1 Introduction 95
10.2 Preventive maintenance 96
10.3 Spare parts 98
10.4 Setter and hatcher 99
10.5 Hatchery climate 100
10.6 Hatchery automation and auxiliary hatchery equipment 103

11 Annexes 104
11.1 Sweating of eggs 106
11.2 Hatching at altitude 112
11.3 Optimization of Brooding conditions for day-old chicks 112
11.4 Cull egg chart white eggs 115
11.5 Cull egg chart brown eggs 115
11.6 Colour spectrum chart brown eggs 116

12 Glossary 117

13 Recording forms 120

The Hatchery Management Guide is a manual for use in daily hatchery practice.
The first chapters in the Incubation Guide consist of several subchapters each containing practical procedures needed
for the successful incubation of layer eggs, from egg handling at the breeder farm, up to placement of the day-old
chicks.
In addition to these procedures, several 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 Hendrix Genetics at:
Villa ‘de Körver’

P.O. Box 114
5830 AC, BOXMEER
The Netherlands, EU
T +31 485 319111

E layinghens@hendrix-genetics.com
layinghens.hendrix-genetics.com
Please note that all figures in this manual are provided as guidelines only. Hendrix Genetics cannot be held liable for
incorrect interpretation of the contents of this manual.
© Copyright 2019 Hendrix Genetics, Boxmeer, The Netherlands.

All rights reserved.
Version L9180-2

1 Introduction

1 Introduction
1.1 Outline of the Incubation Guide

1.2 Golden rules for a hatchery
1.3 Quality Management System

1 Introduction
1.1 Outline of the Incubation Guide

The route ‘from egg to chick’ is essential in hatchery management. Hatchery routing can be divided into five steps:
egg handling, incubation in setter (day 1-18), transfer, incubation in hatcher (day 19-21) and chick handling.
Egg handling
- At the breeder farm
- Transport to the hatchery
- Receipt and quality control
- Repack in setter trays and trolleys
- Pre-storage incubation
- Storage
- Disinfection
Incubation in setter: day 1-18

- Single-stage/multi-stage
Egg transfer
- Candling
- Transfer
Incubation in hatcher: day 19-21

- Incubation program hatcher
- Application of disinfectants during hatching period
Chick handling
- Take-off
- Grading
- Sexing
- Vaccination
- Infra-red beak treatment
- Holding
- Transport
- Unloading and brooding at the farm
Five basic steps in hatchery routing

These five steps constitute the framework of chapters 2 - 6 of this Incubation Guide: each of these chapters describes, in
subchapters, all relevant procedures belonging to one of the steps in hatchery routing.
The procedures are all structured as follows:

• Objective: the aim of the procedure.
• Persons responsible: personnel that usually carry out the tasks described.
• Documents: recording forms related to the procedure; these can be found in Chapter 13: Recording Forms.
• Definitions: descriptions for several specific terms used in the procedure; refer to Chapter 12: Glossary for definitions of
underlined terms.
• Recommended procedure: a step-by-step guideline on how to carry out the tasks.
• Additional notes: supplementary advice, precautions etc. For ease of reading key words within the additional notes
are marked in bold.
• Text boxes: extra information which requires special attention is placed in text boxes.
Chapter 7 contains all procedures for collecting additional hatchery data. These data are relevant in the process of
analyzing where breeder farm and hatchery management and incubation programs could be improved.
Chapter 8 provides general guidelines to monitor hatchery results using a hatchery specific reference set of data
aimed at continuous improvements and to ensure durable operation of the hatcher. It forms the basis for fine-tuning
incubation program’s and troubleshooting.
Chapter 9 describes relevant aspects of hatchery hygiene and includes procedures for cleaning and disinfection as well
as for microbiological monitoring.
Chapter 10 highlights the importance of hatchery climate and preventative maintenance.
Chapter 11 consists of subchapters with more in-depth information about various aspects of incubation management
that is too lengthy or detailed to include in previous chapters.
Chapter 12 is the glossary containing a list of definitions of terms used in the procedures; the terms which are
underlined are explained in the glossary.
Chapter 13 contains all the Recording Forms, whereby the number of the Recording Form corresponds with the chapter
in which they are mentioned.

1 Introduction
1.2 Golden rules for a hatchery

The structure of the table below “Golden rules for a hatchery” corresponds with the steps in hatchery routing. ‘Golden
rules for a hatchery’ forms the basis of good hatchery management. Summarizing some crucial key aspects that arise in
hatchery practice, this list provides a useful tool for hatchery managers in daily hatchery routine.
- Do not clean the room and equipment when hatching eggs are present.
Egg storage room
- Check temperature and humidity daily and compare with recommendation.
- Ensure inlet air to setter meets the recommended climate conditions.

- Thoroughly clean and disinfect the floor every week.
Setter room
- Positive air pressure in relation to other rooms in hatchery.
- Always keep doors closed.
- Check the proper functioning of setter before every new cycle.
- Machine must be dry when eggs are coming in.
Setters
- Load incompletely filled setters correctly.
- Check incubation program or set points and adjust if necessary.
- Room temperature 21 – 27 °C / 70 – 81 °F; avoid draught directly on eggs.

Transfer room - Doors closed after passing.
- On transfer day: no more than 2 trolleys out of the machine.
- Ensure inlet air to hatcher meets the recommended climate conditions.

Hatcher room - Dry and clean.
- Doors closed after passing through.
- Check the proper functioning of hatcher before every new cycle.

- Machines dry and pre-warmed to set point temperature before loading.
Hatchers
- Load incompletely filled hatchers correctly.
- Check set points and adjust if necessary.
- Room temperature 24 – 27 ºC / 75 – 81 ºF.
- Room relative humidity 40 – 65%
Chick handling room
- On take-off day: do not pull more than two trolleys out of the machine at the
same time.
- Room temperature 24 – 27 ºC / 75 – 81 ºF.

- Room relative humidity 55 – 70%
Chick dispatch room - Good air supply and circulation; avoid draught.
- Do not put chick boxes directly on the floor.
- Look and listen to behavior of the chicks.
- Check temperature before loading the truck: 24 – 27 ºC / 75 – 81 ºF.

- Truck must be dry and properly cleaned and disinfected.
Chick truck
- Trolleys must be securely tied.
- Avoid delay during transport.

1.3 Quality Management System
The hatchery, as a segment of the food production chain, aims to produce a safe product of good quality which forms
the input for the next segment of the food production chain: vital chicks that are free of pathogens. All processes in the
hatchery contribute in achieving this goal.
This Incubation Guide provides the hatchery manager with guidelines to operate the hatchery according to clearly
described Standard Operating Procedures (SOP), which could be used also for staff training. The persons responsible
for the correct carrying out of the procedures are specified. Recording forms are useful for tracking and tracing in case
of an uneventful infection of a specific batch of eggs with pathogens relevant to food safety or national disease control
programs. The recording of relevant data also offers the opportunity for evaluation of the production process leading to
continuous improvements. These aspects are required items in most quality management systems. Some rewriting of
(or parts of) the text might be needed to fulfill the individual needs of each hatchery, but this Incubation Guide offers a
good starting point.

2 Egg handling

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

A healthy, well managed breeder flock, receiving a balanced feed ration, has the potential to produce good quality hatching eggs.
At the moment the egg is laid, it contains an embryo consisting of 30,000 – 60,000 cells. At that point in time, each cell is already
programmed for its future function. Only with the best of care, this delicate embryo will realize maximum hatching potential.
The procedure in this subchapter (2.2) describes how to provide optimum care for the hatching eggs at the breeder farm until they are
transported to the hatchery.
2.3 Egg transport to the hatchery

Breeder farms are often situated some distance away from the hatchery. Typically, deliveries of hatching eggs vary from daily to
twice weekly. Egg transport is generally by truck, although when importing hatching eggs air transport may also be used. During
transportation from farm to hatchery, mechanical and temperature shocks should be avoided since this affects hatching potential.
Climate and hygiene must be monitored to prevent a deterioration of hatching egg quality before arrival at the hatchery.
The procedure in this subchapter (2.3) outlines how to transport hatching eggs in optimal conditions to the hatchery.
2.4 Egg receipt

On arrival of eggs at the hatchery, it should be confirmed that the number corresponds with the number recorded by the breeder
farm manager. At this time, hatching eggs should also be separated from non-hatching eggs and a sample for quality monitoring could
be taken.
The procedure in this subchapter (2.4) comprises a general inspection of the quantity and quality of eggs supplied by the breeder farm.
2.5 Setting eggs in setter trays and trolleys

Eggs can arrive at the hatchery on paper or small plastic trays in boxes, in egg containers or on pallets. At some point the eggs need
to be set on setter trays. This offers the opportunity for a complete quality control check and to remove the eggs unsuitable for
hatching. When eggs arrive in the hatchery already placed on setter trays, they only have to be transferred to setter trolleys.
The procedure in this subchapter (2.5) provides relevant points of attention for the setting of eggs in setter trays and trolleys.
2.6 Pre-storage incubation

Pre-storage incubation is a management tool aimed at making embryo’s more storage-resistant and can be applied when eggs arrive
at the hatchery (up to 3 – 4 days after production date). Pre-storage incubation is only beneficial if the embryos in the eggs are in a
very early stage of development. If embryo development is already more advanced when eggs arrive in the hatchery, pre-storage
incubation will lead to increased early embryonic mortality and should be avoided.
The procedure in this subchapter (2.6) provides guidelines how to establish a suitable pre-storage incubation protocol in the hatchery.
2.7 Storage of hatching eggs

Usually, storage of the eggs prior to incubation is normal practice. The storage time, temperature and relative humidity at which the
eggs are stored are very important for the hatching result.
The procedure in this subchapter (2.7) outlines the optimum climatic conditions for storage.
2.8 Disinfecting hatching eggs

Micro-organisms on the surface of eggshells can have detrimental effects on hatchability and chick quality. It is therefore essential
that the eggs are disinfected prior to incubation. This can be done already at the breeder farm, prior to incubation or alternatively at
the moment that the eggs arrive at the hatchery.
The procedure in this subchapter (2.8) outlines how to disinfect hatching eggs in a special designed disinfection room.

2.2 Egg handling at the breeder farm
Objective
To provide optimum care for the hatching eggs until they are transported to the hatchery in order to maintain maximum
hatching potential.
Persons responsible
Breeder farm manager and personnel assigned to collect, grade and store eggs until they are transported to the
hatchery.
Documents
Recording Form 2A: Egg transport card.
Recording Form 2B: Egg receipt form.
Recording Form 2F: Egg storage room: climate conditions.
Definitions
Refer to glossary for definitions of underlined terms.
Recommended procedure
1. Ensure sufficient, comfortable and easily accessible nest space according to the specifications in the specific Parent
Stock Management Guide taking local conditions into consideration. Avoid direct light and draughts into the nests.
2. Keep nests clean at all times. Extra care for nest hygiene should be given at least 1 time per week.
3. Wash and disinfect hands before each egg collection.
4. Collect eggs from the nest at least 4 times per day in case of manual litter nests and at least 2 times per day from
automatic roll away nests under the condition that temperature on the egg transport belt is 20 – 22 °C / 68 – 72 °F.
At lower and higher temperatures, the frequency of egg collection should be increased.
5. Avoid shocks and jolting in handling in order to prevent damage to the fragile embryonic structure and hairline
cracks in the shell.
6. Aim at eggs uniformly cooling down from 41 °C / 106 °F (the hen’s body temperature and thus the egg temperature
at oviposition) to between 22 and 25 °C / 72 and 77 °F in approximately 6 hours. Too fast and too slow cooling
down should be avoided. Therefore, maintain a temperature of 20 – 22 °C / 68.0 – 72 °F in the egg collection room.
7. Separate non-hatching eggs from hatching eggs. Also keep floor eggs separate.
8. Record the number of hatching eggs and non-hatching eggs (optionally per category, such as double yolks, cracked
eggs, floor eggs etc.) into the daily breeder farm records.
9. Place hatching eggs on well-designed egg trays (paper or plastic) or setter trays with sharp end down. Avoid the use
of floppy trays and do not over stack.
10. Print the farm and house number and country of origin clearly on each egg if this is required by legislation.
11. Place the egg trays in egg containers or boxes after all the eggs have cooled down to 22 - 25 °C / 72 - 77 °F. Place
setter trays in farm trolleys and allow eggs to cool down gradually before placement in the egg storage room.
12. Supply each (full) egg container or box or farm trolley with Recording Form 2A: Egg transport card on which egg ID
code, production date and egg numbers are listed.
13. Place the egg containers/boxes/farm trolleys in the egg storage room until they are collected to be transported to
the hatchery.
14. Maintain recommended climate conditions in the egg storage room depending on the intended duration of storage
or as agreed with the hatchery manager (see table below).
15. Monitor the climate conditions daily and record them on Recording Form 2F: Egg storage room: climate conditions.
16. Check proper functioning of any thermometers and hygrometers at regular intervals by comparing with a calibrated
device. Record the date of checking on Recording Form 2F: Egg storage room: climate conditions.
17. Complete Recording Form 2B: Egg receipt form prior to transport to the hatchery and sign the form. This recording
form contains technical data about the parent flock and the quantity and quality of the delivered eggs.

2 Egg handling
Recommended climate condition during egg storage

Storage duration Temperature (°C/°F) Relative humidity* (%) Egg orientation
0-3 days 18-21 / 64–70 75 – 85 Blunt end up
4-7 days 15-17 / 59–63 75 – 85 Blunt end up
8-10 days 12-14 / 54-57 80 – 85 Blunt end up
Preferably small end up or
More than 10 days 12-14 / 54-57 80 – 85 turning the eggs an uneven
time per day
*
The recommended relative humidity range for eggs stored on paper trays is 50 – 75%; the risk for dehydration is
much smaller on paper trays and the occurrence of floppy trays due to too high relative humidity should be avoided.
Ensure sufficient, comfortable and easily accessible nest space

Good Eggs
Normal (oval) shape with one end larger than the other and tapers towards the small end. The shell is smooth, without
pimples, rough areas, wrinkles or ridges. There are no cracks, windows or flat sides.
Additional notes
• A healthy, well managed breeder flock, receiving a balanced feed ration has the potential to produce good quality
hatching eggs. At the moment the egg is laid, it contains an embryo of 30,000 – 60,000 cells. At that point in time,
each cell is already programmed for its future function. Only with the best of care can the hatching potential held in
this delicate embryonic structure be kept at its maximum potential. This care should already be given at the breeder
farm from the moment the egg is laid. Poor egg handling at the breeder farm cannot be compensated later on in the
hatchery!
• Good breeder farm management includes full attention for the production of good quality hatching eggs. This does
not only include careful egg handling, but also aspects like feeding and feed quality, housing and climate, health care,
percentage and quality of males, floor egg prevention etc.
• Breeder farm records are useful to monitor the percentage on non-hatching eggs. In combination with feed-back on
egg quality and hatch results from the hatchery, hatching egg quality can be analyzed leading to further improvement.
‘Physiological zero’
Although the exact level of the so-called ‘physiological zero’ is debated by hatchery specialists and researchers, there
is a consensus that embryonic ¬development, which starts in the hen’s body, will continue as long as internal egg
temperature is higher than 25 - 27 °C / 77 – 81 °F. To maintain best hatching potential, eggs should be cooled down
uniformly and gradually from the time being laid, to between 18 and 25 °C in approximately 6 hours. Too fast cooling
results in under-developed embryos. Slow cooling results in too many advanced embryos. In both cases embryo survival
of stored eggs is reduced.

2 Egg handling
Cooling down
The rate at which hatching eggs cool down depends on several factors:
• Nest type in relation to frequency of egg collection plays an important role.
- Manually collected litter nests: Eggs produced in this type of nests cool down very slowly to environmental
temperature, due to the insulation provided by the surrounding nest litter. Since nest boxes are shared between 5
- 7 hens, warmth is brought to partially cooled-down eggs again every time another hen enters the nest. It is only
once eggs are collected that they are able to cool down properly.
- Automatic nests: In this type of nest, the eggs roll away to an egg transport belt soon after being laid, which
exposes all the eggs to a similar environmental temperature. Cooling down will occur uniformly, but when there
are draughts of cold air over the egg belt there is a risk that eggs cool down too rapidly.
• The type of egg tray used for egg collection and further storage also plays a role. Egg temperature at the moment of
collection will vary from egg to egg, with some still holding a temperature of more than 25 °C / 77 °F In this case,
further cooling is required.
- Paper tray: A newly produced egg, with a temperature close to that of the hen’s body (41 °C / 106 °F), will take
much longer to cool down when placed at the center of a paper tray and covered by the next full tray, then an egg
placed at the side of the paper tray. Packing warm eggs on paper trays directly into egg boxes will certainly lead to
high embryonic mortality!
- Setter tray: Due to the more open character and the fact that filled setter trays are not stacked directly on top of
each other there is an adequate supply of free circulating air over the trayed eggs. This will greatly assist in uniform
cooling, but if the temperature in the egg collection room is too low there is the risk that eggs cool down too
rapidly, especially when exposed to a draught of cold air.
- Plastic trays: These are intermediate between paper trays and setter trays, because plastic is not such a good
thermic insulator as paper and allows some restricted air flow over the eggs.
• Washing of hatching eggs is not included in the above procedure as the risk of internal contamination of dirty eggs
is not eliminated by washing, and due to the potential for incorrect washing practices, the risk might even increase.
Moreover, depending on the detergents used, the protective cuticle could be removed. Rather than focusing on
cleaning dirty eggs, the emphasis should be on preventing eggs from getting dirty in the first place.
• Hatching egg disinfection at the farm is not included in the above procedure. If done correctly and in agreement
with the hatchery, it could be implemented before placement of the eggs in the farm store, or alternatively, daily in
the farm store itself. However, this only makes sense if eggs are placed on setter trays in farm trolleys. See for details
subchapter 2.8: Disinfecting of hatching eggs.
• 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 always be avoided since
sweating provides an ideal environment for the growth of microorganisms that may penetrate the eggshell. See
subchapter 11.1: Sweating of eggs for further explanation.
• The optimal climate settings in the egg storage room should be decided by or at least coordinated with the hatchery
manager in order to avoid sweating during truck loading and to match with intended storage duration at the hatchery
and climate conditions in the hatchery’s egg storage room. Continued storage at the hatchery should at least be at
equal temperatures and definitely not higher!

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

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

Remind truck drivers regularly, for example by a yearly training session, that hatching eggs are precious cargo which
need to be handled with great care at all times. Poor conditions during loading, transport and unloading will have a
negative impact on hatchery results. Points of attention are:
• Avoid sudden temperature changes during loading and unloading.
- Consider using buggy bags, especially in situations of high air velocity and low air temperature. When using buggy
bags be aware of unwanted condensation on the inside of these bags.
- Be aware of direct sunshine as this can rapidly raise the temperature of the eggs.
• Avoid eggs, paper boxes and paper trays getting wet through rain or due to sweating during loading and unloading.
- If needed, buggy bags could be of use.
• Avoid shocks and jolts during loading, transport and unloading in order to prevent damage to the fragile embryonic
structure and develop hairline cracks.
- Shock absorbing trolley wheels, a smooth and even driveway, well-designed egg trays without sharp edges and
trucks with a good suspension system are only a first step.
- A quality-consciousness mentality is an important second step needed for careful loading and driving.
• Keep your eyes not only on the road, but also on the temperature and humidity sensors!
• It is preferred to separate non-hatching eggs directly at the breeder farm. If they are taken into the hatchery, these
are best stored in a separate room until dispatch.
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.
See subchapter 11.1: Sweating of eggs for further explanation.

2.4 Egg receipt
Objective
To verify the numbers of hatching eggs supplied by the breeder farm.
Persons responsible
Hatchery manager and personnel assigned to receive the eggs and to check quantity of the eggs supplied by the breeder
farm.
Documents
Recording Form 2C: Hatching egg stock list.
Definitions
1. On arrival at the hatchery, the egg containers, boxes or farm trolleys are placed in the egg reception room. Each
batch of eggs is accompanied by Recording Form 2B: Egg receipt form which contains technical data about the parent
flock and the quantity and quality of the delivered eggs. This form is supplied by the farm manager. The driver of the
delivery truck completes the data on transport conditions.
2. Ensure each (full) egg container, box or farm trolley is clearly labeled with Recording Form 2A: Egg transport card on
which egg ID code, production date and egg numbers are listed.
3. Check if the number of eggs received corresponds with the information on Recording Form 2B: Egg receipt form. If all
is correct, sign this form. Report deviations to the breeder farm manager.
4. Separate non-hatching eggs from hatching eggs and place non-hatching eggs in a separate room where they will be
taken for disposal as soon as possible.
5. If required, take a representative sample of the batch of hatching eggs received and perform an analysis of hatching
egg quality. See subchapter 7.2: Hatching egg quality upon receipt for the recommended procedure.
6. Record the number of hatching eggs from each batch received on Recording Form 2C: Hatching egg stock list. This
list provides the hatchery manager with actual data on the numbers and background of eggs in stock. The hatchery
manager uses these data to plan the setting of eggs.
7. Place the eggs in either the egg storage room or forward them to the egg handling room where the eggs will be
placed in setter trays and setter trolleys.
Additional notes
• In case floor eggs and/or washed eggs need to be incubated, which is not recommended, keep these separate from
clean nest eggs throughout the entire incubation process, for example on the lower setter trays inside the setter
trolley.
• It is preferred to take non-hatching eggs directly from the breeder farm to an egg processing industry, for example. If
they are first taken to the hatchery, these are best stored in a separate room until disposal.

2 Egg handling
2.5 Setting eggs in setter trays and trolleys

Objective
To set eggs in setter trays and trolleys.
Persons responsible
Hatchery manager and personnel assigned to set eggs in setter trays and trolleys.
Documents
Recording form 2D: Setter trolley card.
Definitions
1. If the eggs are placed on paper or plastic egg trays, place the eggs on setter trays. This could be done manually,
semi-automatically by vacuum lifter or fully automatically. If eggs are already placed in setter trays on farm trolleys
this step is obviously not necessary.
2. Transfer the filled setter trays into setter trolleys.
3. Work carefully to avoid shocks and jolting in handling in order to prevent damage to the fragile embryonic structure
and hairline cracks in the shell.
4. Remove all eggs which do not meet quality criteria for hatching eggs and replace with good hatching eggs.
5. Check the position of the eggs carefully and correct if necessary: eggs must be set with the blunt end (= air cell) up
– sharp end down.
6. Provide each loaded setter trolley with recording form 2D: Setter trolley card on which trolley number, egg ID code
and production date are recorded.
7. Place the loaded setter trolley either in the egg storage room, optionally after pre-storage egg disinfection and/or
pre-storage incubation or proceed with incubation.
Additional notes
• The moment of transferring the eggs to setter trays and trolleys is preferred to be done on the day of arrival in the
hatchery and stored until needed for setting. Alternatively, setting of eggs in setter trays and trolleys could be done
just prior to setting. In the latter case, eggs are stored until needed for setting on paper or plastic egg trays in egg
containers or boxes or on setter trays in farm trolleys.
• Placing eggs on setter trays is essential before eggs can be effectively disinfected or be “pre-storage incubated”.
This is not possible as long as eggs are tightly packed together on plastic or paper egg trays as there is no “free space”
around each egg.
• The need for removing eggs which do not meet the quality criteria for hatching eggs during setting of eggs in setter
trays and trolleys depends on the accuracy with which the eggs were selected at the breeder farm.
• Eggs upside-down (= blunt end down) positioned on the setter tray have a significantly reduced chance to hatch.
• It is NOT recommended to start incubation within 12 hours of arrival at the hatchery. Immediate setting after
transport will increase early embryonic mortality.

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

2 Egg handling
Additional notes
• Pre-storage incubation, i.e. incubating hatching eggs before they are placed in the hatchery storage room, is a new
approach that aims to develop the embryo to the so-called hypoblast stage: a stage of embryonic development that
is better able to survive storage.
• Pre-storage incubation means incubation of eggs for a short period before they are placed in storage. SPIDES (=
Short Periods of Incubation During Egg Storage) is the procedure to incubate eggs for short periods during the storage
period.
• Pre-storage incubation is beneficial if the embryos after oviposition are underdeveloped as a result of too fast cooling
down.
• Negative effects of pre-storage incubation could be expected if nest temperatures are high and the eggs stay in the
nest too long. In that case the embryos may develop beyond the storage resistant stage and pre-storage incubation
will result in increased early embryonic mortality.
• A fresh egg break out of eggs in the storage room would allow inspection of the diameter and appearance of the
germinal disk. This could be useful to predict if a performance benefit is to be expected from pre-storage incubation.
See subchapter 7.2: Hatching egg quality upon receipt for further details.
• Eggs scheduled for storage for more than seven days after production benefit most from pre-storage incubation.
WARNING! Pre-storage incubation is only possible when eggs are placed on setter trays in setter trolleys. Only then
can a reasonably uniform egg temperature during pre-storage incubation treatment be ensured. Pre-storage incubation
of eggs on paper or plastic egg trays placed in egg containers or boxes results in uneven egg/embryo temperatures and
high levels of early mortality as a consequence.
• A s long as pre-storage incubation is performed in a setter located in the setter room (‘clean area’), eggs should be
disinfected first. Ideally, use a specific incubator located close to the egg storage room.
• If eggs are to be stored for a long period (for example more than 10 days) there might be a positive effect to apply
SPIDES (for example every 4 or 5 days). The hypothesis is that these regular heat treatments help prevent embryonic
cell death during further storage.

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

2 Egg handling

Storage duration Temperature (°C/°F) Relative humidity* (%) Egg orientation
0-3 days 18-21 / 64–70 75 – 85 Blunt end up
4-7 days 15-17 / 59–63 75 – 85 Blunt end up
8-10 days 12-14 / 54-57 80 – 85 Blunt end up
Preferably small end up or
More than 10 days 12-14 / 54-57 80 – 85 turning the eggs an uneven
time per day
*
The recommended relative humidity range for eggs stored on paper trays is 50 – 75%; the risk for dehydration is
much smaller on paper trays and the occurrence of floppy trays due to too high relative humidity should be avoided.

Additional notes
• Eggs can be stored on paper or plastic egg trays in egg containers or boxes or on setter trays in farm trolleys or setter
trolleys.
• Storage starts at day of egg production, which is not necessarily the same as the date of receipt in the hatchery’s egg
storage room. Storage includes the days the eggs are kept at the breeder farm and the duration of transport.
• If storage time is not constant, it is recommended to have two separate egg storage rooms, each with its own
specific climate conditions.
• Optimal hatching results and chick quality is achieved when eggs are set between 3 – 6 days after day of lay.
• During storage, a period of adaptation, carbon dioxide is released from the egg, resulting in a pH increase of the
albumen to 8.5. With a virtual constant yolk pH of around 6.5 the embryo, situated on the yolk, will be exposed to a
pH-gradient. This pH-gradient optimizes embryonic development.
• It is not recommended to start incubation within 12 hours after the eggs arrive in the hatchery. Immediate setting
after transport will increase early embryonic mortality. Eggs need a period of rest after transport.
• Storage times longer than one week are not recommended: after 6 days from production date, every day of storage,
the hatchability decreases by approximately 0.7% - 1.0% per day.
• Stored eggs need about one extra hour of incubation time for every storage day in excess of six 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, turning the eggs
an uneven time per day is recommended.
increases, water may condense on the eggshell: we say the eggs are ‘sweating’. This should be avoided at all times
since sweating of eggs provides an ideal environment for the growth of microorganisms that may penetrate the
eggshell. See subchapter 11.1: Sweating of eggs for further explanation.

2 Egg handling
2.8 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
Recording form 2G: Egg disinfection room.
Definitions
Recommended procedure A
Chemical: paraformaldehyde
1. Place the setter trolleys with trayed eggs in the egg disinfection room. Trolleys should be moved in via the egg
receiving/storage room only!
2. Ensure the eggshell surface has a temperature of at least 18 °C / 64 °F , but preferably 20 °C / 68 °F or higher as
formaldehyde is not so effective as a disinfectant at lower temperatures than this.
3. Maintain the correct temperature and relative humidity (21 – 25 °C / 70 – 77 °F and 65 - 75%) in the disinfection
room.
4. Weigh 7 grams of crystalline paraformaldehyde per m³ of disinfection room and place in an electric pan.
5. Record date and time of egg disinfection and amount of crystalline paraformaldehyde on Recording form 2G: Egg
disinfection room.
6. Make sure the fan shaft and the door to the setter room are closed, leave the disinfection room and close the door
behind you.
7. Start the program. The electric pan is heated, and the evaporated formaldehyde gas disinfects the eggs. A
recirculation fan should be running continuously during the entire process.
8. After 30 minutes (including 10 minutes to initiate evaporation), the extraction fan is switched on automatically and
the air inlet valve on the side of the setter room is opened. Note: In case the temperature in the disinfection room
is higher than 25 °C / 77 °F the extraction should be started 5 – 10 minutes earlier to avoid toxic effects of the
formaldehyde on the embryos.
9. Ventilate for 30 to 60 minutes.
10. Optional: Neutralize the formaldehyde gas with ammonia by using the “Formaldehyde Neutralization Unit”
according to the procedure of this unit.
11. Open the door at the setter room side and move the trolleys into the setter room. Leave the door at the egg traying
room side closed!
12. Record if any crystalline paraformaldehyde remains used on Recording form 2G: Egg disinfection room. If all the
paraformaldehyde was not evaporated, investigate the cause and take corrective actions. If required, expose the
eggs again to the disinfection process.

Recommended procedure B
Chemicals: formalin (37 - 40% formaldehyde in water) and potassium permanganate
1. Place the setter trolleys with trayed eggs in the egg disinfection room. Ideally, trolleys should be moved in via the
egg receiving/storage room only!
2. Ensure the eggshell surface has a temperature of at least 18 °C / 64 °F, but preferably 20 °C / 68 °F or higher as
formaldehyde is not an effective disinfectant at lower temperatures than this.
3. Maintain the correct temperature and relative humidity (21 – 25 °C / 70 – 77 °F and 65 – 75%) in the disinfection
room.
4. Make sure the fan shaft and the door to the setter room are closed.
5. First put the potassium permanganate in an enameled pan (20 grams per m³ of disinfection room). Then pour the
liquid formalin (30 ml per m³ of disinfection room) over the potassium permanganate. Be aware that the reaction
starts immediately after adding the formalin. Wear a mask with a specific filter; avoid inhalation!
6. Leave the disinfection room and close the door behind you.
7. Record date and time of egg disinfection and amount of formalin on Recording form 2G: Egg disinfection room.
8. After 20 minutes the extraction fan is switched on automatically and the air inlet valve on the side of the setter
room is opened. Note: In case the temperature in the disinfection room is higher than 25 °C / 77 °F the extraction
should be started 5 – 10 minutes earlier to avoid toxic effects of the formaldehyde on the embryos.
9. Ventilate for 30 to 60 minutes.
10. Optional: Neutralize the formaldehyde gas with ammonia by using the “Formaldehyde Neutralization Unit”
according to the procedure of this unit.
11. Open the door at the setter room side and move the trolleys into the setter room. Leave the door at the egg traying
room side closed!
12. Record if a noticeable of formalin remains in the enamel reaction pan on Recording form 2G: Egg disinfection room. If
there was formalin left over, investigate the cause and take corrective actions. If required expose the eggs again to
the disinfection process.
Additional notes
• Legislation in various countries might not allow the use of formaldehyde/formalin and it can cause uncomfortable
working conditions.
• Several hatcheries have good experiences with other liquid disinfectants for hatching egg disinfection. Dosage
depends of the disinfectant as well as on the application method. Application methods vary from Low Volume Misting
in an enclosed room full of loaded setter trolleys, to applying a fine spray on individual setter trays before loading into
setter trolleys. It is to be preferred to induce a particle size of maximum 5 mµ to avoid that eggs get humid during
disinfection. Contact your disinfectant supplier or Hendrix Genetics for additional information.
All eggs should be reached by the disinfectant

Proper egg disinfection using the described procedures is only possible if eggs are placed on setter trays in setter trolleys
(or farm trolleys). Eggs placed on paper or plastic egg trays are packed too tightly together with the result that the
disinfectant cannot reach all the eggs.
• Disinfect only visually clean eggs. Good disinfection cannot be achieved with floor eggs and dirty eggs which should
therefore not being used as hatching eggs.
• The above described procedures are based on disinfection just prior to setting. However, disinfection of eggs is also
possible at the breeder farm or on arrival in the hatchery.
• When disinfecting eggs at the breeder farm, be aware that formalin can diffuse into the egg during cooling down
from the hen’s body temperature. To avoid early mortality, the eggs need to be cooled down to 20 – 25 °C / 68 – 77
°F before disinfection. This may take between 4-6 hours, depending on ambient conditions.
• To avoid contamination and cross-contamination, disinfected and non-disinfected eggs should never be placed next
to one another.
• If eggs are disinfected on arrival at the hatchery, ensure they are not re-contaminated. All rooms following the
disinfection room should be seen as “clean” areas, and all hygienic instructions should be followed strictly.
• Monitor the efficacy of egg disinfection procedure by taking micro-biological samples. See subchapter 9.5: Hatchery
hygiene monitoring.

3 Incubation in setter:
day 1-18

3.1 Introduction
Procedures for the first 18 days of incubation are described separately for single-stage and multi-stage incubation.
3.2 Single-stage incubation

In single-stage (all in/all out) incubation, the incubator contains only eggs of the same embryonic age. The advantage of
single-stage incubation is that climate conditions can be adjusted according to the needs of the growing embryo.
The procedure in this subchapter (3.2) describes the steps involved in single-stage incubation and provides guidelines for
choosing the optimum set points for temperature, relative humidity, ventilation, frequency and turning for single-stage
incubation.
3.3 Multi-stage incubation

In multi-stage incubation the setter contains eggs of different embryonic ages. Usually 6 or 3 age groups. Consequently,
climate conditions cannot exactly be adjusted according to the needs of all the growing embryos and a compromise has to be
sought to best suit the age groups present in the setter.
An important aspect of multi-stage incubation is the placement of eggs according to a repeated setting scheme, such that
there is a balance between old “hot” eggs and new “cold” eggs. Old “hot” eggs are more than 12 days into incubation
and contain heat-producing embryos. New “cold” eggs are less than 7 days into incubation and contain heat-demanding
embryos.
Recommended set points and setting schemes for multi-stage incubation are described in the procedure in this subchapter
(3.3).

3 Incubation in setter: day 1-18
3.2 Single-stage incubation

Objective
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
Recording Form 3A: Incubator recording form.
Recording Form 9B: Cleaning schedule.
Definitions
1. Check proper functioning of the empty machine and note this on Recording Form 3A: Incubator recording form which
should be attached to the door of the setter.
2. Transfer the setter trolleys filled with trayed eggs from the egg disinfection room to the setter and place the trolleys
according to Recording Form 2E: Setter schedule.
3. In case the setter is not completely filled with eggs place full (or at least nearly full) trolleys on the pulsator side.
4. Load the remaining eggs on setter trays into incompletely filled trolleys from the center upwards and downwards
and leave the top and bottom without setter trays. Distribute these trolleys evenly on the corridor/mixing zone side
by at least keeping the ‘balance’ within a section (a trolley on both sides of the heart of the pulsator) as well as in
opposing sections (same number of trolleys on both sides of corridor/mixing zone). Fill the rest of the setter with
trolleys without setter trays.
5. Write the egg ID codes on Recording Form 3A: Incubator recording form.
6. Ensure the setter trolleys are securely locked in their positions.
7. Start up the setter in order to test the rpms of the pulsator as well as the turning mechanism of the loaded setter in
both directions and record this on Recording Form 3A: Incubator recording form.
8. Select the appropriate incubation program manually. See general guidelines on the next pages for suggested set
points for incubation temperature, relative humidity, ventilation, frequency and turning.
9. Include the pre-heat function in the incubation program as negative time (5-8 hours) at min. 77 – max. 81 °F with
trays in horizontal position). Alternatively, eggs can be pre-warmed in the setter room prior to loading the setter.
Eggs should be pre-warmed for 12 hours when they have been stored up to seven days and 18 hours in case of
longer storage.
10. Fine-tune the starting time of incubation based on observations during the previous chick take-off. Adjust the
incubation timer aiming at the chicks being fully ready for take-off at the intended time; see subchapter 6.2: Chick
take-off.
11. Record the incubation program and the starting time (0:00 on the incubation timer) on Recording Form 3A: Incubator
recording form.
12. Start the setter.
13. Record any changes to the incubation program on Recording Form 3A: Incubator recording form.
14. Candle eggs on day 10 (see subchapter 4.2: 10-day candling) or on the day of transfer (see subchapter 4.3: Candling
and transfer) and carry out an analysis of clear eggs if required (see subchapter 7.5: Analysis of clear eggs).
15. Transfer eggs to the hatcher baskets approximately 17.5 –18.5 days after the start of incubation (see subchapter 4.3:
Candling and transfer).
16. On transfer days, all empty setters, setter trays and setter trolleys, the setter room as well as the transfer room
including all equipment must be cleaned and disinfected followed by thorough drying prior to next use. See
subchapter 9.4: Cleaning and disinfection and place signature on Recording Form 9B: Cleaning schedule.

General guideline single-stage incubation sea level (up to 1.200 meter)
Moment of Incubation Relative Ventilation Frequency Turning
set point temperature 1) humidity 2)
change
°F % % valve % CO2 (%) Set point
(day. hour)
(positions)
- 0.05/ 0.08 77.0 – 81.0 60 0 – 20 0.40 100 horizontal = 0
0.00 100.5 60 0 0.40 100 2
1.00 100.25 60 0 0.40 100 2
2.00 100.0 60 0 0.40 100 2
3.00 100.0 55 10 0.40 75-100 2
4.00 99.9 55 10 0.40 75-100 2
5.00 99.9 55 10 0.40 75-100 2
6.00 99.9 50 20 0.40 75-100 2
7.00 99.8 50 30 0.40 75-100 2
8.00 99.8 50 40 0.40 75-100 2
9.00 99.7 50 40 0.40 75-100 2
10.00 99.7 50 40 0.40 75-100 2
11.00 99.6 50 50 0.40 75-100 2
12.00 99.5 50 50 0.40 75-100 2
13.00 99.4 48 50 0.40 100 2
14.00 99.3 48 60 0.40 100 2
15.00 99.2 48 60 0.40 100 2
16.00 99.1 45 – 48 60 0.40 100 2
17.00 99.0 45 – 48 70 0.40 100 2
18.00 98.8 45 – 48 70 0.40 100 2
1)
The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs. The guidelines
in the table apply to hatcheries at sea level (up to a height of approx. 1200 meter).
The main parameter for the temperature set-point is the eggshell temperature measured with the Braun ThermoScan.
See subchapter 7.3: Analysis of eggshell temperature.
2)
The main parameter for relative humidity set-point is egg weight loss at the day of transfer. The relative humidity
profile can either be constant (guideline is 50%) or slightly declining from 60 to a minimum of 45 – 48%. See
subchapter 7.4: Analysis of weight loss.

Additional notes
he guidelines in the table apply to hatcheries at sea level (up to an altitude of approx. 1200 meter). See subchapter 11.2:
T
Hatching at high altitudes for information on how to adjust these guidelines for higher altitudes.
• The set points in the tables should be used as guidelines only. Based on the extra information in the footnotes 1) and
2)
below, the table set points might need to be adjusted.
• To achieve maximum hatchability, uniformity and chick quality, it is recommended to load the incubator with only one
type of egg in respect of breed, maternal age and storage days.
• When different batches of eggs are to be placed in one setter, a small benefit could be obtained by placing the
eggs with the highest metabolic heat production on the pulsator side and eggs with lower expected metabolic
heat production at the corridor/mixing zone side. During the last days in the setter, the eggshell temperature at the
pulsator side is a usually a little lower compared to corridor/mixing zone side.
• Achieved hatchability, chick quality and results from egg analysis will provide further information on which set points
could be fine-tuned in future cycles. See chapter 7: Tools for fine-tuning for further information.
• Preheating of eggs in an operational setter aims at bringing the eggs to a uniform INTERNAL temperature of 25 °C /
77 °F prior to the onset of incubation. Due to the air flow generated by the pulsator, this is achieved faster compared
to the situation where trolleys with eggs are pre-warmed in the setter room. Good preheating facilitates a uniform
start of incubation for all embryos and contributes to a short hatch window. In case eggs are still wet at start of
preheating period due to application of a liquid disinfectant, it makes sense to open air valves, at 20 % for example,
during preheating to allow eggs to dry.
• Pre-heating time has to be longer if eggs have been stored more than a week since due to the lower storage
temperature, it takes more time to achieve an internal egg temperature of 25 °C / 77 °F.

3.3 Multi-stage incubation
Objective
To incubate hatching eggs in the optimum climate conditions for multi-stage incubation to achieve maximum
hatchability and best chick quality.
Persons responsible
Hatchery manager and personnel assigned to control the incubators and incubation programs.
Documents
Definitions
1. Check proper functioning of the machine and note this on Recording Form 3A: Incubator recording form, which should
be attached to the door of the setter.
2. Transfer the setter trolleys filled with trayed eggs from the egg disinfection room to the setter room.
3. Pre-warm the eggs in the setter room prior to loading the setter. Pre-warm for 12 hours if eggs were stored for up
to seven days or 18 hours in the case of longer storage.
4. Fine-tune loading time based on observations during previous chick take-off. Start loading the machine aiming at
chicks being fully ready by the intended time for chick take-off, see subchapter 6.2: Chick take-off.
5. Place the trolleys according to Recording Form 2E: Setter schedule.
Rule of thumb, “Newly set eggs should be positioned nearest to the pulsator”.
6. Ensure the setter trolleys are securely locked in their positions.
7. After loading the setter, test the rpms of the pulsator and test the turning mechanism in both directions and record
that this has been done on Recording Form 3A: Incubator recording form.
8. Write the egg ID codes on Recording Form 3A: Incubator recording form.
9. If necessary, adjust set points of temperature, relative humidity, frequency of the pulsator and ventilation according
to the general guideline in the table below. Record the starting time and incubator set points on Recording Form 3A:
Incubator recording form.
10. Candle eggs on day 10 (see subchapter 4.2: 10-day candling) or on the day of transfer (see subchapter 4.3: Candling
and transfer) and carry out an analysis of clear eggs if required (see subchapter 7.5: Analysis of clear eggs).
11. Transfer eggs to the hatcher baskets approximately 17.5 –18.5 days after the start of incubation (see subchapter 4.3:
Candling and transfer).
12. On transfer days, empty setter trays and setter trolleys, the setter room as well as the transfer room, including all
equipment, must be cleaned and disinfected followed by thorough drying prior to next use. See subchapter 9.4:
Cleaning and disinfection and place signature on Recording Form 9B: Cleaning schedule.

Additional notes
The guidelines in the table apply to hatcheries at sea level (up to an altitude of approx. 1200 meters). See subchapter
11.2: Hatching at high altitudes for information on how to adjust these guidelines for higher altitudes.
General guideline multi-stage incubation sea level (up to 1200 meter)

Set points 1)
Incubation temperature 99.5 °F 2)
Relative humidity 50% 3)
Ventilation 50% valve opening 4)
Frequency Maximal 5)
Turning (positions) 2
1)
The machine set points may vary between different breeds, flock ages, storage times and sizes of eggs. The guidelines in
the table apply to hatcheries at sea level (up to a height of approx. 1200 meters).
2)
The main parameter for the temperature set-point is the eggshell temperature. The temperature set points aims at
achieving an average eggshell temperature (measured with the Braun ThermoScan type 6020) of 99.8 – 100.0 °F. See
additional notes and subchapter 7.3: Analysis of eggshell temperature. When starting an empty machine according to
the setting scheme as recommended below single stage temperature, set points should be applied initially until day
10-11.
3)
The main parameter for relative humidity is egg weight loss. At the day of transfer, the average egg weight loss should
be approximately 10% (young flocks) to 13% (old flocks). See subchapter 7.4: Analysis of weight loss.
4)
The main parameter for ventilation is the CO2-concentration in the incubator. The CO2-concentration should not
exceed 0.4% and can be measured using a handheld CO2-meter or an electronic integrated CO2-meter. When starting
an empty machine according to the setting scheme as recommended below the valve, set point should be gradually
increased from 0% initially to 50% until the machine is fully loaded.
5)
With multi-stage incubation, it is not recommended to reduce the frequency or the rotations per minute of the pulsator
as this might affect hatchability and chick quality. If saving on the energy consumption is essential, hatchability and
chick quality should closely be monitored.
• The set points in the tables should be used as guidelines only. Based on the extra information in the footnotes 1), 2), 3), 4)
and 5) below the tables set points might need to be adjusted.
• Setting every 3-4 days a setting scheme results in the most even distribution of “warm” and “cold” eggs throughout
the incubator.
• Due to its character, it is not possible in multi-stage incubation to achieve the recommended eggshell temperatures
as in single-stage incubation. The temperature set point is a compromise to achieve recommended eggshell
temperatures as closely as possible. In general, the average eggshell temperature should be 100 - 100.5 °F during the
first 12 days of incubation, but it could be lower than that initially. From day 13-18, the average eggshell temperature
gradually increases to temperatures higher than recommended for single-stage incubation.
• Correct pre-warming in the setter room preferably at 25 °C / 77 °F prior to multi-stage incubation avoids a too
drastic drop of temperature inside the setter when new eggs are loaded. At the same time, it also prevents egg
‘sweating’, which could easily occur when cold eggs are set in a running and warm setter.
• Pre-warming time has to be longer if eggs were stored more than a week because due to the lower storage
temperature, it takes more time to achieve an internal egg temperature of 25 °C / 77 °F.

4 C
andling
and transfer

4 Candling and transfer
4.1 Introduction
During the incubation process, eggs can be candled to remove the clear eggs. These eggs could be infertile or contain
early dead embryos. Candling can be done as early as day 5 - 6 of incubation by an individual candling light, but it is time
consuming - and the risk of candling errors (e.g. accidentally removal of an egg with a normal living embryo) is evident. The
risk of candling errors is reduced if candling is performed at day 9 or 10 of incubation.
However, in many hatcheries, it is common practice to candle eggs on the day of transfer to the hatcher, as this is most
efficient in terms of time and labor productivity.
4.2 10-day candling

Candling half-way through the setter period could be done on a sample-basis, but also all eggs could be candled at that
time. It offers the opportunity to detect in potential problems on breeder farms in an early stage, during egg handling
and early incubation. Also, it allows to adjust the earlier made estimation of expected number of day-old-chicks in case
unexpected problems are unveiled and to anticipate for future settings.
The procedure in this subchapter (4.2) describes the 10-day candling procedure for both sample-basis as well as candling
all eggs by means of either an individual candling light or a so-called ‘candling table’, whereby the entire setter tray is
illuminated from beneath.
4.3 Candling and transfer

After approximately 17.5 - 18.5 days of incubation, eggs are transferred to the hatcher. Candling and clear egg removal prior
to transferring, especially when the percentage of clears exceeds 10 - 15%, has a positive impact on hatchability and chick
quality. In some cases, clears have a market value, whereas take off fees are incurred for unhatched eggs left behind in the
hatcher baskets after chick take-off.
The procedure in this subchapter (4.3) describes the steps of taking out the eggs from the setter and transferring them from
setter trays into hatcher baskets. In these baskets the chicks will hatch approximately three days later. Guidelines for the
loading of the hatchers are given and procedures for candling are summarized.

4.2 10-day candling
Objective
To candle 10-day incubated eggs, either on sample basis or all eggs, and to take out the clears.
Persons responsible
Hatchery manager and personnel assigned to carry out the 10-candling procedure.
Documents
Recording form 8A: Hatching results.
Definitions
Recommended procedure A: “10-day candling on sample basis”

1. Select the setter(s) with 10-day (+ or – 1 day) incubated hatching eggs for candling.
2. Select the egg ID code(s) within the setter(s) for candling and use Recording Form 2E: Setter schedule to locate the
setter trolleys inside the setter.
3. Turn the setter trays to the horizontal position, switch off the setter and take a random sample of setter trays out of
the selected setter trolleys. Switch on the setter again.
4. Use an empty setter trolley or a purposely designed carrier to move the selected setter trays to a climate-controlled
room which can be sufficiently darkened in order to facilitate candling.
5. Candle the eggs with either an individual candling light or a candling table, take out the clear eggs and place these
clears to setter tray on labeled paper or plastic egg trays. Label with at least the egg ID code, production date,
setting date and setter number.
6. Fill up the empty places on the setter tray by moving the remaining eggs backwards to create complete rows,
leaving the first rows empty.
7. Return the setter trays within preferably 15 – 20 minutes back to setter, whereby the empty rows are facing away
from the pulsator. Ensure the setter is switched on again.
8. Count the number of clear eggs per egg ID code, calculate the average percentage of clear eggs per number of eggs
set initially and record the estimated percentage of clear eggs on Recording Form 3A: Incubator recording form and
on Recording form 8A: Hatching results. Also calculate and record the estimated number of remaining eggs after this
sample candling.
9. If required, put the labeled paper or plastic egg trays with clear eggs aside for egg analysis (see subchapter 7.5:
Analysis of clear eggs).

Recommended procedure B: “10-day candling of all eggs”

NOTE: Candling of all eggs at this point in time is not very common but is sometimes applied in GPS-hatcheries to make
a more exact estimate of expected hatchability at an early stage. The most logical moment for candling of all eggs is on
the day of transfer to the hatcher.
1. Select the setter(s) with 10-day (+ or – 1 day) incubated hatching eggs for candling.
2. Turn the setter trays to the horizontal position, switch off the setter and take out a setter trolley. Switch on the
setter again.
3. Move the setter trolley to a climate-controlled room which can be sufficiently darkened in order to facilitate
candling. Preferably the candling is done in the setter room nearby the setter itself.
4. Candle the eggs with either an individual candling light or a candling table, take out the clear eggs and place these
clears per ID code on labeled paper or plastic egg trays.
5. If required for egg analysis, place clears of random selected setter trays per setter tray aside on labeled paper or
plastic egg trays. Label with at least egg ID code, production date, setting date and setter number. See subchapter
7.5: Analysis of clear eggs.
6. Fill up the empty places on the setter tray by moving the remaining eggs backwards to create complete rows,
leaving the first rows empty.
7. Place additional hatching eggs if too many clears are removed during candling; see for more details under additional
notes. In this case, leave the top and bottom of the setter trolley without setter trays.
8. Return the setter trolley within preferably 15 – 20 minutes back to setter, whereby the empty rows are facing away
from the pulsator. Take out the next trolley for candling. Ensure the setter is switched on again each time again
between moving subsequent trolleys.
9. Count the number of clear eggs per egg ID code, calculate the average percentage of clear eggs per number of eggs
set initially and record the percentage of clear eggs on Recording Form 3A: Incubator recording form and on Recording
form 8A: Hatching results. Also calculate and record the number of remaining eggs after this sample candling.
Additional notes
• Do not candle between 12 and 14 days of incubation, as it interrupts the movement of the embryo relative to the
long axis of the egg.
• The frequency of performing a 10-day candling procedure on a sample basis could be for every setting, but it is also
possible to do this for example on a monthly basis.
• Random sampling of setter trays for candling (and if required analysis of clear eggs) entails selecting at least 3
setter trays per ID code from various locations inside the setter. If the variation between these three trays is higher
than expected or higher than normal, then candle three more setter trays. For each setter tray candled the ID code,
production date, setting date and setter number should be recorded as a minimum.
• Especially when using a candling table there is the risk of candling errors (e.g. accidentally removal of an egg with a
normal living embryo). In case of doubt, a quick recheck with an individual candling light is a good option.
• The temperature in the egg candling room should be preferably 25 – 27 °C / 77 – 81 °F and no lower than 21 °C / 70
°F. Draughts directly on the eggs should be avoided. Eggs should be kept out of the setter for no more than 15 – 20
minutes in order to avoid the egg temperature decreasing too much.
• Candling of all eggs is preferably done on the day of transfer to the hatcher (see subchapter 4.3: Candling and
transfer). It is less disturbing for the incubation process and is also more efficient in terms of time and labor
productivity.
• Remove clears when higher than 10 - 15%. When the percentage of clears is lower than 10%, there is no direct need
to remove clears prior to transfer.
• If during candling at day of transfer more than 20% eggs are removed as clears, add eggs from another tray to ensure
each hatcher basket is full. Ideally, eggs should touch each other while lying in the hatcher basket; it seems the sound
and vibrations caused by first chicks to pip are a trigger for other chicks to start pipping as well.

4.3 Candling and transfer
Objective
To candle and transfer eggs from the setter to the hatcher.
Persons responsible
Hatchery manager and personnel assigned to candle and transfer eggs.
Documents
Recording form 8A: Hatching results.
Definitions
1. Plan transfer of eggs from setter to hatcher between 17.5 and 18.5 days after the start of incubation. Transferring
later than 19 days of incubation should be avoided.
2. Record on Recording Form 2E: Setter schedule for each setter trolley to which hatcher the eggs will be transferred.
3. Make as many copies of Recording Form 3A: Incubator recording form as the number of hatchers needed to transfer all
the eggs from one setter. This form accompanies the batch of eggs at the transfer from setter to hatcher.
4. Attach a copy of the form next to the door of each hatcher and highlight the relevant egg ID code on it.
5. Check proper functioning of the required number of empty hatchers and note this on Recording Form 3A: Incubator
recording form.
6. Start up the hatcher at least one hour before transfer. Check the set points of temperature, relative humidity, valve
position or CO2.
7. Turn the setter trolleys inside the setter into horizontal position.
8. Switch off the setter, move setter trolleys one-by-one from the setter to the egg transfer room and ensure each time
between moving subsequent trolleys that the setter is switched on again.
9. If required, candle eggs just prior to transfer by means of an individual candling light, candling table or fully
automatically. Remove the clear eggs. Count the number of clear eggs to egg ID code, calculate the percentage of
clear eggs per number of eggs set initially and record the percentage of clear eggs on Recording Form 3A: Incubator
recording form and on Recording form 8A: Hatching results. Also calculate and record the estimated number of
remaining eggs after this sample candling.
10. Carefully remove potential ‘exploders’ and dispose them in a bucket containing disinfectant. Clean all equipment
with paper towels each time a rotten egg broke and caused contamination and spray with a suitable disinfectant.
11. Transfer eggs in the egg transfer room manually or (semi-) automatically from the setter trays into properly cleaned,
disinfected and dried hatcher baskets.
12. Place additional hatching eggs in each hatcher basket if too many clears were removed during candling; for more
details, refer to additional notes.
13. Ensure the hatcher is switched on again between loading subsequent dolleys and after placement of the last dolley.
14. On transfer days, empty setters, setter trays and setter trolleys, the setter room as well as the transfer room
including all equipment must be cleaned and disinfected followed by thorough drying prior to next use. See
subchapter 9.4: Cleaning and disinfection and place signature on Recording Form 9B: Cleaning schedule.

Additional notes
• Eggs of different ID codes should be kept in separate hatcher baskets.
• To achieve maximum hatchability, uniformity and chick quality it is very important to place only one batch of eggs in
one hatcher (different types of eggs can have different hatching times!).
• For optimum uniformity, do not mix eggs from corridor/mixing zone side and eggs from pulsator side in one hatcher.
• Starting each transfer day with the youngest flocks and ending with the oldest reduces the risk of cross
contamination. Usually the percentage of rotten eggs is higher in the older flocks.
• The temperature in the egg transfer room should be preferably 25 – 27 °C / 77 – 81 °F and no lower than 21 °C / 70
°F. Draughts directly on the eggs should be avoided. Temperatures over 28 – 30 °C / 82 – 86 °F should be avoided
because there is a risk of the eggs overheating due to the absence of air flow.
• Egg transfer and candling should last no more than 30 minutes per setter trolley; the eggs should not be outside the
machines any longer so as to avoid the egg temperature decreasing or increasing too much.
• Hatcher baskets should be completely dry at transfer.
• If paper is used in the hatcher baskets, ensure it does not hamper the horizontal flow of air.
• Consider performing an egg break-out on a representative sample of clears. Samples of clears from randomly selected
setter trays should be set aside on labelled paper or plastic trays. Label the trays with at least ID code, production
date, setting date and setter number. See subchapter 7.5: Analysis of clear eggs.
To candle or not to candle?

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

5 I ncubation in
hatcher: day 19-21

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

Optimal climate conditions in the hatcher are of paramount importance for high hatchability and good chick
quality. By avoiding over-ventilation, relative humidity will rise spontaneously when the first chicks hatch and
decrease again when most of the chicks have hatched and dried. Ventilation can be controlled by the CO2 set
point if hatchers are equipped with a CO2 sensor; otherwise valve positions have to be adjusted manually or by
incubation program.
The procedure in this subchapter (5.2) provides general guidelines for optimal set points for hatchers
5.3 Application of disinfectant during hatching

Disinfecting of eggs directly after transfer helps to counteract the cross contamination which might have
occurred in the setter as a result of exploders or during transfer.
At the start of the hatching process itself a suitable disinfectant can be released into the hatcher to reduce the
risk of chicks getting infected by pathogenic micro-organisms.
Traditionally formalin has been the disinfectant of choice. Evaporation of formaldehyde during the hatch
results in chicks acquiring a pronounced yellow color which is often seen as a sign of healthy chicks by the farm
manager. However, formaldehyde can be unpleasant to staff, and there can be negative side effects of formalin
on the trachea of the new-born chicks. There are already good alternatives available based on other active
ingredients, such as Glutaraldehyde and Hydrogen Peroxide.
The procedure in this subchapter (5.3) explains how disinfectants can effectively be applied.

5.2 Incubation in hatcher: day 19 – 21
Objective
To hatch the chicks in the optimum climate to achieve maximum hatchability and best chick quality.
Persons responsible
Hatchery manager and personnel assigned to manage the incubation period in the hatcher.
Documents
Recording form 9B: Cleaning schedule.
Definitions
1. Ensure the hatcher dolleys and hatcher baskets are properly placed inside the hatcher: Candling and transfer. Ensure
Recording Form 3A: Incubator recording form is attached to the hatcher and the correct egg ID code is highlighted on
it.
2. Enter the appropriate set points manually. If sending and activating an incubation program, ensure the incubation
timer is set correctly in accordance with the stage of incubation. See general guidelines on the next pages for
suggested set points for incubation temperature, relative humidity and ventilation (% CO2 or valve position).
3. Record the set points on Recording Form 3A: Incubator recording form.
4. Adjust the set points according to the needs of the hatching chicks and record these adjustments on Recording Form
3A: Incubator recording form, including the reason for these adjustments.
5. Transfer dolleys with hatcher baskets to the chick room when 95% of the chicks are completely dry and 5% of the
chicks have down on the neck that is not completely dry.
6. Take the dolleys out one by one. Do not empty the hatcher completely but leave the chicks in the hatcher. Keep the
hatcher running while there are chicks inside!
7. On hatch days, all empty hatchers, hatcher rooms and hatcher baskets must be cleaned and disinfected followed by
thorough drying prior to next use. See subchapter 9.4: Cleaning and disinfection and place signature on Recording Form
9B: Cleaning schedule.

General guideline hatcher climate based on CO2-controlled valves sea level (up to 1.200 meter)
Temperature set Relative humidity Ventilation CO2 1)
Remarks point set point set point
°F % %
Transfer 98.5 50 0.45
First chicks: The humidity increases spontaneously 2) 98.5 50 0.45
10% of chicks: humidity has increased
98.5 50 3) 0.45
spontaneously to 60% 2)
Chicks start to dry: 4)
98.0 - 97.8 - 97.5 5) 50 5) 0.25
Actual relative humidity dropping 6 – 8% after humidity peak.
1)
In case Automated Hatching System is used, ventilation (valve position) is controlled by the CO2 concentration in the
machine. The recommended CO2 concentration may vary slightly depending on breed and the hatchery altitude.
2)
Humidity increases spontaneously during pipping.
3)
Ensure the “Relative humidity high alarm” is set to + 30% to avoid unnecessary alarm. Actual relative humidity might
go higher than 78% but will normally not exceed 83%.
4)
Chicks start to dry; this moment can be recognized by the actual relative humidity dropping 6 – 8% after having
achieved the humidity peak.
5)
If chicks have not started to dry, do not lower the temperature, but wait a few hours. Only lower the temperature if
chicks are panting as a sign of being overheated and reduce temperature in two steps if required. Relative humidity
could be increased to 60% at this moment to minimize dehydration, especially when there is a chance that relative
humidity may drop below 60% before the chicks are pulled.

General guideline hatcher climate without CO2-controlled valves ; sea level (up to 1200 meter)
Temperature Relative Ventilation
set point humidity set
Remarks point % valve Reference: CO2 1)
°F % % %
Transfer 98.5 50 30 0.45
First chicks: The humidity increases spontaneously 2)
98.5 50 40 0.45
10% of chicks: humidity has increased
98.5 50 3) 50 0.45
spontaneously to 60% 2)
Chicks start to dry: 4) 98.0 - 97.8
50 5) 70 – 80 5) 0.25
Actual relative humidity dropping 6 – 8% after humidity peak. - 97.5 5)
1)
The CO2 concentration can be used as a reference for the ventilation set point. The CO2 concentration can be
measured using a handheld CO2 meter or can be read from the integrated CO2 meter. When using a handheld CO2
meter do not enter the machine but keep the door closed (instead, the CO2 concentration can be measured in the
exhaust ducts of the hatcher). The recommended ventilation may vary slightly depending on breed and the hatchery
altitude.
2)
Humidity increases spontaneously during pipping.
3)
Relative humidity will increase spontaneously and in general there is no need to increase the relative humidity set
point. If actual relative humidity remains too low check whether the ventilation can be reduced. If required set the
“relative humidity high alarm” to + 30%.
4)
Chicks start to dry; this moment can be recognized by the actual relative humidity dropping 6 – 8% after having
achieved the humidity peak.
5)
If chicks have not started to dry, do not lower the temperature, but wait a few hours. Only lower the temperature if
chicks are panting as a sign of being overheated and reduce temperature in two steps if required. Relative humidity
could be increased to 60% at this moment to minimize dehydration, especially when there is a chance that relative
humidity may drop below 60% before the chicks are pulled.
Additional notes
The guidelines in the table apply to hatcheries at sea level (up to an altitude of approx. 1200 meter). See subchapter
11.2: Hatching at high altitudes for information on how to adjust these guidelines for higher altitudes.
• The set points in the tables should be used as guidelines only. Based on the extra information in the footnotes 1), 2), 3),
4)
and 5) below the tables set points might need to be adjusted.
• Achieved hatchability, chick quality and results from egg analysis will provide further information based on which set
points could be fine-tuned. See chapter 7 for further information.
• To achieve maximum hatchability, uniformity and chick quality, it is very important to place only one batch of eggs in
one hatcher (different types of eggs can have different hatching times!).
• If desired, apply a disinfectant at the start of the hatching process of the chicks as described in subchapter 5.3:
Application of disinfectant during hatching period.

5.3 Application of disinfectant at start of the hatching process

Objective
To reduce contamination by pathogenic micro-organisms. In the case of formalin application at start of hatch, the chicks
will get a uniform yellow color.
Persons responsible
Hatchery manager and personnel assigned to apply disinfectants at start of hatching period.
Documents
Safety instructions provided by the disinfectant manufacturer.
Definitions
Recommended procedure A: “Disinfecting of eggs directly after transfer”

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

2. Dose 100 ml formalin for each hatcher sharing the same hatcher room and clean air plenum.
3. Make this amount available for the air supported nozzle. This could be a simple jerry can from where the nozzle
sucks itself or a special container from where the formalin is brought by air pressure to the nozzle.
4. At the end of the day when all eggs are transferred to this specific hatcher room, activate the air supported nozzle
which fill the clean air plenum with a dense fog of formalin. The nozzle should have sufficient capacity to finish the
formalin in approximately 30 minutes (+/- 5 minutes). The hatchers will “inhale” this cloud of formalin, and it will
leave the hatchers through the outlet again.
5. The next morning, ensure the dosed formalin has all been finished.
Recommended procedure B: “Formalin treatment of eggs and at start hatch in the hatcher”
Chemical: formalin (37 – 40%)
1. Wear a gas mask with a suitable filter to avoid inhalation of formalin.

2. Place a plate underneath the hatcher dolleys. Ensure that the evaporating surface of this plate is of the right size:
0.30 x 0.30 m or a diameter of 0.35 m-0.50 m.
3. Fill the plate with 100 – maximum 250 ml of formalin (37 – 40%) before the chicks have externally pipped.
4. Ensure all formalin is evaporated when chicks are drying (e.g. when relative humidity starts declining) to avoid
excessive irritation to the chick’s respiratory system. Adjust the amount mentioned under step 3 of this
procedure if needed.
Recommended procedure C: “Application of disinfectant at start hatching period”

Chemical: “alternatives for formalin”
Some hatcheries have good experiences with applying other liquid disinfectants during the hatching period.
Contact your disinfectant supplier or Hendrix Genetics Layers for additional information.

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

6 Chick handling

6.1 Introduction
After leaving the hatcher, the chicks have to undergo several procedures until they are finally placed in
the farm. The post hatch performance will be negatively affected by sub-optimal chick handling and poor
hygiene.
6.2 Chick take-off

Accurate timing of removal of the newly hatched chicks from the hatcher is extremely important. Removing
chicks too early as well as too late has negative consequences for chick quality.
The procedure in this subchapter (6.2) describes guidelines for timing chick take-off and preparing the chick
room for subsequent chick handling.
6.3 Vaccination of day-old-chicks

Vaccination of day-old-chicks at the hatchery offers the advantage that it occurs under better controlled
conditions compared to the situation in the farm. Also, the larger numbers of birds passing through the
hatchery compared to the farm allows for investing in automated equipment which delivers good results if
operated by skillful hatchery workers.
The procedure in this subchapter (6.3) provides general guidelines for spray vaccination and for sub-cutaneous/
intramuscular vaccination; for more specific information you should refer to the vaccine manufacturer’s
instructions.
6.4 Sexing of day-old-chicks

The procedure in this subchapter (6.4) explains 3 different sexing methods.
6.5 Chick dispatch and transport

Newly hatched chicks are not yet able to control their body temperature and are almost fully dependent on
climatic conditions. With insufficient attention, chicks can easily get chilled or overheated with long-lasting
effects.
The procedure in this subchapter (6.5) provides a guideline for optimizing climatic conditions for temporary
storage in the chick dispatch room and during transport.
6.6 Unloading and brooding chicks at the farm

Good breeder and hatchery management, together with optimized incubation and transport conditions, is
no guarantee of successful post-hatch performance. Of the many factors that have an impact on this, chick
reception and brooding management are probably the most decisive. It is difficult to recover from a poor start
during the first days.
The procedure in this subchapter (6.6) gives recommendation for this important period.

6 Chick handling
6.2 Application of disinfectant at start of the hatching process

Objective
To take the chicks out of the hatcher at the correct time and prepare them for transport.
Persons responsible
Hatchery manager and personnel assigned to handle chicks.
Documents
Recording Form 6B: Chick passport
Recording form 8A: Hatching results
Recording form 9B: Cleaning schedule.
Definitions
1. Prepare the chick room timely for chick handling:
• the temperature should be between 24 – 27 °C / 75 – 81 °F and should be uniform throughout the chick room;
hot/cold spots and draughts directly on the chicks should be avoided;
• the relative humidity should be 40 – 65%;
• check proper functioning of all machinery (hatcher basket de-stacker, transport belts, chick counter, automatic
vaccinator, chick box stacker and de-stacker).
2. Transfer hatcher dolleys with hatcher baskets to the chick room when 95% of the chicks are completely dry and 5%
of the chicks have down on the neck that is not yet completely dry.
3. Take the dolleys out one by one. Do not empty the hatcher completely but leave the chicks in the hatcher. Keep the
hatcher running while there are chicks inside!
4. Ensure strictly separated handling of chicks from different egg ID codes to minimize mistakes during counting and
further chick transportation.
5. De-stack the hatcher baskets and take out the chicks. Place the chicks on transport belts if appropriate.
6. Assess the quality of chicks and separate second grade chicks. Aim at delivering only vital chicks of good quality.
7. If required, place a random sample of hatcher baskets aside for analysis of unhatched eggs. See subchapter 7.6:
Analysis of unhatched eggs.
8. If required, sex the chicks. See subchapter 6.4: Sexing of day-old-chicks.
9. If required, vaccinate the chicks according to the vaccine manufacturer’s instructions.
10. Count the chicks, manually or by automatic chick counters, and place the appropriate number into chick boxes.
See also subchapter 6.5: Chick dispatch and transport.
11. Stack the chick boxes and place them correctly into the chick dispatch room until loading the truck for transport to
the farm. See also subchapter 6.5: Chick dispatch and transport.
12. Record number of saleable chicks as well as the number of second grade chicks on Recording Form 8A: Hatching
results.
13. On hatch days, all empty hatchers, hatcher rooms and hatcher baskets as well as the chick handling room including
all equipment must be cleaned and disinfected followed by thorough drying prior to next use. See subchapter 9.4:
Cleaning and disinfection and place signature on Recording Form 9B: Cleaning schedule.

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

• Signs of too early pulling: too many wet chicks and the membranes inside empty eggshells do not break up when
crushing the shell in your hand.
• Signs of too late pulling: nearly all chicks totally dry, extended wing feathers, dehydrated legs, too much meconium in
hatcher basket, membranes inside the empty eggshells break up in many small pieces when crushing the shell in your
hand.

6 Chick handling
6.3 Vaccination of day-old-chicks

Objective
To vaccinate the chicks correctly based on the requirements of the customers or standard vaccination program of the
hatchery and ultimately the prevention of diseases.
Persons responsible
Hatchery manager, veterinarian and personnel assigned to vaccinate the chicks.
Documents
Recording Form 6B: Chick passport.
Definitions
General guidelines “spray vaccination”

NOTE: Based on a spray vaccinator mounted over the conveyor line for chick boxes
1. Read the vaccine manufacturer’s instructions and follow these carefully, even if these deviate from the guidelines
below.
2. Check the correct working of the spray vaccination equipment before every use. Adjust the spray vaccinator
according to the size of the chick boxes and the speed of the conveyor belt. Test if the total surface of the chick box
is uniformly covered by spray e.g. by placing absorbent paper inside an empty chick box.
3. Apply coarse spray only. Install a suitable nozzle and adjust pressure to achieve this.
4. Store vaccines in a correctly working refrigerator kept for this sole purpose until use.
5. Prepare the vaccine in a clean and dust-free vaccine preparation room. Prepare only the amount of vaccine that
can be finished within a maximum of 60 minutes. Prepare new vaccine in a timely manner to avoid delay in chick
handling.
6. Dilute the required number of vaccine doses in the correct amount of water (general guideline 0.15 liter / 1000
doses). Ensure the water is of good quality, not chlorinated and low in mineral content. Use demineralized water if
tap water does not meet these criteria. Use marked buckets or vessels dedicated only to this purpose.
7. Check regularly that no vaccine is wasted and that all chicks are uniformly covered by spray or by placing absorbent
paper inside an empty chick box. The addition of special blue dye to the vaccine allows for a better visualization.
8. Compare the number of doses prepared with the actual number of chicks vaccinated. If it deviates by more than
10%, either readjust the vaccination equipment or adjust the amount of water for diluting.
9. Record the name and batch number of the vaccine used on Recording Form 6B: Chick passport.
10. Avoid placing wet chicks in a chick dispatch room with a suboptimal temperature or draughts.
11. Clean all vaccination equipment thoroughly after every use. Ensure that absolutely no traces of any chemicals like
detergents and disinfectants stay behind as residues. Place signature on Recording From 9B: Cleaning schedule.

General guidelines “sub-cutaneous/intramuscular vaccination”
NOTE: Based on semi-automatic pneumatic vaccinator
1. Read the vaccine manufacturer’s instructions and follow these carefully, even if these deviate from the guidelines
below.
2. Check the correct working of the vaccination equipment before every use. Adjust the cylinder of the vaccinator for
the required amount of milliliters and check its output by manually triggering the vaccinator at least 10 times and
collecting the vaccine discharged in a calibrated cylinder; readjust if there is a deviation in volume more than 5% of
the expected amount.
3. Select the correct size and gauge of the needle in relation to the vaccine to be used.
4. Store the vaccines in a correctly working refrigerator kept for this sole purpose until use. An exception is for Marek’s
vaccine, which is stored in liquid nitrogen. Take oil-emulsion vaccines out of the refrigerator up to 8 – 10 hours
before use to allow it to slowly warm up and to reduce its viscosity.
5. Prepare the vaccine according to the vaccine manufacturer’s instructions. Especially for live vaccines, prepare only
the amount of vaccine that can be finished within a maximum of 60 minutes.
6. Vaccinate the chicks sub-cutaneous (in the neck) or intra-muscularly (in the thigh) by positioning the chick correctly
on the vaccinator.
7. Check a few chicks regularly to evaluate the site of injection and the correct administration of the vaccine without
causing trauma to the chick or even dead chicks. The addition of special blue coloring agent to the vaccine allows for
a better visualization of the injection site.
8. Replace the vaccinator needle after every 2000 chicks or earlier if the needle is bent or burred.
9. Work carefully and conscientiously in order to avoid injection-trauma to the chicks or self-injection. If self-injection
occurs, especially with oil-emulsion vaccines, consult a medical doctor immediately and show the doctor the
vaccine bottle on arrival.
10. Compare the number of doses prepared with the actual number of chicks vaccinated. If it deviates more than 10%,
readjust the vaccination equipment.
11. Record the name and batch number of the vaccine used on Recording Form 6B: Chick passport.
12. Clean all vaccination equipment thoroughly after every use. Ensure that absolutely no traces of any chemicals like
detergents and disinfectants stay behind as residues. Place signature on Recording Form 9B: Cleaning schedule.

6 Chick handling
Additional notes
• The general guidelines above can easily be adapted to the use of other vaccination equipment, such as spray
cabinets and manual syringes.
• Never mix different vaccines on your own initiative. If different vaccinations are required, use only registered
combinations formulated by the vaccine manufacturer and tested for compatibility.
• Vaccines can be either live (in the form of freeze-dried pellets or frozen in Liquid Nitrogen) or inactivated (in the
form of oil-emulsion).
• After diluting live vaccines, they have a limited lifespan and should therefore be used within 1 hour. Any residual
traces of chemicals such as disinfectants will kill the live, attenuated virus and render the vaccine ineffective.
• During spray vaccination the water serves as a transport medium for the live virus to the day-old-chicks. The vaccine
will attach to the mucosa cells of the chicks’ eyes and upper respiratory tract. Preening (where the chick cleans its
feathers with its beak) optimizes vaccine uptake. Once in the body, the virus will multiply inside the mucosal cells, to
develop good local immunity in the respiratory tract.
• When administering vaccines by spray vaccination, it is important that the spray is ‘coarse’, ie. that droplets are
at least 150 microns in volumetric mean diameter. Any smaller and the vaccine will be inhaled too deeply into the
respiratory tract, resulting in an excessive post-vaccination reaction. This presents as mild disease symptoms in the
flock 3- 5 days after vaccination - and will have a negative effect on production.
Color codes for droplet size

Category Symbol Color Code Approx. VMD Range (microns)
Extremely fine XF Purple <60
Very fine VF Red 60-145
Fine F Orange 145-225
Medium M Yellow 226-325
Coarse C Blue 326-400
Very coarse VC Green 401-500
Extremely coarse EC White 501-650
Ultra coarse UC Black >650
• The quality of sub-cutaneous/intramuscular vaccination depends largely on the operator. Staff training, motivation,
sufficient breaks, good working environment all contribute to successful vaccination.
• The batch number of the vaccine should always be recorded. If any problems arise, it will help the vaccine
manufacturer in tracking and tracing.
• Inform customers which vaccination birds have received at the hatchery. Spray vaccination that targets the
respiratory organs again should be avoided within 14 days of arrival on the farm as much as possible.

6.4 Sexing of day-old-chicks
Objective
To separate males and females accurately before delivery to the customers.
Persons responsible
Hatchery manager and personnel assigned to sex the chicks.
Documents
Definitions
1. Separate the males and females by one of the sexing methods described below. Ensure the sexing method is
applicable to the specific breed.
2. Keep males and females strictly separated after sexing and record accurately on Recording Form 6B: Chick passport.
3. Monitor regularly a sample of sexed chicks for the accuracy of sexing. This could be a sample from all staff involved
in sexing, but more samples from individual staff members may be necessary from time to time – for example, those
who are still in training.
4. Count males and females separately and determine the sex ratio. If this ratio deviates too much from 50:50, the
accuracy of sexing should be checked and improved.
5. Cull any chicks that are considered to be second class. See 7.7 Assessing chick quality by using Pasgar@Score for the
second-class definitions.
Hatchery Management
Hatchery Management
Guide - Version
Guide L9180-2 55 55
- Version L9180-1
6 Chick handling
Hendrix Genetics B.V.
Villa ‘de Körver’, Spoorstraat 69, 5831 CK Boxmeer
3 methods of sexing P.O. Box 114, 5830 AC Boxmeer, The Netherlands-EU
T +31 485 801 911 W hendrix-genetics.com
In general there are 3 sexing methods that can be used depending on the breed. Colour sexing and feather sexing can
only be applied in specific breeds, and whether or not it is applicable should be checked with Hendrix Genetics. Cloaca
or vent sexing can be used for all breeds, but requires specially trained staff.
Colour sexing Hendrix Genetics B.V.
COLOR SEXING BROWN BREEDS

Most commonly applied for final product of brown egg layers based on sex-linked cross of silver/gold genes (see photo
P.O. Box 114, 5830 AC Boxmeer, The Netherlands-EU
below), but also possible with sex-linked cross of barred/non-barred genes, which is then done by head spot sexing.
The day-old-chicks canFemales

be sexed on their external appearance. Breeding companies supply clear instructions supported
by photos to also allow accurate sexing of chicks where, from their appearance, the sex is not obvious in the first
instance.
COLOR SEXING BROWN BREEDS
Color sexing brown breeds
Females Females
Males Males
T +31 485 801 911 W hendrix-genetics.com Hendrix Genetics B.V.
60% 30%
Males
60%
60% 30%
30%
EXINGCOLOR
BROWN BREEDS
SEXING - EXCEPTIONS
BROWN BREEDS - EXCEPTIONS
Color sexing brown breeds - Exceptions
Females Females Females
L7160
L7160
4% 3% 1% 1% 1%
3% 4% 1% 3% 1%
1% 1% 1% 1%
Males
Males Males
L7160

Feather sexing
This method of sexing is relatively easy to learn. It is based on the sex-linked gene for fast- or slow feathering.
Procedure:
Feather
Feather sexing
1. Spread out the wing like a fan, holding the legs of the chick down-wards.
sexing
2. Examine the wing from the top. Feathers in the bottom row are called “primaries” and those in the top row are
called ”coverts”.
3. Sex the chicks based on observations as explained below.
Fast feathered: female

Primary feathers
Fast
Fast longerfemale
feathered:
feathered: than coverts
female
Primary feathers longer thancoverts
Primary feathers longer than coverts
Slow feathered: male

Primary Slowfeathered:
feathered:
feathers
Slow male
same size as coverts
male
Primary feathers same size as coverts
Primary feathers same size as coverts
Ultra slow
Ultra slowfeathered: male
feathered: male
Coverts longer than primaries
Ultra slow feathered: male

6 Chick handling
Cloacal or vent sexing

This method needs specially trained staff, with good eyesight, good manual dexterity and the ability to concentrate for a
long time. Experience is very important, and it requires a well illuminated workplace.
The procedure involves expelling the faecal material (meconium), turning outward the vent area and finally looking for
the presence or absence of a rudimentary male sex organ.
Vent sexing; a skill not easily learned!
Additional notes
• If sexing is performed by hired staff that also performs this task in other hatcheries, be very vigilant to ensure they
comply with the hygienic procedures of the hatchery. Provide them with hatchery clothing and shoes. Do not allow
them to bring in their own equipment like lamps and seats.

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

Temperature (°C/°F) Relative humidity (%) CO2 (ppm) Air flow
24 – 27 / 75 – 81 55 – 65 1500 Sufficient

6 Chick handling
Additional notes
• Optimum rectal temperature for day-old-chicks is 40.0 – 40.5 °C / 104.0 – 104.9 °F. Newly hatched chicks are
dependent on external climatic conditions to regulate their body temperature for the first few days.
• The aim is an air temperature at chick level of 32.0 – 36.0 °C / 90 – 96 °F , thus INSIDE the chick boxes; the room or
truck temperature is secondary.
• An exact optimal dispatch room or truck temperature cannot be provided. The optimal temperature depends on
several factors. The number of chicks per box and the air velocity through the chick box are perhaps of most influence.
For example, the higher the speed of air through the chick boxes, the higher the optimal air temperature of the chick
dispatch room or truck.
Look and listen to the behavior of the chicks!

Abnormalities in chick behavior are related to sub-optimum climate (see table below). Day-old-chicks kept under ideal
climatic conditions breathe quietly through their nostrils, are evenly spread in the chick boxes, will not make much noise
and will be relatively inactive or even sleeping.
• Occasionally place some chicks on your wrist or against your cheek to sense the temperature of the feet; when these
are “cold to the touch” the chicks’ body temperature is too low.
• Additionally, the cloacal temperature of a sample of chicks should be measured by a Braun ThermoScan. Ensure the
probe is in direct contact with the bare skin of the vent. The optimum chick vent temperature is 40 – 40.5 °C / 104 –
105 °F.
• Properly placed climate loggers (avoid direct contact between chicks and sensors) can provide useful information
about the conditions during transport.
• The correct loading of the chicks at the chick dispatch room depends on the method of ventilation/air circulation.
o Horizontal air flow generated by chick room coolers/heaters or chick room fans: Position the stacked chick boxes
in uninterrupted rows with minimal 30 cm between each row. The fan should blow preconditioned air in alternate
corridors between these rows.
o Ceiling fans: Position each stack of chick boxes such that around each stack there is minimal 30 cm free space.
Chick’s behavior in relation to climate

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

6.6 Unloading and optimization of brooding chicks at the farm
Documents
See 11.3

7 Tools for fine-tuning

7.1 Introduction
For evaluating hatchery results, it might suffice to just collect basic hatchery data of each batch of eggs incubated. These
basic hatchery data are number of eggs set, number of eggs removed during candling and number of chicks hatched.
More detailed data are needed to establish a hatchery specific set of data. These data will be very useful in the process of
analyzing where hatching egg quality, hatchery management and incubation programs could be improved and is especially
relevant when hatch results are below expectations.
7.2 Analysis of hatching egg quality upon arrival

Egg quality determines for a great part the hatch results. Therefore, it is advisable to regularly monitor egg quality, both
externally as well as internally, of a representative sample of received eggs. A fresh egg break-out also allows to judge the
size and quality of the germinal disc. By doing so, problems are detected in an early stage and open communication with the
supplier can be started aimed at improving or at least maintaining egg quality.
The procedure in this subchapter (7.2) comprises a general inspection of the external and internal (including germinal disc)
quality of eggs supplied by the breeder farm.
7.3 Analysis of shell temperature

The procedure in this subchapter (7.3) 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.
7.4 Analysis of 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 subchapter (7.4) describes the steps in measuring egg weight loss.
7.5 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 analyzing causes of high percentages of
clear eggs at transfer and consequently poor hatchability.
The procedure in this subchapter (7.5) describes the analysis of clear eggs.
7.6 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 analyzing causes of poor hatchability.
The procedure in this subchapter (7.6) describes the analysis of unhatched eggs.
7.7 Analysis of 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 in this subchapter (7.7) outlines the use of the score method: a practical, objective evaluation of chick quality
for hatchery managers. score also forms a practical tool for locating problems in the incubation process when chick quality is
suboptimal.

7.2 Analysis of hatching egg quality upon arrival

Objective
To evaluate the quality of hatching eggs supplied by the breeder farm upon arrival in the hatchery.
Persons responsible
Hatchery manager and personnel assigned to check the quality of the eggs supplied by the breeder farm.
Documents
Recording Form 7A: External hatching egg quality upon receipt.
Recording Form 7B: Internal hatching egg quality upon receipt.
Recording Form 7C: Fertility and embryo quality upon receipt.
Definitions
Recommended procedure “external egg quality”

1. Measure the eggshell temperature by using an infra-red contact thermometer of 5 – 10 eggs throughout the batch
of eggs on arrival at the hatchery and record on Recording Form 7A: External hatching egg quality upon receipt.
2. Take a random and representative sample (of each) batch of hatching eggs received. A representative sample
consists of at least 180 eggs.
3. Check the quality of each egg carefully and use Recording Form 7A: External hatching egg quality upon receipt to
record the number of eggs not meeting the criteria for good external hatching egg quality as described by each of
the categories listed below:
• dirty – includes manure, conveyer marks, blood, egg contents, dust, etc.
• misshaped – too round, too long, irregular shape (flat-sided eggs)
• upside down – if in doubt use a candling light in a darkened room; the blunt end (= side with air cell) should be
upwards.
• abnormal shell color – too white (in case of colored or brown egg layers)
• poor shell quality – includes thin and rough shells, wrinkles, body-checked eggs
• hairline cracks – use a candling light in a darkened room to recognize hairline cracks
• obvious cracks – these can easily be seen with the naked eye; egg membranes could be broken as well.
• too small/too big – there are no international standards, but usually less than 50 grams and more than 70 grams
are out of the normal acceptable range for hatching eggs.
NOTE: If an individual egg falls into more than 1 of the categories, then record only the most prominent ‘defect’.
Alternatively, use a recognizable method of recording this egg for the appropriate categories to avoid counting this egg
twice or three times.
4. Communicate openly with your hatching egg supplier if more than 3% of the eggs in the sample are recorded under
one or more of the mentioned categories, with the mutual aim of improving quality.
5. If required, continue with the procedures outlined below for assessing “internal egg quality” and/or “fertility and
embryo quality”.

Recommended procedure “internal egg quality”
1. Take 10 eggs of good external quality from the sample that was used for checking external egg quality.
2. Open these eggs one by one onto a plate or petri dish.
3. Check the quality of each egg carefully and use Recording Form 7B: Internal hatching egg quality upon receipt to record
the number of eggs not meeting the criteria for good internal hatching egg quality as described by each of the
categories listed below:
• Air cell depth – more than 2 mm; estimate by looking inside the broken shell; alternatively, before opening the
egg a candling light in a darkened room could be used
• Albumen - thin and watery; white and cloudy
• Yolk – flabby and flat; too pale color; mottled appearance
• Presence of blood and/or meat spots
NOTE: If an individual egg falls in more than 1 of the above categories, record only the most prominent ‘defect’.
Alternatively, use a recognizable method of recording this egg for the appropriate categories to avoid counting this egg
twice or three times.
4. Increase sample size to 30 eggs if 1 egg in the sample of 10 eggs is classified as poor internal quality for one or more
of the categories.
5. Communicate openly with your hatching egg supplier if more than 3 eggs in the sample are recorded as poor
internal quality for one or more of the categories, with the mutual aim of improving quality.
6. If required, continue with the procedure below for assessing “fertility and embryo quality”
Recommended procedure “fertility and embryo quality”

1. Take 10 eggs from the sample that was used for checking external egg quality or internal egg quality.
2. Open these eggs one by one onto a plate or petri dish; take care the yolk does not break. Alternatively, place the
eggs upright on an egg tray and remove the shell and egg membranes carefully on the blunt end.
3. Look carefully for the white dot on the yolk; this is the germinal disc, either fertilized or non-fertilized.
4. Record on Recording Form 7C: Fertility and embryo quality upon receipt for EACH egg which of the following
categories is applicable:
• Infertile – compact white spot with ruffled edges
• Fertile, well-developed embryo – doughnut-like opaque ring with translucent center; diameter approx.
3.5 – 5 mm
• Fertile, under-developed embryo – embryo too small (≤ 3.5 mm) with white dots in center of opaque ring
• Fertile, over-developed embryo – embryo too big (> 5 mm)
• Fertile, abnormal embryo – no translucent center, abnormal color
5. Increase sample size to 30 eggs if 1 egg in the sample of 10 eggs is classified as infertile or fertile with under- or
over-developed or abnormal embryo.
6. Take action if the number of infertile eggs is higher than normal for a specific flock age. Take action if more than 3
of the embryos are either under- or over-developed or abnormal. The action involves first of all to communicate
openly with your hatching egg supplier, with the mutual aim of improving quality.

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

Additional notes
• The quality of hatching eggs is one of the major determining factors for the performance of the hatchery.
• Analysis of hatching eggs on arrival could be done at each egg reception, but it could also be decided to do this for
each breeder flock at regular intervals (for example every 5 weeks).
• An individual egg might have one or more characteristics of eggs of poor external and internal quality. Avoid that such
an egg is counted twice or three times by recording this particular egg on the recording from.
• Because the growing embryo fully depends on the nutrients present in the egg, the albumen and yolk must also be of
high quality.
• If the quality of hatching eggs on arrival at the hatchery is not optimal or over time is deteriorating faster than you
expect, communicate openly with your egg supplier, with the mutual aim of improving and/or maintaining quality.
• Under-developed embryos as described in the procedure above point to eggs which cooled down too fast after
oviposition. These embryos are not storage resistant. Pre-storage incubation of batches of eggs with a high number
of under-developed embryos might bring performance benefits, especially if these eggs are to be stored. See
subchapter 2.6: Pre-storage incubation.

7.3 Analysis of eggshell temperature

Objective
To measure eggshell temperature as a basis for adjusting/optimizing/fine-tuning temperature set points in the
incubation program.
Persons responsible
Hatchery manager and personnel assigned to control the incubation process.
Documents
Recording Form 7D: Eggshell temperature.
Definitions
1. Before starting, the Braun ThermoScan should be warmed in the incubator for 15 minutes (if this is not done,
measurements will be inaccurate). Ensure an intact plastic cover (lens filter) is mounted on the infrared probe.
2. Turn setter trays to the horizontal position; stop the setter (NOT by the emergency stop!). Open the door and if
needed temporarily remove one setter trolley out of the setter in order to gain access to the inside of the setter.
Go inside.
3. Immediately close the door; switch on the setter; switch on the light. These actions should be carried out by
a second person who stays out of the setter
4. Measure in an operational setter with a closed door.
5. Place the infrared probe on the eggshell just under the air cell (measuring on the air cell gives a difference of 0.5°F).
6. Measure with the infrared probe placed at a 90° angle on the eggshell to ensure full contact of the probe with the
eggshell (measuring at the wrong angle gives 0.5 - 1.5°F deviation).
7. Measure the eggshell temperature of a minimum of 9 eggs in the center of the setter tray. For this the setter tray
should be carefully partially pulled out of the trolley
8. Measure eggs from one setter tray on a minimum of 3 trolleys in each setter.
9. Record the measured values on Recording Form 7D: Eggshell temperature.
10. Ensure setter trays are properly pushed back in the trolley.
11. Indicate to the person outside the setter when you have finished taking the eggshell temperatures. The second
person should stop the setter and open the door. Replace the trolley you removed, shut the door and start the
setter again.
12. Take the average eggshell temperature of a minimum of 27 eggs, including only eggs with a living embryo. This is the
reference for the eggshell temperature on that day of incubation.
13. Adjust the incubator temperature set point if the actual average eggshell temperature deviates too much from the
desired eggshell temperature (see table on the next page).
Measure the eggshell temperature with the probe placed at

a 90° angle on the eggshell below the air cell.

Desired average eggshell temperature (°F)
Incubation timer (days) minimum mean maximum
0 99.9 100.0 100.1
1 99.9 100.0 100.1
2 99.9 100.0 100.1
3 99.9 100.0 100.1
4 99.9 100.0 100.1
5 99.9 100.0 100.2
6 99.9 100.0 100.2
7 99.9 100.0 100.2
8 99.9 100.0 100.2
9 99.9 100.0 100.2
10 100.0 100.1 100.3
11 100.0 100.2 100.4
12 100.0 100.2 100.4
13 100.0 100.3 100.7
14 100.0 100.3 100.7
15 100.0 100.4 100.8
16 100.0 100.4 100.9
17 100.0 100.5 101.0
18 100.0 100.6 101.2
19 100.0 100.6 101.2
Additional notes
• WARNING: this procedure should be carried out by qualified personnel only because data must be collected in an
operational machine. For safety, ensure that there are trolleys in front of each pulsator.
• The procedure is based on measuring with a Braun ThermoScan; using other devices is not recommended because
they might result in different values. The Braun ThermoScan is accurately calibrated in the narrow temperature range
normal for incubation.
• The Braun ThermoScan is a sensitive device and rough handling might affect its accuracy. To check the proper
working of the Braun ThermoScan, measure some eggs between day 3 and 5; the reading should be 100 °F +/- 0.2 °F
with temperature set points recommended in the guidelines in this Incubation Guide.
• Measurements taken in a machine which is turned off will result in unreliable data because eggshell temperature
changes quickly when the airflow is nil.
• It is recommended to always measure at the same period of the day, thereby considering the moment the incubation
program will make set point changes.
• Do not measure within 1 hour after a set point change.
• Usually eggshell temperature is only measured at the corridor/mixing zone side. During the last days of incubation, the
eggshell temperature at the pulsator side is a little lower compared to corridor/mixing zone side. Therefore, during this
period, aim for the higher part of the desired temperature range in the corridor/mixing zone side.

7.4 Analysis of egg weight loss

Objective
To measure egg weight loss as a basis for adjusting/optimizing/fine-tuning relative humidity set points in the incubation
program.
Persons responsible
Documents
Recording Form 7E: Egg weight loss.
Definitions
1. Mark the empty setter trays (WT) and weigh them. For reliable information several trays per setter should be
marked and weighed.
2. Weigh the marked trays with eggs before incubation starts.
3. Calculate the weight of the eggs only (= weight of loaded tray - weight of empty tray = W0).
4. Likewise, calculate the weight of the eggs only on, for example, day 10 and 18 of incubation (W10 … W18).
5. Calculate the weight loss from the start of incubation (see example and recording form 7E: Egg weight loss) and plot
the result in the graph on Recording Form 7E: Egg weight loss.
6. Adjust incubator set points of relative humidity if the weight loss deviates too much from the recommendation (see
table below).
Optimum weight loss depends on flock age

Recommended weight loss (%) at 18 days
Age breeder flock (weeks)
calculated from fresh egg weight
25 – 40 10 – 11
40 – 50 11 – 12
50 - 60 12 – 13
Additional notes
• Example: the empty tray weight (WT) is 1,000 g. Before start of incubation, the 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. This figure can be plotted in the graph on Recording
Form 7E: Egg weight loss; it shows that the weight loss at 18 days is approximately 12% if linear weight loss is assumed.
This is a good weight loss for medium aged to old flocks. There is no need to adjust the relative humidity set point.
Example:
Before incubation At day 10
Weight of tray with eggs 10,300 g 9,677 g
Weight of empty tray (WT) - 1,000 g - 1,000 g
Weight of eggs only W0 = 9,300 g W10 = 8,677 g
((W0 – W10)/W0)) x 100% = ((9,300 – 8,677)/9,300) x
Weight loss over 10 days =
100% = 6.7%

• The recommendations for optimal egg weight loss are based on fresh egg weight, whereas in the practice of the
hatchery, the calculation of weight loss often is based on egg weight at setting. Depending on storage duration and
storage conditions, an addition of 0.5 to 1% to the calculated weight loss may be needed.
• The relative humidity profile can either be constant (guideline is 50%) or slightly declining from 60 to a minimum of
45 – 48%.
• At a constant relative humidity throughout the setter period weight loss will be linear.
• With a gradual declining relative humidity, the daily weight loss will show a gradual increasing tendency. But does
not differ so much from linearity. If, with this relative humidity profile, the weight loss needs to be increased, it is
preferred to lower the initial relative humidity set points rather than reducing the final relative humidity set points
below 45 - 48%.
• For a correct calculation of the weight loss, do not remove eggs from the marked trays.
• In case relative humidity is measured by the wet bulb – dry bulb principle: Ensure that the humidity sensor is well
maintained (e.g. the cotton wick is clean and wet at all time). More information can be found in the setter manual.
• The increasing size of the air cell can also give a useful indication of egg weight loss.

7.5 Analysis of clear eggs

Objective
To evaluate fertility and the pattern of embryonic mortality during incubation for establishing a hatchery-specific
reference.
Persons responsible
Documents
Recording Form 7F: Analysis of clear eggs.
Recording Form 8B: Results egg analysis and Pasgar©Score.
Definitions
1. Collect clear eggs from randomly selected setter trays from various positions in the setter. See also subchapter 4.2:
10-day candling and subchapter 4.3: Candling and transfer.
2. Ensure all clear eggs are placed on paper or plastic egg trays and label the trays with at least the Egg ID code,
production data, setting date and setter number.
3. Count the number of clear eggs per setter tray and record on Recording Form 7F: Analysis of clear eggs.
4. Open the eggs at the air cell end using forceps. If needed for good observation, pour out the contents onto a plate
or petri dish.
5. Classify the eggs according to the categories on Recording Form 7F: Analysis of clear eggs and fill in this form.
6. Calculate the percentages per category based on total eggs set on the sampled trays.
7. Add this data to Recording Form 8B: Results egg analysis and Pasgar©Score.
Additional notes
• The examination of clear eggs from just one setter tray is not enough to show a characteristic pattern in the
percentages of death at the various stages of incubation.
• Random sampling of setter trays for candling and analysis of clear eggs entails selecting at least 3 setter trays per
ID code from various locations inside the setter. If the variation between these three trays is higher than expected or
higher than normal, then candle three more setter trays. For each setter tray candled, the ID code, production date,
setting date and setter number should be recorded as a minimum.
• If on the day of chick take-off, an egg analysis on unhatched eggs from the same setter trays is planned, setter
trays and subsequently the hatcher baskets should be clearly marked. Records of analysis of clear eggs should then
also be made on Recording Form 7H: Analysis of unhatched eggs; the records of unhatched eggs collected on the day of
chick take-off can then be added to the same recording form.
• It is often impossible to distinguish between infertile eggs and eggs that contained an embryo that died early if
candling is done at transfer. For a better estimation of fertility, consider candling on day 10.
• The frequency of performing an analysis of clear eggs could be for every setting, but it could also be done, for
example, on a monthly basis. A regular program of analysis of clear eggs allows you to generate a hatchery specific
reference.
• In case of disappointing hatchery results, an egg analysis can be performed, and the results can be compared with
the obtained reference. Refer to subchapter 8.5: Trouble shooting for possible causes of deviation from the reference.

7.6 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
Documents
Recording Form 7G: Analysis of unhatched eggs.
Definitions
1. Take a random sample of hatcher baskets and take out the saleable chicks.
2. Count the number of second class and dead chicks per hatcher basket and record on Recording Form 7G: Analysis of
unhatched eggs.
3. Place the unhatched eggs per hatcher basket on labeled paper or plastic egg trays. Label with at least the egg ID
code, production data, setting date and hatcher number
4. Count the number of unhatched eggs per hatcher basket and record on Recording Form 7G: Analysis of unhatched
eggs.
5. Open the eggs at the air cell end using forceps.
6. Classify the eggs according to the categories on Recording Form 7G: Analysis of unhatched eggs and fill in this form.
7. Calculate the percentages per category based on the total number of eggs set originally in the random sample.
8. Add this data to Recording Form 8B: Results egg analysis and Pasgar©Score.
Additional notes
• The examination of unhatched eggs from just one hatcher basket is not enough to show a characteristic pattern in
the percentages of death at the various stages of incubation.
• Random sampling of hatcher baskets for analysis of unhatched eggs entails selecting at least 3 hatcher baskets per
ID code from various locations inside the hatcher. If the variation between these 3 baskets is higher than expected or
higher than normal, then select 3 more baskets. For each hatcher basket sampled, the egg ID code, production date,
setting date and hatcher number should be recorded as a minimum.
• If clear eggs are removed during candling, the number of eggs found at the day of chick take-off does not represent
the total number of unhatched eggs. In case clear eggs have been removed from a random sample of setter trays
for analysis after candling (see subchapter 7.6: Analysis of clear eggs), these setter trays and consequently the hatcher
baskets could be marked for later analysis of unhatched eggs. Records of analysis of clear eggs should then also be
made on Recording Form 7G: Analysis of unhatched eggs; the records of unhatched eggs collected on the day of chick
take-off can then be added to the same recording form. Also consider not removing clear eggs during candling from a
random sample of purposely marked setter trays for later analysis of unhatched eggs.
• When unhatched eggs are analyzed on the day chicks are taken out, it is very difficult and often impossible to
distinguish between infertile eggs and eggs that contained an embryo that died early. For a better estimation of
fertility, consider candling on day 10.
• The frequency of performing an analysis of unhatched eggs could be for every hatch, but it is also possible to do
this, for example, on a monthly basis. Performing a regular analysis of unhatched eggs allows to generate a hatchery
specific reference.
• In case of disappointing hatchery results, an egg analysis can be performed, and the results can be compared with
the obtained reference. Refer to subchapter 8.5: Trouble shooting for possible causes of deviation from the reference.

7.7 Assessing chick quality by using Pasgar©Score

Objective
To evaluate and compare chick quality from different batches of eggs.
Persons responsible
Documents
Recording Form 7H: Pasgar©Score.
Definitions
1. Take a random sample of 30-50 chicks from the batch of eggs to be analyzed.
2. Score the randomly selected chicks individually for the five parameters and write each score on Recording Form 7H:
Pasgar©Score.
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.
6. Add this data to Recording Form 8B: Results egg analysis and Pasgar ©Score.
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 over immediately (within seconds) from lying on its back to standing on its feet (score=0). If this
action takes more than three seconds, the chick scores one point for reflex (score = 1).
Navel: The ‘navel’ of the day-old chick is normal if it is fully closed, which means that the yolk sac is fully
retracted (score = 0). If the navel is open or a black knob is visible, the navel scores 1.
Legs: The normal ‘legs’ of a day-old chick are not swollen and show a normal color (score = 0). Legs are
scored 1 when they are swollen and/or red.
Beak: The normal ‘beak’, including nostrils of a day-old chick is clean (score = 0). The beak scores 1 if it is
dirty and/or has a red dot (score = 1).
Belly: The thickness of the belly (= volume of the yolk sac) depends on the volume of the yolk sac before the
yolk is withdrawn into the abdomen. The volume of the yolk sac is mainly determined by humidity and
temperature in the setter. A normal belly feels soft and smooth and these chicks score = 0 for belly.
If the belly feels hard and the skin is tense, the belly scores 1.

Example: bad navel: Example: bad beak: red dot Example: red hocks
yolk sac not fully retracted
Example:
Chick number Reflex Navel Leg Beak Belly Pasgar©score
1 0 1 0 0 1 8
2 0 0 0 0 0 10
3 0 1 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 1 4 1 1 2 61
The mean Pasgar©Score for this sample of 7 chicks is 61/7 = 8.7
4 out 7 chicks = 57% shows navel problems
Additional notes
• The frequency of determining Pasgar ©Score could be for every hatch, but it could also just be done, for example,
on a monthly basis. Regular determination of the Pasgar ©Score allows you to generate a hatchery specific reference.
• In case of disappointing hatchery results and chick quality, Pasgar©Score can be determined and can be compared
with the obtained reference. Refer to subchapter 8.5: Trouble shooting for possible causes of deviation from the
reference.

8 Data analysis
for continuous
improvements

8.1 Introduction
This chapter provides general guidelines for monitoring hatchery results using a hatchery specific reference set of data
aimed at continuous improvements. It provides general guidelines for:
• the construction of a hatchery specific database of hatchery results;
• the evaluation of hatchery results based on the data collected in the hatchery specific database in order to
create a reference point;
• a procedure for troubleshooting if hatching results are below the reference point.
8.2 Basics of hatchery specific database

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

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

This subchapter describes how the hatchery specific database can be used to calculate average hatchery results. These can
be used as a hatchery specific reference against which actual hatchery results or results of individual breeder flocks can be
evaluated.
8.5 Trouble shooting

If hatching results are lower than expected when compared to the reference data set, a troubleshooting procedure can be
initiated. An overview of management tools to locate sources of suboptimal hatchability or chick quality is described in this
subchapter.

8 Data analysis for continuous improvements
8.2 Basics of hatchery specific database

The basis for a hatchery specific database is accurate and consistent record keeping. Generally, each batch of eggs
incubated is specified by a combination of different variables such as the start date of the incubation cycle, egg ID-code
and production date. Other data can be added if required, such as setter and hatcher numbers, egg weight losses etc.
A hatchery specific database can be designed according to the following two levels:
1. A database of basic hatchery results which are generally easy to collect from every batch of eggs incubated. See
Recording Form 8A: Hatching results
2. A more detailed database containing results of procedures described in subchapter 7.5: Analysis of clear eggs,
subchapter 7.6: Analysis of unhatched eggs and subchapter 7.7: Assessing chick quality: Pasgar©Score. These results
can be summarized on Recording Form 8B: Results egg analysis and Pasgar©Score. 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.

8.3 Construction of a hatchery specific database
For the construction of a hatchery specific database, hatchery results need to be collected and organized in a
spreadsheet. In this spreadsheet the different variables are organized in the columns. ‘Flock ID’, ‘egg storage period’,
‘date of egg setting’ or ‘late embryo mortality’ are examples of variables that can be organized in the columns. The
rows of the spreadsheet contain the hatchery results collected during the different incubation cycles and recorded on
appropriate recording forms as mentioned above.
Using a spreadsheet table to organize the hatchery data makes it possible to select and analyze interactions between the
different variables. The table below shows an example of a suitable spreadsheet. The headers of the columns contain
the names of different variables. In a spreadsheet, the number of variables that can be organized in the columns are
unlimited (visualized by the column with the dotted line).
Example:
Egg- Breed Setting Production Flock Storage No. Total Total Saleable …….
ID date date age days of eggs no. of hatchability (first class)
set chicks % chicks (%)
1
2

8.4 Evaluation of hatchery results

The main advantage of data collected in spreadsheets is the possibility of extracting averages or other types of
summarized data in a simple way. The summarized data can then be used to prepare a hatchery specific reference. An
example of a hatchery specific reference based on overall averages is shown in figure 1a and 1b: the blue line comprises
the average of hatchability from all eggs delivered to the hatchery. The red lines are the results from one specific flock:
fig 1a shows hatching results from parent flock 1 and hatching results of parent flock 2 are presented in fig 1b.
From these figures, it can be concluded that for eggs produced in the next production cycle of flock 1, breeder
management and/or incubation management need to be continuously evaluated and improved to prevent a decrease in
hatchability when the flock is aging.
Eggs produced by flock 2 (figure 1b) show hatchability higher than the overall average, even when the flock is aging.
From this it can be concluded that breeder and/or incubation management is optimum for eggs produced by flock 2.
Evaluation of hatching results could then be done less intensively compared to the attention needed for eggs produced
by flock 1.
Since hatching results (=hatchability) are influenced by many variables, it is advisable to consult a professional
statistician if a detailed and more reliable analysis is needed. A professional statistician can unravel and separate, for
example, the possible influences of the location of a specific setter on hatchability from the influence of breeder flock
management. Without the help of a professional, we can often reach conclusions which might be completely wrong
- for example, the total number of data available could be too low to come to a significant conclusion. The help of a
professional statistician will prevent mistakes and wrong conclusions.
Figure 1a and 1b
Examples of production graphs of 2 different parent flocks
Hatchability parent flock 1

100
80
Hatchability (%)
60 Average of hatchabilities from all eggs

delivered to the hatchery
40 Actual hatchability of parent flock 1 or 2
20
0
25 30 35 40 45 50 55 60
Maternal age (weeks)
Hatchability parent flock 2

100
80
Hatchability (%)
60
40
20
0
25 30 35 40 45 50 55 60
Maternal age (weeks)

8.5 Troubleshooting
In case of suboptimal results, first the problem has to be specified. By comparing the achieved results with the hatchery
specific reference set of data it is possible to accurately define what is suboptimal about hatchability or chick quality.
For example, hatch results of eggs produced by flock no. 1 (figure 1a) drops below the overall hatchery average when
the flock age is more than 37 weeks.
In order to improve hatch results, the need might arise to collect additional data on the batch in question or at least on
the next batch with the same egg ID-code by carrying out:
Subchapter 7.5: Analysis of clear eggs;
Subchapter 7.6: Analysis of unhatched eggs;
Subchapter 7.7: Assessing chick quality: Pasgar ©Score.
The troubleshooting table in this subchapter can be used to find possible causes for the defined suboptimal results. It
will be possible to exclude some potential causes based the available file of continuous records, whereas other potential
causes for the suboptimal results will require further investigation.
When the cause of the suboptimal results is found, formulate a corrective action and communicate it to the person
responsible for the specific procedure. Obviously, it is important to follow up on 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.
Adjusting incubation programs

If the analysis of the troubleshooting table at the end of this subchapter leads to the conclusion that the incubation
program may need adjustment, then records of the incubation conditions before and after the adjustment should be
made:
• Eggshell temperature; subchapter 7.3: Systematic analysis of eggshell temperature;

• Egg weight loss; subchapter 7.4: Relative humidity and egg weight loss;
• CO2 concentration; subchapter 3.2: Single-stage incubation, subchapter 3.3: Multi-stage incubation and subchapter
5.2: Incubation in hatcher.

To bear in mind when troubleshooting

In many cases, the source for suboptimal hatching results or chick quality may be found in factors other than incubation
conditions.
When seeking the cause of suboptimal results, bear the following aspects in mind.
• Maternal age: young flocks produce small eggs and small chicks.
• % of second-class eggs: thin shells require adjustments of relative humidity, while contaminated eggs can greatly
reduce hatching results and chick quality.
• Egg handling at the breeder farm: factors that play a role are egg hygiene, frequency of egg collection, climate etc.
• Egg transport: long transport times at sub-optimal conditions (temperature, hygiene, bad driving and road conditions)
can depress hatching results.
• Storage duration: each day of storage (in excess of three days from production) reduces the hatchability by 0.7%-
1.0%! Stored eggs need about one extra hour of incubation time for every storage day in excess of three days; taking
off the chicks too early will result in high percentages of unhatched eggs.
• Egg storage conditions: compare storage duration and recommended climate conditions.
• Fumigation with formalin: was the duration and temperature correct during fumigation? If not, disinfection may have
been ineffective or detrimental.
• Disinfection with other disinfectants: did these block the cuticle or pores in the eggshell, and with that, hamper gas
exchange and weight loss by reducing evaporation of water?
• Egg transfer and candling: evaluate the transfer time; eggs should not be kept outside the incubator for more than 30
minutes.
• Hatching process: a high level of unhatched chicks may indicate a problem in the hatching phase. Also compare
incubation duration with pre-incubation storage times.
• Parent flock: before concluding that the hatchability was too low, first compare the results with the history of the
parent flock. There may be a fertility, nutritional or health problem in the breeder flock.
• Egg analysis: opening clear and unhatched eggs may reveal causes of bad hatching results. See subchapter 7.5: Analysis
of clear eggs and subchapter 7.6: Analysis of unhatched eggs and Recording Form 8B: Results egg analysis and Pasgar©Score.
• Chick quality: compare chick quality based on the procedure described in subchapter 7.7: Assessing chick quality:
Pasgar©Score with incubation conditions and Recording Form 8B: Results egg analysis and Pasgar©Score.
• Chick boxing and dispatch: in hot weather, reduce the numbers of chicks in the chick boxes. Also, carefully monitor
climate conditions during chick dispatch.
• Day-old-chick transport: long transport times in sub-optimal conditions (temperature, hygiene and road conditions)
can lead to a deterioration in chick quality and may cause chick losses before arrival at the farm. First-week mortality
may also be increased.

Troubleshooting table
This troubleshooting table aims to assist the hatchery manager in finding probable causes for suboptimal hatchery
results; however, Hendrix Genetics does not pretend that this troubleshooting list is complete and applicable to all
situations.
Problem Probable cause

• Males sterile or badly selected
• Too many or insufficient males
• Old males
Infertility
• Disease
• Inadequate feed and water space allowances
• Seasonal effect (e.g. high breeder-house temperature)
• Poor and rough egg handling

Died at “membrane stage” • High nest temperature in combination with low frequency of egg collection
(day 1–2) • Broodiness
• Prolonged or improper egg storage
• Incorrect egg disinfection
• Chilled or overheated hatching eggs

• Incorrect incubation temperature
• Incorrect egg disinfection
• High numbers of floor eggs, cracked eggs
Died at “blood ring stage” and contaminated eggs
(day 3–4) • Disease
• Nutritional causes
• Turning failure
• Broodiness
• Feed contamination

Died at “eye stage” • Turning failure
(day 5–7) • Prolonged or improper egg storage
• Disease

• Eggs too long out of the setter during candling if done between 7–10 days
Died from “egg tooth stage” until start • Poor ventilation of setter and/or setter room
yolk sac absorption • Incorrect humidity in incubator
(day 8–17) • Turning failure
• Disease
• Insufficient turning
• Incorrect incubator temperature or humidity
• Eggs incubated upside down
Death of chicks before internal pipping • Air cell in the wrong place
• High humidity in setter
• High humidity in hatcher before 10% of chicks
have hatched
• Insufficient turning
• Incorrect incubator temperature or humidity
• Eggs incubated upside down
Death of chicks after external pipping
• Air cell in the wrong place
• High humidity in hatcher before 10% of chicks have hatched

Troubleshooting table continued

Problem Probable cause
• Low humidity in hatcher
Death of chicks after external pipping • Temperature too high or too low for a short period
• Poor ventilation in hatcher
• Low humidity and temperature 1–19 days

• Low hatcher temperature
• Hot and cold spots during incubation
Delayed hatch
• Improper egg collection
• Prolonged egg storage
• Excessively large eggs
• High temperature in setter

Premature hatch
• Small eggs
• Low temperature 20–21 days

• High humidity 20–21 days
Sticky chicks • Poor or inadequate air circulation in hatcher
• Turning failure
• Prolonged egg storage
• Eggs dehydrated
Dry chicks • Low humidity at hatching
• High temperature 20–21 days
Unhealed navels • Low temperature
Protruding navels • Temperature fluctuations
• High humidity in hatcher
• Small eggs
• Low humidity in setter
Chicks too small
• Thin porous shells
• Low temperature in hatcher

Large and flabby chicks (poor reflex) • Poor ventilation in hatcher
• Omphalitis (inflamed navels)
• Large eggs
• High temperature in hatcher

Weak chicks • Inadequate ventilation in hatcher
• Heredity
Crossed beak
• Virus infection
• High temperature during first days in setter

Missing eyes
• Rough egg handling
Twisted neck, stargazers • Possibly nutrition
• Incorrect incubation temperature during last days in setter and in hatcher
Crooked toes
Spraddled legs • Smooth hatching trays
Head above right wing • High temperature in setter

9 Hatchery hygiene

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

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

This subchapter summarizes recommendations to prevent the introduction of pathogens into the hatchery by applying strict
biosecurity rules.
9.3 Prevention of cross-contamination

This subchapter summarizes recommendations to minimize the risk of spreading pathogens between hatchery rooms.
9.4 Cleaning and disinfection

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

This subchapter summarizes recommendations for microbiological monitoring of the hatchery’s hygienic status.

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

One of the most obvious vectors for the introduction of pathogens are the hatching eggs and egg trays. Floor eggs and
dirty eggs should not be considered as hatching eggs and therefore should stay out of the hatchery, particularly because
they are potential exploders. It is important that hatching eggs are well supported during transport in order to avoid
hairline cracks, which provide unchecked entry points for bacteria and fungi to get inside the egg. Once the shell -
a critical defense mechanism - is breached, the result is not only loss, but also a serious breach in hatchery biosecurity.
Purpose designed setter trays for on-farm traying are a perfect alternative to the single use of pulp trays. In any case,
only new pulp trays should be used – and setter trays and farm trolleys should be cleaned and disinfected between each
use.
Hatching eggs should be disinfected before entering the clean area of the hatchery; see subchapter 2.8: Disinfecting
hatching eggs for the recommended procedure.
Vertical transmission, from breeder hen to day-old-chick by egg yolk contamination, of specific pathogens like
Salmonella enteritidis and Mycoplasma Gallisepticum can only be prevented by strict monitoring of the breeder flock.
Monitoring for Salmonella spp. includes taking fluff samples from the hatcher from every specific batch of eggs. Yet still
we should accept that chicks will hatch between the onset of a breeder flock being infected and the identification of this
infection, so continuous measures do need to be in place to prevent cross contamination (see subchapter 9.3: Prevention
of cross contamination).
People (hatchery staff and visitors)

To avoid people acting as vectors and bringing pathogens into the hatchery, a well-designed entrance facility is essential.
The following facilities should be present:
• a wardrobe for clothing and shoes worn outside the hatchery;
• a washbasin (soap, disposable paper towels, hot and cold-water tap) or even better - a shower;
• a clear separation between the “clean” and the “dirty” area;
• a wardrobe with clean, disinfected clothing and footwear to be worn inside the hatchery.
Any area accessed prior to the changing rooms and showers in a hatchery should be regarded as a ‘dirty area’, with
the ‘clean area’ of the hatchery incorporating the setter room, candling and transfer room, hatcher rooms and chick
handling and dispatch rooms at minimum.
Technical areas, for example electrical installations or the boiler room, should be located at the outside of the building,
so that engineers have no cause to enter the clean area of the hatchery. Similarly, offices for administrative personnel,
canteens for truck drivers and meeting rooms for customers should be clearly and effectively separated from clean areas
of operation.
Only necessary visitors should be allowed into the hatchery. Visitors should sign in their name, company, date of last
contact with live poultry and purpose of the visit on the appropriate form on entering the hatchery, see Recording
Form 9A: Registration of visitors, and should follow the same hygiene instructions applying to hatchery personnel. Pay
particular notice to items visitors want to bring inside like tools, mobile phones, etc. and inform them about the policy
of the hatchery pertaining to these items.
A regular check of the Salmonella status of hatchery staff and an up-to-date Salmonella test for visitors might also be
part of the hygiene policy of the hatchery.

9 Hatchery hygiene
Air
Prevention begins when designing a new hatchery project. The location should be carefully chosen, taking the position
of other poultry farms and public roads in relation to prevailing wind direction into consideration. Air filters in the air
handling unit(s) minimize the introduction of pathogens, often attached to dust particles, into the hatchery. Biofilters
are recommended if a higher level of protection is required.
Rodents
Strict rodent control, based on prevention and continuous monitoring, is also essential to keep these unwelcome visitors
out of the hatchery. Prevention includes keeping the surroundings of the hatchery neat and tidy, avoiding the attraction
of rodents with food such as hatchery waste, and making the hatchery vermin-proof. Monitoring should not only be
based on seeing rodents themselves, but much more on observing the signs of their presence - for example, footprints
and droppings. Out-sourcing of rodent control to a specialized company might be considered to ensure this aspect
of hatchery hygiene continues to get full attention. Besides, such a company has the knowledge and experience of
rodenticides in relation to the buildup of resistance to specific rodenticides in the local rodent population.
Other vectors
Pathogens could enter the hatchery in or on other vectors, such as water, birds, beetles, pet animals, contaminated
paper chick boxes (e.g. Aspergillus) or dirty chick boxes after a previous chick delivery. One should be alert for each of
these vectors and take adequate action if required.

9.3 Prevention of cross contamination
For good hatchery hygiene, it is equally vital to prevent contamination spreading from one room to another. To prevent
cross-contamination, it is important to clearly demarcate the different hygienic zones in the hatchery:
• egg arrival area
• setter room
• candling/transfer room
• hatcher room
• chick handling and dispatch room
Uni-directional flow
The processes in the hatchery should be carried out according to a one-way traffic system in line with the egg flow
through the hatchery. The hatchery manager who first looks in the chick handling room and moves from there
straight, without changing, to the setter room acts as a transport medium for micro-organisms. Likewise, the hatchery
maintenance engineers, constantly moving through the hatchery, are a risk factor for cross contamination.
Different colored hatchery clothing and shoes, as well as tools such as floor scrubbers, greatly help to enforce hygiene-
responsible behavior by hatchery personnel.
“Clean should never meet dirty”

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

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

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

Strictly applying the “One batch per hatcher” rule, enabled by limiting the capacity of the hatchers, greatly prevents the
risk of cross contamination, for example from older to younger batches.
In a well-designed hatchery the number of hatchers per hatcher room is based on the daily production of chicks. This
avoids recontamination after cleaning and disinfection, and thus minimizes the risk of contaminating the next day’s
hatch. If a specific batch is known to be infected with Salmonella, the decision, often enforced by legislation, is either to
destroy the eggs before they hatch or to pull the infected chicks at the end of the hatch day.

9 Hatchery hygiene
9.4 Cleaning and disinfection

It will be impossible to have a hatchery completely free of micro-organisms, even when the strictest biosecurity rules are
implemented. Regular cleaning and disinfection control the multiplication of micro-organisms effectively.
Procedure
It is essential to clean prior to disinfection since organic material inhibits the chemical action of disinfectants. Good
cleaning also removes up to 85 percent of micro-organisms. Instructions for cleaning and disinfecting every hatchery
room or any hatchery equipment should be formulated and clearly displayed in the relevant area; see Recording Form
9B: Cleaning schedule. For specific procedures of cleaning and disinfecting hatchery equipment, see the relevant
manuals.
The following general routine is recommended:
1. Remove all loose debris such as fluff and eggshells.

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

Consider at least the following points when choosing chemicals for cleaning and disinfection and discuss these with your
supplier:
• pH-values: alkaline soaps remove organic dirt (protein, fat) – acid soaps remove mineral deposits (such as calcium).
Depending on water hardness, the occasional use of acid soap will help maintain smooth surfaces.
• Foam or non-foaming: In washing machines non-foaming soaps should be used. To increase the contact-time between
soap and dirt, a foaming soap should be used for hatchery rooms and equipment; it allows for excellent cleaning
results with relative low water pressure.
• Compatibility: check that the soap does not render the disinfectant ineffective.
• R ange: broad-spectrum disinfectants provide efficacy against a variety of micro-organisms and are preferred over
narrow- range disinfectants, unless these are needed to remove specific pathogens such as Aspergillus.
• Residual activity: to help avoid recontamination.
• Method of application: for example, room disinfection requires gas or fog, while setter disinfection is best achieved
with a spray.
• Corrosiveness: some chemicals used for cleaning and disinfection are very corrosive to certain materials. Check which
materials are used in the hatchery equipment (see technical specifications in user manuals!) and ensure the chemicals
are safe to use with these materials.
• Safety for hatchery staff and environment: provide protective clothing and masks for the cleaning staff.
• Pricing: cheaper is not necessarily better. Also consider the concentration required when comparing products.
Commercial disinfectants often contain more than one active ingredient which complement each other in the fight
against a wide variety of pathogens - together with buffering agents, wetting agents, sequestering agents etc. in order
to ensure their efficacy in contact with organic matter, in cold water, in low and high pH and to increase the shelf life.
Every cleaning and disinfection should be recorded; see Recording Form 9B: Cleaning schedule; review the cleaning
schedule regularly and especially when your microbial monitoring indicates any deterioration in hygiene status.

Recommended cleaning and disinfection frequency hatchery rooms and equipment
Room Cleaning frequency Room and equipment Cleaning frequency
Egg receiving room Once every week Hatcher room Once every week
Egg storage Once every week Hatchers After each hatch
Egg setting room Once every week Chick handling room After each handling
Setter room Once every week 1)
Chick dispatch room After each handling
Setters After each incubation cycle Racks, egg trays, hatcher After each use
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.

9 Hatchery hygiene
9.5 Hatchery hygiene monitoring

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

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

Here, guidelines are restricted to the routine program which involves the sampling of air and surfaces in rooms used
for hatchery practice. The purpose of sampling is to evaluate the effectiveness of a sanitation program and should be
performed only after a clean-up has occurred. For microbial monitoring, use is often made of solidified agar in Petri
dishes containing nutrients matching the metabolic needs of bacteria and fungi. If bacteria and fungi are present,
they will grow on this media when incubated. They will multiply and become visible as colonies. The number of these
colonies is an indication of the hygienic state of the surface sampled.
For inspecting flat surfaces (walls, ceilings), one of the following methods may be used:
• Swab and streak procedure: rub a sterile swab that has been moistened in a sterile solution or a manufactured sterile
culturette over a predefined area (2.5 cm-5.0 cm) of sample surface. Then gently streak over the surface of an agar
plate several times in a zig-zag fashion.
• Rodac plate procedure: “RODAC” stands for Replicate Organism Detection and Counting. Rodac plates are plastic
plates where the base is filled with agar gel. This agar layer is slightly higher than the edge of the plate so that direct
contact is made with the surface to be sampled. Remove the cover of the plate and press the agar gently on the
surface to be monitored (do not move while contact is made). The cover should be replaced after the impression is
made, taking care not to touch the agar.
The Rodac plate can be used for monitoring air. Expose the Petri dish with the selected media by carefully placing the
plate media-half on the bottom on a flat surface within the environment to be monitored. Gently remove the cover.
Leave the media exposed to the air for the specified time. For relatively clean areas, a 10-minute sampling time is
sufficient.
The agar plates which are being evaluated for bacterial contamination should be incubated for 48 hours at 37 - 37.5°C
/ 98.6 – 99.5°F in a microbiological incubator or a setter (place the plates in a plastic bag and set where they will not
be disturbed). Plates are incubated upside down so that drops of condensation will not fall onto the inoculated surface.
After incubation, the colonies on the agar media can be counted and recorded.
Evaluating and monitoring hygiene conditions should be based on the hatchery’s own criteria. In general, an excessive
number of colonies indicate poor sanitation procedures or a hatching egg production problem. For detailed advice on
sampling, reading and evaluating agar plates, see instructions and advice from the agar media manufacturers.
It is advisable to maintain records of all results so that changes occurring over time can be observed in the various
areas being monitored. See Recording Form 9C: Hatchery microbiological monitoring. The results should also be carefully
correlated with hatchability and livability data.

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

10 Hatchery
maintenance

10.1 Introduction
Modern hatcheries are capital intensive and production orientated companies. The down time of equipment and machinery
is prohibitively expensive and affects the financial results of the hatchery. To achieve maximum results, the hatchery
equipment should be kept in top condition by a well-organized preventive maintenance program. This is more efficient than
waiting for equipment break-down followed by repair. Key ingredients for the success of a preventive maintenance program
are using original spare parts and a having a skilled and dedicated technical staff.
10.2 Preventive maintenance

This subchapter explains the importance of a well-organized preventive maintenance program. Relevant aspects of such a
program includes defining who is responsible for preventive maintenance, scheduling the maintenance activities, recording
what was done and which parts were replaced and analyzing history records of preventive maintenance in order to fine-tune
the interval and instructions for preventive maintenance.
10.3 Spare parts

This subchapter asks attention for the importance of having a certain minimum level of essential parts on stock and gives
advice on how to organize the technical workshop.
10.4 Setter and hatcher

This subchapter indicates a special point of interest concerning the preventive maintenance for setters and hatchers. An
important aspect is to check the proper functioning of the incubators before every new cycle.
10.5 Hatchery climate

This subchapter summarizes the importance of a good internal hatchery climate and advises to check the climate conditions
in all relevant rooms on a regular basis. Where there are deviations from the recommended climate conditions, the cause
should be identified, and actions should be taken to rectify the situation. Preventive maintenance of climate related
equipment is essential.
10.6 Hatchery automation and auxiliary hatchery equipment

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

10 Hatchery maintenance
10.2 Preventive maintenance

Hatcheries are capital intensive companies and their success depends on the uninterrupted operation of all relevant
equipment. This does not only apply to setters and hatchers but also to the stand-by generator, the climate control
system incl. chiller, alarm system, hatchery automation, waste system, trucks etc.
Waiting for equipment break-down is the opposite of a well-organized preventive maintenance program. Equipment
break-down and malfunctioning equipment should be avoided, because:
• It always comes unexpected and at inappropriate moments, such as halfway in an incubation cycle or in the middle of
the night or during a festive season.
• The technical engineer of the hatchery is not available or does not know exactly how to repair or solve an urgent
problem
• Relevant spare parts might not be on stock and it will at least take a few days before receiving urgently ordered spare
parts.
• During the period of equipment break-down followed by the required repair, costs are being made, for example
because hatchery staff are idle for some hours until they can commence their activities again.
• Depending on the time of the break-down or malfunctioning of equipment, it almost surely has a negative effect on
hatchery results.
Equipment break-down and malfunctioning equipment can be avoided by implementing a well-organized preventive
maintenance program.
Preventive maintenance includes:

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

The recommended maintenance intervals and the instructions from the Original Equipment Manufacturers should
be followed initially. The accurate recording of maintenance activities will generate a useful maintenance history of
the equipment. By analyzing this data over a longer time period, the frequency of preventive maintenance as well
as specific instructions for maintenance activities can be adjusted. When making these kinds of modifications to the
preventive maintenance plan keep in mind that the purpose is to avoid or reduce the number of breakdowns of hatchery
equipment. By this kind of systematic approach of preventive maintenance hatchery equipment will always be in top
condition.
To make sure that all preventive maintenance activities are performed, and nothing is accidentally forgotten, a detailed
checklist for each item of hatchery equipment is a useful tool. The responsible employee who carries out the preventive
maintenance ticks off all activities on this checklist. Final records should be made on the individual maintenance card
belonging to each item of hatchery equipment and his signature should be placed as a proof that maintenance was
carried out.

10.3 Spare parts

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

10.4 Setter and Hatcher
At least twice daily monitoring the performance of setters and hatchers is essential. Temperature, relative humidity,
ventilation, CO2 and turning are crucial factors for hatchability and chick quality. The integrated alarm system is
monitoring these factors 24/7 and generates an alarm if the difference between set points and actual values is too
high to draw the attention from the responsible hatchery staff. After a power failure setters and hatchers start-up
automatically as soon as power is back. In the meantime, the alarm system will warn hatchery staff.
By listening (for example strange noise in bearing of main- or turning motor) and looking (for example excessive cooling
activity on machine display in one of the sections) to the machines, it is possible to notice failures before they lead to
breakdowns or incubation problems. If this kind of failures are noticed at an early stage, there is no need to interrupt the
hatching process. There is then still ample time to organize the required parts and the repair can be planned for the next
down time between incubation cycles. By doing so, the repair does not interrupt a running incubation cycle and thus
there is no negative influence on hatchability chick quality.
V-Belts for example are typically wear and tear parts in setters and hatchers which should be replaced preventatively
on a time-based schedule according to the maintenance instructions in the machine manuals. These are very essential
in relation to hatchability and chick quality, so must be in top condition. Always replace spare parts per machine, as the
operational hours of all sections is equal. The same applies to electronic humidity and CO2-sensors; to guarantee their
accuracy, needed for a correct working controller of the incubator, replacement on a time-based interval, according to
the maintenance instructions in the machine manuals, is advised.
Recording Form 10A: Setter maintenance card
Recording Form 10B: Hatcher maintenance card

10.5 Hatchery climate

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

Temperature Humidity CO2
Room °C RH % Dew point °C maximum
% / ppm
egg handling 19 – 25 50 – 65 - 0.12 / 1200

egg store: 1)
18 – 21 75 – 85 -
0 – 3 days
15 – 17 75 – 85 - 0.50 / 5000
4 – 7 days
12 – 14 80 – 85 -
≥ 7 days
air inlet setter 2) 21 – 27 ≤ 70 11 – 19 0.09 / 900
transfer 3)
21 – 27 40 - 65 - 0.12 / 1200
air inlet hatcher 2)
21 – 27 ≤ 70 11 – 19 0.09 / 900
chick handling 4)
24 – 27 40 – 65 - 0.12 / 1200
chick dispatch 4)
24 – 27 55 – 65 - 0.15 / 1500
Recommended climate conditions for the main hatchery rooms (Fahrenheit)

Temperature Humidity CO2
Room °F RH % Dew point °F maximum
% / ppm
egg handling 66.2 – 77.0 50 – 65 - 0.12 / 1200

egg store: 1)
64.4 – 69.8 75 – 85 -
0 – 3 days
59.0 – 62.6 75 – 85 - 0.50 / 5000
4 – 7 days
53.6 – 57.2 80 – 85 -
≥ 7 days
air inlet setter 2) 69.8 – 80.6 ≤ 70 51.8 – 66.2 0.09 / 900
transfer 3)
69.8 – 80.6 40 - 65 - 0.12 / 1200
air inlet hatcher 2)
69.8 – 80.6 ≤ 70 51.8 – 66.2 0.09 / 900
chick handling 4)
75.2 – 80.6 40 – 65 - 0.12 / 1200
chick dispatch 4)
75.2 – 80.6 55 – 65 - 0.15 / 1500
1)
Egg ‘sweating’ must be prevented when moving eggs from a cold room to a warmer room;
see subchapter 11.1: Sweating of eggs
2)
Optimal temperature and humidity for setter and hatcher inlet air depends also on external climate conditions and
energy costs needed to condition the inlet air.
3)
Avoid draughts directly on eggs and limit the time egg stay in the transfer room to 15 – 20 minutes.
4)
Room climate is secondary and depends on air velocity as well. The climate AT CHICK LEVEL should be ideal;
see subchapter 6.5 Chick dispatch and transport.

The acceptable range for humidity of inlet air for setters and hatchers is indicated as dew point. With the conversion
tables below, it is easy to check if a certain combination of relative humidity and temperature is within the acceptable
(= high-lighted) dew point range of 11 – 19 °C / 51.8 – 66.2 °F.
Example:
Measured air inlet setter / hatcher
Acceptable?
Temperature (°C/°F) Relative humidity (%)
26 / 79 65 Yes, 65% RH is within the range.
26 / 79 70 No, 70% RH is too high.
Conversion tabel dew point (°C)

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

Conversion tabel dew point (°F)

T°F/RH% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 95%
59 °F 31.4 34.7 37.7 40.4 42.8 45.1 47.2 49.2 51.1 52.8 54.5 56.1 57.6
61 °F 33.1 36.5 39.5 42.2 44.7 47.0 49.1 51.1 53.0 54.8 56.5 58.0 59.6
63 °F 34.9 38.3 41.3 44.1 46.6 48.9 51.0 53.1 54.9 56.7 58.4 60.0 61.5
65 °F 36.7 40.1 43.1 45.9 48.4 50.8 52.9 55.0 56.9 58.7 60.4 62.0 63.5
67 °F 38.4 41.9 44.9 47.7 50.3 52.7 54.8 56.9 58.8 60.6 62.3 64.0 65.5
69 °F 40.2 43.7 46.8 49.6 52.2 54.5 56.7 58.8 60.7 62.6 64.3 65.9 67.5
71 °F 42.0 45.5 48.6 51.4 54.0 56.4 58.6 60.7 62.7 64.5 66.3 67.9 69.5
73 °F 43.7 47.2 50.4 53.3 55.9 58.3 60.5 62.6 64.6 66.5 68.2 69.9 71.5
75 °F 45.5 49.0 52.2 55.1 57.7 60.2 62.4 64.5 66.5 68.4 70.2 71.9 73.5
77 °F 47.2 50.8 54.0 56.9 59.6 62.0 64.3 66.5 68.5 70.4 72.1 73.8 75.5
79 °F 49.0 52.6 55.8 58.8 61.5 63.9 66.2 68.4 70.4 72.3 74.1 75.8 77.4
81 °F 50.8 54.4 57.7 60.6 63.3 65.8 68.1 70.3 72.3 74.2 76.1 77.8 79.4
83 °F 52.5 56.2 59.5 62.4 65.2 67.7 70.0 72.2 74.3 76.2 78.0 79.8 81.4
85 °F 54.3 58.0 61.3 64.3 67.0 69.6 71.9 74.1 76.2 78.1 80.0 81.7 83.4
87 °F 56.0 59.8 63.1 66.1 68.9 71.4 73.8 76.0 78.1 80.1 81.9 83.7 85.4
89 °F 57.8 61.5 64.9 67.9 70.7 73.3 75.7 77.9 80.0 82.0 83.9 85.7 87.4
The characteristics of the air that enters the setter or hatcher has an effect on the incubator’s behavior. When setter
inlet air is (both) cold and(/or) dry, the humidifier inside the setter might be activated too much. This leads to a local
cold-spot close to the humidifier and should thus be avoided. Another example is when hatcher inlet air is (both) warm
and(/or) humid. This might lead to excessive condensation on the cold walls of the hatcher and eventually to water
on the floor; this situation should also be avoided.The level of CO2 in inlet air of setters and hatchers should also be
measured since this is a good indicator of the quality of air entering the incubators.
It is advisable to take weekly readings of the climate conditions of every room in the hatchery where steps of the
incubation process occur and to record these on Recording Form 10D: Checklist climate conditions in hatchery. Use good
quality handheld thermometers, hygrometers and CO2-meters and get these calibrated and certified at least once per
year. The accuracy of these handheld instruments should be at least similar as the accuracy of the sensors used for
climate control.
Compare the readings of the handheld instruments with the actual set points and the acceptable range of deviation
from the set point. When the actual readings, after several times repeating the measurement, deviate too much from
the set points, the cause should be identified, and actions should be taken to rectify the situation.
Too high CO2 concentrations in the clean air plenum may indicate that the filters of the air handling unit need to be
replaced. Modern air handling units (AHU) are engineered with a “blocked filter’’ sensor. The AHU will give an alarm
when the filter is dirty and should be replaced. When these replacement intervals are recorded on Recording Form 10C:
Hatchery equipment maintenance card it is possible to plan to change the filters preventive on a time-based interval.
Check and clean air fans, ventilation grill, clean or replace protection filters of sensors. Include these activities in the
preventive maintenance program.
Paying attention to air pressures in the various pressure-controlled rooms and comparing those with set points is
important for correct air flow (‘from clean to dirty’) in the hatchery and for optimal performance of the incubators.
Instruct all employees in the hatchery to close the doors when they are leaving a room; opening doors disturb the room
air pressures and temperatures. This will have not only a negative effect on the hatchability but will also lead to increase
of the energy costs.

10.6 Hatchery automation and auxiliary equipment
Equipment such as trolley loaders and unloaders, washing machines, vaccinators, chick counters, candling and transfer
machines, vacuum waste system etc. are some examples of equipment of the wide range of hatchery automation.
Even when there is a problem in the automation line, the production should continue. Therefore, it is important to make
‘escape plans’ so that it is clear what to do when critical equipment stops working.
For example: When there are problems in automation of egg transfer and the engineers are working to solve the
problem, eggs can be transferred with simple semi-automatic equipment.
Also, auxiliary equipment such as the stand-by power generators, the trucks for egg and chick transport, fork lifters,
water supply, snow plough and the truck wash installation need preventive maintenance.
For example: The preventive maintenance for the stand-by generator should be on a time-based schedule. It should be
started up every week to check its functioning and the level of gasoil should be checked at the same moment. A power
failure from the public supplier is only a disaster if the standby generator fails due to neglected preventive maintenance!
Because of the number and variety of parts for all of this auxiliary equipment, it is important to identify the most critical
and/or common parts and keep them on stock in the hatchery. Often controllers, transmissions, belts, pumps, nozzles
are specially designed for this application and ordering and delivering can take some time.
The maintenance intervals of the Original Equipment Manufacturer should be followed as a minimum. Some of this
specialized equipment requires service checks by specialists from the manufacturer. Integrate these visits in the
preventive maintenance schedule and make sure that the visit is organized when it is required.
For every equipment listed under hatchery automation use Recording Form 10C: Hatchery equipment maintenance card.
Finally, even though the hatchery building itself is not defined as ‘equipment’ it also requires maintenance at a regular
interval to keep it looking good and extend its lifetime.

11 Annexes

11.1 Sweating of eggs
11.2 Hatching at altitude
11.3 Optimization of brooding conditions for day-old chicks
11.4 Cull egg chart white eggs
11.5 Cull egg chart brown eggs
11.6 Colour spectrum chart brown eggs

11 Annexes
11.1 Sweating of eggs

‘Sweating’ of eggs refers to the phenomenon of condensed water sitting on the eggshell surface. This occurs when cold
eggs are suddenly exposed to a higher environmental temperature. The warm air with a certain moisture content cools
down rapidly directly around the colder eggs. Since cold air can contain less water than warm air, relative humidity will
increase until the air is saturated. And at that moment, condensation will take place on the cool egg surface.
The term ‘sweating’ is, if taken literally, misleading, because the water on the shell does not in fact come from within
the egg. The same physical process is seen when a bottle of water is removed from a refrigerator on a warm summer
day.
Sweating of eggs should be avoided because moisture on the shell surface weakens the egg’s natural defense
¬mechanisms, providing as it does an ideal environment for the growth of micro-organisms, and further facilitating their
penetration through the shell pores.
Once inside the pores, micro-organisms are protected from most routine egg sanitizing operations, therefore presenting
a potential risk for contamination. Bacteria and fungi which manage to pass through the shell membranes will multiply
at a rapid rate when they are exposed to incubation temperature because the defense mechanism in the albumen is no
longer able to protect the growing embryo.
This of course will lead to increased embryonic mortality, ‘exploders’ and infected day-old-chicks (increased first week
mortality).
Clearly moisture on eggshells should be prevented. Egg sweating is prevented when the difference in temperature
between the egg storage room and ‘the outside’ (e.g. loading platform of the truck, egg traying room, setter) is small
and the ‘outside’ humidity is low.
The table below can be used to predict whether sweating will occur if no additional measures are taken. For a wider
range of temperatures and humidities, a so-called ‘Mollier’ diagram or psychrometric chart provides a useful tool and is
explained below.
There is also a risk of eggs sweating if they are set too cold in a setter that is already running to temperature, as is the
case in multi-stage incubation practice.
Eggs will ‘sweat’ if the relative humidity (% RH) in the egg traying room is higher than:
Temperature egg traying room:
Temperature of storage room 1)
15 °C / 59.0 °F 18 °C / 64.4 °F 21 °C / 69.8 °F 24 °C / 75.2 °F
21 °C / 69.8 °F - - - ≥ 85% RH
18 °C / 64.4 °F - - ≥ 83 % RH ≥ 71% RH
16 °C / 60.8 °F - ≥ 89% RH ≥ 74 % RH ≥ 60% RH
11 °C / 51.8 °F ≥ 74% RH ≥ 64% RH ≥ 53 % RH ≥ 44% RH
1)
It is assumed that the temperature of the eggs equals the temperature of the egg storage room.

Advice
• If the risk of sweating is high, pre-warm eggs gradually at least six hours prior to removing them from the egg storage
room. This can be achieved by first bringing the eggs to a room with an intermediate temperature (for example from
the colder egg storage room for long stored eggs to the warmer egg storage room for short stored eggs) prior to
moving them to the warmest room (for example the setter room). It is important to realize that not all eggs warm
up at the same, uniform speed, especially with low air circulation and if stored on paper trays and stacked closely
together.
• Store at a higher temperature, combined with a shorter storage period.
• Connect the truck picking up the hatching eggs directly with the storage room to minimize any temperature
differences from the outside environment.
• Ensure that the climate in the truck is the same as in the egg store.
• Maintain humidity below the levels indicated in the table.
• Prior to placement in the setter, place the filled setter trolleys at a room temperature of 25 ˚C with good air circulation
for several hours. This pre-warming of the eggs before setting is particularly important when using multi-stage
incubation.
‘Sweating’ of eggs explained by Mollier diagram (°C)

The Mollier diagram describes the relation between temperature, moisture and energy in air. It forms the basis for the
calculations needed for designing hatchery climate control, but it can also be used to predict when sweating of eggs will
occur.
To predict if sweating will occur, it is necessary to know only the meaning the following 2 lines of the diagram:
1. The horizontal lines, which represent the temperature of the air; the values are indicated in degrees Celsius on the
vertical axis on the left.
2. The curved lines in the diagram represent the relative humidity of the air; the values are indicated as %RH on the
curved lines themselves.
In the worked example below, it is assumed that the temperature in the setter room is 25 °C. The diagram represent
three possible levels of relative humidity in the setter room: 50 % (diagram 1), 60 % (diagram 2) and 70 % (diagram 3).
If eggs are brought into this setter room from the egg store the air directly surrounding these eggs will cool down from
25 °C to approximately egg temperature. This is indicated by the vertical lines. As we move down these lines, they cross
through several curved relative humidity lines. In other words, the relative humidity of the air directly surrounding the
eggs is increasing. Once the relative humidity of the air directly surrounding the eggs reaches 100 %, the air can no
longer hold the water in vapour form (the air becomes saturated because a relative humidity higher than 100 % does
not exist) and the excess moisture will condense onto the egg shell.
From the Mollier diagrams below, considering a setter room with a temperature of 25 °C, it is possible to state that:
• With a humidity of 50% in the setter room, sweating will occur if eggs are lower in temperature than approx. 13.89
°C (indicated by diagram 1).
• With a humidity of 60% in the setter room, sweating will occur if eggs are lower in temperature than approx. 16.72
°C (indicated by diagram 2).
• With a humidity of 70% in the setter room, sweating will occur if eggs are lower in temperature than approx. 19.17 °C
(indicated by diagram 3).
Practically this means that there is a higher risk for sweating if relative humidity in the setter room is high. This could
be the case immediately after cleaning the setter room, but also in hot and humid countries. In those situations, eggs
should be gradually warmed up prior to bringing them into the setter room. Alternatively attempts could be made to
lower the relative humidity in the setter room.
For every situation, the Mollier diagram can be used to determine if there is a risk for sweating and what can be done
to prevent it happening.

Diagram 1
Diagram 2

Diagram 3

11 Annexes
‘Sweating’ of eggs explained by a psychrometric chart (°C)
A psychometric chart contains the same information as the Mollier diagram; however, the lines run a bit different.
To predict if sweating will occur, it is necessary to know only the meaning the following 2 lines of the diagram:
1. The horizontal lines, which represent the temperature of the air; the values are indicated in degrees Celsius on the
horizontal axis.
2. The curved lines in the diagram represent the relative humidity of the air; the values are indicated as %RH on the
curved lines themselves.
In the worked examples below, it is assumed that the temperature in the setter room is 25 °C. The diagrams represent
three possible levels of relative humidity in the setter room: 50% (diagram 1), 60% (diagram 2) and 70% (diagram 3).
If eggs are brought into this setter room from the egg store, the air directly surrounding these eggs will cool down from
25 °C to approximately egg temperature. This is indicated by the horizontal coloured lines. As we move these lines
towards the left, they cross through several curved relative humidity lines. In other words, the relative humidity of the
air directly surrounding the eggs is increasing. Once the relative humidity of the air directly surrounding the eggs reaches
100%, the air can no longer hold the water in vapour form (the air becomes saturated because a relative humidity
higher than 100% does not exist) and the excess moisture will condense onto the eggshell.
From the psychrometric charts below, considering a setter room with a temperature of 25 °C, it is possible to state that:
Diagram 1

Diagram 2
Diagram 3

11 Annexes
11.2 Hatching at high altitudes

The effects of high altitude on hatchability and chick quality depends largely on the altitude at which the hatching eggs
are produced - and how the hatchery manager adjusts the incubation program.
Barometric pressure declines with altitude, as does the partial pressure of oxygen and absolute humidity. Because at
lower density molecules can move more freely, the overall diffusion through the pores of the eggshell of oxygen, carbon
dioxide and water is increased. Moreover, at altitude fresh ventilating air will tend to be colder and drier than at sea
level.
Oxygen availability
The oxygen content of air is always 21 percent, but the reduced partial pressure at altitude provides less oxygen from a
given volume of air. The resulting reduced oxygen supply to the embryo is only partially compensated by the increased
rate of diffusion of oxygen through the eggshell and by the embryo’s higher capacity for binding oxygen to the blood
hemoglobin. At altitudes above 2,000 meters, it can help to inject oxygen into the setter and the hatcher, to raise the
oxygen level from 21 to 23 - 25 percent. 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 increased rate of diffusion in combination with the drier air at altitude will result
in increased moisture loss from the eggs. However, there is evidence that breeder flocks may adapt to altitude by
producing eggs with a lower effective pore area similar to the adaptation of wild birds to altitude. This compensates for
increased diffusion and therefore water vapor loss through the eggshell at any altitude may remain the same as at sea
level. When choosing the relative humidity set point for incubation, this potential adaptation of shell conductance to
altitude should be taken into consideration. Confirmation if the optimal relative humidity set point has been chosen can
only be obtained by checking that the actual egg weight loss is correct.
Three ‘altitude’ scenarios

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

In general, this will give good results. Relative humidity set points could probably be kept similar to sea level because the
increased rate of diffusion may be compensated by the lower effective pore area of the eggshell. Ventilation rates should
be higher than normal for sea level, such that the embryo is provided with sufficient oxygen. During humid external
conditions, increase ventilation, as humidity reduces oxygen levels in the air still further. This higher ventilation rate
may cause reduced humidity in the setters and hatchers and thus constantly activated humidifiers. Especially during the
last days in the setter, it is beneficial to reduce relative humidity set point even further and to even accept the resulting
higher than optimal weight loss (e.g. 13 – 14%).
3. Eggs produced at altitude: hatchery at sea level

Generally, this will give good results. The set points for relative humidity may need to be reduced to achieve optimum
weight loss as the eggs will probably have a reduced effective pore area compared to eggs laid at sea level.

Advice
• Fine-tune relative humidity set points by weighing trays of eggs before setting and again at transfer at 18 - 18.5 days.
Exact set points for relative humidity are dependent on altitude of hatchery and eggshell conductivity (age flock,
nutrition, genetics, altitude of breeder flock). Optimum weight loss for good hatchability and chick quality is indicated
in subchapter 7.4: Analysis of weight loss.
• Judge the size of the air cell as an indicator of weight loss.
• Be aware of signs that indicate insufficient weight loss and/or a shortage of oxygen during an egg break-out. These
signs are: too many wet, fully developed embryos that fail to pip. If this is observed, reduce set points for relative
humidity and/or increase ventilation rate.
• Ensure that humidity and CO2 sensors are calibrated for altitude or alternatively find the correct set point to be used
(see table under additional notes).
Note: CO2 set point should be adjusted for altitude because the CO2-sensor is calibrated for sea level. The set points in
the table below are corrected for the different altitudes and are similar to the recommended set points for hatcheries
at sea level. If a higher ventilation rate at altitude is required to accommodate for the reduced oxygen level from 1000
meter onwards the CO2-set points in the table could be reduced by 0.05 – 0.1%.
Altitude (meters from sea level) Setter Hatcher

0 – 500 0.40 0.45
500 – 750 0.40 0.45
750 – 1.000 0.35 0.40
1.000 – 1.500 0.35 0.40
1.500 – 2.000 0.30 0.40
2.000 0.30 0.35

Optimization of Brooding
11 Annexes
conditions for Day-old Chicks
11.3 Optimization of brooding conditions for day-old chicks
Preparation before arrival Litter Material

• Start to heat up the house before the chicks will arrive to fulfill temperature • When chicks are being placed, the litter material should have a minimum of 30˚C
parameters on time. (86˚F)
• Concrete floors should have a minimum of 28˚C (82˚F) before any litter material • Infrared contact temperature should be measured as close to the object (= litter
is distributed. or concrete floor) as possible. This to avoid that air temperature influences the
• Be aware that litter material acts as insulation. measured contact temperature of the litter. The further away the object is, the
• Do not distribute the litter too long before arrival of the chicks. less accurate the reading will be.
• Do not use too much litter material. Floor coverage of 1 cm. is enough. • Measure the litter temperature at several positions throughout the house.
• If a concrete floor is not warm enough before litter distribution, chicks will be • Most Infra-red contact thermometers need time to acclimate with the
chilled when they lie down on the litter material. temperature inside the house before they can be used.
• Set point for air temperature at arrival of the chick should be 33-35˚C (92 – 95˚F).
Chick Body Temperature House Air Temperature

• Chick body temperature can be measured with an infrared ear thermometer. • Find correct set point for house air temperature by managing the body
• Place the probe gently onto the cloaca of the chick. Ensure proper contact temperature of the chicks.
without penetration. • Start checking body temperature of the chicks every hour after placement.
• Push and release the start button while holding the probe against the vent • Change the set point for house air temperature with the distance from optimum
area of the chick body temperature as measured.
• Hold the probe against the cloaca until hearing a long beep which indicates the • This means that if body temperature is only 38˚C one hour after placement,
end of the measurement process. Optimum chick body temperature is 40˚C house air temperature has tob e elevated with 2˚C.
(104˚F). • Keep checking body temperature until the correct temperatures have been
• Take temperatures of at least 20 chicks throughout the house to get an achieved and situation is stabilized.
indication of the situation. • At day 5 of age the chick will normally be able to keep up their own body
• Day old chicks cannot regulate their own body temperature yet, so they temperature (within limits) and a rise in body temperature will
depend on ambient conditions. Be aware that chick body temperature reacts automatically follow to about 41˚C (106˚F).
quikly after ambient conditions have been changed. • From there on, set point for house air temperature
can be gradually reduced (e.g. 0,5˚C per day).
L7160-1

T +31 485 319 111
hendrix-genetics.com

11.4 Cull egg chart white eggs
11.5 Cull egg chart brown eggs

11 Annexes
11.6 Colour spectrum chart brown eggs

12 Glossary

12 Glossary
Batch of eggs: A clearly defined group of eggs from one breeder flock and preferably one production
house and produced on the same day (or more practically with no more than 3 -5
days difference in production date.
Batch of chicks: A clearly defined group of chicks originating from a specific batch of eggs and set and
incubated together.
Braun ThermoScan: Thermometer based on infrared radiation and specifically designed and calibrated to
measure human body temperatures of 37 - 40°C (accuracy 0.1°C).
Chick dispatch room: Room used to bring together chicks in boxes that are destined for one chick farm.
From this room the chick boxes are loaded into trucks.
Candling/candle: The selection and removal of infertile eggs and eggs containing dead embryos by
exposing trays of eggs to candling light.
Clear eggs: Eggs which are transparent to candling light. Clear eggs are infertile or contain
embryos which died early in incubation.
Crystalline paraformaldehyde: A disinfecting powder that evaporates when it is heated electrically.
Draughts: A flow of air of lower temperature into a room of higher temperature; often a draught
is experienced as unpleasant and creates discomfort.
Egg container: Trolley for transporting stacked paper or plastic trays with eggs.
Egg disinfection room: A room specially designed for disinfecting eggs. Located at breeder farm, at entrance
for eggs to the hatchery or between egg handling room and setter room.
Egg ID code: Each batch of eggs should be given a label with a batch-specific identification (ID)
code, e.g. a combination of a farm and house number and egg production date.
Eggshell temperature: Temperature of the surface of the egg, which is used as a reference for embryo
temperature. The eggshell temperature is measured by placing the probe of a Braun
ThermoScan halfway down the side of the egg in order to avoid the air cell.
Eggshell temperature on The average eggshell temperature of a minimum of 27 eggs per setter (3 setter trays;
specific day of incubation: a 9 eggs/setter tray) containing living embryos.
Egg storage room: Area in breeder farm and in the hatchery with equipment to maintain a stable
temperature and relative humidity for the storage of hatching eggs under optimal
conditions.
Egg tray: 30-egg capacity stackable paper or plastic tray designed for holding eggs with sharp
end down.
Egg traying room: Area for traying eggs. The egg traying room might be the same area as the egg
receiving room.
Electric pan: An electric pan connected to a programming unit used for the evaporation of
crystalline formaldehyde.
Embryonic age: Age of the embryo expressed as the time the egg has spent in the incubator.

Exploder: Gas producing bacteria inside the egg can cause the egg to explode spontaneously of
when triggered by for example egg transfer.
External pipping: When the chick’s beak has cracked the eggshell we say the chick has pipped
externally.
Farm trolley: Trolley for transporting setter trays with eggs from farm to hatchery.
Floor eggs: Eggs laid outside the nest. Floor eggs are heavily contaminated with micro-organisms
and should never be sent to the hatchery. But, if floor eggs are sent to the hatchery,
they should be treated and incubated separately.
Hairline cracks: Eggs with fine cracks in the shell that may only be detectable by candling.
Hatcher: Incubator cabinet designed to incubate hatching eggs at the appropriate temperature,
humidity and air composition during the last three days of embryonic development,
hatching and drying of chicks. A hatcher is loaded with eggs from the same section in
the setter.
Hatcher basket: Carrier for hatching eggs during the last three days of embryonic development and
during hatching.
Hatcher dolley: Cart designed to stack hatcher baskets onto to be placed in a hatcher.
Hatching eggs: Eggs from breeder farms with clean, smooth and intact shells and with oval shape and
within required size range.
Incubation program: The incubation program defines per day the incubator set points for temperature,
humidity, valve or carbon dioxide, turning and the frequency of pulsator.
Infertile eggs: Eggs that were never fertilized by sperm. The unfertilized oocyte can be recognized
as a white dot in the center of the yolk.
Internal pipping: When the chick’s beak has penetrated the inner shell membrane and thus reached
the air cell, we say the chick has pipped internally; from this moment onwards, the
chicks inside the eggs can make sound and can be heard.
Meconium: The first manure of greenish color produced by the hatched chicks and visible on
empty eggshells and chick paper.
Misshapen eggs: Eggs with shells that have ridges, spiral grooves or a flat wrinkled side.
Multi-stage incubation: An incubator containing eggs with embryos of different ages.
Non-hatching eggs: These include floor eggs and poor-quality eggs (dirty eggs, hairline and cracked eggs,
misshapen eggs, eggs with poor shell quality and eggs out of the required size range).
Oviposition: The actual laying of the egg.
Chick Score: An objective method for evaluating the quality of day-old chicks.
Pre-heating: Heating of eggs in an operational setter to a uniform temperature of 77 – 81 °F prior

to the onset of incubation.

13 Recording Forms

2A Egg transport card 120
2B Egg receipt form 121
2C Hatching egg stock list 122
2D Setter trolley card 123
2E Setter schedule 124
2F Egg storage room: climate conditions 125
2G Egg disinfection room 126

3A Incubator recording form 127

6B Chick passport 128

7A External hatching egg quality upon receipt 129
7B Internal hatching egg quality upon receipt 130
7C Fertility and embryo quality upon receipt 131
7D Eggshell temperature 132
7E Egg weight loss 133
7F Analysis of clear eggs 134
7G Analysis of unhatched eggs 135
7H Pasgar ©Score 136

8A Hatching results 137
8B Results egg analysis and Pasgar ©Score 138

9A Registration of visitors 139
9B Cleaning schedule 140
9C Hatchery microbiological monitoring 141

10A Checklist climate conditions in hatchery 142
10B Setter maintenance card 143
10C Hatcher maintenance card 144
10D Hatchery equipment maintenance card 145

Recording Form 2A: Egg transport card
Supplier
Name________________________________________________________________________________________________________
Address______________________________________________________________________________________________________
Postal code__________________________________________________________________________________________________
Telephone____________________________________________________________________________________________________
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 2B: Egg receipt form
Name________________________________________________ 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___________________________________________
Egg ID-code Production Hatching eggs Non-hatching eggs

date Normal size Small Washed eggs Floor eggs Others
TOTAL DELIVERED
TOTAL RECEIVED
Climate storage room at breeder farm

Temperature_________________________________________ Humidity (%)_________________________________________
Transport conditions
Departure time_______________________________________ Arrival time__________________________________________
Truck temperature____________________________________ Truck temperature____________________________________
Truck disinfectant____________________________________
Signatures
Name supplier________________________________________ Name driver__________________________________________
Signature supplier____________________________________ Signature driver______________________________________
Name recipient_______________________________________
Signature recipient___________________________________

Recording Form 2C: Hatching egg stock list
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.

Recording Form 2D: Setter trolley card
Trolley number_______________________________________________________________________________________________
Egg ID-code__________________________________________________________________________________________________
Production date______________________________________________________________________________________________

Recording Form 2E: Setter schedule
Egg ID-code Production Date of receipt Number of Number of Stock Remarks

date hatching eggs eggs set

Recording Form 2F: Egg storage room:
climate conditions
Storage duration Temperature (°C/ °F) Relative humidity (%) Egg orientation
0-3 days 18-21 / 64.4–69.8 75 – 85 Blunt end up
4-7 days 15-17 / 59.0–62.6 75 – 85 Blunt end up
8-10 days 12-14 / 53.6-57.2 80 – 85 Blunt end up
More than 10 days 12-14 / 53.6-57.2 80 – 85 Small end up or
alternatively turning the
eggs every 24 hours
Date Temperature Humidity Remarks Date Temperature Humidity Remarks

(°C/ °F) (%) (°C/ °F) (%)
Calibration date thermometer_________________________________________________________________________________
Calibration date hygrometer___________________________________________________________________________________

Recording form 2G: Egg disinfection room
Date Time No. of trolleys Disinfectant Amount Remaining Remarks

in disinfection disinfectant
room

Recording Form 3A: Incubator recording form
Setter number________________________________________ Hatcher number______________________________________
Setting date__________________________________________ Hatching date________________________________________
Starting time_________________________________________ Starting time_________________________________________
Incubation program___________________________________
Temperature______________________ RH (%)____________________________ Ventilation________________________
Check setter V-belt and bearing Check setter V-belt and bearing
Heating Heating
Cooling Cooling
Humidifier Humidifier
Sensors Sensors
RPM’s RPM’s
Turning
Transfer date and time________________________________________________________________________________________
Egg ID-code Production Trolley numbers Number of eggs (Estimated) (Estimated)

date set Clears (%) number of eggs
after (sample)
candling
TOTAL
Adjustments to set points setter and hatcher
Date Time Display time (day. Adjustments to set Reason

hour) points

Recording Form 6B: Chick passport
Setting date__________________________________________ Setter number________________________________________
Hatching date________________________________________
Egg ID-code Number of chicks Quality of chicks Treatments Person carrying

(♂ male / ♀ female) out the treatments
Departure time_______________________________________ Arrival time__________________________________________
Truck temperature____________________________________ Truck temperature____________________________________
Truck disinfectant____________________________________
At the farm
Floor temperature____________________________________ Number of chicks_____________________________________
Litter quality_________________________________________ Chick quality_________________________________________
Feed & water supply__________________________________
Signatures
Name truck driver____________________________________ Name customer______________________________________
Signature truck driver_________________________________ Signature customer___________________________________

Recording Form 7A: External hatching egg quality
upon receipt
Egg ID-code__________________________________________ Breed________________________________________________
Production date______________________________________ Maternal age_________________________________________
Date of receipt_______________________________________ Date of quality control________________________________
Core temperature (5 – 10 eggs)________________________________________________________________________________
Sample size
Category Number of eggs % of sample
Dirty
Misshaped
Upside down
Abnormal shell color
Poor shell quality
Hairline cracks
Big cracks
Too small
Too big
TOTAL

Recording Form 7B: Internal hatching egg quality
upon receipt
Egg ID-code__________________________________________ Breed________________________________________________
Category Number of eggs within...
Sample of 10 eggs Additional 20 eggs
Air cell depth > 2 mm
Albumen thin and watery
Yolk
• Flabby and flat
• Very pale color
• Mottled
Blood- or meat spots
TOTAL

Recording Form 7C: Fertility and embryo quality
upon receipt
Egg ID-code__________________________________________ Breed________________________________________________
Category Number of eggs within...
Sample of 10 eggs Additional 20 eggs
Infertile
Fertile, diameter approx. 3.5– 5 mm;

doughnut-like opaque ring with
translucent center
Fertile, embryo too small (≤ 3.5 mm);

white dots in center of opaque ring
Fertile, embryo too big (> 5 mm)
Fertile, abnormal embryo

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

Recording Form 7E: Egg weight loss
Setter number________________________________________________________________________________________________
Name of incubation program__________________________________________________________________________________
Trolley
Tray
Egg ID-code
Production date
Breed
Maternal age
Storage days
Incubation time: 0 days 0 0 0 0 0 0
Weight empty tray = WT
Weight tray + eggs
Weight eggs only = W0
Incubation time: A days A= A= A= A= A= A=
Weight tray + eggs
Weight eggs only = WA
Weight loss =
((W0 - WA )/ W0 )x 100%
Incubation time: B days B= B= B= B= B= B=
Weight tray + eggs
Weight eggs only = WB
Weight loss =
((W0 – WB )/ W0 )x 100%
14 13% weight loss

Weight loss (%)
12 12% weight loss

11% weight loss
10 10% weight loss
8
6
4
6 8 10 12 14 16 18
Incubation time
Recording Form 7F: Analysis of clear eggs
Egg ID-code__________________________________________ Breed________________________________________________
Setter number________________________________________ Storage days_________________________________________
Hatcher number______________________________________
Trolley
Basket
Total unhatched eggs
Category Number of eggs Totals
No. Description
1 Contaminated / rots
2 Crack at set
3 Crack at transfer
4 Thin/porous eggshell (dehydrated)
5 Infertile (irregular whit spot)
6 Early dead, 1 – 2 (membrane)
7 Early dead, 3 – 4 (blood ring)
8 Early dead, 5 – 7 (eye)
9 Mid dead, 8 – 10 (egg tooth)
10 Mid dead, 11 – 14 (feathers)
Late dead, 15 – 17 (embryo turned

11
to length axis of egg)
12 Late dead, > 17 (start yolk sac absorption)
13 Internal pipped
14 External pipped
15 Malposition
16 Malformation (Exposed brains)
17 Malformation (crossed beak)
18 Dead chicks in tray
19 2nd Grade chicks
20 Females / Males

Recording Form 7G: Analysis of unhatched eggs
Egg ID-code__________________________________________ Breed________________________________________________
Hatcher number______________________________________
Trolley
Basket
Total unhatched eggs
Category Number of eggs Totals
No. Description
1 Contaminated / rots
2 Crack at set
3 Crack at transfer
4 Thin/porous eggshell (dehydrated)
5 Infertile (irregular whit spot)
6 Early dead, 1 – 2 (membrane)
7 Early dead, 3 – 4 (blood ring)
8 Early dead, 5 – 7 (eye)
9 Mid dead, 8 – 10 (egg tooth)
10 Mid dead, 11 – 14 (feathers)
Late dead, 15 – 17 (embryo turned

11
to length axis of egg)
12 Late dead, > 17 (start yolk sac absorption)
13 Internal pipped
14 External pipped
15 Malposition
16 Malformation (Exposed brains)
17 Malformation (crossed beak)
18 Dead chicks in tray
19 2nd Grade chicks
20 Females / Males

Recording Form 7H: Pasgar©Score
Egg ID-code__________________________________________ Breed________________________________________________
Hatcher number______________________________________
Trolley (optional)_____________________________________
Basket (optional)_____________________________________
Chick Pasgar© Chick Pasgar©

Reflex Navel Leg Beak Belly Reflex Navel Leg Beak Belly
no. Score no. Score
1 26
2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50
Subtotal Total
Average Pasgar©Score

Start date Egg ID Production Breed Maternal Storage % clears % saleable % saleable % 2nd class 1st week
incubation code date age days chicks of chicks of chicks mortality
cycle eggs set transferred
eggs
10
11
12
13
Recording Form 8A: Hatching results
14
15
16
17
18
19
20
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21
22
139
Start date Egg ID Production Breed Maternal Storage Egg analysis (7F and 7G) Pasgar©
incubation code date age days Score
cycle (7H)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1
2
3
4
Recording Form 8B: Results egg analysis
5
6
7
8
9
10
11
12
13
14
Hatchery Management Guide - Version L9180-2

15
and Pasgar©Score
16
17
18
19
20
21
140
22
Recording Form 9A: 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 Purpose of visit

in contact with live
poultry?

Recording Form 9B: Cleaning schedule
Room/equipment_____________________________________________________________________________________________
Instructions__________________________________________________________________________________________________
Detergent____________________________________________________________________________________________________
Disinfectant__________________________________________________________________________________________________
Frequency____________________________________________________________________________________________________
Date Name Signature Date Name Signature

Recording Form 9C: Hatchery microbiological
monitoring
No. of sample Room Description of objects Number of colonies Score

Recording Form 10A: Setter maintenance card
Setter number________________________________________________________________________________________________
Date P/C* Description Action Signature
* P = preventive maintenance; C = corrective maintenance

Recording Form 10B: Hatcher maintenance card
Hatcher number______________________________________________________________________________________________

Recording Form 10C: Hatchery equipment
maintenance card
Name hatchery equipment____________________________________________________________________________________

Recording Form 10D: Checklist climate conditions
in hatchery
Date_________________________________________________________________________________________________________
Room Temperature (°C / °F) Relative humidity (%) CO2 (% / ppm)
Set point Actual Set point Actual Actual
Egg handling
Egg store: Store 1: 1 – 3 days
Store 2: 4 – 7 days
Store 3: over 7 days
Air inlet setter
Transfer
Air inlet hatcher
Chick handling
Chick dispatch
Pressure-controlled rooms Air pressure (Pa / inch H2O)
Set point Actual
clean air plenum setter
dirty air plenum setter
clean air plenum hatcher
dirty air plenum hatcher
air preparation room
Calibration date thermometer_________________________________________________________________________________
Calibration date hygrometer___________________________________________________________________________________
Calibration date CO2 -meter__________________________________________________________________________________
Calibration date pressure sensors_____________________________________________________________________________

Notes

Credits
Authors
Photography
Main Photographer: Hendrix Genetics B.V.
Additional credits: Pas Reform (Pages 5, 11, 22, 31, 51, 62, 75, 76, 78, 85, 93, 94, 104, 105, 115, 118 & back cover)
With special thanks to:

Pas Reform Hatchery Technologies
Bovendorpsstraat 11
7038 CH Zeddam
The Netherlands
© Hendrix Genetics B.V., 2019
No part of this publication may be reproduced and/or published in print, photocopied or replicated by any other means
whatsoever without the prior permission of Hendrix Genetics B.V.
Authors have composed the contents of this publication with great care and to the best of their knowledge the
information provided is accurate. However, the authors accept no liability of any nature, resulting from actions and/or
decisions based on the information provided.
For more information please check layinghens.hendrix-genetics.com

Day 1 Day 2 Day 3 Day 4 Day 5
hendrix-genetics.com
DISCLAIMER: This Hatchery Management Guide has been prepared by Institut de Sélection Animal B.V. to inform readers of its activities in the broadest sense. It is by no means
intended to be complete, not even on the aspects mentioned herein. There are no implied or explicit guarantees given by Institut de Sélection Animale B.V. and its shareholders as
to the accuracy and completeness of the provided information in this Hatchery Management Guide.

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Hatchery Management Guide - Version L9180-2 3

Villa ‘de Körver’

T +31 485 319111

© Copyright 2019 Hendrix Genetics, Boxmeer, The Netherlands.

4 Hatchery Management Guide - Version L9180-2

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1.1 Outline of the Incubation Guide

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1.1 Outline of the Incubation Guide

Incubation in setter: day 1-18

Incubation in hatcher: day 19-21

Five basic steps in hatchery routing

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The procedures are all structured as follows:

Chapter 10 highlights the importance of hatchery climate and preventative maintenance.

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1.2 Golden rules for a hatchery

- Ensure inlet air to setter meets the recommended climate conditions.

- Room temperature 21 – 27 °C / 70 – 81 °F; avoid draught directly on eggs.

- Ensure inlet air to hatcher meets the recommended climate conditions.

- Check the proper functioning of hatcher before every new cycle.

- Room temperature 24 – 27 ºC / 75 – 81 ºF.

- Check temperature before loading the truck: 24 – 27 ºC / 75 – 81 ºF.

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2.2 Egg handling at the breeder farm

2.3 Egg transport to the hatchery

2.4 Egg receipt

2.5 Setting eggs in setter trays and trolleys

2.6 Pre-storage incubation

2.7 Storage of hatching eggs

2.8 Disinfecting hatching eggs

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Recommended climate condition during egg storage

Ensure sufficient, comfortable and easily accessible nest space

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Hatching eggs; a precious cargo …

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2.5 Setting eggs in setter trays and trolleys

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Recommended climate condition during egg storage

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2.8 Disinfecting hatching eggs

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All eggs should be reached by the disinfectant

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2.2 Egg handling at the breeder farm

2.3 Egg transport to the hatchery

2.4 Egg receipt

2.5 Setting eggs in setter trays and trolleys

2.6 Pre-storage incubation

2.7 Storage of hatching eggs

2.8 Disinfecting hatching eggs

3.2 Single-stage incubation

3.3 Multi-stage incubation

4.2 10-day candling

4.3 Candling and transfer

5.2 Incubation in hatcher: day 19-21

5.3 Application of disinfectant during hatching

6.2 Chick take-off

6.3 Vaccination of day-old-chicks

6.4 Sexing of day-old-chicks

6.5 Chick dispatch and transport

6.6 Unloading and brooding chicks at the farm

7.2 Analysis of hatching egg quality upon arrival