HATCHERY MANAGEMENT

GUIDE SIMPLIFIED
Organized By Dr/ Hesham kotb
• The performance objective for the hatchery is to
provide the highest number of perfect layers chicks
with a good delivery and the best liveability, which
of course is influenced by the quality of received
eggs.
• ››The hatchery can transmit the quality received
and can damage the quality, but cannot increase the
quality of eggs received and cannot increase
fertility.
• ›› Both of the latter points are the result of good
Parents farm Management.
HANDLING HATCHING EGGS
Selection and management of hatching eggs
• The hatching eggs are not only eggs, but they contain living embryos with all the genetic potential.
• For good genetic transmission we need to guarantee the best condition of these embryos, and the first step is to have good hatching
eggs: this is a crucial point.
• Many factors can influence the quality of hatching eggs:
• ›› Health condition of parents stock flock
• ›› Age of the parents’ stock
• ›› Feed & water quality
• ›› Medication treatments
• ›› Type of housing and climate control, temperature
• ›› Percentage and quality of male, spiking of male
• The above factors determine the quality of our eggs in terms of the lay, the uniformity in size, the eggshell quality, the
nutrients and maternal antibodies transmitted, the albumen and yolk percentage composition and the fertility.
• ›› Cleanness and condition of nest
• ›› Collecting of hatching eggs
• ›› Disinfection of hatching eggs
• ›› Storage and managements of eggs
• The above factors determine hygiene status and the capacity of embryos to survive in storage.
• In the deposition, the temperature of the eggs is around 40 °C and they cool down
considerately after.
• The surface is slightly wet: “cuticle paint isn’t dry and fixed”.
• At this moment, our eggs are cooling down to the surrounding temperature, which causes
contraction
• This means that air enters the eggs through the pores (in variable amounts according to
breeder, age and eggshell quality) and creates the air cell
• This is a very critical point in time, and our goal here is to minimise the number of
microbes which enter the eggs.
• For this reason, it is very important that eggs are laid in as clean a nest as possible.
• Our external disinfection processes cannot kill all microbes, especially aspergillus spores,
which may enter at this time.
• Only the difficult and high risk process of dipping with special pressure machines and
special products can kill all “visitors” which enter the eggs through the shell and mem-
brane; some hatcheries use this treatment for floor eggs.
• Floor eggs are not considered hatching eggs, as they are already contaminated after
having been in contact with the farm floor and with possible excrements, where the
proportion of E. coli and other bacteria are relatively high. For this reason, if the
hatchery decides to use these eggs, it must consider the high risk of spreading the
contamination and related problems to other eggs and to hatching layer chicks
• Therefore, floor eggs are stored and incubated separately and preferably have a
dedicated trolley and a dedicated setter (which is a better option than having a setter at
the bottom of every trolley). This way, they are easier to trace through every part of the
process, which guarantees the best biosecurity and reduces the risk of direct
transmission.
• Good hatching eggs must follow these criteria :
• ›› Clean eggshell (no defecation litter, blood)
• ›› Uniformity (no undersized or oversized eggs), weight range according to hatchery’s
decision (usually 50 to 70)
• ›› No cracks
• ›› Well-shaped
• ›› No double yolk
•›› Set in trays or in pulp trays with the pointed end facing downwards
•Warning: the production of hatchability eggs in farms situated at more than 1000 m above sea
level needs particular attention and different settings.
•It is important that the hatchery records the number of eggs removed from each flock and reports
back to the parents’ farm. Below is an example of a records form.
Disinfection of hatching
• Hatching eggs need to be disinfected as microorganisms multiply fast in the incubation
climate of the hatchery and the temperature and humidity are perfect reproduction
grounds which we need to control.
• Some customers decide to disinfect as soon as possible after deposition and repeat the
process before setting in incubation; others disinfect during truck transport from the
farm; others disinfect on the arrival of storage eggs in the hatchery, before they even
enter the room.
• This is the personal choice of every customer, but it is important not to forget that eggs
can be already contaminated during the process, either from operators’ hands during the
selection process, from dirty lift vacuums, from dirty trays, or from loss of liquids from
damaged eggs.
• The real cleanness of all eggs managements is of utmost importance.
• Customers have to decide on the type of product they use. For many years the cheapest
and most efficient product was Formalin, fumigation with which is efficient but
hazardous to human health
• including that of the operator.
• Safety fumigation rooms with secure Formalin control and facilities for deactivation of residual gas are available. These guarantee the
safety of the operator and can therefore be of great use, but it is important to check whether they are permitted in the relevant country, as
well as taking into consideration that fumigation can in-crease mortality in embryos and overdosage can lead to malformation in
chicks.
• In case of use of Formalin, remember:
• ›› Never fumigate with formaldehyde within the first 96 hours of incubation.
• ›› The maximum correct dosage is 7 g/m³.
• ›› Never exceed a fumigation time of 25 minutes, max. room temperature of 21–24 °C, max. humidity 65–70 %.
• ›› Re-ventilation of the fumigation chamber with safe clean air (to avoid recontamination of our hatching eggs) at the right temperature, as
eggs do not react well in quickly changing conditions; check that the air-equipment can change the total air conditions within a few
minutes.
• As alternatives to Formalin, a lot of different chemical products are available.
• These can be based on glutaraldehyde, stabilised hydrogen, peroxide, peracetic acid, activated chlorine or quaternary ammonium.
• These agents can be sprayed, fogged, vaporised or used in an immersion bath, and are safer for human health.
• Some of these products can be used in combination with each other for increased efficiency against various bacteria, viruses and moulds,
for example disinfectants that contain quaternary ammonium combined with glutaraldehyde, and disinfect-ants containing hydrogen
peroxide combined with peracetic acid can have the same effect as disinfectants with hydroxyl radical and oxygen compounds.
• It has to be noted, however, that not all products can be mixed together, as certain chemical products can have chemical reactions: please
make sure to control the combinability so as not to prepare a solution which is dangerous for both the operator and for the eggs.
• Please also be careful of over-dosage, which can lead to the covering of pores or damage of cuticles. It is important that the
disinfectant reaches all eggs, and that the eggs do not get wet: for this reason, eggs should ideally be placed in trays with space for
the necessary ventilation, as eggs in carton pulp trays or in boxes do not undergo the right process.
• In case of immersion in dedicated liquids, attention has to be paid to the cleanness and sanitised conditions of the solution, which should
be at a temperature respecting the eggs natural temperature
 HANDLING HATCHING EGGS
• This means that eggs should not be warmed to more than 24  °C or cooled drastically,
and that eggs have to dry quickly and in a clean and controlled area after immersion.
• Please verify the corrosiveness of the product in use; many chemical products can
damage structure, floor, trolley and trays.
• The effective dosage changes the value of disinfections, and for this reason it is
important to monitor consumption and percentage in use, as well as using a secure
system of dispenser.
• A peristaltic pump is a good tool, but every different system needs a format control
routine.
• It is important that the hatchery controls the real efficiency of the product in use with
accurate analysis, using shell tampons “swab”, or by the simple use of Rodac Plates.
• The hatchery should then decide on the relative dosage, whether the type of product can
be used and in which form, and the application desired.
 Optimal egg storage condition
• At the time of deposition, a fertile egg al-ready contains a small live embryo, which is made up of approximately 30,000–
55,000 cells.
• This is a living miracle and we have to preserve the vitality of these cells until the point of incubation. Please remember to
avoid the instable temperature of eggs and to use your knowledge of handling carefully.
• The developments of the embryo’s life start in the body of the hen approximately 24 hours before the egg is laid, when the
follicle is ovulated and fecundated. In these hours cellular replication is working very quickly – especially considering that the
internal temperature of the body of the hen is 41 °C. Now our goal is to stop the fast
• cellular replication while at the same time maintaining the best liveability and reducing the cellular mortality as much as
possible.
• In the past we spoke of “physiological zero”, which was under 26 °C, but in reality this “zero” does not exist, as the replication
and the mortality of embryo cells is still a concern.
• The temperature range between 26 °C and 37 °C is unbalanced and the velocity of cellular mortality is much higher than
replication.
• If the conditions don’t stay within the right parameters, we experience the “early dead” of our embryos. This is why it is
especially important in countries with a hot climate to have more frequent egg collections, reducing the percentage of
blastoderm mortality (early dead -72 h).
• Ideally, eggs should be cooled down uniformly and gradually from the hen’s body temperature to between 17 °C and 22 °C in
6–7 hours.
• Please check the table showing different optimal egg storage temperatures and humidities in consideration of the storage
time, set from the arrival of eggs at the correct temperature.
• Humidity during storage is not as important as the temperature. In short and medium storage it doesn’t have an big influence,
however, it should be kept between 60 % and 75 %.
• In long storage, the correct value can help reduce the risk of extremely high weight loss of eggs.
 Egg storage room: climate
conditions
• For eggs that will be set in the first 4 days, it isn’t necessary to drop the temperature;
the right value helps the albumen of eggs to reach the perfect pH and also helps to
bring about the right weight loss of eggs, but in the special circumstance of a Single
Stage process, this isn’t easy to reach.
• In a layer hatchery, it is common to store eggs for up to 10 days.
• For this storage length the use of S.P.I.D.E.S (Short Period Incubation During Eggs
Storage) is recommended.
• In a well-planned schedule this isn’t a complication for hatchery life, it just needs
careful attention and management.
• If S.P.I.D.E.S isn’t possible, it is still important to have the correct temperature and to
avoid the jumps (ups and downs) in temperature.
• For this reason, egg delivery trucks have to fix a set-point temperature at the farm
storage room value and the operators in the hatchery have to send eggs into a storage
room at the right temperature, in order to continue with the previous incubation
schedule.
• It is important to remember that eggs should avoid condensation too and that closed
pores have the effect of reducing the exchange of oxygen and carbon dioxide and of
influencing relative weight loss of eggs, and can also facilitate penetration of
microorganisms into the eggs, increasing their contamination.
 • A possible solution for contaminated and explosive eggs is
Recommended climate conditions during egg storage the use of a dipping machine, as such eggs can damage
Storage Time Temperature Relative Humidity Egg Position
the quality of many other chicks.
days °C °F % • A dipping machine can help a lot, but this process needs
delicate attention and perfect selection of a product to
0–4 21–19 69–64 75–60 Trays use as well as relative conservation.
Trays & S.P.I.D.E.S (if done ……..
5–7 18–17 63–61 78–70
temperature fixed at 18–17 °C
• A good dipping process can increase hatchability from 0.5
permanently)
% to 1 %, and some eggs are cracked, depending on their
eggshell quality, but it guarantee less contaminated chicks
8–9 16–15 60–57 80 Blunt end up but ……. if S.P.I.D.E.S, and no explosion at all in the setter.
trays at 18–17 °C
10 14–12 56 88 Recommended to turn eggs but
• The egg rooms can easily be kept the right set-point, to
or more …….. if S.P.I.D.E.S, trays at 18–17 °C
reduce risk of sweating.
• Even if a S.P.I.D.E.S process isn’t routine, it is better have
several different storage rooms where it is possible to
select the right set-point, de-pending on the different eggs
requested The sufficient climate capacity, in warming,
cooling and air flow, helps to reduce the risk of mistakes
and condensation.
Eggs will sweat if the relative humidity % RH outside storage room is higher than:
Temperature Temperature outside the storage room
of storage room 15 °C 18 °C 21 °C 24 °C • To preserve the hatchability during long storage without
21 °C – – – >85%
S.P.I.D.E.S, it is sensible to turn the eggs. If it isn’t possible
to have an automatic turning system, it is recommendable
18 °C – – >83% >71% to turn the eggs by hand 3 times a day, approximately
16 °C – >89% >74% >60% every 8 hours.
12 °C >74% >64% >53% >44%
 HANDLING HATCHING
EGGS
Loss of weight module
• If the eggs are not in trays, but in carton pulp trays, it is of benefit to
store the eggs upside-down, with the pointed end UP.
› Incubation data › Transfer data › Hatch data
• However, please take care not to move or transport eggs in this
Recommended loss of weight by age
position, because the right position of air cells can be lost, which
Young Flock Min 10.5 % Right 11 % Max 11.5 % could increase the percentage of malpositioned chicks.
Age 25 to 32 weeks
Medium Flock Min 11 % Right 11.5 % Max 12.5 % • Beyond 8 to 10 days of storage, even at optimal storage conditions, it
Age 33 to 49 weeks is normal that hatchability will drop by around 0.5 % every day. This
Old Flock Min 11 % Right 12 % Max 13 % percentage increases to 1–1.5 % every day after day 11, and the
Age 50 to 63 weeks chicks’ quality decreases proportionately.
• It is important to consider the storage day in terms of the weight loss
of eggs. During the storage time, eggs lose weight, which is especially
relevant in very long storage times.
• If we know the weight of eggs at day 3–4 from the day they were
laid, we can set both Single-Stage or Multi-Stage setters to preserve
the right humidity, in order to have the perfect fix point.
at this point. ›› The clear eggs have a weight loss relative toeggshell quality; from 6 % t – 8 % max • Remember:
• ›› The right weight loss condition is calculated from day 3 of storage,
Egg weight loss in optimal storage condition as it is recommendable to carry out a weight test at this point.
5 days 7 days 9 days 11 days 13 days 15 days 17 days 19 days • ›› The clear eggs have a weight loss relative to eggshell quality; from
6 % t – 8 % max
Brown breeds 0.07 % 0.34 % 0.68 % 1.06 % 1.19 % 1.56 % 1.64 % 1.77 %

White breeds 0.09 % 0.53 % 0.71 % 1.10 % 1.24 % 1.61 % 1.73 % 1.84 %
S.P.I.D.E.S Incubations or
Pre-storage incubation
• What is Short Period of Incubation during Eggs Storage?
• Some time ago this was not thought well of in any incubation
philosophy, but in recent years hatchery specialists have tested
this process with fantastic and incredible results, with the
S.P.I.D.E.S eggs at long storage being able to hatch with good
percentage and good chick quality.
• It is very important have knowledge like this, because with a
little management we can bring about a great improvement in
our performance.
• This process consists in helping and increasing the cellular
replication during storage.
• This is possible by increasing the temperature.
• In the past we tried to reach the set-point temperature of
incubation during the first test, but we quickly noted that this
did not help. However, the easily reachable temperatures of
33 °C/35 °C are sufficient for cellular replication, and keep our
embryos alive at hypoblast time. Concerning the following
scheduling incubation step, or S.P.I.D.E.S, we reduce the time
for decreasing temperature and return the eggs to the storage
room more quickly.
• A modern hatchery which knows about the prevision of eggs storage in advance can organise a perfect
schedule to arrange the cellular replication or S.P.I.D.E.S. Some hatcheries have dedicated machines or
“special rooms” where this is arranged directly in the storage.
• In order to favour reduced movements of eggs and relative costs of the operator, eggs have to be at a
minimum of storage day 3 - 5 before being warmed up.
• Some brands of S.P.I.D.E.S machines can have a fantastic programme and the sufficient capacity to arrange
this process in 8/10 hours from; warm-up – temperature – drop – storage set.
• Please remember that our embryos have a higher possibility of surviving and hatching after this if the egg
storage is 12 days.
• If we need to conserve the eggs for even more days, it is necessary to arrange an-other cellular replication
between days 10 and 12 and to repeat this interval of time for the necessary schedule.
• We have experience and data for programmes with up to cellular replications and for over 35 days of
storage in layers, and even more for turkeys.
• It is important to remember to reduce the incubation time schedule;
• ›› N° 1 S.P.I.D.E.S of less than around 4 hours
• ›› N° 2 S.P.I.D.E.S of less than 6 hours
• ›› N° 3 and plus S.P.I.D.E.S of less than 6–8 hours
• Please remember that this length of time can change the processes of time and temperature. It is important
to verify the effect of the process in the eggs with accurate testing and to balance the conditions of our
hatchery.
• It is important to remember that different warming and cooling capacity of machines used for S.P.I.D.E.S. can
influence the value of the programme. Please verify the performance in an early candling test.
 HANDLING
HATCHING EGGS
HANDLING HATCHING EGGS
• During the S.P.I.D.E.S process it isn’t necessary to turn the eggs on any storage day.
• NOTE: important storage advice:
• ›› Eggs have to cool gradually from the body temperature of hens, (41 °C) to 22 °C – 18 °C within 6–8 hours, in as clean an atmosphere as possible.
• ›› The right selection of a gentle cleaning process, which doesn’t remove cuticles or lead to the formation of micro cracks, is important.
• ›› Record the farm and the date of production for every tray.
• ›› Correct fumigation or alternative disinfection for a good storage start.
• ›› The storage start is from the deposition day, not from the day of arrival at the hatchery.
• ›› Minimise egg storage days in order to minimise negative effects.
• ›› There should be optimal climate conditions during the whole storage period, including the right temperature for the setting. Please also control and
note issues or mistakes of the rooms (see table for days).
• ›› Having two separate egg storage rooms with dedicated temperature and humidity control helps you to manage the processes well.
• ›› During storage, remember not to place the eggs directly in an air flow or humidification system, or near a wall or on the floor, with a little free space
from the trolley. This helps the uniformity of the condition of eggs.
• ›› Keep weight loss of eggs under control and in respect of exigencies from day 3 of storage.
• ›› Organise the S.P.I.D.E.S in right schedule.
• ›› ABOUT LOHMANN TIERZUCHT GmbH: LOHMANN LSL is more negatively affected by long storage than LOHM-ANN BROWN. When using LOHMANN
SILVER, it is important have a minimum of 3 days of storage in order to gain the best hatching potential. This is more evident in young flocks of
LOHMANN BROWN and LOHMANN LSL.
SETTER
Single-Stage VS Multi-Stage Incubation
• Single Stage = all eggs are set together in the same setter and in the same embryonic development, which
can give a better biosecurity and specific environment for every different day.
• The conditions of setting prepared ad DOC, for genetics, breeder age, egg size and storage, all IN all OUT give
the possibility of washing and an easy cleaning and disinfection process at the setter.
• This maintains and controls turning, sensor calibration and mechanic parts, which prevents breakdown.
• Setting can change depending on the capacity and adaptability of the different constructor brand to arrange
Circadian incubation (change of temperature in the last days), hypercapnia incubation (high level of carbon
dioxide in first week), management of setter at embryonic temperature, and impact on quality and
performance in relation at the number of setting eggs, which don’t need a constant number and which are
more flexible. Moreover, some brands of Single-Stage setter can work in relatively high pressure gaps, which
can help when setting a biosecurity cascade atmospheric pressure.
• In contrast, a Multi-Stage incubator is filled with eggs of different embryonic ages, in order to balance all the
zones. Some models have fixed trays, which are more balanced, and others have trolleys, but every machine
has eggs of different embryonic ages inside it. These machines are more easily controllable and don’t need
any special programmes, but they have an average in all values with a fix set-point.
SINGLE-STAGE
• ›› Environmental conditions can be adjusted according to the particular needs of the developing
embryo
• ›› Hypercapnia and Circadian incubation
• ›› Perfect temperature from setting to transfer, relative to embryonic temperature
• ›› Variability capacity and flexible set eggs
• ›› Use of different ambient pressure for increased biosecurity, from egg storage to setter to
transfer to hatcher and at process and delivery of chicks
• ›› Shorter hatcher windows from 26–32 hours
• ›› Better uniformity of chicks
• ›› Better cleanness and biosecurity, only one flock, and setter can wash and disinfect easily
• ›› Lower mortality
• ›› Better meat conversion and body growth, as well as bone structure composition
• ›› Easy tracing of eggs, easy flock management, and with necropsy easy solution of incubation
issue
MULTI-STAGE
• ›› Average of conditions for all the eggs setting in machine
• ›› Problematic works with partial empty setter
• ›› Stable value of CO2, approx. 2,700 ppm
• ›› Differences in chicks and related problems in uniformity
• ›› Long hatch window: + 33 hours and often much longer
• ›› Fix parameters and temperature from setting to transfer
• ›› Low body growth, bone structure damaged, possible fibrosis effect in muscles
• ›› Poor cleanliness and poor biosecurity
• ›› Complicated tracing and it is easy to make mistakes or errors in flocks
• These are the principal differences between the two philosophies of incubation.
• Multi-Stage can, of course, seem more simple in terms of management and control, and doesn´t need an egg programme.
• Multi-Stage can also be useful when energy breakdowns occur and can have good economic effects in terms of energy efficiency.
However, the modern technology in heat recovering and the use of the free warming product from embryos have eliminated the
disadvantage that the Single-Stage process is more expensive in term of energy.
• Please also remember that the setter can be washed and controlled after every incubation cycle.
Pre-Warming before setting
• Pre-Warming, or pre-heating, is a process that prepares the eggs for the start of incubation after storage.
• At this time, the temperature of eggs slowly increases, starting from the storage temperature of 25° C (77 °F). During these hours, eggs are prepared for the
increase in cellular replication following incubation, and the positive effect of recompacting the eggs and reducing the relative hatch windows is apparent.
• In broiler production it is naturally very important that the chicks are uniform and have the same size, but this is very important for layers too. The uniformity
promotes liveability, standardises the condition and increases the chicks’ quality; a good process of pre-warming reduces the risk of condensation.
• Some Multi-Stage hatcheries have a special room where this process is arranged. It is important that this room has a good ventilation and a uniform
temperature and air flow. Beware of arranging this process in a corridor or in a room where the temperature isn’t uniform, as this will only increase the risk of A
non-uniform warming and cancel the good effect of this process. However, if there is no other available solution, try to stabilise and standardise the setter
corridor room at a temperature of 25 °C.
• Keep trolleys separated with a minimum of 25 cm on each side, as this helps the air flow and increases the time to 8–12 hours.
• A control of the internal egg temperature in the different levels of the trolley can help verify if conditions are good or bad.
• Warning: do not arrange this in a machine with a currently functioning timer when there isn’t a real pre-warming.
• Don’t give the necessary control in temperature and uniformity in this case either, as that can only cause damage.
• Everything is easier in Single-Stage hatchery, because a good machine has perfect control in more performance programmes as the possibility of changing
the time (hours), moderating the turning action and ventilation and increasing the temperature. This can be very useful in the special case of eggs which are in
storage for a very long time, when the pre-warming process needs to last longer.
• Many different conditions can change the pre-warming, including hours of storage, days of storage, storage temperature, flock age, egg size, and warming
capacity of setter brand to reach the set-point.
• ›› Eggs of very short storage (3–4 days) in a storage room at 20 °C don’t need pre-warming. They can be damaged and their early dead mortality rate can
increase.

• ›› Eggs of 5–8 days of storage need a mini-mum of 6 hours.

Setting time and set pattern if requested
• The setting time is really important for our final results, and for this reason the prevision incubation time is the basis for good results and good chicks.
It is the standard attitude to use a fixed schedule time for the Multi-Stage incubator, which can vary according to the breeder (LOHMANN LSL needs
some extra hours), age of flock (youngest and oldest need a bit more time), storage of eggs (where S.P.I.D.E.S. is not used, after 9 days of storage it in-
creases from 30 to 50 minutes every day +) and season (summer reduces it by 1 hour; winter increases it by 1 hours).
• Every Multi-Stage incubator brand has a perfect set pattern and a balanced setter, where all the machines have to work as much as possible and at full
capacity. If this is no real possibility, a control of CO2 at 2,700 ppm can help to determine the valve set-up and can help to bring about the correct
weight loss of eggs.
• Concerning total difference in real Single-Stage, where the programme in use can justify a different time, the table gives some indication of the
respective embryologic temperature (100 °F–100.2 °F for LOHMANN BROWN, 100.1 °F–100.4 °F for LOHMANN LSL).
• It is important to follow the conditions and setting recommended for every different incubation brand. Air flow and temperature in particular can
have various different effects and for this reason it is important to use a dedicated and specific programme. It is rare that a programme built for a
particular brand also has positive results for another brand.
• This is the reason why we have decided not to present any programmes in the Lohmann incubation guide: programmes have to be decided upon and
tested individually, hatchery by hatchery, with the objective of having the perfect embryo-logic temperature, perfect weight loss of eggs, and perfect
embryological time. Re-member that chronological time is a count of hours = time………Embryological time is the effect of air flow, temperature, CO2
and humidity, and isn’t a fixed figure but rather can be subject to all these influencing values which can either move our embryos forwards or delay
the chronological time, extending or reducing our real hatch window time.
• Some machines have the option of recovering energy with reduction of an rpm fan, or alternatively the option of balancing the temperature with air
flow velocity. The objective of using some of these options is achieving uniformity of temperature at minimum cost, and it is possible to use them at
the recommendation of the constructor.
• In some special conditions, the right set pattern can help our embryos a lot.
 SETTER
breeder age or storage time can vary. All eggshell temperature and reducing the

• In the special case where we set different Indicative Time for LOHMANN LSL female line In male line improve all time of 3/4 hours

typologies of eggs in the same incubator, Flock Age Storage Age 7–10 11–14 +15

breeder age or storage time can vary. 24–30

1–6
507–509
No 1 SPIDES
509–511
No 1/2 SPIDES
511–513
No 2 SPIDES
513–515

• All the following information is indicative 31–49 505–507 507–508 509–511 511–513

and has the objective of achieving uniform 50–63 508–510 511–512 513–515 516–517

eggshell temperature and reducing the 64 + 510–511 512–513 514–516 516–518

hatch windows time, for improving chicks

uniformity and liveability Indicative Time for LOHMANN BROWN female line In male line improve all time of 3/4 hours

• Optimizing egg setting in consideration of Flock Age Storage Age 7–10 11–14 +15

average temperature of the machine 1–6 No 1 SPIDES No 1/2 SPIDES No 2 SPIDES

Optimizing egg setting in consideration of 24–30 505–507 507–509 510–512 512–513

air flow of the machine 31–49

50–63
504–506

505–506
506–507

507–509
508–510

510–511
510–512

512–514

• Optimizing egg setting in consideration of 64 + 505–508 508–510 511–513 514–516

different breeder flock age, eggs storage

tec.
Temperature
• When the hatchery manager asks about perfect incubation temperature, he or she is normally referring to the set-point fix in the
setter machine.
• For most constructor brands. This is the air temperature, which is dictated from a sensor, which is positioned in the centre of the
zone controlled.
• All hatchery managers know that is a delicate and critical relationship between this temperature and real hatchability performance
and chicks’ quality.
• We have just mentioned that the incubation time and chicks’ developments have a relationship to the temperature of our
embryos, and accelerations or retardations of the chick’s development cause extra costs in performance and quality.
• Optimising the eggshell temperature is the key to the optimum condition of embryos, and a simple control of this is the eggshell
record data.
• The perfect temperature is, for the most part of incubation, around 100 °F– 100.2 °F for LOHMANN BROWN and 100.1 °F–100.3 F°
for LOHMANN LSL, in last part of incubation these temperatures gradually increase, and we know from experience and from many
tests that it is very complicated to have a perfect view of the incubation process in the first two weeks, as, on same tray, on any
day, the recognised temperature of eggs can vary. This is why it is important to control a sufficient number of embryos in different
trays and in different positions, to remove data from infertile eggs, and to make averages.
• If the number of infertile eggs increases a lot because of the health or age of the flock, it is important to take action to regulate the
temperature, even when the setters are not full of eggs. For this reason, it is important to consider the brand and trays and to use
the right setter trays fill-up
• IMPORTANT
• If we don’t need the complete setter capacity follow a schematic for have A better AIR-FLOW in the setter
 SETTER
Heat production of the embryo per kg egg mass
• It is important not standardise these data in
different brands of incubator, but rather to
test and control brand by brand (air flow,
(W
 / k
g)

4
production

3,5
warming and cooling system and relative
3
action is different and can cause different
2,5
reactions in our embryos).
Heat

1,5

• Every breed has a different metabolic heat

1

0,5

0
production, and for this reason our only
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Incubation time (days)
reference to the air temperature set-point is
Broiler
LOHMANN BROWN layers
the necropsy and the quality of the chicks,
LOHMANN LSL layers Adapted from Janke, Tzschenktke and Boerjan (2004)
where we undertake repeated accurate
controls.
 Humidity
• In the incubation process, water vapour moves through the pores of eggs to the setter atmosphere.
• This is very important because it has a great effect on our weight loss target for the eggs, which is determined by external data
concerning number of pores (normally determined by age of flock, size or breeder), eggshell quality (size, health and breed), and
the humidity value set in humidity set-point.
• In Multi-Stage incubation, this value normally ranges between 52% and 55%, and is balanced by a humidifier system.
• In Single-Stage incubation there are different solutions possible: some brands use the same methods as at Multi-Stage incubation
with a little adjustment in humidity value from 60 % at the start of incubation to 45% at the end of the process, which is followed
by a constant weight loss of eggs and which involves, in some cases, a strong action of the humidity system on the last day of
incubation.
• This is needed for the essential formation of an air cell and the simultaneous evaporation of water, to optimise water and minerals
in embryonic compartments; the movement of water from albumen to the sub-embryonic cavity guarantees the right balanced
proportion of nutrients.
• Different philosophies exist in extreme Single-Stage brands, where there is no humidity system in the setter, and where the setter
starts with a humidity value of around 80 %, and conserves the eggs’ humidity in first week with the proximity of the damper.
• This humidity value constantly decreases until it is 30 %–35 % in the final stages of the process. The objective is to not use
external water, which can have negative effects in temperature stability in a micro-climate and in biosecurity, but all of these
points are possible with a good control of an active damper.
• Remember, in both situations it is extremely important to reach the right weight loss of eggs for the respective age, in order to
have a correct fix point, for a good hatcher performance
 Ventilation
• Ventilation is very important for our embryos: we would like to share this argument in two parts
• 1. The correct ventilation in terms of air flow.
• 2. The correct provision of oxygen and the right conditions for the weight loss of eggs.
• N°1
• In Multi-Stage setters it is very important to always have, the maximum of air flow power for all trays setting, in order to
guarantee the same treatment of all different eggs of various ages.
Recommended CO2 value Time
ppm % • In Single-Stage machines the air flow is very important at the start of the setter process, to guaran-tee uniformity of
Multi-Stage 2,700 0.27 All temperature and short warm-up. These are positive points and they reduce the rate of very early embryonic mortality. However,
incubation incubation when they reach the set-point in the first 4/5 hours up until day 12/14 of the process, our eggs don’t need extreme air flow; the
process production of warmth of our embryos is very limited, and if the machine has the possibility of safe energy, we take this
time opportunity. The requirement changes in the last week of incubation are a guarantee of good air flow, good embryonic
Single-Stage 7,000– 0.7–1 Start to temperature, performance, and a reduction in hatch windows time.
10,000 9 days max
Single-Stage 2,700– 0.27– 9–19 days • N°2
4,000 0.40
• Damper/Valve action has to guarantee the correct provision of oxygen, every time. It is important to control our machine in this
phase, and as every different setter has its own plan and system of works, it is crucial to remember some basic important points
in first 7/9 days. Carbon dioxide (CO2) can help the embryos at the start and help to improve the blood vessels and the size, but
after 11 days, CO2 is a poisonous gas which can increase mortality in chicks.
• The drive of valves with a CO2 sensor is a very useful tool in the situation of a partially empty setter, or with a low fertility flock.
• It is important to remember that both situations can influence the attainment of the right weight loss of eggs for the age, in
order to have a correct fix point for a good hatcher performance
Turning
• It is very important to replicate the natural action of a hen, in order to guarantee the correct eggshell temperature, to make sure
that air flow has only one line of direction, and to change the position of eggs. The objective is to:
• ›› Resolve adhesion of embryo to the shell membrane
• ›› Correct development of air cell position
• ›› Improve development of vascular area, which helps yolk condition and relative use from chicks
• ›› Allow normal transfer of albumen proteins in amniotic fluid
• ›› Improve the blood vessels under the shell, to maximise oxygen absorption
• ›› Avoid the lower growth of embryos shown in unturned eggs
• ›› Help the embryos to reach the normal correct hatching position
• ›› Reduce malposition and reduce the number of unhatched eggs
• The turning has to take place every hour.
• Some brands may have the possibility to change the frequency or to leave the eggs for some minutes in the plane position. This is
a good resource and can be advantageous.
• It is important for the eggs to have an angle of 43°–45° and for them to be turned in the correct asymmetric movement.
• Turning has to be slow and gentle and without any “catapulting” actions. It is very important that hatchery takes care and
organises routine control of actions and angles, because a malfunction can completely destroy the hatching performance.
 SETTER
• Turning isn’t necessary after day 15 of incubation. For this reason, if the cooling capacity of our
machine isn’t sufficient, the flat position that helps the air flow velocity can only help the
embryos when they are at the right uniform temperature
• Warning: at this position these eggs can’t have a good asymmetric angle and a
good angle of 45° on both sides.

1st week 8–15 days 16–17 days 18–19 days

of incubation
Stop or 60 min/60
45 min/1 min flat 60 min/1 min flat 60 min/10 min flat min
 CANDLING AND TRANSFER
• Candling
• Candling is an easy and sure methodology to determine percentage hatchability:
• ›› Early candling gives advance information about the condition of the farm, percentage fertility, correct
storage conditions, health of the farm and condition of embryos at the start of the incubation process.
• Previous candling can be carried out after 6 days of incubation by an individual candling lamp, and the
following breakout of eggs, shown in reliable percentage values, indicates the early deaths from blastoderm
-72 h and early mortality “blood ring” at 3–6 days.
• These values help to determine the approximate hatch, and help us to decide the incubation number well in
advance.
• This method is humane and doesn’t destroy or damage the live embryos. It is important to have a
representative number of eggs in the test (dirty or floor eggs don’t give a reliable average).
 Medium candling
• is carried out in some hatcheries at around day 10 of incubation, in
special cases in the oldest flock with poor fertility.
• It is done in order to refill the tray with fertile eggs and to improve
the uniformity of temperature during the setter process, to have
more space following the incubation, and also to reduce and speed
up the transfer job.
• It is possible to use a “candling table” in dark room, although
automatic candling machines that can carry out this process also exist
Transfer candling
• is the most common method for every hatchery, as it isn’t necessarily an extra job.
• During the transfer operation from tray setter to hatcher basket, the eggs can be processed with a “candling table” or automatic
machine, which can remove all the clear eggs and dead embryos.
• Extra attention must be paid when the percentage of removed eggs is over 15 %, as it is important to refill the hatcher basket.
• At the moment, only prototype machines for refilling exist, and in general this refilling process is done manually. However, it is always
necessary to heed the fragile condition of the eggs, so as to avoid damaging the embryos.
• The candling is important, because any clear eggs transferred to the hatcher don’t produce metabolic heat and therefore create an
unstable climate.
• In situations with different flocks with different fertility rates in the same hatcher, this causes problems during hatching, from
increases in hatch window time to the percentage of embryos which are piped but don’t hatch.
• All tests which have taken place confirm that chicks’ quality is improved through the candling of eggs, and that the number of chicks
damaged during the chicks take-off is reduced.
• In conclusion, these are the reasons for candling:
• 1. Early detection of farm problems, male condition and general health and storage conditions; right S.P.I.D.E.S. use; correct
incubator conditions and management
• 2. Creation of a good collection of reference data, to use with necropsy for identifying and resolving problems quickly, and to have a
general view of the farm and the hatchery
• 3. Good estimation of the percentage of hatched chicks
• 4. Optimisation of space in setter (previous and middle candling)
• 5. Separation of waste into a different category of risk and reduction of costs (eggs to shell calcium); the possibility of selling unfertile
eggs for use as animal food; reduction in terms of kilograms of waste in the hatchery per day
• 6. Improvement of quality of chicks; improvement of performance; optimisation of hatcher space and use
 TRANSFER
• The transfer process was standardised in the past at 444 hours, and is now set for all Multi-
Stage incubators.
• In order to balance the temperature and the air flow of the setter, all hatcheries work with
this clear chronological order, including the transfer from setter tray to hatcher basket after
18.5 days.
• And in hatcheries that work with Single-Stage? There is a possibility of change at our
exigencies, we don’t have to balance the setters of all our incubation machines, which can be
empty from day 16 to 19, but is important to remember that at some point, the target at
18.5 is the perfect parameter for the eggs’ weight loss data, the hatcher basket isn’t built for
having the same air flow of the setter trays, and the majority of brands of hatcher have more
cooling capacity, extreme air flow and ventilation.
• For this reason, in early transfer, we have to control and prepare a good programme which
maintains in hatchers the setter condition from day 16 to day 18.5.
• The problem isn’t to stop turning but the anticipated transfer can cause some problems at
hatch windows time and can reduce hatchability by around 0.5–1 %.
• At the same time a delayed transfer is possible, if our hatch windows target is perfectly
standard, but an excessive delay at day CANDLING AND TRANSFER 19.5 can disturb the
embryos just starting with internal cut, at this time eggs are more fragile and can be
damaged from the automatic vacuum transfer machine.
• Incubation time is calculated from the moment that our eggs reach the set-point, not from the effective switch-on of the
incubator or from pre-heating start. For this reason we have to know the effective time that our machine needs for keeping
eggs at the right temperature, and it is from this basis that our chronological time starts.
• A really important point is the climate of the room and condition of transfer, warm (25 °C – 28 °C) and in high hygiene and
biosecurity, the basket that has to be washed and disinfected, totally dried and wormed, which process should be gentle and as
short as possible.
• If an automatic machine is in use to keep this movement soft and stop it causing damage, and the hatcher machine is switched
on and at the right temperature just at set-point, the hatcher programme, if present, should run in the perfect stage. If
manually operated, the operator has to fix about the chrono-logical requirements
• Operators need to pay attention to biosecurity by cleaning and sanitising hands at every possible contamination; the Roth
eggs (contaminated eggs that are not re-moved by automatic candling because it is dark) have to be removed. This is very
important because these eggs can explode in baskets with chicks which have just hatched, and contaminate all chicks that have
an open navel and are there-fore more vulnerable. This can cause real increases in first week mortality and infection at the
yolk sac.
• If some flock operators arrange a refill, it is important that the same percentage of live embryos for all baskets is calculated in
advance, as well as the hatcher condition number. The operator should organise the level and the distribution of the hatcher
dolly. To organise a perfect balanced hatcher, follow the set pattern if necessary; below are two different examples:
• Filling up hatcher Dolly to guarantee the best embryo/chick condition
• Filling up hatcher Dolly to guarantee the right air-flow
HATCHER
The Hatching cycle
• After the routine transfer from setter trays to the hatcher basket and relative hatcher machine, the embryos have to
continue their natural development and prepare for the hard cycle of the hatch. The general climate conditions are very
important because our embryos have to finalise the transformation of internal organs and pre-pare the piping and the
relative exit from the eggs.
• In these last days, our embryos turn their body position along the long axis of the eggs, and by positioning the beak
under the right wing, they are now in a perfect position. The yolk starts to retract in the abdominal cavity, and the navel
starts to close. At the same time, blood circulation undergoes the necessary modifications. Now our chicks are
ready…….. Turn the beak and start with the internal piping of membrane , continue with a circular cut of eggs relative to
our external climate and conditions, keeping our internal condition liveability and perfect chick development
(embryological time), we have start our hatch windows. Simple in this description but this is . . . the miracle of life.
• The phase during hatching is different, and we can help our chicks with different set stages. This is necessary in both
philosophies of works, namely Single-Stage and Multi-Stage, because we can help a lot with the right action.
• Some brands of hatcher have some interesting tools to better follow the chicks’ condition, others believe more in
different forms of control. Of course, carbon dioxide is a sure value that can help reveal a lot about the real condition of
our hatcher machine, in relation to the situation that we have done in a full complete cycle.
• Uniforming and stabilising the embryos’ time with the right condition and synchronising chronological and embryological
time creates a very nice advantage.
• As mentioned in the previous chapter, in this guide we don’t want to suggest any dedicated programme, as the
variability of and the differences between one hatcher brand and others need a dedicated investigation and test, but an
important target to consider is the right hatch windows time. Of course, depending on the age of the flock and the
storage period , for a good chicks’ condition and for best liveability hatch window start with the first 5 % of chicks from
the total chicks pull-out(it takes minimum26 to 30 hours for Single-Stage and 28 to 32 for Multi-Stage).
• Warning: the definition of hatch windows isn’t completely correct: in reality between 5 % and 98 % of chicks hatch, but it
is impossible to have total control of every hatch basket in order to verify these parameters without having a negative
influence on the climate of the hatcher, (the real hatch windows time in hours is shorter, but it certainly is more easy to
calculate in the form described).
 The Hatcher operation
• This is a very important part of the process, because in this part it isn’t possible to correct a wrong incubation action, but it is very easy to destroy the
entire good job.
• In hatchers the conditions can change in a short time and very frequently, and these factors are more complicated to control using an automatic
system. For this, some brands are developing tools to better follow the hatcher condition or using virtual intelligence systems to change the step and
relative set-point at necessity, which are free in terms of time and connected to the real condition and advancements of the hatch. The objective is to
help and facilitate the piping out of our chicks, with a stimulation effect, and it is done for chicks which have just hatched, ensuring the right condition of
drying and for cicatrising of the navel, which helps bring about the best quality of chicks.
• ›› It is important that our temperature has to drop in relation to the number of chicks hatched, and a drop to real temperature could help to conserve
and improve our chicks’ quality after the end of the real “hatch window time”.
• ›› Humidity improved from the natural increase at the hatch can help to maintain a constant high value, but at the end, the real “hatch windows” have
to change and decrease to help all chicks to dry in perfect way, which is important because the stability value of humidity UP and DOWN can destroy
chicks’ quality.
• ›› CO2 (carbon dioxide) at a value of 7,000 ppm can help in the stimulation step. Knowledge about the real density of CO2 helps us to understand
when our machine needs the change of steps and starts to provide more ventilation. Sometimes the fertility of the flock can make a big difference.
• ›› Ventilation and an extra fan for fresh air have to work with respect to real hatcher condition: improving the ventilation in the early phase can stop
the hatch; delay in the use can change the climate condition of the chicks hatched.
• To determine optimum timing, the flock age is the inherent factor; embryos at the youngest of 30 weeks and at the oldest of 60 weeks need an
additional 5/6 hours of time, as is also the case for the long storage eggs that have not undergone the S.P.I.D.E.S process. The value is standardised in
all our hatchery processes in these points, namely uniformity and reduction of variability, optimum time, a nice fluff condition and a good general
condition.
• Use of a disinfection product during the hatch is very important and gives an advantage in bacteria and mycosis control. In the past it was common to
use an evaporation plate with Formalin, positioned in the hatcher machine at day 19 and with a quantity sufficient to cover all processes of the hatch.
This is very dangerous for the operator and for the chicks in high dosages, and, if extended, this evaporation over 12 hours can lead to permanent
damage of the chicks in the hatcher (can damage trachea and encourage reactions to vaccines). However the efficiency, the cost, the easy utilisation
and the positive characteristic of giving the chicks a very beautiful yellow colour have pushed managements to continue using it, although in some
countries local governments don’t permit its use anymore. In other countries it is permitted but only with some restrictions and safety systems for the
operator. Many different typologies of products can carry out good disinfection during the hatcher process, especially if sprayed in regular frequency of
time or in evaporation. Here, peroxide is one of the best and if it is used by specific evaporation staff, it is a perfect substitution.
• Remember, in the hatch process our chicks
have a continued hatch, and with increase in
number there is a relative increase of
contamination. For better control, a timed
dosage of disinfectant is very useful.
• Disinfection which starts and finishes in one
shot isn’t a perfect job because of the decrease
in terms of active ppm: the solution loses
capacity over time. In a test, the value of
disinfection is very high on day 19, at over 50
ppm, but near 0 on day 20.5. For this reason it
is better to spread a higher dosage of the
disinfectant that we have chosen.
• IMPORTANT: all disinfectants have to strictly
follow the “technical sheet info” in terms of the
right dosage and the system of utilisation.
• Make sure to verify the activity with chicks’
fluff analysis and to check whether they are
compatible and not aggressive with the ma-
terial construction of our hatcher machine;
some disinfectants are good for bacteria con-
trol but extremely corrosive and dangerous.
• Interesting hatcher graph with a good
and a perfect hatch window
 Monitoring chicks and quality control
• In this guide, we have spoken of “chicks’ quality”. This is the appearance of the chicks in the basket of day-old chicks, and
in general this is determined by the hatchery operator according to how the chicks look and what they feel like to touch.
• ›› Activity attention and fast reaction of chicks
• ›› Uniformity
• ›› Good navel condition, closed, with perfect cicatrising
• ›› Nice yolk sac absorption with a soft belly, but not too slim
• ›› Legs in perfect condition, not dehydrated or damaged, no red hooks
• ›› Beak clean and not damaged or inflamed, caruncles perfect
• ›› Fluff condition vaporised dry and not dirty, with a nice smell
• In summary, the first point of control should be reached for if our chicks don’t respect one of these conditions.
• 1. In a normal case, a right pull-out time at the right ventilation condition is the key for active and reactive chicks.
• 2. Uniformity varies with the quality of hatching eggs and their size and weight at deposition. Other factors that can
damage or promote our chicks’ uniformity include genetic background, age, health of eggs, shell composition and relative
different weight loss of eggs.
• 3. Incubation and hatcher should be stable in temperature and humidity, for the chronological development is the solution
at no perfect chick’s navel.
• 4. Perfect weight loss of eggs, correct pull-out time, development in the right embryologic temperature, correct hatcher
ventilation and qualitative hatching of eggs in good health and with the right percentage of yolk/albumen/shell, are points to pay
attention to, for having a soft and nice belly.
• 5. Right pull-out time, correct temperature at the end of the incubation time, correct temperature in the hatcher machine,
favourable condition for short hatch windows, and darkness in the hatcher, to maintain good chicks’ legs.
• 6. Long permanence in machine long hatch windows, and hard cutting and exit from eggshell.
• 7. Ventilation and oxygen at hatching of chicks, correct temperature for the chicks which have just hatched, poor eggs tournament,
eggs health and sanitiser condition at the production farm.
• It is important to remember that in hatchery life, some adjustments are necessary in consideration of flock age, season, and some
other variable conditions (pull-out chicks in incubation time or prepare a different programme) the correct monitoring of chicks
can help you to take some different decisions and find a solution for the best setting. Different systems exist for monitoring format
and for standardising the chicks’ quality, which depend on the subjective opinion of every hatcher manager. It is important not to
forget the following:
• when we ask visitors to the hatchery for their opinion about the quality of some of the chicks, we commonly receive these
answers: Nice . . . Not bad . . . not good . . . These are not form of answering. for a good hatchery process and some monitoring we
can answer the question with reliable data.
• A good hatchery has a “Quality Control Operator” who has to follow all the chicks’ pull-out and monitor the quality of the hatch
(percentage and chicks conditions), record data and inform the hatchery manager about mistakes or issues. It is important that the
good collaboration and the total agreement between these two members of staff exists.
Pasgar Score chicks evaluation:
• This high-quality formula, which is carried out at the chicks’ pull-out in the hatcher basket, can value our chicks with a numerical
average. It is my preferred formula as it is easy and not subjective (operator can-not be influenced by personal opinion).
• Take 50 chicks from the hatchery basket, not specifically selected, and one by one test them for each of these 5 points;
• 1. Reflex, the reaction of the chicks to a reversed body: if the chicks stand up in regular position in a maximum time of 3 seconds,
the score is =0; if chicks need more time or don’t try to take the correct position the value is =1
• 2. Navel: a perfect navel has a score of =0: an open navel, a black button, a strictly navel, a brogue or an inflamed and red navel
has a value of =1
• 3. Legs: good and strong legs of normal skin colour, score =0; dehydrated red and very slim legs, red hook, blood vessel in strong
evidence, value =1
• 4. Beak: a clean and normal horn colour, nice and clear caruncle, score=0; a dirty or red beak, dirty and red caruncle, value =1
• 5. Belly: a soft and smooth belly scores =0; a tight and hard full belly, or chicks which immediately expel meconium when their
belly is touched, value=1
• Every chick starts with a value of 10 points;
• all positive scores don’t affect the value and every negative score decreases the value. What is important in this test is the total
average. If it is over 9, it shows a good chicks’ quality; if it is from 8 to 8.95 it shows a medium quality, and scores of 7.95 and
below indicate a low chicks’ quality.
• The practical value of this test is the valuation in numerical value, and it leads to percentage discoveries of critical points and
improvement areas where we have to direct our attention.
Chicks’ yield
• When monitoring chicks’ weight in relation to weight of eggs at the set
incubation time, it is very important to follow the same trays from the
recording of weight of eggs at the setter to the hatch pull-out.
• Count good chicks and record an average weight and divide for the eggs
weight percentage.
• This helps to inform us if the weight loss of eggs at incubation/transfer
time was right and if the correct parameters were from 67.5 %–66 %.
• If the delivery time is from 2 to 6 hours, or, in the case of very short
delivery, 1 hour, a low percentage isn’t a problem but if the delivery at
the farm is very long, a value of 69 %–70 % helps the liveability.
• Regarding standardised time for prime flocks, every 2 hours more in the
hatcher is relative to 1% of weight loss.
Chicks’ uniformity
• The chicks must have the same weight under the condition of good
parameters.
• The uniformity of hatching eggs is also very important for this data.
The uniformity has to stay over 85 %.
Chicks’ length
• Another monitoring test is the recording of length in cm.
• This shows a perfect hatcher profile, and a perfect hatcher pull-out in
case of real short delivery.
• This test is a little more complicated and needs attention and
objectivity when recording.
• It is normally used in broiler hatcheries.
Empty eggshell evaluation
• ›› This monitoring test unfortunately needs good practice and experience, because it isn’t easy to recognise the borderline
between one condition and another condition, but we can start with this helpful information:
• ›› Shell Membranes are still moist and stay connected to the eggshell; inside the eggs there is a substance which looks similar to
latex; the blood vessels in the membrane are visible but fine; and the eggshell is extremely clean. All these points confirm the
anticipated pulling-out. Chicks are “fresh”, and for the best quality and performance we have to improve the chronological time.
• ›› Shell are crushed in the hand; membrane can appear separate from egg-shell in many places; and eggshell looks dirty and
covered in meconium. All these points confirm retarded chicks pulling-out. Chicks are “crispy”, total percentage is high, but for the
best chicks’ quality and relative liveability we have to reduce our chronological time.
• ›› A large blood vessel which can be observed inside the eggshell and a big discharge of urea are clear indicators of overheating.
• ›› The height of cutting in the eggshell is a forfeit indication of weight loss of eggs. A high cut near the obtuse pole of eggs is a clear
example of insufficient weight loss, water and relative amniotic liquid quantity is too much for the perfect chick’s metabolism, and
some chicks don’t manage to complete the cut and the hatch.
• ›› The lower cut is the opposite problem. Weight loss of eggs is high, the low quantities of amniotic liquid obligate some chicks to
take up a malposition and in some embryos the feet can move over the head and stop the head from cutting.
• ›› In the ideal hatching conditions, the cutting of the eggshell is flat/plane and follows a continue line. The change of the cutting
line upwards and down-wards shows improper conditions and bad state of chicks.
Monitoring using necropsy
›› This is a real and true test of our process, because embryos can’t lie.
›› Every hatchery controls the process of carrying out professional and
correct necropsies.
›› This shows us the effective value of our hatching eggs, of our setting
programme and of our maintenance and functioning of our machines,
but this needs a chapter of its own.
 NECROPSY AND BREAKOUTS ANALYSIS
Making breakouts Analysis
• The necropsy is a sure way of monitoring in order to have all our flocks under maximum control, in necropsy of eggs we can see
the real performance and know if our performance is at the right condition and in line with the genetic potential of our eggs.
• The best hatchery can transform the eggs into qualitative chicks if it does a perfect job, but it cannot improve the genetic value. It
can destroy or it can damage the chicks’ quality. But we repeat, it cannot change the base or genetic value. But what is this value?
. . . Is really important to know.
• Carrying out a correct necropsy is very important for our process, in order to make sure that our hatchery respects the genetic
value. Of course, for this we need a sufficient number of eggs in the test, and we need to arrange good and affable breakouts.
• Hatcheries have to prepare a dedicated table practice, which is easy to clean, comfortable for the operator, and which manages
the breakouts with maximum biosecurity.
• In our process, the “Quality Control Team” arranges “early candling” and relative breakouts. We want these tests to be done just
in order to have some information in advance (right hatchability previous percentage) and to guarantee control on the fertility
value and have a clear vision of early dead in previous hours (easier to identify in the first part of incubation).
• In this guide we are using LOHMANN TIERZUCHT analysis format, because it is part of my experience and in this format we
conserve more than 30 years of data:
• Necroscopy Analysis in order to resolve possible mistakes during incubation process
INFERTILITY IN CLEAR EGGS WITH
NO EMBRYONIC DEVELOPMENT
• ›› Males undernourished: follow a recommended feeding programme to provide adequate nutrition; replace underweight males.
• ›› Too few males: increase the number of males in the flock; artificially improve the frequency of insemination.
• ›› Seasonal decline of fertility: use young cockerels which are more resistant to environmental stress.
• ›› Competition among breeding males: do not use many males; rear all males together; place temporary partitions in large pens.
• ›› Diseased flock: conduct an approved disease control programme.
• ›› Frozen combs and wattles: provide comfortable housing; properly select and maintain drinking fountains.
• ›› Old males: replace with younger males.
• ›› Selected mating in pens: artificially inseminate infertile hens; replace males in the pen/house.
• ›› Male sterility: replace males in the pen/house.
• ›› Crowded breeders: provide the recommended floor space;
• ›› Improper artificial insemination techniques or use of old / over-diluted semen
VERY EARLY DEAD BLASTODERM
PHASE – 72 HOURS
• ›› Males undernourished: follow a recommended feeding programme to provide adequate nutrition; replace underweight males.
• ›› Too few males: increase the number of males in the flock; artificially improve the frequency of insemination.
• ›› Seasonal decline of fertility: use young cockerels which are more resistant to environmental stress.
• ›› Competition among breeding males: do not use many males; rear all male together; place temporary partitions in large pens.
• ›› Diseased flock: conduct an approved disease control programme.
• ›› Frozen combs and wattles: provide comfortable housing; properly select and maintain drinking fountains.
• ›› Old males: replace with younger males.
• ›› Selected mating in pens: artificially inseminate infertile hens; replace males in the pen/house.
• ›› Crowded breeders: provide recommended floor space; follow recommendations of LOHMANN TIERZUCHT GmbH.
• ›› Improper artificial insemination techniques or use of old/over-diluted
• semen: follow recommendations of LOHMANN TIERZUCHT GmbH. › Eggs damaged by environment: gather eggs frequently with accurate control of conditions. › Eggs stored for too long or
incorrectly: store eggs at the wrong temperature, or too cold or too warm, or at an instable temperature and humidity; bad and incorrect or inappropriate S.P.I.D.E.S. process; long interval from
one S.P.I.D.E.S. process to another. › Shaker eggs and trouble in handling and transport: pay attention to gentle handling. › Improper disinfections: follow disinfections recommendations and
dosage and time recommendations. › Eggs of the day: incubate eggs without waiting for minimum time from the production day; improve blastoderm mortality; instable pH is wrong for
incubation; a minimum of 48 hours is necessary to stabilise pH and conditions.
 EARLY DEAD BLOOD RING, 3 – 6
DAYS
• ›› Improper storage: follow recommended egg storage and gathering recommendations.
• ›› Improper incubation temperatures: check calibration and accuracy of incubator set-point; follow
recommended temperature settings.
• ›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels.
• ›› Improper disinfections: follow disinfections recommendations and dosage and time recommendations.
• ›› Bacteria contamination: handle eggs gently and check eggshell quality of transport eggs; check cleanness
of nests and conditions of the farm floor; make sure the operator has clean hands; check the share of new
males; look out for floor and dirty eggs; be careful of improper or accidental showers of eggs; look out for the
sweating of old eggs in storage; be careful of changes of new males; pay attention to aspergillus or mycosis
contamination; control and improve disinfection processes.
 Medium dead mortality, 7 – 12 days:

• ›› Improper incubation temperature: follow recommended incubation, not too warm and not too cold.
• ›› Improper eggs turning: control turning functions for eggs. This is especially important in the first 12 days of the process.
• ›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value; if location is high above sea level then
add oxygen.
• ›› Inherited low hatchability, poultry disease: check genetic potential; test for diseases in flocks, make use of medical
care; check health; investigate factors under veterinarian action.
• ›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels.
• ›› Micro cracks and bacteria contamination: handle eggs gently and check eggshell quality of transport eggs, check
cleanness of nests and conditions of the farm floor, make sure the operator has clean hands; check the share of new
males; look out for floor and dirty eggs; be careful of improper or accidental showers of eggs, look out for the sweating of
eggs in storage; be careful of changes of new males, pay attention to aspergillus or mycosis contamination; control and
improve disinfection processes.
SETTER
LATER MORTALITY, 13 – 16 DAYS
• ›› Improper incubation temperature: follow recommended incubation, not too warm and not too cold.
• ›› Improper eggs turning: control turning functions for eggs. This is especially important in the first 15 days
of the process.
• ›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value; if location is high above
sea level then add oxygen.
• ›› Inherited low hatchability, poultry disease: check genetic potential; test for diseases in flocks; make use
of medical care; check health; investigate factors under veterinarian action.
• ›› Micro cracks and bacteria contamination: handle eggs gently and check eggshell quality of transport
eggs; check cleanness of nests and conditions of the farm floor; make sure the operator has clean hands;
check the share of new males; look out for floor and dirty eggs; be careful of improper or accidental showers
of eggs; look out for the sweating of eggs in storage; be careful of changes of new males; pay attention to
aspergillus or mycosis contamination; control and improve disinfection processes. › Improper breeder
nutrition: feed breeders a diet with balanced nutrient levels.
Contamination:
• ›› Micro cracks and bacteria contamination:
• handle eggs gently and control eggshell quality of transport eggs;
• check cleanness of nests and conditions of the farm floor;
• make sure the operator has clean hands;
• be careful of improper or accidental showers of eggs;
• look out for the sweating of eggs in storage; be careful of changes of new males,
• look out for floor and dirty eggs; pay attention to aspergillus or mycosis contamination;
• control and improve disinfection processes.
Malformed brain exposed:
• ›› Brain exposed: high temperature in the first 9 days of incubation
General malformations
• ›› Improper incubation temperature: follow recommended incubation,
not too warm and not too cold.
• ›› Extreme low humidity in process: control average weight loss of
eggs; control humidifier action.
• ›› Improper eggs turning: control turning functions for eggs. This is
extremely important in the first 15 days of the process.
• ›› Improper ventilation: increase ventilation and control carbon dioxide
(CO2) value, if location is high above sea level then add oxygen.
• ›› Farm health, poultry disease: check genetic heredity consanguinity;
test for diseases in flocks; make use of medical care; check health;
investigate factors under veterinarian action.
• ›› Improper transport and management, shaker: pay attention to gentle
transport and handling.
• ›› Improper breeder nutrition: feed breeders a diet with balanced
nutrient levels.
• Please note: Some specific malformations have a direct relation to certain
conditions. Please check data for values and interpretations.
 Malformed beak:
• ›› Cruxes beak: incubation temperature too high in the first 11 days.
• ›› Parrot beak: extremely high concentration of disinfectant or too
long an exposure; intoxication from chemical agents.
Malposition of air cell:
• ›› General malposition; head in middle of legs; head on left side: wrong turning;
wrong angle; too high or too low incubation temperature; incorrect humidity;
shaking during eggs handling; shocks in turning .
• ›› Lateral air cells: problems with turning at the wrong angle; transport of eggs
blunt-up; wrong positioning in trays; bad trays (too much space for little eggs).
• ›› Horizontal position of embryos, with big air cells: excessive weight loss of eggs;
micro cracks; turning failure.
• ›› Feet on head: low level of amniotic liquid; control weight loss of eggs, eggs
percentage composition (Yolk/albumen%, feed breeder vitamin support).
Malposition: wings under head:
• ›› Head over wings:
• ›› control turning; control symmetric action to right/ left at the
same angle;
• ›› bad trays (too much space for little eggs).
Upside-down eggs:
• ›› Upside-down chick’s position: wrong positioning of eggs at collection;
transport of eggs blunt-up.
• These are eggs and embryos which were lost just before the
transfer process due to
• wrong flock conditions,
• wrong farm conditions,
• wrong handling of eggs,
• wrong setting and wrong incubation.
• The following records can be attributed to genetics, farms,
and setter and hatcher issues.
DEAD AT TRANSFER TIME, 17 – 18.5
DAYS
• ›› Improper incubation temperature : follow recommended incubation, not too warm and not too cold.
• ›› Improper eggs turning: control turning functions of eggs and relative correct angles.
• ›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value, if location is high above
sea level then add oxygen.
• ›› Inherited low hatchability, poultry disease: check genetic potential; test for disease in flocks; make use of
medical care; test health, investigate factors under veterinarian action
• ›› Improper humidity value: too low or too high humidity.
• ›› Transfer anomaly: control transfer at the right time and in a warm room, warm basket or warm hatcher
machine which is switched on; avoid thermic shock and inopportune shower of eggs.
• ›› Disinfection in hatcher after transfer: some hatcheries have use of fumigation in processes or choose
special disinfection immediately after transfer. Always control product and relative dosage.
• ›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels.
 DEAD AT HATCHER TIME, 19 – 21 DAYS
• ›› Improper incubation temperature : follow recommended incubation, not too warm and not too cold.
• ›› Improper eggs turning: control turning function of eggs and relative correct angle.
• ›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value, if location is high above sea level then add oxygen.
• ›› Improper hatcher conditions: verify the hatcher setting programme and respect the steps.
• ›› Inherited low hatchability, poultry disease: check genetic potential; test for disease in flocks; make use of medical care; check health;
investigate factors under veterinarian action.
• ›› Improper humidity value: too low or too high humidity
• ›› Transfer anomaly: control transfer at the right time and in a warm room, a warm basket or a warm hatcher machine which is switched on;
avoid thermic shock and inopportune shower of eggs.
• ›› Disinfections during hatcher time: some hatcheries use special methods of disinfection during the hatcher process time. Always control
product and relative dosage.
• ›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels. If this is a problem in this period, it is easy to note that
some chicks have a big oedema in the back of the head.
• ›› Wrong hatcher step: check effective embryological time and synchronise with hatcher time and programme.
Pip live chicks:
›› Improper incubation temperature :follow recommended incubation, not too warm and not too cold.
›› Improper eggs turning: control turning function of eggs and relative correct angle.
• ›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value, if location is high above sea
level then add oxygen.
• ›› Improper hatcher conditions: verify the hatcher setting programme and respect the steps.
• ›› Inherited low hatchability, poultry disease: check genetic potential; test for disease in flocks; make use of
medical care; check health; investigate factors under veterinarian action.
• ›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels. If this is a problem in this
period, it is easy to note that some chicks have a big oedema in the back of the head.
• › Wrong hatcher step: check effective embryological time and synchronise with hatcher time and programme.
• ›› Wrong time: a wrong time or a too short time increases the problem
Pip dead chicks:
›› Improper incubation temperature: follow recommended incubation, not too warm and not too cold.
›› Improper eggs turning: control turning function of eggs and relative correct angle.
›› Improper ventilation: increase ventilation and control carbon dioxide (CO2) value, if location is high above sea level then add
oxygen.
›› Improper hatcher conditions: verify the hatcher setting programme and respect the steps.
›› Inherited low hatchability, poultry disease: check genetic potential; test for disease in flocks; make use of medical care; check
health; investigate fac-tors under veterinarian action.
›› Improper breeder nutrition: feed breeders a diet with balanced nutrient levels. If this is a problem in this period, it is easy to
note that some chicks have a big oedema in the back of the head.
›› Wrong hatcher step: check effective embryological time and synchronise with hatcher time and programme.
›› Wrong time: a wrong time or a too long time increases the problem.
›› Contamination by aspergillus: be aware that contamination can cause many issues at our embryos in piping out time; the
percentage of E-coli increases to a very high value and can kill our chicks in this delicate phase. A correct disinfection with the
right product at the right dosage can help.
 No pip embryos:
• ›› Chicks are live but no cut eggs:
• check point of descript over,
• setting programme,
• calibration of machine;
• pay particular attention to the right time for the typology of eggs
 Chicks dead in basket:
• ›› Perfect chicks, fully formed but dead: be aware that the chicks may be
dead due to external issues: the operator may have moved the basket
aggressively, the chicks may have suffered because of a damaged basket or
because of an extremely long hatch window time or an extremely long
process in the hatcher at critical conditions.
• ›› Chicks are fully formed and have a soft body and a bad smell: check for
contamination; check E-coli value; check for aspergillus; introduce the right
disinfection format in the hatcher process; pay attention that dirty eggs, if
used, can cause these problems.
 Broken eggs in setter:
• ›› Eggs which have been damaged in farm collection, in
storage, handling or in setter time: check eggshell and share
information with farm management; improve the actions of the operator;
request more gentle action.
Broken eggs in hatcher:
• ›› Embryos with eggshell injury or shock during transfer;
signs of a dry or sticky membrane on embryo’s body:
• control transfer
• action: if automatic, set to slow and if manual, ask for
consideration and attention - otherwise these damaged eggs will
not hatch.
Aspergillus:
• ›› If aspergillus is present in the air chamber, the membrane is a strong yellow
colour: provide a fast reaction with an increase of biosecurity and specific
treatments on arrival from the hatchery, but it is important to avoid the
possibility of replication in the hatchery or in the machine.
• These are eggs and embryos which were lost just before the transfer process due to wrong flock conditions, wrong farm conditions, wrong
handling of eggs, wrong setting and wrong incubation. The following records can be attributed to genetics, farms, and setter and hatcher
issues.
 Perfect LOHMANN BROWN, Necropsy
Age Fertil- Day Day Day Day Roth Mal- Malf. Brain Malp. Malp. Ups. Day Day Pip Pip No Pip Dead Brock Brock
ity 0–2 3–6 7–12 13–16 formed Beck Exp. Wing Dow. 17–18 19–20 Live dead bask setter Hatch

24 10/20 2/5 2/5 0.5/1 0.7/1.3 0.1/0.5 0.1/0.7 0.1/0.7 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1.3 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

25 7/15 2/4 2/4 0.3/1 0.3/1.3 0.1/0.5 0.1/0.7 0.1/0.6 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1.1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

26 5/10 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1.1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

27 7 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

28 5 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

29 4 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

30 4 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/1 0.5/1.5 0.5/2 0.5/2 0.3/1 0.1/0.5 0/0.3 0/0.3

31 3 2/3 2/3 0.3/0.7 0.3/0.7 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

32 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

33 2 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

34 2 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

NECROPSY 35

36

37

38
2

2
2/3

2/3

2/3

2/3
1/3

1/3

1/3

1/3
0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3

0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3

0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3

0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3
0/0.3

0/0.3

0/0.3

0/0.3

AND
39 2 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

40 2 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

41 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

42 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

43 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

BREAKOUTS
44 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

45 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

46 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

47 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

48 3 2/3 1/3 0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3 0/0.3

ANALYSIS 49

50

51

52

53
3

3/4

3/4
2/3

2/3

2/3

2/3

2/3
1/3

1/3

1/3

2/3

2/3
0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3

0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3

0.1/0.5 0.1/0.5 0.1/0.5 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.5 0.1/0.5 0/0.3

0.3/0.6 0.3/0.6 0.5/1

0.3/0.6 0.3/0.6 0.5/1

0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3

0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3
0/0.3

0/0.3

0/0.3

0/0.3

0/0.3

54 3/4 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

55 3/4 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

56 3/5 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

57 3/5 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

58 3/5 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

59 3/6 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/0.7 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0/0.3 0/0.3

60 3/6 2/3 2/3 0.3/0.6 0.3/0.6 0.5/1 0.1/0.7 0.1/0.5 0.1/0.4 0.3/1 0.1/0.4 0/0.4 0.5/0.7 0.5/0.7 0.3/0.7 0.3/0.7 0.2/0.7 0.1/0.5 0.1/0.5 0.1/0.5

61 4/7 2/3.5 2/3.5 0.3/0.7 0.3/0.7 0.5/1 0.1/0.9 0.1/0.7 0.1/0.4 0.3/1 0.1/0.4 0/0.4 0.5/1 0.5/1 0.5/1 0.5/1 0.3/1 0.1/0.5 0.1/0.5 0.1/0.5

62 4/7 2/3.5 2/3.5 0.3/0.7 0.3/0.7 0.5/1 0.1/0.9 0.1/0.7 0.1/0.5 0.3/1 0.1/0.4 0/0.4 0.5/1 0.5/1 0.5/1 0.5/1 0.3/1 0.1/0.5 0.1/0.5 0.1/0.5

63 5/8 2/3.5 2/3.5 0.3/0.7 0.3/0.7 0.5/1 0.1/0.9 0.1/0.7 0.1/0.5 0.3/1 0.1/0.4 0/0.4 0.5/1 0.5/1 0.5/1 0.5/1 0.3/1 0.1/0.5 0.1/0.5 0.1/0.5

64 5/8 2/3.5 2/3.5 0.3/0.7 0.3/0.7 0.5/1 0.1/0.9 0.1/0.7 0.1/0.5 0.3/1 0.1/0.4 0/0.4 0.5/1 0.5/1 0.5/1 0.5/1 0.3/1 0.1/0.5 0.1/0.5 0.1/0.5

65 5/9 2/3.5 2/3.5 0.3/0.7 0.3/0.7 0.5/1 0.1/0.9 0.1/0.7 0.1/0.5 0.3/1 0.1/0.4 0/0.4 0.5/1 0.5/1 0.5/1 0.5/1 0.3/1 0.1/0.5 0.1/0.5 0.1/0.5

Attention: all values are relative at eggs with perfect storage 3 to 6 day in perfect health perfect hatchability eggs uniformity and Genetic condition.
The table is the result of a huge collection of data, collected to define the perfect parameters of actions.
PROCESSING OF CHICKS
• At the exit from the hatcher machine, the general environmental
conditions are important.
• We have to remember that this is a delicate phase and that our chicks
are stressed about external conditions.
• Any movement and transport can scare them, which is why a fast
processing can help.
 Chicks’ temperature
• An easy and clear indication of chicks’ condition is the body temperature, which is very
important because we don’t want to dam-age the quality of our hatched chicks in take-off
and handling. It would be a paradox if any action on embryos in perfect condition, which
respected hatcher time, increased the risk of damaging liveability and destroying quality only
because of the poor conditions in the processing stage before delivery.
• At collection, pay attention to rectal temperature. It provides very helpful and very ac-curate
data, but testing this temperature can damage the rectum of the chicks and some
unfortunate chicks may die. For this reason, I prefer take ventral temperature. Remember to
take a large sample (many chicks), because the temperature can vary a lot due to size and
sexual differences, but our chicks stay within a perfect range of temperatures when
• During chicks’ selection, sexing, and vaccination, the body temperature isn’t a valuable piece
of data, because the chicks’ external conditions and stress factors interfere. Average chicks’ body temperature
• It is easy to check temperature visually, because: Temperature in
machine 40.5– 105–
• ›› At low temperatures, the chicks huddle together in a corner to try to maintain body
temperature and reduce their maximum activity or immediately 39.5 °C 103 °F
• ›› At temperatures which are too high, the chicks open their becks and pant. In this state after hatcher take-out
they lose a lot of humidity and some chicks’ liveability is reduced. They become noisy (cry) Temperature of chicks
and spread their wings to try to reduce body temperature; the fluff looks smooth. when 39.5– 103–
Significantly improving air flows and humidity value can greatly help our chicks to regain the relaxing in delivery
right body temperature quickly. basket 38.5 °C 101 °F
 Chicks’ take-off and sexing
• LOHMANN TIERZUCHT GmbH varieties of commercial layers are all either colour sexable or
feather sexable. These different processes need different amounts of time (chronological time),
which have to be calculated by the hatchery manager in advance, in relation to the number of
workers and the distance of delivery. This is done so that the wings develop correctly, which
means that chicks can be sexed more easily, so error is reduced.
• In a normal air flow, the recommended temperature that guarantees chicks good room conditions
is 25 °C (77 °F) and the recommended relative humidity is around 45–65 %. These values are, of
course, relative to the room and the quantity of chicks in the process.
• In a biosecurity hatchery, the chicks’ processing room needs a negative pressure, because this
condition allows the removal of fluff in a secure way and doesn’t necessitate moving from room
to room in a dangerous condition. This is different for a vaccination room, which has to maintain
as clean an atmosphere as possible, and for a vaccine storage room, which has to stay at a
pressure above environmental pressure here it has to be guaranteed that the only exit of air from
this room happens when the operator prepares vaccine dilution and injection bags.
• Chicks’ take-off has to respect the welfare of the chicks and must give the chicks and the operator
the best conditions in terms of temperature and oxygen while producing as little fluff and noise as
possible.
Chicks’ vaccination
• Every country, every customer and every hatchery has a specific preference for a typology of vaccine and system,
which can be INOVO, intra-muscles in legs, in neck with handle injection, semi-automatic injector, total automatic robot
or sprayed.
• All these tools are used differently and have different things to look out during use. However, whatever the vaccine and
the method of use, it is very important to follow the manufacturer’s instructions for every vaccine concerning the
system of providing the vaccine, the dosage, the term of use after reconstruction/DE-frozen (time and temperature)
and the disinfection. Everything is very important in this delicate job and our main objective is to protect our chicks
from poultry disease. This isn’t easy because it is important to damage neither the value of the vaccine, nor our chicks.
• Don’t mix different vaccines on your own initiative; if several different vaccinations are required, use only registered
combinations formulated by the different manufacturers and respect the “pause” time between one vaccination and the
next. Use authorised diluents conserved in perfect conditions and check that the use of some products doesn’t
damage “the vaccination title”.
• The vaccine world is experiencing a continuing upgrade process. New products and new discoveries can change the
use and the priority, so we need the latest in-formation, where it is just as important to respect the use and the
conditions. Every vaccine manufacturer gives the perfect recommendations for their entire selection of different
vaccines, and it is important to respect this for all the different systems used. Do not change the vaccine preparation,
but notice and verify the dos-age for every system.
• INOVO: This is the most modern vaccination and is in continued evolution. The embryos are vaccinated in the eggs
transfer time from day 18.5 (no earlier, in order not to lose per-centage) to day 19.5. In the past there was only one
provider, but now several different brands of constructor build this type of eggs injector machine. In this vaccination it is
really important that the general biosecurity of the vaccine dispenser pipe to the needle of the INOVO machine, is
cleaned at the hatchers and is disinfected after every dosage with a good product. This is the basis for reducing late
mortality, and it is necessary to pay maximum attention to contamination of eggs and aspergillus, which can
completely destroy the hatchability. Advantages of INOVO vaccination include the velocity of the process and the
reduced stress to the chicks, the early start of anti-body coverage and the 100 % guarantee of injection in the right
place
 Manual injector
• This is the most widely spread vaccination system in all
countries and is cheap and easy to use, but it is very
important that the operator has manual experience and
carries out the task gently and accurately without any hard
or brutal actions towards the chicks.
• Attention needs to be paid to avoid damaging the legs or
neck bones, and the needle should be changed and
disinfected frequently.
• Remember that chicks can be effectively vaccinated as soon
as the solution enters the body: for this reason accurate
control should be practised by the vaccine operator and use
of colour in diluents can prove useful in the best vaccination
procedures and resolve many problems without injuring our
chicks.
Semi-automatic vaccinator
• Various different providers build these high-performance
machines.
• When using, remember to use the dedicated specific
injection settings for legs or neck.
• In these vaccinators, the cleanness and biosecurity are of
course important, but attention also has to be paid to
vaccine dosage, which has to be controlled by way of a
regular schedule.
• A routine change of needles is also important, and it helps
to trace the effective vaccination with a coloured diluent.
• The machine has to stay dry and clean, as loss of the vaccine
and the presence of residual blood or fluff are not tolerable.
 Total automatics vaccinator
(robot)
• In recent years these systems have become much more
commonplace in many hatcheries.
• This is a very nice machine that uses relatively
sophisticated technology, and to do a good job the
operator only has to load the chicks into a carousel system,
which can arrange different vaccinations in a fixed place.
• Additionally, some of these machines can carry out extra
processes on the chicks.
• It is important to control the condition of the needles
(avoid bent needles, which can cause injury and death) and
the frequency of needle disinfections, as a loss of the
vaccine and residual blood or fluff are not tolerable.
• You should also arrange the solution quickly
Spray vaccinations
• This is easiest system, isn’t invasive, and doesn’t cause problems
for infection, if the preparation of solution follows the vaccine
manufacturer’s recommendations. Please be aware, however,
that it isn’t totally free of risks:
• it is important know that our chicks need some time to relax and
return to a tranquil condition after vaccination (it is a very
stressful event for our day-old chicks) in perfect climate
conditions.
• When using spray vaccination, the dosage of water, the size of the
nozzle that determines the vaccine distribution and the
temperature of the solution and of the room where the vaccine is
used are all very important.
• The chicks need some time in an illuminated room for a proper
assimilation of some typologies of vaccine.
Holding and delivery of chicks
• The holding or storage of chicks
has to maintain the perfect
conditions for the chicks: a dark
or blue light condition helps them
to relax, for example.
• Checking body temperature is the
key for maintaining perfect
conditions, whether or not we
have a holding cabinet.
• Transport of day-old chicks from
the hatchery to the farm is a
delicate phase, as the wrong
transport conditions can totally
destroy chicks’ quality and
liveability, and therefore ruin the
good work done in the farm
production stage and in all
hatchery processes.
• The risk of exposing the chicks to
the wrong conditions is real, and
the goal is to maintain the right
environment for the whole
delivery time.
PROCESSING OF CHICKS
• The day-old chicks have a natural equipment, that is “the residual yolk percentage in correct parameters”, and this makes the
chicks comfortable without food and water for the first 48 hours.
• It is of primary importance that the temperature stays under control inside at the chicks’ box.
• A clear indicator of good climate conditions is when the chicks are breathing calmly through closed nostrils and are spread out
within all box sur-faces; this allows for the conservation of humidity and the avoidance of stress, as the chicks don’t have to use
energy for thermoregulation of the body and they therefore have more energy to use for liveability.
• Of course, the temperature set-point of transport is relative to the air flow velocity inside the truck: the higher the air velocity the
higher the temperature set-point, and vice versa.
• ›› Optimise the delivery in consideration of transport time, truck climate capacity and condition of roads.
• ›› Remember that a strong air flow can help in critical temperature conditions.
• ›› Use a data logger to record conditions and place it in the right place in the chicks’ box; count and control the loose chicks.
• ›› Load and unload quickly; in a normal truck there is no good ventilation in this phase and boxes aren’t well distributed.
• ›› Adjust the number of chicks/box in relation to the climate conditions (season-size) and the previously scheduled hours of
transport time.
• ›› Use proper food and hydrate food for chicks in the case of extra-long delivery.
• ›› The truck driver should be trained and should have professional motivation for taking care of live chicks and for optimising time
and transport
 QUALITY ASSURANCE
Implementing a basic quality assurance system in
hatcheries
• Quality assurance is a complex system which includes different interrelated
programmes.
• It has the aims of keeping quality at high levels by preventing any hazards and
defects, and of satisfying customers.
• Together with other quality functions like quality policy, quality design, quality
control and quality improvement, quality assurance closes the circle of a complex
quality system that can help companies to comply with changing requirements
both from customers and from regulatory governments.
• Quality assurance systems include documents that describe operations and
activities that directly relate quality and safety, and should be followed by people
inside organisations.
• In companies that operate with quality management systems, the quality
assurance activities are integrated into the quality management systems.
Prerequisite programmes – the basis of a
quality management System
• In order to build a quality management system in any one organisation, some different steps need to be
followed in order to create a solid structure that can success-fully provide the company with the capability to
meet all quality requirements.
• In addition to different practices that have been developed by national governments, some practices that
work as prerequisite programmes have been developed to be used at international level for the purposes of
facilitating fairness in global food trade, and for the protection of health of consumers worldwide.
• Some recognised programmes originally designed for the food industry are described in the “Recommended
International Code of Practice, General Principles of Food Hygiene” of the Codex Alimentarius Commission,
Food and Agricultural Organization/ World Health Organization (FAO/WHO) Food Standards Programme.
• These Codex Alimentarius prerequisite programmes cover the following sections: Primary Production;
Establishment: De-sign And Facilities; Control of Operation; Establishment: Maintenance And Sanitation;
Establishment: Personal Hygiene; Transportation; Product Information and Consumer Awareness; and
Training.
• The following recommendation guide for hatcheries has been designed while taking into consideration some
requirements from Codex Alimentarius Recommended International Code of Practice, General Principles of
Food Hygiene. For a better understanding, it is recommended to read the complete Codex Alimentarius
guide: Recommended International Code of Practice, General Principles of Food Hygiene.
• In this hatchery guide, the Codex will be referred to only on some topics regarding biosecurity, control of
operation and cleaning and disinfection.
Control of operation
• The main purpose of this section is to reduce the risk of unsafe
products by taking preventive measures to assure the safety and
suitability at an appropriate stage in the operation and by controlling
hazards.
• Product business operators should control hazards through the use of
systems such as HACCP (Hazard Analysis and Critical Control Points).
• These systems should be applied throughout the chain, in order to
control hygiene throughout the product life cycle through proper
product and process design.
Example of a control procedure:
eggs control at reception – process description
• In order to be sure that all trolleys with eggs from farms are received in good condition at the hatchery, the eggs are further collected and processed after
their arrival, before being set into trays.

• Due to the fact that at the hatchery, only good quality eggs with no or reduced or hazards will be used, some methods and ways of control must be carried
out besides the measures that have been taken at the farm level related to eggs hygiene; in this, eggs’ reception inside the hatchery is accomplished.

• Certain principles and techniques must be used in order to make an evaluation of the process of egg collection at farms, and also concerning transport in
order to identify negative aspects influencing use of eggs further. This step eliminates eggs that are less likely to hatch and would negatively influence
quality of chicks, or that are contaminated with yolk, dried blood or faeces, which pose a biological threat.

• Eggs are currently transported from farms by trucks. Upon arrival it is necessary to check if the eggs are being shipped securely so that they do not arrive
broken. In order to properly receive eggs, please maintain the following procedure:

• 1. After the truck is positioned at the hatchery bay, open the door in order to receive the eggs from the trucks. Once the truck is docked, safely position the
truck loading ramp in order to unload the trolleys.

• 2. Remove the trolleys with eggs from the truck and place them into the egg reception room.

• 3.Visually inspect the trolleys in order to check that the eggs have arrived in good condition, are well positioned on trays, are not dirty and do not present
great damage (content leaking through trays).

• 4.After inspection, place the trolleys in the transfer room in order to further process the eggs.

• Other measures that can be used in order to identify and eliminate some hazards:

• 1..Eggs surface sampling – to be tested microbiologically and for yeasts and moulds.

• 2..Monitoring temperature and humidity in trucks.

• 3. Use of a machine for grading in transfer, in order to select the eggs and eliminate eggs with hairline crack.
Product analysis Control activities in order to monitor the process in one hatchery

Process Control action Quality control Analysis measurement Monitoring Quality indicator
Eggs reception Inspection and eggs Visual inspection of Check if eggs have arrived Every trolley Compare with targets
and storage monitoring trolleys in good condition, are well
positioned on trays, are not
• There shall be procedures in order to monitor dirty or damaged, and are
leaking through trays
that all specified product requirements are met, Eggs surface sampling Bacteria (colonies, Every flock – Reduce colonies.
including legal requirements and specifications. Salmonella and Aspergillus), before fumigation
other mould and yeasts
No Salmonella.
No Aspergillus

• Microbiological, physical and chemical analysis Eggs grading,

Eggs weight
Data collection from Number of eggs not
Scale measurement
% of eggs
Every flock
Every flock
Egg weight (g)
Small eggs – big eggs;
required for this purpose shall be performed selection and eggs candling and processed hairline cracks

internally and/or subcontracted. transfer

Eggs
transfer process
Fumigation control Eggs surface sampling Bacteria (colonies, Every flock – Reduced colonies.
fumigation
• A test plan shall be drawn up for internal and
Salmonella and Aspergillus), before fumigation No Salmonella, no
moulds and yeasts Aspergillus

external analysis, based on hazard analysis and Clean eggs

storage
Monitoring
environment
Cool storage Temperature and
humidity
Every day Compare with targets

assessment of associated risks, which covers raw Eggs short S.P.I.D.E.S. Incubators Process control Time and temperature Every S.P.I.D.E.S. Compare with targets
materials, finished products as well as processing periods of
incubation
equipment and packaging materials. during storage
S.P.I.D.E.S.

• The test results shall be documented and Eggs

incubation
Incubation
monitoring
Eggs weight Scale measurement Every flock Egg weight (g)

periodically evaluated in order to analyse the setters Setters activity control Check next parameters:
- Temperature
Every setter Visual check of gra-
phics and comparison
trend. - Humidity
- CO2
with targets

- Ventilation
• Corrective measures shall be introduced for any - Turning

unsatisfactory results.
Infertile and early dead If necessary By flock Compare with targets
control at 7 days
Eggs candling Data collection from Clear eggs and Every transferred Compare with targets
and transfer eggs candling and early dead trolley
transfer process
Eggs weight at transfer Scale measurement Every flock Egg weight loss (%)
Control activities in order to monitor the process in one hatchery
Process Control action Quality control Analysis measurement Monitoring Quality indicator
Control activities in order to monitor the process in one hatchery
Eggs incubation Setters activity control Check next parameters: Every hatcher Visual check of
hatchers - Temperature graphics and
- Humidity compare with targets Process Control action Quality control Analysis measurement Monitoring Quality indicator
- CO2 Maintenance Preventive Follow manufacturer Keep records about Organise case by case, Visual check of
- Ventilation
maintenance instruction for all maintenance procedures a daily, weekly, graphics and
Chicks take off Day-old chicks’ Day-old chicks’ quality Pasgar Score Every flock Compare with targets equipment monthly, compare with targets
quality and yearly schedule
Uniformity Every flock Compare with targets
laboratory sampling
Chick weight Calibration Follow manufacturer’s Keep records about Organise a Keep records
Chick yield recommendation for calibration yearly schedule
Breakout analysis Every flock Compare with targets all equipment
Chicks to be sampled Bio-burden analysis Every flock Bacterial contaminati- Repair Follow manufacturer’s Keep records about all Organise case by Keep records and
for laboratory for on, yeast and moulds instruction for all repaired equipment case, a daily, weekly, analyse the trend
bio-burden analysis repaired equipment monthly,
Fluff to be sampled Salmonella Every flock No Salmonella yearly schedule
for laboratory Training Training Employees need to be Keep records about Organise periodical Organise open
Meconium to be E-coli Every flock E-coli trained internally or participation training sessions sessions and
sampled for laboratory externally verification activities
Chicks Sexing Sexing errors Male or female selection All day-old chicks Monitor by hour Refresher training Organise periodical Keep records about Organise periodical Organise open
Chicks Control of Bacterial contamination Every flock Bacterial training sessions for participation training sessions sessions and
vaccination vaccine preparation contamination employees, taking into (twice a year verification activities
consideration the spe- for example)
Vaccination Control of vaccine activity Vaccinated Monitor and compare
cificity of their work
day-old chicks with targets
Control of Laboratory control Sampling plan Bacterial
vaccine residues contamination
Chicks or eggs Packaging control Sampling of boxes Laboratory control Sampling plan Bacterial, yeasts and
packaging mould contamination
Chicks storage Storage monitoring Storage rooms Check next parameters: Every room Compare with targets
activity control - Temperature
- Humidity
- Ventilation
- Chicks body temperature
Eggs candling Data collection from Clear eggs and Every transferred Compare with targets
and transfer eggs candling and early dead trolley
transfer process
Eggs weight at transfer Scale measurement Every flock Egg weight loss (%)
Cleaning and Floors, walls and Clean and disinfection Visual check Records Corrective action
disinfection in windows cleaning records
the hatchery Cleaning of setters
Cleaning of
hatchers
Cleaning of
equipment
Cleaning and disin- Clean and disinfection Sampling for laboratory Sampling plan Bacterial, yeasts and
fection of trays and samples mould contamination
baskets
Clean and disinfection Sampling for laboratory Sampling plan Bacterial, yeasts and
samples mould contamination
Personal hygiene Personal health Health status of Health certificates Plan Heath status
employees
Visitors monitoring Records or health certificates Every visit Health status
Laundry cleaning Clean and disinfection Sampling for laboratory Sampling plan Bacterial, yeasts and
in the hatchery samples mould contamination
TROUBLE SHOOTING
• We need to have the right processes and the right conditions of biosecurity.
• The necessary analysis and tests for having total control of equipment can help to
limit the issue and to give us “Peace of Mind”, but some problems can still occur.
• This is natural, and a correct and fast reaction helps a lot to minimise the
problem.
• Data and comparison with the hatchery target average helps towards a
preventive discovery of an issue, and optimal adjustments of conditions, the
correct necropsy and a good analysis of breakouts is the key for the solution.
• REACT quickly and don’t lost time; hatchery operators have to continue following
the best principles. This is the correct attitude, instead of a decrease in
performance having to push our hatchery to revolution.
• We have to switch ON the red light and improve our attention.
Practice based on technical service
• 1) Parents farm problem; health of group and fertility issues.
• 2) Storage issue, wrong condition of S.P.I.D.E.S.
• 3) Human error and wrong track and trace of our eggs; mixed flock; change of data and relative equipment
(machine).
• 4) Decrease of hatcher performance; loss of some embryos from problems relative to setter conditions.
• 5) Accidental break in trolley or in transfer process.
• 6) High loss in hatchery machine (setter/ hatcher) from missing of alarm; software failure; human mistake;
breakdowns.
• 7) Poor biosecurity in vaccine preparation and application.
• 8) Aspergillus contamination and presence of E-coli, leading to a decrease in liveability.
• 9) Transport issues; wrong delivery
• 10) Farm issues; wrong home condition.
• These are the principal 10 points ON practice life, which were investigated in a case of troubleshooting.
 SEXING GUIDE
• Males are slow-feathering in
cockerel chicks primaries (row of
feathers in picture 2) and are
shorter than or of the same length
as coverts (row of feathers in
picture 1)
• Males are slow-feathering in cockerel
chicks primaries (row of feathers in
picture 2) and
• are shorter than or of the same length
as coverts (row of feathers in picture 1)
HYGIENE
Biosecurity in hatcheries
• “Biosecurity” refers to a series of practices designed to prevent
hazards (biological, chemical and physical) from coming into contact
with birds inside the hatchery.
• Components of biosecurity:

• ›› Isolation

• ›› Traffic control

• ›› Sanitation
Isolation
• Potential sources of contamination need to be considered when deciding where to locate product establishments, as
well as the effectiveness of any reasonable measures that might be taken to protect products.
• Establishments should not be located in any place where, after considering such protective measures, it is clear that
there will be a threat to product safety or suitability. In particular, establishments should normally be located away
from:
• ›› environmentally polluted areas and industrial activities which pose a serious threat of contaminating product;
• ›› areas subject to flooding, unless sufficient safeguards are provided;
• ›› areas prone to infestations of pests;
• ›› areas where wastes, either solid or liquid, cannot be removed effectively.
• Pests pose a major threat to the safety and suitability of products.
• Pest infestations can occur where there are breeding sites and a supply of raw products.
• Good hygiene practices should be employed to avoid creating an environment conducive to pests.
• Good sanitation, inspection of incoming materials and good monitoring can minimise the likelihood of infestation and
thereby limit the need for pesticides.
• The hatchery building shall be designed to include adequate space for all work areas.
• Physical separation is recommended for different areas, in order to restrain biological cross-contamination by
humans
Traffic control
• People known or suspected to be suffering from, or to be a carrier of, a disease or illness likely to
be transmitted to a product (day old chick), should not be allowed to enter any product handling area if
there is a likelihood of their contaminating the products.
• Any person so affected should immediately report the illness or symptoms of illness to the
management.
• Medical examination of a product handler should be carried out if any disease clinically or
epidemiologically indicated.
• Visitors to manufacturing, processing or handling areas should wear protective clothing and
adhere to the other personal hygiene provisions in this section. The number of visitors should be
minimised.
• All incoming materials shall be delivered and stored in such a manner as to prevent
spoilage, deterioration, damage and contamination.
• All chemicals, vaccines and drugs shall be properly sourced for their intended purpose and
labelled properly at all times.
Sanitation – cleaning procedures
and methods
• Cleaning can be carried out by the separate or the combined use of physical
methods, such as scrubbing, turbulent flow, vacuum cleaning or other methods
that avoid the use of water, and chemical methods using detergents, alkalis or
acids.
• Cleaning procedures will involve, where appropriate:
• ›› removing gross debris from surfaces;
• ›› applying a detergent solution, to loosen soil and bacterial film and hold them in
solution or suspension;
• ›› rinsing with water in order to remove loosened soil and residues of detergent;
• ›› dry cleaning or other appropriate methods for removing
and collecting residues and debris;
• ›› where necessary, disinfection with sub-sequent rinsing, unless the
manufacturer’s instructions indicate on scientific basis that rinsing is not
required
 Cleaning programmes
• Cleaning and disinfection programmes should ensure that all parts of the establishment are appropriately clean, and should also
include the cleaning of cleaning equipment.
• Cleaning and disinfection programmes should be continually and effectively monitored for their suitability and effectiveness and,
where necessary, documented.
• Where written cleaning programmes are used, they should specify:
• ›› areas, items of equipment and utensils to be cleaned;
• ›› responsibility for particular tasks;
• ›› method and frequency of cleaning;
• ›› monitoring arrangements.
• Cleaning activities shall be carried out in periods of non-production. If this is not possible, these operations shall be con-trolled so
as not to affect the product.
• Where a company hires a third-party ser-vice provider for cleaning and disinfection activities, all requirements specified within this
section shall be clearly defined in the respective contract.
• Where appropriate, programmes should be drawn up in consultation with relevant specialist expert advisors.
• The efficiency of cleaning and sanitisation should be checked and recorded at routine intervals by the quality control responsible.
• Mechanisms of monitoring and verification of the effectiveness of cleaning include:
• ›› visual inspection;
• ›› contact microbiological swabs or plates;
• ›› ATP bioluminescence techniques;
• ›› microbiological testing of partly pro-cessed and finished products;
• ›› microbiological and chemical checks of rinse water.
• The monitoring of cleaning should be formally documented, records should be maintained, any trends should be analysed and,
where required, corrective action should be implemented to improve cleaning and sanitisation practices.
Example of a control procedure:
cleaning and disinfection – process description

• The objectives of a cleaning procedure are:

• ›› to ensure that all hatchery areas are properly cleaned, sanitised and maintained at the highest level of
cleanliness;
• ›› to minimise as far as practicable the numbers of microorganisms;
• ›› to reduce cross-contamination between clean and dirty areas of the building and between batches of eggs in
incubation and chicks in hatchers;
• ›› to minimise the build-up of bacterial flora in the environment of the building.
• Responsibilities
• This procedure applies to hatchery employees involved in the cleaning and the sanitising of different areas. It is
the responsibility of the hatchery area supervisor to ensure that these procedures are followed.
• Process description
• The procedure definition section of a procedure will contain a step-by-step description of the task or function to
be carried out.
• Removal of debris from a surface takes three steps:
1) ´eparating the debris from the surface;
2) Dispersing the debris in the cleaning solution;
3) Preventing dispersed debris from reattaching to the surface.
For equipment
• All equipment and other surfaces that could come into contact with products should be
cleaned and sanitised case by case at the end of the shift in which they were used,
following these steps:
1. Where possible open / disassemble the equipment.
• Physically remove product debris by hand or with tools such as water pressure machineries.
• Visually check equipment for missing parts or parts / surfaces that are worn to the extent that
debris will accumulate and cause product contamination.
• Apply an approved cleaner to parts and clean according to manufacturer’s directions. Note that it
is recommended to clean floors first and then clean equipment from top to bottom.
• Rinse equipment parts with warm po-table water to remove remaining debris. Note: a potability
certificate for water from the municipal water authority or a satisfactory well test report (done at
least every 6 months) should be avail-able to prove that the water supply is potable.
• Sanitise equipment with an approved sanitiser that is mixed and used according to the
manufacturer’s directions.
• Check and reassemble the equipment.
For areas
1. Physically remove product debris by hand or with tools such as water
pressure machineries.
2. Apply an approved cleaner.
3. Rinse equipment parts with warm potable water to remove remaining debris.
4. Sanitise equipment with an approved sanitiser that is mixed and used
according to the manufacturer’s directions. This procedure can be applied
taking into consideration additional documents like:
5. Map of the designated areas for cleaning.
6. The cleaning programme for every areas.
7. Work instructions for different cleaning areas.
Example of a control procedure: cleaning
and disinfection of baskets and trays
• Objectives of cleaning and disinfection of baskets and trays
cleaning procedure:
• ›› to ensure that egg trays and baskets are properly cleaned,
sanitised and maintained at the highest level of cleanliness;
• ›› to minimise as far as practicable the number of
microorganisms;
•›› to reduce cross-contamination between clean and dirty areas
of the building and between batches of eggs in incubation and
chicks in hatchers;
•›› to minimise the build-up of bacterial flora in the setters and
hatchers.
 Steps Instructions Baskets washing machine Tray washing machine Expected results

HYGIENE 1 Start the machines

Use potable water
Temperature of the water: 60 °C
Pressure: 20–30 (cleaning) –
15-20 (pre-cleaning) bars
Time: 15 min
To start the process at the time
when the temperature of the
water is enough for the cleaning
programme

Introduce the cleaning agent

• Responsibilities Introduce the cleaning agent Manual or automatic Manual or automatic Monitor the recommended
quantity of cleaning agent

• This procedure applies to hatchery employees involved in 2 Automatically, the machine

uses a pre-cleaning
Automatic process

the cleaning and sanitising of tray and baskets. It is the programme to remove the dirt

responsibility of the quality control specialist (or hatchery

supervisor area) to ensure that these procedures are
followed.
• Process description
3 Cleaning: automatic equipment Automatic process

• The washing equipment is cleaned and disinfected in the spreads the cleaning agent on
the surface of tray and baskets.

following steps:
• 1. Physically remove product debris by the use of water
pressure.
• 2. Clean using a cleaning agent. 4 Rinsing: automatic Visually check if the area and
pressure water at: equipment are clean. If not
• 3. Rinse with warm potable water to remove remaining Temperature :15–20
°C Final rising: 10 °C
repeat the steps 1–3

debris and cleaning agent. Pressure: 5–10 bars

5 Disinfection: the equipment Visually check to monitor that all

• 4. Disinfect using an automatic system. Sanitise au-tomatically spreads
disinfectant on surfaces of
equipment surfaces are clean. If
not, repeat the steps 1 to 4 and
equipment with an approved sanitiser that is mixed and trays and baskets Agent: check again. Monitor the conti-
nuous usage of the disinfectant.
used according to the manufacturer’s directions.
• 5. Check and reassemble the equipment.
Documentation and
data storage
• An appropriate system of records on
processing, production and distribution
• needs to be kept for a period of time that exceeds Manual
the life cycle of the product.
• Documentation can enhance the credibility and Prerequisite
effectiveness of the safety control system. HACCP
Programmes
• At the same time, an effective back-up system is
essential. Procedure (SOP)
• The requirements with regard to documents and
data control shall apply equally to electronic data as Work Records Manual
they do to data in paper format. Instructors Documents Annexes
• This is especially true in the management of
obsolete files, documents and data held
electronically either in a memory that has personal
ac-cess only or on a server.
Hazard Analysis and Critical Control Point –
the next step in building a quality management system
• Prior to application of HACCP to any sec-tor of the food chain, that sector should have in place prerequisite programmes
such as good hygienic practices according to the Codex General Principles of Food Hygiene, the appropriate Codex Codes
of Practice, and appropriate food safety requirements.
• These prerequisite programmes to HACCP, including training, should be well established, fully operational and verified in
order to facilitate the successful application and implementation of the HACCP system.
• HACCP is an acronym used to describe the Hazard Analysis and Critical Control Point, a systematic approach used to
identify, evaluate and control safety hazards. HAC-CP is very logical sequence of steps that cover all stages of production in
order to identify the hazards that are likely to occur at any stage and put methods of control in place that will prevent
them.
• Developed in the early 1960s, HACCP is a system of control based on prevention that provides a structured approach for
the assurance of the safety of specific
• products and their associated processes.
• In essence, it involves:
• ›› Identification and evaluation of hazards, such as biological, chemical and physical contaminants and the conditions
leading to their presence and proliferation;
• ›› Identification of the specific requirements for control, in order to reduce or eliminate the hazards;
• ›› Mechanisms to measure and continuously assess the efficacy of the HACCP system.
• Popular in the food industry, HACCP is used in animal farms and
hatcheries today in order to limit the presence of hazards along the Eggs reception
food chain.
Eggs incubation – hatchers
and storage
• All LOHMANN hatcheries have implemented HACCP systems in order to
better control the hazards and to be sure that our products have a
higher degree of safety along the chain.
• The application of HACCP principles consists of the following tasks, as Chicks’ take off
identified Eggs grading,
selection and transfer
• in the Logic Sequence for Application of HACCP.
• 1) Assemble HACCP team.
• 2) Describe product.
Chicks’ sexing
• 3) Identify intended use. Eggs fumigation
• 4) Construct flow diagram.
• 5) On-site confirmation of flow diagram. (Note the following figure)
• 6) Hazard analysis - list all potential hazards associated with each step, Clean eggs storage Chicks’ vaccination
conduct a
• hazard analysis, and consider any measures to control identified
hazards.
Short periods of incubation
• 7) Identify Critical Control Points (CCP).
Chicks’ packaging
during eggs storage
• 8) Establish critical limits for each CCP.
• 9) Establish a monitoring system for each CCP.
• 10) Establish corrective actions. Eggs incubation setters Chicks’ storage
• 11) Establish verification procedures.
• 12) Establish Documentation and Record Keeping.

Eggs candling Schematic representation of a

and transfer hatchery process flow diagram
 INFORMATION
HOW LOHMANN TIERZUCHT IS CALCULATING THE ENERGY CONTENT
OF FEED AND RAW MATERIALS (INTERNATIONAL WPSA-FORMULA):

ME MJ/kg = g crude protein x 0.01551

+ g crude fat x 0.03431
+ g starch x 0.01669
+ g sugar x 0.01301 (as saccharose)
• Lohman tierzucht hatchery guide is the only source of this presentation