Critical batches, locations and moments

Critical batches, locations and moments

Being aware of and focusing on risk situations in your management practices can help prevent many problems. This applies to certain critical batches, places or moments in the hatching process.

Critical batches

It is always possible to identify critical, at-risk eggs in the batches of hatching eggs. For example, eggs from older breeder flocks. These eggs have a thinner eggshell and less weight uniformity. Or floor eggs that have been washed and still added to the batch in the setter. Think about any critical eggs that may be present in each batch delivered, which problems could occur and how to respond in a timely and correct way.

Critical locations

There are critical locations in each hatchery where there is a higher risk of potential problems. Points known to be critical should be inspected daily, such as day-old chicks that might be held in a place that is too cold: this causes mortality in the first week. Try to make an inventory of these locations and optimise the conditions. Eggs placed in the middle of paper egg flats/pulp trays in the centre of the trolley are another example of a critical location. These eggs will have difficulty cooling. Or what about a hygiene lock where people are sometimes very creative in by-passing the protocols (e.g. a director who is just giving visitors a quick look at the hatchery and forgets about all the hygiene regulations).

Critical batches: dirty eggs should not be put in the setter at all in order to avoid cross contamination. High mortality in the first week and other problems with the flock can be so serious that using these eggs is not worthwhile. If you decide to incubate them anyway, make sure dirty eggs and washed eggs (as shown here) are marked with a special label in the setter tray to flag up that these eggs need special treatment. Place these eggs at the bottom of the trolley. A critical location: water accumulating on the floor of the setter is a breeding ground for bacteria. The machines must be completely dry before being refilled with eggs. Evaporating water uses so much energy that the hatching eggs at the bottom of the trolleys will be incubated at too low temperatures for copyright protected too long. This will have a negative impact on uniformity and hatch window. A power outage (power cut, voltage dip, emergency power test) can make the incubators suddenly jump to another phase of the program, restart or even jump to the pre-heat program. The same applies to the climate control systems (frequency controller failure). This is a critical moment. Modern hatchery equipment is less susceptible to this, but always check if unexpected situations occur.

Critical moments

Every moment in the process involves certain risks relating to the hatching results and chick quality. The hatchery employees need high levels of knowledge and skills to ensure they are aware of these moments and know how to respond adequately. Any movement of the hatching eggs is a critical moment, as it causes vibration and temperature fluctuations (condensation). Day 18 - when the eggs are transferred - is also a critical moment. Eggs can crack or break and cool considerably or overheat in a very short time. Chicks in the holding area is critical: they are likely to get overheated, but draughts and cold spots can lower the chicks’ temperature, all leading to higher mortality during transport and at the farm.

Moment Quality risk

Egg laying at the breeder farm • Poor hatching egg quality (too round, too elongated, infertile, soiled, etc.) • Eggs cooled down too slowly • Inclusion of floor eggs • Soiled laying nests • Poorly connected egg belts • Rough handling • Insufficient hygiene • Poor health of parent stock • Too old parent stock • Damaged eggs

Storage at the breeder farm

• Eggs cooled down too quickly • Poor climate (and no uniform climate conditions) • Poor storage conditions • Stored too long • Insufficient hygiene • Damaged eggs • Malfunctions • Eggs stored in wrong position (point upwards • Temperature fluctuations (day/night, partly because doors open and close more often during the day) • Incorrect disinfection Transport • Poor climate conditions • Jolting during transport • Outside temperature influences • Insufficient hygiene • Malfunctionscopyright protected Storage at the hatchery

Disinfecting hatching eggs • Insufficient coordination with breeder farmer • Poor climate conditions • Insufficient hygiene • Stored too long • Malfunctions • Damaged eggs • Temperature fluctuations (day/night, partly because doors open and close more often during the day)

• Incorrect disinfectant concentration • Gas vs fogging • Temperature not optimal • Fog not uniformly distributed (not all eggs disinfected uniformly) • Air distribution/movement through egg mass • Duration of disinfection • Insufficient ventilation to remove disinfectant residue

Moment Quality risk

Setter • Condensation on too cold eggs • Heating up not uniform and too long for some eggs (> 24 hours) • Fumes from disinfectants • Poor climate conditions (too cold/hot, too dry/ humid, not uniform, insufficient CO2/O2 exchange) • Eggs turned badly or at insufficient intervals • Insufficient machine maintenance • Insufficient hygiene • Bangers • Malfunctions

Candling on day 18 and transfer

• Rough handling • Poor climate conditions • Insufficient hygiene • Malfunctions • Bangers • Wet baskets (too high throughput: too short drying time) • Insufficient machine maintenance • Process takes too long (uncontrolled egg temperature) Hatcher • Poor climate conditions (too cold/hot, too dry/ humid, not uniform, insufficient CO2/O2 exchange) • Poor hatching • Poor embryo uniformity (long hatch window) • Insufficient hygiene • Too long in the hatching baskets • Feed and water: insufficient quality and availability • Malfunctions Sorting and selection • Insufficiently skilled employees • Incorrect climate • Insufficient hygiene • Rough handling • Poor quality chicks • Order of pulling (washed eggs, suspect farms last) • Maintenance of chick handling equipment (interruptions cause delay, which is bad for the chicks)copyright protected

Packing, loading and transport • Unsuitable chick density • Insufficient hygiene • Wait time • No access to feed and water • Duration of transport • Poor climate conditions • Malfunctions

Arrival at poultry farm • No access to feed and water • Unsuitable climate (especially floor temperature) • Insufficient hygiene • Insufficient knowledge poultry farmer • Insufficient coordination with hatchery • Malfunctions • Rough handling • Not evenly distributed in the house