Chicken Operation Manual for ACI Single Stage

Transcription

1 Jamesway Incubation Systems Chicken Operation Manual for ACI Single Stage MANOPSCACI Revision B

2 Jamesway Incubator Company Inc. 30 High Ridge Court Cambridge, Ont., Canada N1R 7L3 tel: (519) fax: (519) for customer service: This book and its contents are the property of the Jamesway Incubator Company Inc. Reproduction in whole or in part, by any means, without permission of Jamesway Incubator Company Inc. is prohibited Jamesway Incubator Company Inc.

3 Table of Contents 1. Introduction to the ACI Introduction The Single Stage Concept Advantages of the Jamesway ACI Single Stage Incubation System Bio-Security Flexibility Optimized Hatchability and Chick Quality An Overview of the Single Stage Incubation System Size and Capacity Options of ACI Single Stage Incubators Size and Capacity Options of ACI Single Stage Hatchers ACI Single Stage Component Identification Sentry Control System Display Panel Fibre Optic Hub Machine Controller Operator s Interface Panel and Status Lights Temperature and Humidity Probe Room Sentry - Optional Ventilation, Heat and Cooling System ECU - Environmental Control Unit Environmental Control Unit Water Supply Damper Hatcher Exhaust Plenum Egg Rotation System Compressed Air Supply Farm, Incubator and Hatcher Racks Farm Racks SST Egg Transport System The Automatic Incubator Rack Loader Incubator Racks Hatcher Racks Egg Flats Hatcher Dollies and Hatcher Baskets Accessories Back Up Alarm Velometer Air Flow Meter Egg Flat Cabinet Egg Flat Storage Battery Operated Circuit Tester Digital Thermometer Incubator Rack Tester Water Tester... 31

4 2. ACI Single Stage Requirements Ventilation Requirements Egg Room Optimum Settings ACI Single Stage Incubator Rooms Optimum Settings ACI Single Stage Hatcher Rooms...36 Pull/Wash Room Chick Room Clean Room Water Requirements Cooling Water System Heating Water Recommendations Humidity Water Supply Recommendations for Humidity Water Supply Electrical Requirements Standard Air Requirements Compressed Air ACI Single Stage Profiles ACI Single Stage Profiles Broiler Breeders and Broilers Layers Operational Procedures Procedures Egg Handling Basics Obtaining and Storing the Eggs Transferring the Eggs to the Incubator Racks Methods for Loading Eggs into the Incubator Rack Preparation Method 1: from Farm Rack to Incubator Rack Method 2: Traying Up by Hand Method 3: Automated Loading a Full Set Loading a Partial Set Final Inspection of Loaded Racks Start Up Left or Right Hand? Pre-Start Check Initial Start Up Setting Procedures Loading Racks into the Incubator Switching on the Incubator Guidelines for Egg Setting and Transfer Procedures Transferring Eggs from Incubator Racks to Hatcher Baskets Method 1: Manual To Finish the Transfer Wash and Sanitize Incubators Hatching the Eggs Taking Off the Hatch Method 1: Manual Method 2: Semi Automated and Fully Automated Wash and Sanitize Hatchers... 67

5 5. Routine Maintenance Maintenance Time Schedules Daily Weekly After Every Transfer/Wash Three Month Maintenance Schedule Maintenance Schedule for ACI Incubators and Hatchers Chick Development and Troubleshooting Hatchability Chick Development and Troubleshooting Hatchability Chicken Embryology, The Timing of Major Embryonic Developments Before Egg Laying Between Laying and Incubation During Incubation Analysing Hatch Residue Chicks Hatch Late Fully Developed Embryo with Beak not in Air Cell Fully Developed Embryo with Beak in Air Cell Chicks Pipping Early Chick Dead After Pipping Shell Malpositions Sticky Chicks (albumen sticking to chicks) Sticky Chicks (albumen sticking to down) Chicks Covered with Egg Remnants Eggs Exploding Clear Eggs Blood Ring (embryonic death 2-4 days) Dead Embryos, 2nd Week of Incubation Air Cell Too Small Air Cell Too Large Chicks Hatch Early Chicks Too Small Chicks Too Large Trays Not Uniform in Hatch or Chick Quality Soft Chicks Chicks Dehydrated Mushy Chicks Unhealed Navel, Dry Unhealed Navel, Wet and with Odour Chicks Cannot Stand Crippled Chicks Crooked Toes Spraddle Legs Short Down Closed Eyes... 84

6 7. Appendices Appendix I: Operator s Interface Panel Configuration Menu...87 To Access These Features To Select the Available Menu Options To Start the Calibration Function To Start the Calibration Function Calibration To Keep the New Settings Alarms Setpoints To Use Setpoints Appendix II: Carbon Dioxide Sensor Operating Instructions Installation To Replace the Eprom Using the Carbon Dioxide Sensor Machine State To Change Setpoints Edit Profile Carbon Dioxide Setup Concentration of Span Gas High Carbon Dioxide Alarm Minimum Safety Damper Opening...90 Safety Damper Starts At Day Setpoint Control Hysteresis Damper Duty Cycle Change Calibration To Calibrate the Zero Point To Calibrate the Sensor Span Carbon Dioxide Units Alarms Operator Interface Panel Display To Access this Screen To Calibrate the Carbon Dioxide Sensor...91 Appendix III: The Importance of Egg and Chick Transportation Bacterial Contamination Temperature Control Avoid Temperature Shocks Relative Humidity Motion Transportation of Day-Old Chicks Control Temperature and Humidity Giving Enough Ventilation Preparing for the Flight Appendix IV: Give Day-Old Chicks the Best Start Arrival of the Chicks Mortality during Brooding Hygiene and Health Control of Wet Droppings Water before Feed... 99

7 Appendix V: Hatchery Sanitation: Concepts, Logistics and Assessment Quality Control Programmes Minimise Contamination Prevention through Design Chemical Control Appendix VI: Practical Hatchery Sanitation Guidelines to Assure Quality Prevent Problems from Entering or Multiplying Define an Effective Program for Each Facility The Effectiveness of a Sanitiser and Disinfectant Routinely Monitor the Process Hatchery Monitoring Program The 50 Critical Sampling Points Problem Solving if There Is One Determine the True Results Appendix VII: What to Do with Hatchery Waste Systems to Remove Waste Vacuum Disposal What to Do with Waste Premium Pet Food Appendix VIII: Breakout Analysis Guide for Hatcheries Fresh Egg Breakout Candling Breakout Analysis Hatch Day Breakout Breakout Procedure: Embryo Mortality Determination Identifying Fertility Keep Accurate Records Glossary

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9 1. Introduction to the ACI single stage concept advantages overview sizes & capacities component identification Operation Manual for ACI Single Stage - Chickens 9

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11 INTRODUCTION TO THE ACI THE SINGLE STAGE CONCEPT The Jamesway ACI (Advanced Concepts in Incubation) Single Stage Incubation System provides the industry with a very efficient means of hatching high quality chicks. By definition, Single Stage Incubation is a system in which all eggs are loaded into the incubator at the same time and all eggs are removed at the same time, with a distinct interruption of operation between each set of eggs inside the unit, i.e., All-in, All-out. Jamesway developed the ACI Single Stage Incubation System to complement the existing Jamesway Multi Stage Incubation System in order to meet the industry s technological and genetic demands. This sophisticated system combines state of the art components and controls with ease of operation and low maintenance. Operation Manual for ACI Single Stage - Chickens 11

12 ADVANTAGES OF THE JAMESWAY ACI SINGLE STAGE INCUBATION SYSTEM BIO-SECURITY Warm temperatures and high humidity levels required for incubation also provide an ideal climate for bacterial growth. The ACI Single Stage machines can be thoroughly cleaned and sanitized after each cycle of eggs without any disruption to the incubation process. This high level of cleanliness not only improves chick quality but also reduces early field mortality. As well, any contamination that does occur is contained within the batch of eggs inside the machine and can be addressed during or after the incubator is emptied. FLEXIBILITY Variable settings and set time, as well as partial sets, can be handled with ease. In times of reduced demand, the machine can be switched off. The ACI Single Stage Incubation System s all-in, all-out feature along with fully programmable controls allows for transfer time variation. OPTIMIZED HATCHABILITY AND CHICK QUALITY The ACI Single Stage Incubation System was developed to incubate a large number of eggs under conditions that closely match those provided by the hen, e.g., increased CO 2 levels. In nature, the brooding hen provides the eggs with a progressively changing environment. Using the Jamesway ACI Single Stage System, this natural environment can easily be maintained and monitored. 12 Operation Manual for ACI Single Stage - Chickens

13 AN OVERVIEW OF THE SINGLE STAGE INCUBATION SYSTEM Exhaust Air Machine temperature, fresh air volume and humidity are adjusted and programmed to best suit each batch of eggs (see ACI Single Stage Profiles). Roll-in racks are positioned on either side of the Environmental Control Unit. The Environmental Control Unit (ECU) governs the system s ventilation, heating, cooling and humidity functions. Fresh air enters through the front of the machine and exhausts through the back of the machine. Circulation fans, along with automatically controlled fresh air and exhaust dampers, operate to maintain optimal environmental conditions for each egg batch. Due to the specific airflow pattern of the ACI Single Stage machine, only one sensing point is required to maintain optimal temperature and humidity. Fresh Air Machine environment adjusted as required Air Conditioned Air ECU provides air quality exchange returning Sentry from Egg Mass eggs Temperature & Humidity Sensors (CO 2 Sensor optional) "read" the machine environment Machine Controller Profiles Machine conditions are recognized by temperature and humidity sensor probes, centrally located over the egg mass, and information is sent to the Sentry Controller, which adjusts the machine for proper function. Incubator racks are rolled into the machine through doors on either side of the ECU. After incubation, the eggs are transferred to the hatcher where they remain until hatched. After the hatch is complete, the chicks are removed from the hatcher, processed and delivered to the prospective grow out operation. Environment Control Unit What are profiles? Profiles are user defined machine environment parameters (primarily temperature, humidity and damper, optionally CO,etc.) versus time in cycle. 2 These parameters are: Specific to the type of egg being incubated. Change (sometimes several times per day) depending on stage of embryonic development in order to optimize hatchability and hatchling quality. In general fewer changes are made during the first half of incubation than in the second half. Operation Manual for ACI Single Stage - Chickens 13

14 SIZE AND CAPACITY OPTIONS OF ACI SINGLE STAGE INCUBATORS Large Incubator Series Depth: 9 ft. 4-1/4 in. (2851 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 17 ft. 7-1/2 in. (5372 mm) Capacity: 51,840 to 60,480 JAMESWAY Medium Incubator Series Depth: 9 ft. 4-1/4 in. (2851 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 13 ft. 2-1/2 in. (4026 mm) Capacity: 34,560 to 40,320 JAMESWAY Small Incubator Series Depth: 9 ft. 4-1/4 in. (2851 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 9 ft. 8-1/2 in. (2959 mm) Capacity: 17,280 to 20,160 JAMESWAY Extra Small Incubator Series Depth: 5 ft. 9 in. (1752 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 9 ft. 8-1/2 in. (2959 mm) Capacity: 8,640 to 10,080 JAMESWAY 14 Operation Manual for ACI Single Stage - Chickens

15 SIZE AND CAPACITY OPTIONS OF ACI SINGLE STAGE HATCHERS Medium Hatcher Series Depth: 9 ft. 4-1/4 in. (2851 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 13 ft. 2-1/2 in. (4026 mm) Capacity: 25,920 to 30,240 JAMESWAY Small Hatcher Series Depth: 9 ft. 4-1/4 in. (2851 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 9 ft. 8-1/2 in. (2959 mm) Capacity: 17,280 to 20,160 JAMESWAY Extra Small Hatcher Series Depth: 5 ft. 9 in. (1752 mm) Height: 8 ft. 3 in, (2515 mm) Basic Width: 9 ft. 8-1/2 in. (2959 mm) Capacity: 8,640 to 10,080 JAMESWAY Operation Manual for ACI Single Stage - Chickens 15

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17 TEMPERATURE SETPOINT ACTUAL TURN HUMIDITY FANS LIGHTS ALARM BYPASS ALARM CANCEL ACI SINGLE STAGE COMPONENT IDENTIFICATION SENTRY CONTROL SYSTEM This system provides comprehensive machine management using fibre optics to communicate between the Sentry Display Panel and the Machine Controller comprising a solid state humidity sensor, and platinum temperature probe. Setpoints are maintained by proportional regulation of temperature and humidity. Temperature and Humidity Sensors (probes) for accurate evaluation of the machine's environment. ROOM SENTRY JAMESWAY Room Sentry is a temperature and humidity sensing device. High and low temperature, as well as humidity alarm ranges can be programmed into Room Sentry. Mechanical Women Operator's Interface Panel contains the switches necessary for machine function. Incubator Room Hatcher Room Plenum Electrical Water Men Shop Storage Break Room Office Machine Controller regulates the machine environment. Each has an individual cable to the Fibre Optic Hub. Egg Room Clean Room Room Wash/Pull Storage Chick Room Master Sentry Display Sentry Display Panel allows the operator to view all required data for hatchery operations. Fibre Optic Hub allows for multiple machine hook-up. Each component feeds in on its own cable. Fibre Optic Cable links all information systems. Hatchcom Computer System allows for a variety of tasks to be performed simultaneously without interfering with incubation equipment monitoring. The addition of Hatchcom to the system is optional. Operation Manual for ACI Single Stage - Chickens 17

18 TERM. COLOUR 1 RED 2 YELLOW 3 BLUE 4 BLACK 5 ORANGE PB 4839 DISPLAY PANEL Sentry System display panels should be strategically located throughout the hatchery. Any number of displays can be connected to the network; however, a minimum of one is required for the system to function. Each machine can be accessed from each and every display. This allows full hatchery monitoring and control from any display connected to the network. All machine control and performance features are accessed from the display. This display is menu-driven allowing the operator to change setpoints, cancel an alarm, enter graph data, change alarm parameters, enter a profile, etc. Screen Alarm Light Only one display may be setup as a Master Display. The Master Display is the unit that drives the network. It can be identified by noting the word Master in the top left of its screen. There are several special features that this unit can perform that are not available at other display panels, such as password enabling/disabling. Printer Port Keypad FIBRE OPTIC HUB The fibre optic hub is a data distribution point on the network. Each hub has ten ports. Typically two are reserved for hub to hub communication. The remaining eight are used to connect to machine controllers, display panels, etc. The fibre optic cable is the pathway for data on the network and connects hubs to hubs, machines, displays and other optional accessories. Fibre Optic Wiring label located on the inside of the box top. FIBRE OPTIC HUB POWER SUPPLY WIRING (ACDC or Condor POWER SUPPLY) LINE VOLTAGE /240 CONNECT TOGETHER 3+4 LINE CONNECTION Power Supply Fibre Optic Box - closed Fibre Optic Hub Circuit Breaker 18 Operation Manual for ACI Single Stage - Chickens

19 MACHINE CONTROLLER A Machine Controller is located at each machine. This unit performs both the environment control and monitoring of the incubator or hatcher. All instrumentation and control devices are connected to the machine controller. Machine Controller Module Sensor Module Transformer Power Supply Power Interface Module OPERATOR S INTERFACE PANEL AND STATUS LIGHTS Please refer to Page 87 in the Appendices for configuring the Operator s Interface Panel. POWER ALARM ALARM BY-PASS This GREEN light indicates the power is on. The light flashes when machine is offline. This RED light signals an alarm state. This AMBER light indicates that the alarms have been placed in by-pass mode. Interior light switch Fan switch (GREEN) turns on the fans, and places the machine in operational mode. Turn switch allows the eggs to be turned manually, (incubators only). Emergency Stop (Push) Button is safety feature of the machine. It allows the machine to be quickly shut down. TEMPERATURE HUMIDITY SET POINT ACTUAL FANS LIGHTS ALARM BYPASS TURN ALARM CANCEL Displays temperature and humidity, both, set point and actual. Switching off enables the audible alarm. This switch has a key. Once the key is removed the alarm cannot be permanently disabled unless the key is used. Allows an audible alarm to be cancelled for a short period of time. If the alarm is not corrected, the alarm will sound again. Operation Manual for ACI Single Stage - Chickens 19

20 TEMPERATURE AND HUMIDITY PROBE Platinum Temperature probe - for measuring the ambient temperature inside the ACI Single Stage machine. Solid State Humidity Sensor - for measuring the percentage relative humidity. Control Cable links the machine controller and the Temperature and Humidity Sensors. Temperature probe measures the ambient temperature inside the machine. Roof Humidity probe measures the percentage relative humidity. Attach protective cover over humidity probe when washing the machine. Remove afterwards. ROOM SENTRY - OPTIONAL Room Sentry can operate as a stand alone unit or be connected to the Sentry Network by the fibre optic cable. Using a platinum resistance temperature probe and a electronic humidity sensor, Room Sentry gives an immediate response alarm should temperature and/ or humidity problems arise. Alarm ranges can be changed or calibrated remotely if the unit is connected to a Sentry Display Panel. If the unit is stand alone, the changes and calibration can be done at the unit. TEMPERATURE HUMIDITY ROOM SENTRY JAMESWAY 20 Operation Manual for ACI Single Stage - Chickens

21 VENTILATION, HEAT AND COOLING SYSTEM ECU - ENVIRONMENTAL CONTROL UNIT The Environmental Control Unit provides an optimal conditioned air pattern. Circulation fans mounted in the ECU force air upward, over the top of the racks, back through the egg mass, and re-enter the module below the heat exchanger (coils) and fans, ensuring that the air is conditioned before it passes over the egg mass. Air out. Air in. Environmental Control Unit Four fans circulate the air. Damper Drive Box controls both air intake and exhaust according to the profiles. Air out. Air in. Operation Manual for ACI Single Stage - Chickens 21

22 ENVIRONMENTAL CONTROL UNIT Fans and Assembly Fans may be four or five blade, cycle or cycle rpm, 1/3 HP, 230 V, 1.9 A. These energy efficient fans provide the air flow in the ACI machines. Fans 1 and 4 rotate clockwise, while fans 2 and 3 rotate counter-clockwise pushing air upward. Right and Left Hand Coil Assembly provides circulation of hot and cold water for the heating and cooling functions of the ACI machine. The number of coils per foot varies with the size of the ACI machine. Fan Assemblies are hinged for ease of cleaning. Humidity Drum Motor Assembly operates the turning of the humidity drum for the dispersion of the water for humidity. Junction Box Assembly Male & Female Valve Coupler for connection of hot and cold water supply to ECU. Duct Assembly connects ECU to intake damper opening. Side Panel provides the enclosure of the ECU unit. Float Assembly controls the level of water in the humidity pan assembly for proper humidity. Frame Assembly with castors mobility allows for ease of cleaning. Humidity Pan Assembly provides water for humidity. Humidity Drum Assembly turns and picks up water out of humidity pan assembly for dispersion. 22 Operation Manual for ACI Single Stage - Chickens

23 WATER SUPPLY For each unit, cold water temperature should be 65 F (18 C) and hot water temperature should be 140 F (60 C). Maximum flow per machine for each is 3 US gal./min. (11.4 L/min). Pressure drop through the unit is psig at 3.0 US gal./min. ( kpa at 11.4 L/min). For cooling, Jamesway recommends a recirculatory system using a water chiller and pump, with full back up capability. For the boiler and pump, Jamesway recommends a full re-circulatory system with full back up capability. Humidity water supply is less than 65 psig (448 kpa). Refer to Water Requirements on page 37. Solenoid Valve Cold Water Supply Hot Water Supply out out in in Water Manifold Front of machine Check Valves Operation Manual for ACI Single Stage - Chickens 23

24 DAMPER Air intake is controlled by the damper system to ensure that the best levels of O 2 and CO 2 are maintained at all times during the incubation cycle. Intake Damper - for fresh air. Located in the lower front centre panel. Exhaust Damper - Incubator: located on the centre roof panel at the back. Hatcher: located on the centre back wall panel near the top. The Damper Control regulates the opening and closing of both the intake and exhaust dampers, maintaining the pre-programmed damper position for each egg batch. It includes the damper motor assembly, plastic drive block and magnet assembly, and printed circuit board (damper position sensors). The damper drive box adjusts the air intake and exhaust openings according to the information received from the machine controller. HATCHER EXHAUST PLENUM Plenum Options 1. Tower Plenum to ceiling 2. Tower Plenum 3. Flush Plenum Entrance Door The hatcher plenum floor should slope towards a common trough that runs along the length of the far wall. The trough should slope 1/2 in. per 10 ft. (4mm/m) towards a common drain located at the end opposite the entrance door. This floor design will aid ease of clean out. Note: This illustration is for reference purposes only. If further details are required, please refer to The Hatchery Design Manual for Single Stage or contact a Jamesway representative. 24 Operation Manual for ACI Single Stage - Chickens

25 EGG ROTATION SYSTEM COMPRESSED AIR SUPPLY Compressed air is required for turning the turning actuators of the incubator racks. Requirements are 0.05 SCFM (0.085 m 3 /hr) at 65 psig (448 kpa) per rack per hour. Optional valve for extension, capped Valve to each machine for maintenance Drain plug Regulator and Filter Assembly Operation Manual for ACI Single Stage - Chickens 25

26 FARM, INCUBATOR AND HATCHER RACKS FARM RACKS Eggs can be loaded onto Farm Racks at the farm, delivered directly to the hatchery and used for egg storage until incubation. The eggs are then transferred to the incubator racks. All Farm Racks have durable nylon wheels and are zinc electroplated. These features resist corrosion and improve ease of cleaning. SST EGG TRANSPORT SYSTEM Jamesway s SST Egg Transport System can double the amount of eggs that a typical transport vehicle can deliver from the farm to the hatchery. The interlocking side rails of the plastic flats stack securely on special guides moulded into Jamesway s reusable plastic pallets. Once the pallets are loaded, the flats are secured for transport with a plastic wrap that is easily removed when the eggs arrive at the hatchery. Safe transport is further secured by inflatable air pillows that are placed between the pallets and the walls as well as between the two pallets down the length of the trailer. This system ensures there is less breakage and hairline cracks during transport. The flat is constructed from resilient polypropylene material that gently cushions eggs to protect against breakage. The material is also highly intolerant to microorganisms, and easy to clean and disinfect, reducing the potential for disease. Each SST egg flat holds 84 eggs and can be used in all Jamesway incubator racks and if required in Jamesway farm racks. Two transportation pallets are available; the three column pallet (5,544 eggs) and the six column (11,088 eggs). THE AUTOMATIC INCUBATOR RACK LOADER The Automatic Incubator Rack Loader is for use with the SST Egg Transport System. The Incubator Rack Loader can off load the egg flats from the transport pallets and load them into the incubator racks at a rate of 100,000 eggs per hour. 26 Operation Manual for ACI Single Stage - Chickens

27 INCUBATOR RACKS Each rack is constructed of 30 percent zinc electroplated and 70 percent hot-dipped galvanized steel, and is equipped with pneumatic cylinders for egg turning, polyurethane (non-kink) air-lines, mercury switch activated turning indicators, and four injection moulded plastic wheels. Each rack holds a variable number of eggs depending upon egg type and the size of the egg flat. Incubator Racks can be used as Farm Racks. Eggs can be loaded onto the Incubator Racks at the farm and remain on the rack until the end of the incubation cycle. Egg Flat Part Number Number of Eggs/Flat Number of Flats/Rack Total Egg Capacity/Rack PB ,320 PB ,040 PB3179B ,040 PB ,620 PB ,040 PB ,040 HATCHER RACKS Dollies with plastic baskets are standard equipment with ACI Single Stage hatchers. See page 29. Galvanized steel hatcher racks along with galvanized steel hatcher baskets (shown here) are optional for use in hatchers. Type of Rack Maximum Outer Dimensions Trays Depth Width Height Farm Rack in in in mm 683 mm 1917 mm 30 Hatcher in in in mm 749 mm 1825 mm 30 Incubator in in in mm 673 mm 2054 mm Operation Manual for ACI Single Stage - Chickens 27

28 EGG FLATS Egg flats are constructed from resilient polypropylene material that gently cushions eggs to protect against breakage. The material is also highly intolerant to microorganisms, and easy to clean and disinfect, reducing the potential for disease. They are available in a number of sizes to suit different hatchery needs, hatcher dollies and hatcher baskets. 28 Operation Manual for ACI Single Stage - Chickens

29 HATCHER DOLLIES AND HATCHER BASKETS Hatcher Dollies have double columns for baskets. They are zinc electroplated and have durable nylon wheels. These two features resist corrosion and improve ease of cleaning. Hatcher Baskets are constructed of polyethylene for rigidity, lightweight and stability. The light colour allows for quick visual inspection for cleanliness. Baskets may be stacked 15-high. This allows 30 baskets in total. Type of Dolly Maximum Outer Dimensions Baskets Depth Width Height Double Column 50 in. 32 in. 71 in. 30 (Chicken) 1270 mm 813 mm 1803 mm Operation Manual for ACI Single Stage - Chickens 29

30 ACCESSORIES BACK UP ALARM This alarm utilizes a regular mercury thermostat and provides a secondary independent monitoring system for the ACI machine in the case of overheating or failure of the regular alarm system. Green & red LEDs indicate the state of the circuit. Control Box Test switch verifies proper functioning of the LEDs and alarm relay. It does not test circuit operation. Thermostat Junction Box Rest switch cancels the alarm. The Back-up Alarm System is a secondary method of monitoring above normal operating temperatures in an incubator or a hatcher. Mercury thermostats are used as the temperature sensing devices. Recommended thermostats: for incubators 101 F for hatchers 100 F. 30 Operation Manual for ACI Single Stage - Chickens

31 EGG FLAT CABINET This flat storage cart is adequate for one set* of flats. It is used at transfer time to move empty flats to the wash room or storage area. Generally, it is only required for those hatcheries that transfer manually. *(36/42 egg 360 flats, 60 per compartment) EGG FLAT STORAGE Two flat storage carts are required for one set* of flats. It is used at transfer time to move empty flats to the wash room or storage area. Generally, it is only required for those hatcheries that transfer manually. *(77/84 egg 90 flats, 30 per stack, 3 stacks) BATTERY OPERATED CIRCUIT TESTER INCUBATOR RACK TESTER DIGITAL THERMOMETER WATER TESTER VELOMETER AIR FLOW METER Operation Manual for ACI Single Stage - Chickens 31

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33 2. ACI Single Stage Requirements ventilation requirements water requirements electrical requirements air requirements Operation Manual for ACI Single Stage - Chickens 33

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35 VENTILATION REQUIREMENTS Most modern hatchery operations in use today will implement a Heating, Ventilation and Air Conditioning (HVAC) system. The sophistication and type of system will depend largely on climactic as well as economic conditions. It is recommended that fresh air of the correct temperature, humidity and pressurization be provided to the area in front of the incubators and hatchers. This conditioned air enters the machine through a dampered air intake located on the lower half of the centre post between the doors of the machine. Normally, the stale air from incubators exhausts directly to the outside atmosphere through an exhaust in the rear on the roof, but it is equally feasible to connect the machines to a common duct powered exhaust, or to provide individual non-powered machine exhausts through the roof of the building. Incubator plenums are becoming more popular and usually work best with a pressure controlled exhaust fan. Hatchers should be allowed to vent into a plenum behind the machines. This plenum or dust corridor can then be exhausted naturally or power assisted. An open drain should be installed in this room to facilitate cleaning. If this system cannot be used, each hatcher can be individually exhausted to the outside of the building. Exhaust ducts must be provided with clean-outs at convenient locations. EGG ROOM Egg Room General Conditions Optimum Temperature, dry bulb F C Relative Humidity 75-80% 75-80% Avoid direct blasts of cool air onto exposed eggs. Keep the velocity of the re-circulating air to a minimum. This is necessary to prevent dehydration of the eggs. If eggs are held longer than 7 days, a lower temperature is recommended. OPTIMUM SETTINGS ACI SINGLE STAGE INCUBATOR ROOMS Incubator Room General Conditions Minimum Temperature, dry bulb 70 F 21 C Maximum Temperature, dry bulb 85 F 29 C Optimum Temperature, dry bulb 73 F 23 C Relative Humidity 50% 50% Incubator Room Fresh Air Supply per Incubator Large Cabinets cfm* m 3 /h Medium Cabinets cfm m 3 /h Small Cabinets 0-75 cfm m 3 /h Extra Small Cabinets 0-60 cfm m 3 /h Room Pressure Differential to outside in. w.g Pa * cfm (cubic feet per minute), in.w. g. (inches water gauge), Pa (Pascals) Operation Manual for ACI Single Stage - Chickens 35

36 OPTIMUM SETTINGS ACI SINGLE STAGE HATCHER ROOMS Hatcher Room General Conditions Minimum Temperature, dry bulb 70 F 21 C Maximum Temperature, dry bulb 85 F 29 C Optimum Temperature, dry bulb 73 F 23 C Relative Humidity, %RH 50% 50% Hatcher Room Fresh Air Supply per Hatcher Medium Cabinets cfm m 3 /h Small Cabinets cfm m 3 /h Extra Small Cabinets cfm m 3 /h Room Pressure Differential to outside in.w.g Pa * cfm (cubic feet per minute), in.w. g. (inches water gauge), Pa (Pascals) PULL/WASH ROOM This room should have a controlled environment for worker and chick comfort. Since this is one of the dirtiest rooms in the hatchery, it is common to have a negative pressure relative to the rest of the hatchery. This is achieved by using an exhaust fan with proper proportions of make up air. Pull/Wash Room General Conditions Optimum Temperature, dry bulb F C CHICK ROOM It is very important to provide proper ventilation for newly hatched chicks. This includes the appropriate amount of outside air as well as proper heating and/or cooling. Although the velocity of the re-circulating air should be kept to a minimum, it is crucial that all chicks have access to sufficient circulating air. This is necessary to provide oxygen to the newly hatched birds. Chick Room General Conditions Optimum Temperature, dry bulb F C Relative Humidity, %RH 40-50% 40-50% Fresh Air Supply per 10,000 chicks 300 cfm 510 m 3 /h 36 Operation Manual for ACI Single Stage - Chickens

37 CLEAN ROOM This is the cleanest room in the hatchery and is used to temporarily store recently cleaned equipment. It should have a positive pressure relative to the rest of the hatchery and an adequate fresh air supply. It is important to provide an air exchange with outside air to allow drying of the equipment. Clean Room General Conditions Optimum Temperature, dry bulb F C WATER REQUIREMENTS Water supply for ACI machines consists of three separate systems: Cooling Water, Heating Water and Humidity Water. Note: To properly size your cooling and or heating system for ACI incubators and hatcher please contact your Jamesway representative. 1. COOLING WATER SYSTEM (for incubators and hatchers) Jamesway recommends a re-circulatory system with a full backup capability (water chiller and pumps). Cooling Water System General Conditions Optimum Temperature at unit 65 F 18 C Optimum Flow per Machine 3 US gal./min L/min Pressure Drop through Machine US gal./min L/min Note: If holding eggs use 55 F (13 C) for optimum temperature at unit. 2. HEATING WATER RECOMMENDATIONS (for coiled heat exchangers, ECU) Jamesway recommends a re-circulatory system with full backup capacity (boiler and pumps). Heating Water General Conditions Optimum Temperature at ECU 140 F 60 C Optimum Flow per Machine 3 US gal./min L/min Pressure Drop through Machine US gal./min L/min Operation Manual for ACI Single Stage - Chickens 37

38 3. HUMIDITY WATER SUPPLY (evaporation pan with circulating mesh drum) Humidity Water Supply Requirements Usage per Cabinet 1.25 US gal./h 4.73 L/h Pressure 65 psig 448 kpa Room Temperature 70 F 21 C Room RH 40% 40% Machine Temperature 100 F 38 C Machine RH 55% 55% Average Outside Air Flow 175 cfm 297 m 3 /h Humidity water requirements of a typical humidity water supply given the above conditions. RECOMMENDATIONS FOR HUMIDITY WATER SUPPLY To avoid excessive scale build up, Jamesway recommends that the water for humidity meets the following parameters. 1. Since most hatchery water supplies do not meet the criteria listed below, treat the water for the humidity water supply, using a reverse osmosis (RO) or other suitable water treatment system. 2. Separate the humidity water supply from the water supply to the rest of the hatchery. 3. The pressure must be a minimum of 65 psig (5 bars) at all times. A booster pump may be necessary on the water line to ensure the minimum pressure is maintained. The system must be capable of providing each incubator or hatcher with 1.25 US gal. (4.73 L) of water per hour. 4. Water supplied to the incubator and hatcher spray nozzles should meet the following characteristics: No sediment (a 10 micron filter is suggested). TDS (Total Dissolved Solids) less than 10.0 ppm (parts per million). ph range of 6-8. Hardness less than 2.0 ppm. No iron, manganese and hydrogen sulfide, or as close to 0.0 ppm as possible. Bacteria, zero (0) bacteria count (no detectable amount). Dissolved organic compounds less than 2.0 ppm. 38 Operation Manual for ACI Single Stage - Chickens Reduced maintenance, cleaner machine interior, minimal scale buildup, improved sanitation, longer equipment life and optimum machine performance are some of the benefits gained by investing in water quality. ELECTRICAL REQUIREMENTS STANDARD One single pole 20 A circuit breaker protecting each load carrying conductor. Where two breakers are used, they must be mechanically connected. Total connected load at 230 V is 7.6 A with a starting load of 9 A. This includes four (4) 230 A, 0.44 kw single phase motors.

39 AIR REQUIREMENTS COMPRESSED AIR Compressed air is required for the turning actuators of the incubator racks. Requirements are 0.05 cfm ( m 3 ) at 65 psig ( kpa) per rack once per hour. Calculate the total requirement by multiplying the above base requirement by the total number of racks in the incubator. Note: When sizing the compressor, the number of incubators turning simultaneously should be taken into consideration. Compressed Air Requirements for Turning Actuators Incubator Rack CFM/Cabinet M 3 /Cabinet Large Cabinet Medium Cabinet Small Cabinet Extra Small Cabinet Operation Manual for ACI Single Stage - Chickens 39

40 40 Operation Manual for ACI Single Stage - Chickens

41 3. ACI Single Stage Profiles breeder, broiler guidelines layer guidelines Operation Manual for ACI Single Stage - Chickens 41

42 42 Operation Manual for ACI Single Stage - Chickens

43 ACI SINGLE STAGE PROFILES Variable environments allow for improved performance in different flocks. ACI Single Stage machines can be programmed to specific settings, which in turn allows flexibility in the environment. The profiles listed here are specifications for an average flock and should be used as a guideline. Implement profiles for each particular situation (breed, age of flock, age of eggs, etc.) that occurs. BROILER BREEDERS AND BROILERS ACI Chicken Incubator 1 - Example Profile 1 Days Temperature Humidity Damper in Cycle F C %RH % Note: Manually disable the high humidity alarm for the first 10 days of incubation. Moisture loss plays an important part in the incubation process. In the example above the damper is closed until day 9. As a consequence high incubator humidity results in reduced moisture loss during the first 9 days. To achieve the desired weight loss the balance of the moisture must be lost in the time remaining. Warning: The values shown in the example above are to be used as a guideline only. The profile is not specific to any location, and does not take into account breed, age of flock or age of egg. Operation Manual for ACI Single Stage - Chickens 43

44 ACI Chicken Incubator 1 - Example Profile 2 Days Temperature Humidity Damper in Cycle F C %RH % Note: Manually disable the high humidity alarm for the first 10 days of incubation. Moisture loss plays an important part in the incubation process. In the example above the damper is closed until day 9. As a consequence high incubator humidity results in reduced moisture loss during the first 9 days. To achieve the desired weight loss the balance of the moisture must be lost in the time remaining. ACI Chicken Hatcher 1 - Example Profile 1 Days Temperature Humidity Damper in Cycle F C %RH % Warning: The values shown in these examples are to be used as a guideline only. These profiles are not specific to any location, and do not take into account breed, age of flock or age of egg. 44 Operation Manual for ACI Single Stage - Chickens

45 ACI Chicken Hatcher 1 - Example Profile 2 Days Temperature Humidity Damper in Cycle F C %RH % ACI Chicken Hatcher 1 - Example Profile 3 Days Temperature Humidity Damper in Cycle F C %RH % Warning: The values shown in these examples are to be used as a guideline only. These profiles are not specific to any location, and do not take into account breed, age of flock or age of egg. Operation Manual for ACI Single Stage - Chickens 45

46 LAYERS ACI Chicken Incubator 1 - Example Profile 1 Days Temperature Humidity Damper in Cycle F C %RH % Note: Manually disable the high humidity alarm for the first 10 days of incubation. Moisture loss plays an important part in the incubation process. In the example above the damper is closed until day 5. As a consequence high incubator humidity results in reduced moisture loss during the first 5 days. To achieve the desired weight loss the balance of the moisture must be lost in the time remaining. Warning: The values shown in these examples are to be used as a guideline only. These profiles are not specific to any location, and do not take into account breed, age of flock or age of egg. 46 Operation Manual for ACI Single Stage - Chickens

47 ACI Chicken Incubator 1 - Example Profile 2 Days Temperature Humidity Damper in Cycle F C %RH % Note: Manually disable the high humidity alarm for the first 10 days of incubation. Moisture loss plays an important part in the incubation process. In the example above the damper is closed until day 3. As a consequence high incubator humidity results in reduced moisture loss during the first 3 days. To achieve the desired weight loss the balance of the moisture must be lost in the time remaining. Warning: The values shown in these examples are to be used as a guideline only. These profiles are not specific to any location, and do not take into account breed, age of flock or age of egg. Operation Manual for ACI Single Stage - Chickens 47

48 ACI Chicken Hatcher 1 - Example Profile 1 Days Temperature Humidity Damper in Cycle F C %RH % ACI Chicken Hatcher 1 - Example Profile 2 Days Temperature Humidity Damper in Cycle F C %RH % Warning: The values shown in these examples are to be used as a guideline only. These profiles are not specific to any location, and do not take into account breed, age of flock or age of egg. 48 Operation Manual for ACI Single Stage - Chickens

49 4. Operational Procedures egg handling basics obtaining & storing eggs transferring eggs from farm racks to incubator racks start-up setting procedures guidelines for egg setting & transfer procedures transferring eggs from incubator racks to hatcher baskets wash & sanitize incubators hatching eggs wash & sanitize hatchers Operation Manual for ACI Single Stage - Chickens 49

50 50 Operation Manual for ACI Single Stage - Chickens

51 PROCEDURES EGG HANDLING BASICS Store eggs small end down from the time of collection. During transportation, keep the temperature as uniform as possible to prevent condensation, and avoid temperature shocks, especially during loading and unloading. OBTAINING AND STORING THE EGGS Bring eggs in cases and/or farm racks into the egg room through the dock entrance. Place the eggs in the store room until they are required for setting. Egg rooms, including the HVAC system, should be cleaned and sanitized every day. Note: The egg store room should be designed to hold a one-week supply of eggs. Recommended storage temperature for 1 to 6 days is between 65 F and 68 F (18 C to 20 C). A relative humidity of 75 to 80 percent is required to avoid moisture loss. Do not allow the eggs to be exposed to strong air currents, as excess moisture loss will occur even though the relative humidity remains high. If eggs are to be stored longer than seven days, the temperature should be lowered, but not below 58 F (14 C). Relative humidity should remain at 75 to 80 percent. Turning the eggs is also beneficial if eggs are held longer than seven (7) days. Moving the farm rack. Watch where you are going! Operation Manual for ACI Single Stage - Chickens 51

52 TRANSFERRING THE EGGS TO THE INCUBATOR RACKS When the desired number of eggs to set has been determined, transfer the appropriate quantity of egg cases from the egg store room to the egg work room. Bring Jamesway incubator racks from the wash room to the egg work room. (Prepare two to twelve racks depending on the size of the incubator.) If farm racks were used, push the egg flats through into the incubator racks. For a fuller explanation, see Method 1: from Farm Rack to Incubator Rack on the following page. If the eggs were collected on the farm in Jamesway system egg flats, remove the flats from the egg cases and place in the incubator rack. For a fuller explanation, see Method 2: Traying Up by Hand on the following page. Transferring eggs from the farm rack to the incubator rack Remove egg cases. Take farm racks (and plastic filler flats) to the equipment wash room. Thoroughly clean and sanitize. Return clean plastic flats to the egg loading dock for return to the farm. METHODS FOR LOADING EGGS INTO THE INCUBATOR RACK PREPARATION While the incubator is being preheated and monitored, prepare two to twelve incubator racks (depending on the capacity of the incubator) for the eggs. All racks should been thoroughly cleaned and sanitized beforehand. At a testing station, connect rack air lines to check that the egg turn is functioning properly. A regulated air pressure of psig ( kpa) should be available. The transfer of the eggs should take place in the egg room where the temperature should be between 65 F (18 C) and 68 F (20 C). Note: Before moving the incubator rack, ensure the turn lock pin is in place. This pin prevents the rack from turning during transport and must be used. 52 Operation Manual for ACI Single Stage - Chickens

53 METHOD 1: FROM FARM RACK TO INCUBATOR RACK Farm Racks are the most common method of transporting and storing eggs today. Eggs are placed directly into plastic flats from the nest and loaded into the Farm Rack, which is then transported to the hatchery. Unload farm racks from the bottom to the top. Alternate tiers to maintain balance. To transfer eggs from the Farm Rack to the Incubator Rack, roll both racks up against each other so that all the tiers are lined up. In this position, slide one egg tray at a time from the Farm Rack into the Incubator Rack or, using a broom handle, push all egg flats in one tier, at one time, into the incubator rack. Start at the top left corner and work down. Unload farm racks from the bottom to the top. Alternate tiers to maintain balance. METHOD 2: TRAYING UP BY HAND If eggs have been transported to the hatchery with egg trays in cartons, traying must be done by hand. Place a metal transfer pallet on a table. Place a case of eggs close to the table at a convenient height. Lift the plastic flat from the carton by using the posts or finger holes of the flat. After placing flats on the pallet, carefully remove the pallet from the table and slide into the incubator rack. Transferring eggs from the farm rack to the incubator rack While the egg trays are held in position with a thumb, the pallet is pulled out of the rack. Continue this process until the rack is fully loaded. Start at the top left corner and work downwards. When traying by hand, start at the top and fill one column before filling the other. Operation Manual for ACI Single Stage - Chickens 53

54 METHOD 3: AUTOMATED A vacuum lift may be used to load eggs into the egg flats. Refer to equipment manufacturer s instructions for proper operation. LOADING A FULL SET Place two to twelve racks side by side, depending on size of incubator. Start with the first tray at the top left tier of the incubator rack. Load eggs working downward until the first tier is full. Continue loading eggs, starting with the top of the right tier. Work top to bottom. After completing the second or right tier of the first rack, repeat the process to fill all racks required. Fill one column at a time. Start at the top left tier and work downwards. LOADING A PARTIAL SET When partial setting an ACI incubator, balance the load on either side as equally as possible. Full racks are to be placed adjacent to the ECU, empty racks against the wall. If possible avoid sets that are less than half the capacity of the machine. Examples: A medium ACI holds eight racks, four on either side of the ECU. Rack capacity is 5,040 eggs. 1) Set - 28,000 eggs: Nearly six racks could be filled. However, to balance the load four racks are filled and the rest of the eggs are loaded into the remaining four racks (one column of approximately twelve trays each). Empty trays are located at the top. 2) Set - 26,000 eggs: Four racks full, four partially loaded racks. The partially loaded racks hold approximately eight or nine trays each, located in the lower section of one column only. Loading for a partial set, as in example 1 - the rest of the eggs. 54 Operation Manual for ACI Single Stage - Chickens

55 FINAL INSPECTION OF LOADED RACKS After the racks have been loaded; check that all egg trays are properly positioned in the egg tray frames. For proper egg turn, ensure that all egg flats are pushed towards the back. The egg flat must not protrude past the front frame rail. If it does the flat will get caught on the turning bar assembly resulting in broken eggs and damaged flats. Check the position of all egg trays Test the racks for ease of turning before placing them in the incubator. Use the test pressures indicated below. If the rack turns easily at this pressure then there is less likelihood of turning problems in the machine. One rack - use a pressure of psig ( kpa). Multiple racks - use a higher pressure of 65 psig (448 kpa). Level the eggs before transporting them to the incubator. To level eggs, reverse the air line connection for a short duration, or level by hand. Test for correct turning Insert the turn lock pin to prevent racks from turning while they being moved to the incubator. Inserting the pin in the turn lock prevents accidental turning Operation Manual for ACI Single Stage - Chickens 55

56 START UP After every new installation of a Jamesway incubator or hatcher, a Jamesway technican will start up each incubator to ensure it is functioning correctly. The start up procedure should be followed after every clean-out and sanitation of incubators and hatchers, as described in Chapter 5 Routine Maintenance. Note: The Technican should have operated and checked your equipment for correct function after completing the installation. If there is any doubt, turn to the maintenance section of this manual for component checks and procedures. LEFT OR RIGHT HAND? Many instructions in this manual refer to left and right. Therefore, all hatchery operators and workers must follow a common method of determining these designations. To determine the left-right orientation, stand in front of the machine and look into the cabinet. Your left is the machine s left. Your right is the machine s right. PRE-START CHECK When all equipment has been thoroughly cleaned and sanitized, you are ready to start up the incubator. Stand in front, facing the machine to determine left and right sides Open the Control Box. Check the boards, ensuring the inside is free of debris, especially metal shavings. Warning: Ensure that all employees are clear of fans and egg turning prior to start-up. Check the interior of the incubator. It should be clean and free of debris. 56 Operation Manual for ACI Single Stage - Chickens

57 INITIAL START UP Before using the machine for the first time, or after a period of prolonged inactivity, it is recommended to test the machine by carrying out the following checks. Note: Following the check, the machine should be left to operate at incubation temperature for a minimum of 24 hours. This screen shows communication alarm, etc. You cannot proceed and check if machine is functioning normally when a communication alarm is active. Temperature and humidity readings will not update on display. 1. Turn on the power to the machine. 2. Access the Machine State screen from the display unit of the Sentry Network and check to ensure the machine is functioning normally: Environment: Check temperature and humidity against a recommended device. Status: check all operating functions. Damper position: check operation. Alarms: check correct operation. 3. Make any changes to the setpoints by accessing the Change Setpoint screen. This screen shows the humidity on when temperature has reached setpoint. The damper is closing. Note: Check and operate all functions for at least 24 hours before attempting to set eggs in a new machine. The screen shows cooling on when temperature is above setpoint. The damper is opening. Operation Manual for ACI Single Stage - Chickens 57

58 SETTING PROCEDURES Generally speaking, if eggs are set at a specific time, the pull time should be 21 days later, plus or minus 4 to 6 hours, depending on breed and age of flock. Before loading the incubator check the profile. Is it correct for the type of eggs to be incubated? LOADING RACKS INTO THE INCUBATOR Open door. Switch off fans (if on). Remove threshold. Ensure the ECU (Environmental Control Unit) is correctly positioned. Pull racks from either the front or the back. Watch where you are going! Warning: During air line hook up no alarm will sound. Ensure employees do not have fingers in the racks as the racks will turn, possibly causing injury. Push in racks, one by one, filling all positions on either side. Load the racks against the wall first. Connect air lines. Ensure all lines are fastened securely. Connect air lines of racks nearest the wall to air lines hanging from the ceiling; match colours. Connect rack air lines of similar colour to those of adjoining racks. Air lines of racks adjacent to the ECU are connected to the air lines hanging from the ceiling above the ECU. Connect turn indicator cables. Connect the cables of the racks nearest the side wall to the cord hanging from the ceiling. Connect the male plug to the female socket of adjoining racks. The cable of the rack adjacent to the ECU is connected to the drop cord hanging from the ceiling above. Connecting air lines Connecting air turn cables Press the Manual Turn Button on the Display Panel to activate the air valve. The incubator racks will turn through 90. This is an additional check to see if all air lines have been correctly connected. (Alarm will sound.) 58 Operation Manual for ACI Single Stage - Chickens

59 SWITCHING ON THE INCUBATOR Check that the start-up temperature and humidity are correctly set on the Display Unit. Turn on the fans by depressing the fan switch on the front of the machine once. Wait a few seconds for the fans to start up. Check turning. Press the "Turn" switch on the Operator Interface Panel. The warning buzzer sounds for several seconds prior to the turn. Once turning is complete, check the Display screen. The TURN VALVE: should indicate "ON" when the RACK LOCATION: shows "LEFT". TURN VALVE: and RACK LO- CATION: should be "OFF" and "RIGHT" respectively (see "Typical start-up screen"), when the racks are turned in the opposite direction. Press the turn button again to return racks to the original position. Typical start-up screen Note: The left half of the incubator should be used as an indicator of whether or not turning is correct. Warning: During air line hook up no alarm will sound. Ensure employees do not have fingers in the racks as the racks will turn, possibly causing injury. Note: If the profiles in this manual are used, the High Humidity alarms should be disabled during the first 10 days. Check the following on the display unit of the Sentry Network to ensure that the machine is functioning normally: System Alarms; Low Temp. & Low Humidity - flashing. System status; Damper position, heating, fans. Temperature and Humidity readouts. Alarm lamp on front of machine - flashing. Temperature Setpoint. Humidity Setpoint. This is a typical screen after a machine has been loaded and incubation initiated. Alarm override is active, profile #1 is active, and both machine low temperature and low humidity alarms have not been cancelled. Setup alarm override for desired period e.g., if machine takes 6 hours to achieve setpoint override low temperature, low humidity, and high humidity for 6.0 hours. Enable alarm by turning key. Alarm light goes out (Refer to Sentry Display Manual for further details). Note: Check calibration once the machine has come up to temperature and settled down. It is recommended that incubator calibration should be checked after every set with a thermometer verified for accuracy. Note: In the event of a power outage incubator doors must be opened to prevent overheating of eggs. If eggs in the incubator are at 14 days of incubation or older remove racks from cabinet. Operation Manual for ACI Single Stage - Chickens 59

60 GUIDELINES FOR EGG SETTING AND TRANSFER PROCEDURES A variety of methods can be used with success in the ACI Single Stage machine, as long as some guidelines are followed. It is important that eggs be grouped and identified from farm all the way through to the hatch process. Once the eggs are in the egg room, determine when they will be set into the incubator. Group the total set together, with each rack identified. Number each rack of eggs according to its location in the incubator. Record the location of each rack on a set sheet. At transfer time, the location and identity of the eggs must be maintained. Once transfer from the incubator has begun, complete the process into the hatcher without delay. Take care not to damage the eggs. Remove one incubator rack at a time from the incubator. Locate the new position of the eggs in the hatcher. Transfer. When eggs are transferred into the hatcher racks their location and identity must be recorded for the chick processing. Remember: During transfer, handle eggs with care. Do not transfer eggs into wet hatcher baskets. Do not bang the basket down on the table during transfer. Do not slam or tilt baskets in the racks or dollies. Once transfer has started, it must be completed for all of the racks. Do not allow eggs to cool excessively during transfer. Do not remove all incubator racks from one side and then the other side. Do not remove racks without levelling eggs first. Do not flip eggs too quickly during transfer. Turn in a smooth gently rotating motion. Ensure all racks or dollies are positioned properly in the hatchers. It is extremely important that a balanced air flow in the incubator and hatchers be maintained while the transfer is in progress. Do not remove all the eggs first on one side of the incubator and then on the other side as this may cause air flow disruption and overheating. 60 Operation Manual for ACI Single Stage - Chickens

61 A large ACI Single Stage Incubator ECU transfers to two (2) medium ACI Single Stage Hatchers ECU ECU OR to three (3) small ACI Single Stage Hatchers ECU ECU ECU Operation Manual for ACI Single Stage - Chickens 61

62 TRANSFERRING EGGS FROM INCUBA- TOR RACKS TO HATCHER BASKETS METHOD 1: MANUAL The manual method of transfer requires two people and must be completed within a reasonable length of time, so that eggs do not cool excessively. Place a work table on front of the hatcher. Place a bucket of warm water and disinfectant under or to the side of the work table. This is for discarded eggs. Position an empty egg flat cabinet in the work area. Remove a dolly with empty baskets from the hatcher. Remove one (1) rack of eggs from the incubator. Move to the hatcher room and position it in front of the hatcher. Method for removing eggs from incubator racks. Start at the top right hand column and move downwards. Remove all trays from the right column before proceeding to the left. Person A stands between the incubator rack and work table, while Person B stands between the hatcher dolly and work table. Person A slides the transfer pallet into the top right column and removes the eggs from the incubator rack. See the illustration for transfer pattern. Person A will then place the pallet with eggs on the work table. At the same time, Person B removes a top plastic hatcher basket from the dolly and places the basket on the work table. Inspect and pull cracked eggs. Placing the pallet on the table Typical Setup Inspecting eggs for cracks 62 Operation Manual for ACI Single Stage - Chickens

63 Person A and Person B will now place the hatcher basket over the flats and pallet. With one hand on the hatcher basket and the other under the pallet they turn the basket, eggs, and pallet upside down in a gentle, smooth rotating motion. Do not flip the eggs quickly as this will cause damage. Place the basket over the flats and pallet Once the eggs have been inverted, place the basket gently on the table. To avoid breakage, do not bang the basket on the table. Turning the basket, eggs and transfer pallet Person A removes the pallet while Person B removes the eggs flats and places them in the storage cabinet or cart. Removing the flats and pallet Operation Manual for ACI Single Stage - Chickens 63

64 Person A picks up the hatcher basket filled with eggs and places it on the right hand side of an empty hatcher dolly. Do not slam the basket into the dolly as eggs will be damaged. Person A now takes another empty basket and places it on the table. Continue removing the trays of eggs from the right column in an downward direction. (See illustration on page 60.) Continue placing hatcher baskets with eggs on right side of dolly. Stack one column at a time. When all the eggs have been transferred, place the hatcher dolly into the hatcher and close the hatcher door. Remove the empty incubator racks from the work area and return to the incubator for the next rack. Place them in front of the hatcher, leaving as much work space as possible, allowing easy access to the hatcher door. Hatcher baskets are first stacked on the right hand side. The right stack will contain all the eggs from the right column of the incubator rack. The left stack will contain all the eggs from the left column of the incubator rack. Repeat the process as described above until all eggs have been transferred. TO FINISH THE TRANSFER Switch on the fans. Install thresholds. Close the hatcher door. TEMPERATURE HUMIDITY SET POINT ACTUAL 98.5 F 98.4 F 58 % RH 58 % RH FANS LIGHTS ALARM BYPASS When machine has reached temperature and humidity setpoint, enable alarm. To test machine alarm switch the fans off momentarily. The alarm should sound. Alternatively, depress and hold ALARM CAN- CEL button until alarm sounds. TURN ALARM CANCEL When all hatchers have been transferred go to Display and check that profiles are active and machines are functioning correctly. (See Sentry Control System Display Panel Guide for further details) When the transfer is complete, the empty incubator racks must be cleaned and sanitized before reloading. Has the machine reached both temperature and humidity setpoints? If so, enable the alarm. Note: Check hatcher calibration bi-weekly (every fourth hatch). Use thermometer which has been verified for accuracy. 64 Operation Manual for ACI Single Stage - Chickens

65 WASH AND SANITIZE INCUBATORS Wash and sanitize the machine after each transfer. Warning: Disconnect the machine from electrical supply before commencing clean-out. Turn off power. Protect humidity probe and carbon dioxide sensor (if present) with the covers provided. (In older units remove the ISM and place cap on plug. Carefully clean the ISM using a cloth dipped in disinfectant solution, before spraying water inside the unit. The ECU can either be removed or left in place. Place the thresholds in a convenient place for cleaning. Lift the motors into the vertical position. In older units, unlatch the ceiling duct door, if applicable. Remove the skirts from the ECU. Place in a convenient place for cleaning. Disconnect the water line from the humidity pan. Remove the plug. Allow the pan to drain. Scrub, by hand, obvious dirt such as residue from exploded eggs. Using a power hose, thoroughly wash the entire machine and ECU. Rinse and sweep water from the machine. Thoroughly wash the machine and its contents Apply a disinfectant solution. Replace skirts, duct, plug, water line, and remove covers from sensors. In older units remove cap from cable and plug cable into ISM. Mount ISM. Allow machine to dry completely before reloading. Operation Manual for ACI Single Stage - Chickens 65

66 HATCHING THE EGGS During the time the eggs are in the hatcher, record the temperature and humidity twice daily. Monitor the hatch 12 hours prior to pull time. There should be no more than 50 to 60 percent of chicks hatched at this time. Ten percent of those chicks should be wet or just hatched. Note: In the event of a power outage hatcher doors must be opened to prevent overheating of chicks. Remove dollies from hatcher if necessary. To avoid excessive dehydration, remove the chicks from the hatcher 6 hours after hatching has been completed. TAKING OFF THE HATCH There are various methods used to pull the hatch, ranging from the traditional manual method to the semi automated and the fully automated. METHOD 1: MANUAL Turn off alarm. Switch off fans, open door, remove threshold and take the dolly out from machine. Replace threshold, close door and switch on fans. When taking off the hatch, remove the lid from one column. Destack that column before going onto the next. Place the dolly in front of machine or move to take-off area. Remove the lid from the top plastic basket. Remove the top basket from one column and place on work table. Transfer the chicks from the hatcher basket to the chick box. Destacking hatcher baskets When all the chicks have been removed from the plastic basket, put the basket with shells and unhatched eggs onto an empty dolly. Continue in a downward direction. When all the chicks have been removed from the first column, go onto the second column. When all the chicks have been removed from the first dolly, remove another from the hatcher and repeat the process. Switch off the hatcher after completing. Carefully transfer chicks 66 Operation Manual for ACI Single Stage - Chickens

67 METHOD 2: SEMI AUTOMATED AND FULLY AUTOMATED Refer to manufacturer s instructions. After the hatch is pulled, the chicks are processed, packed and transported to the grower. To avoid mortality, ventilation must be adequate and temperature and humidity must be controlled. Important: For further information on the effective handling of eggs and chicks, see Appendix III, The Importance of Egg and Chick Transportation, and Appendix IV, Give Day-Old Chicks the Best Start. Rinse and sweep water from the machine. Apply a disinfectant solution. Replace skirts, duct, plug, water line, and remove covers from sensors. In older units remove cap from cable and plug cable into ISM. Mount ISM. Allow machine to dry completely before reloading. WASH AND SANITIZE HATCHERS Wash and sanitize the machine after each hatch is removed. Warning: Disconnect the machine from electrical supply before commencing clean-out. Turn off power. Protect humidity probe and carbon dioxide sensor (if present) with the covers provided. (In older units remove the ISM and place cap on plug. Carefully clean the ISM using a cloth dipped in disinfectant solution, before spraying water inside the unit. Scrub obvious dirt and residue by hand The ECU can either be removed or left in place. Place the thresholds in a convenient place for cleaning. Lift the motors into the vertical position. In older units, unlatch the ceiling duct door. Remove the skirts from the ECU. Place in a convenient place for cleaning. Disconnect the water line from the humidity pan. Remove the plug. Allow the pan to drain. Scrub, by hand, obvious dirt such as residue from exploded eggs. Using a power hose, thoroughly wash the entire machine and ECU. Hand washing baskets using a power hose. All baskets, transfer pallets, egg flats, dollies and racks must be thoroughly cleaned and disinfected after each use. Operation Manual for ACI Single Stage - Chickens 67

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69 5. Routine Maintenance daily weekly after every transfer/wash 3 month 6 month Operation Manual for ACI Single Stage - Chickens 69

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71 MAINTENANCE TIME SCHEDULES DAILY Access the Machine State screen on the display unit of the Sentry Network and check the temperature, humidity and damper positions against the setpoints. Check the machine functions. Check the profile number and day in cycle. Visually check the automatic drain attached to the filter on the incubator compressed air regulator. This can be done when the compressed air pressure reading is taken. If water has built up inside the unit, the automatic drain components may have failed and will need replacing. Drain plug WEEKLY Drain Compressor Tank. All compressors come with a drain petcock located underneath the pressure vessel. Open the petcock and drain until the air escaping is clear of water or vapour. Air Regulator AFTER EVERY TRANSFER/WASH Door and Threshold Seals. Check for torn or missing door seals. Replace if worn or damaged. Good door seals are required for proper air flow. Racks. After washing the incubator racks, grease wheels and castor plate bearings. One or two pumps on the grease gun are adequate. More than this causes the grease to be forced out through the rubber seals. Check the turning operation. Use an air line connected to a psig ( kpa) supply. If there is any rubbing or binding locate the problem area and rectify. Check the turn sensors and cables by using a battery operated turn tester. Operation Manual for ACI Single Stage - Chickens 71

72 Fan Vibration. Either remove the ECU (Environmental Control Unit) and connect to 220 V supply, or enter the machine with the fans running and check the fans for excessive vibration. If you are unable to read the nameplate clearly the fan is vibrating too much. Switch off the fans. Disconnect the defective motor. Switch the fans back on. If all vibration ceases, replace the motor or the fan blade. Note: Allow the fans to stop completely before switching them back on. If you do not, some of the fans may run backwards. All fans should be blowing the air upwards. If a fan is running backward switch off, remove and repair (capacitor may be defective). ECU and Water Hoses. Check for leaks. Humidity Drum. Check that the humidity drum is rotating by depressing and holding the "Turn" switch on the Operator Interface Panel. The drum should rotate freely. Warning: Turn off the power before disconnecting or changing a motor. THREE MONTH MAINTENANCE SCHEDULE Perform these checks only when the machine is empty. Check the Control Box. Open the Control Box and examine the Sentry boards, wiring connections and relay contacts for obvious faults such as discoloured wiring and burnt or blackened areas. Pay special attention to the terminals or connections and relay points. Disconnect the Control Box from electrical supply, and vacuum interior if dust or down has accumulated. Make sure that the boards and plug connections are firmly seated after vacuuming. Warning: If the power has not be turned off, use extra caution during examination. Check the Damper System. The knob on the damper drive box will indicate that the damper is closing or opening. From the Sentry Display Unit access the Change Setpoint screen and alter the damper position. Then climb to the roof of the machine and ensure that the damper acts accordingly. If the damper is not moving, the motor may need to be replaced. If the knob on the drive box is turning but the damper is not moving, replace the plastic drive block on the threaded rod in the damper drive. Check the RPM of the drive motor. It should be turning at 6 RPM. Check that both the intake and exhaust damper slides are free and not binding anywhere. At the same time ensure that both openings are equal. See also: Appendix V, Hatchery Sanitation: Concepts, Logistics and Assessment, Appendix VI, Practical Hatchery Sanitation Guidelines, and Appendix VII, What to Do with Hatchery Waste. 72 Operation Manual for ACI Single Stage - Chickens

73 MAINTENANCE SCHEDULE FOR ACI INCUBATORS AND HATCHERS All of the items mentioned below should be checked, as scheduled. Actual readings should be recorded and compared with the optimum. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. ITEMS TO BE CHECKED TIME SCHEDULE A) Temperature Calibration 1. Display reading F or C 2. Check reading F or C 3. Set point F or C B) Humidity Calibration 1. Set point RH FWB or CWB 2. Display reading RH FWB or CWB 3. Check reading RH FWB or CWB C) Compressed Air 1. Reading 2. Water build up? 3. Tank - drain D) General Machine 1. Doors seal properly 2. Doors latch properly 3. Door Gasket condition 4. Threshold gasket condition 5. Caulking - all joints 6. Damper zero position 7. Damper operating properly. See page Damper motor, 6 rpm 9. Damper slides not binding 10. Damper openings equal 11. Water hose connections 12. Water hose couplings 13. Air lines 14. Air connections 15. Turning drop cords Incubators Hatchers Both Both After Every Monthly Every Every Transfer/Wash *denotes weekly 3 Months 6 Months Operation Manual for ACI Single Stage - Chickens 73

74 ITEMS TO BE CHECKED TIME SCHEDULE 16. Temperature sensor condition 17. RH Sensor 18. RH Cover 19. CO 2 sensor (optional) 20. CO 2 cover 21. ECU track & guides 22. ECU umbilical cable E) Environmental Control Unit (ECU) 1. Fan condition (vibration?) 2. Fan rotation 3. Junction box 4. Junction receptacle 5. Heating & cooling coils 6. Heating & cooling quick-c. couplers 7. Humidity drum 8. Humidity motor 9. Water pan and float valve 10. Castors - grease 11. Castor plate bearings - grease F) Controls Incubators Hatchers Both Both After Every Monthly Every Every Transfer/Wash 3 Months 6 Months Switch off power to control box! Failure to do so may result in electrical shock. Note: It is absolutely necessary that the control box be clean and free of any dirt (especially metal filings), and moisture for proper operation. Boards, relays, connections and wires will discolour if there is excessive heat. Excessive heat usually is caused by poor connections. Problem should be corrected as required. 1. Control box - clean, vacuum if required 2. Control box - check for moisture 3. Lid assembly, relays and connections 4. Board clean, vacuum if necessary 5. Board condition 6. Board plugs firmly seated 7. Wiring condition 8. Water manifold and valve condition Operator Interface Panel (OIP) 9. OIP LCD display 10. OIP fan switch 74 Operation Manual for ACI Single Stage - Chickens

75 ITEMS TO BE CHECKED TIME SCHEDULE 11. OIP turn switch 12. OIP alarm by-pass switch 13. OIP alarm cancel 14. OIP emergency shut-off 15. Status Lights power light (Green) 16. Status Lights alarm light (Red) 17. Status Lights alarm by-pass light (Amber) G) Racks and Dollies Incubators Hatchers Both Both After Every Monthly Every Every Transfer/Wash 3 Months 6 Months Note: When checking racks and the turn operation, look for excessive wear, binding or rubbing of any parts. The air cylinder and fittings should be checked for leaks including damaged or worn lines. 1. Racks and Dollies - wash 2. Castors and Plate Bearing - grease 3. Rack or Dolly condition 4. Turn operation condition 5. Air cylinder and fittings condition 6. Turn Sensor box and cords condition Water Supply (See pages 34 & 35.) Note: Both the hot and cold water supply should be tested at the ECU to ensure that it falls within the guidelines. A water supply test unit should be used to ensure the desired specifications are met. See page 31. Warning: Use caution when handling hot water hoses, connections and tester during the test. Ensure side panels are installed on ECU during this procedure. Lower sides of fans are exposed if side panels are not installed. H) Hot Water Supply Test Procedure 1. Inlet temperature F or C 2. Outlet temperature F or C 3. Temperature difference F or C 4. Inlet pressure psi or kpa 5. Outlet pressure psi or kpa 6. Pressure difference psi or kpa 7. Flow rate gal./min. or L/min Disconnect inlet hot water hose from ECU. Connect inlet hot water hose to lower hose of tester. Connect upper tester hose to ECU. Adjust temperature set point so it is below actual. Switch on fans. Allow temperature to rise and stabilize. Record inlet temperature, pressure and flow. Switch off fans, disconnect tester and reconnect machine hose to ECU. (continued on the next page) Operation Manual for ACI Single Stage - Chickens 75

76 ITEMS TO BE CHECKED TIME SCHEDULE Incubators Hatchers Both Both After Every Monthly Every Every Transfer/Wash 3 Months 6 Months Disconnect outlet hot water hose from ECU. Connect outlet hot water hose to upper hose of tester. Connect lower tester hose to ECU. If necessary readjust temperature set point so it is below actual. Switch on fans. Allow temperature to rise and stabilize. Record outlet temperature, pressure and flow. Switch off fans, disconnect tester and reconnect machine hoses to ECU. J) Cold Water Supply Test Procedure 1. Inlet temperature F or C 2. Outlet temperature F or C 3. Temperature difference F or C 4. Inlet pressure psi or kpa 5. Outlet pressure psi or kpa 6. Pressure difference psi or kpa 7. Flow rate gal./min. or L/min Disconnect inlet cold water hose from ECU. Connect inlet cold water hose to lower hose of tester. Connect upper tester hose to ECU. Adjust temperature set point so it is above actual. Switch on fans. Allow temperature to fall and stabilize. Record inlet temperature, pressure and flow. Switch off fans, disconnect tester and reconnect machine hose to ECU. Disconnect outlet cold water hose from ECU. Connect outlet cold water hose to upper hose of tester. Connect lower tester hose to ECU. If necessary readjust temperature set point so it is above actual. Switch on fans. Allow temperature to fall and stabilize. Record outlet temperature, pressure and flow. Switch off fans, disconnect tester and reconnect machine hoses to ECU. K) Humidity Water Supply 1. Pressure at ECU psi or kpa L) Voltage Check Points (Machine Controller) Voltage should be checked when necessary, for example, troubleshooting. 1. Power supply cable to PTA410 board Colour of Common wire is Green/Yellow. Black to common (-12 VDC) Red to common (+12 VDC) Green to common (+5 VDC) 2. Fan motors M1 TB10-6 to TB10-11 (220 VAC) M2 TB10-7 to TB10-11 (220 VAC) M3 TB10-8 to TB10-11 (220 VAC) M4 TB10-9 to TB10-11 (220 VAC) 3. Humidity drum motor M5 TB10-10 to TB10-11 (220 VAC) 4. Interior light TB10-13 to TB10-14 (110 or 220 VAC) 5. Transformer TB6-1 to TB6-2 (120 VAC) 6. Damper open TB6-4 to TB6-3 (120 VAC) 7. Damper close TB6-5 to TB6-3 (120 volts AC) 8. Egg turn solenoid TB6-6 to TB6-3 (120 VAC) 9. Hot water solenoid TB6-8 to TB6-9 (120 VAC) 10.Cold water solenoid TB6-11 to TB6-9 (120 VAC) 76 Operation Manual for ACI Single Stage - Chickens

77 6. Chick Development & Troubleshooting Hatchability chicken embryology analysing chick residue Operation Manual for ACI Single Stage - Chickens 77

78 78 Operation Manual for ACI Single Stage - Chickens

79 CHICK DEVELOPMENT AND TROUBLESHOOTING HATCHABILITY CHICKEN EMBRYOLOGY, THE TIMING OF MAJOR EMBRYONIC DEVELOP- MENTS BEFORE EGG LAYING Fertilization Division and growth of living cells Segregation of cells into groups of special function (gastrulation) BETWEEN LAYING AND INCUBATION No growth, state of inactive embryonic life DURING INCUBATION DAY 1 Development of area pellucids and area opaca of blastoderm Major developments visible under microscope 18 hours, Appearance of alimentary tract 19 hours, Beginning of brain crease 20 hours, Appearance of vertebral column 21 hours, Beginning of formation of brain and nervous system 22 hours, Beginning of formation of head 23 hours, Appearance of blood islands 24 hours, Beginning of formation of eyes DAY 2 DAY 3 Embryo begins to turn on left side Blood vessels appear in the yolk sac Major developments visible under microscope: 25 hours, Beginning of formation of veins and heart 30 hours, Second, third and fourth vesicles of brain clearly defined, as is heart, which now starts to beat 35 hours, Beginning of formation of ear pits 36 hours, First sign of amnion 46 hours, Formation of throat Beginning of formation of nose, wings, legs, allantois Amnion completely surrounds embryo Operation Manual for ACI Single Stage - Chickens 79

80 DAY 4 DAY 5 DAY 6 DAY 7 DAY 8 DAY 9 Beginning of formation of tongue Embryo completely separates from yolk sac and turned on left side Allantois breaks through amnion Preventriculus and gizzard formed Formation of reproductive organs - sex division Beginning of formation of beak and eggtooth Main division of legs and wings Voluntary movement begins Indication of digits in legs and wings Abdomen more prominent due to development of viscera DAY 10 DAY 12 Beginning of formation of feathers Embryo begins to look bird-like Mouth opening appears Beak start to harden Skin pores visible to naked aye Digits completely separated Toes fully formed DAY 14 DAY 15 DAY 16 Embryo turns its heat towards blunt end of egg Small intestines taken into body Scales, claws, and beak becoming firm and horny Embryo fully covered with feathers Albumen nearly gone, yolk increasingly important as nutriment DAY 17 Beak turns toward air cell, amniotic fluid decreases, and embryo begins preparation for hatching DAY 18 DAY 19 Growth of embryo nearly complete Yolk sac draws into body cavity through umbilicus Embryo occupies most of space with in egg except air cell DAY 20 Yolk sac completely drawn into body cavity Embryo becomes chick, breaks amnion, starts breathing in air cell DAY 21 Allantois ceases to function and starts to dry up Chick hatches First few visible feathers DAY 13 Appearance of scales and claws Body fairly well covered with feathers 80 Operation Manual for ACI Single Stage - Chickens

81 ANALYSING HATCH RESIDUE Analysing hatch residue is a useful hatchery management tool that will provide valuable information in isolating problems in both the breeder and the hatchery programs. The following is a list of problems that may be observed and there possible cause(s). 1. CHICKS HATCH LATE Possible causes: Variable room temperature Large eggs Old eggs Incorrect thermometer Temperature to low, 1 to 19 days Humidity too low, 1 to 19 days Temperature too low in hatchery 2. FULLY DEVELOPED EMBRYO WITH BEAK NOT IN AIR CELL Possible causes: Inadequate breeder ration Temperature too high, 1 to 10 days Humidity too high, 19th day 3. FULLY DEVELOPED EMBRYO WITH BEAK IN AIR CELL Possible causes: Inadequate breeder ration Incubator air circulation poor Temperature too high, 20 to 21 days Humidity too high, 20 to 21 days Shell quality 4. CHICKS PIPPING EARLY Possible causes: Temperature too high, 1 to 19 days Humidity too low, 1 to 19 days 5. CHICK DEAD AFTER PIPPING SHELL Possible causes: Inadequate breeder ration Lethal genes Disease in breeder flock Eggs incubated small end up Thin-shelled eggs Eggs not turned first two weeks Eggs transferred too late Inadequate air circulation, 20 to 21 days CO 2 content of air too high, 20 to 21 days Incorrect temperature, 1 to 19 days Temperature too high, 20 to 21 days Humidity too low, 20 to 21 days 6. MALPOSITIONS Possible causes: Inadequate breeder ration Egg set small end up Odd-shaped eggs set Inadequate turning 7. STICKY CHICKS (ALBUMEN STICKING TO CHICKS) Possible causes: Eggs transferred too late Temperature too high, 20 to 21 days Humidity too low, 20 to 21 days Down collectors not adequate Operation Manual for ACI Single Stage - Chickens 81

82 8. STICKY CHICKS (ALBUMEN STICKING TO DOWN) Possible causes: Old eggs Air speed too slow, 20 to 21 days Inadequate air in incubator Temperature too high, 20 to 21 days Humidity too high, 20 to 21 days Down collectors inadequate 9. CHICKS COVERED WITH EGG REMNANTS Possible causes: Nutrition Humidity too high Temperature too low 10. EGGS EXPLODING Possible causes: Bacterial contamination of eggs Dirty eggs Improperly washed eggs Incubator infection 11. CLEAR EGGS Possible causes: Infertile Eggs held improperly Too much egg fumigation Very early embryonic mortality Immature males Male-female ratio Females fat Parasites Nutrition Overcrowding flock 12. BLOOD RING (EMBRYONIC DEATH 2-4 DAYS) Possible causes: Heredity Diseased breeding flock Old eggs Rough handling of hatching eggs Incubating temperature too high Incubating temperature too low Holding temperature Contamination Shell quality Young flock Nutrition Humidity Fumigation Insufficient turning of eggs 13. DEAD EMBRYOS, 2ND WEEK OF INCUBATION Possible causes: Inadequate breeder ration Disease in breeder flock Eggs not cooled prior to incubation Temperature too high in incubator Temperature too low in incubator Electrical power failure Eggs not turned Too much CO 2 in air (inadequate ventilation) Genetics Contamination Shell quality Humidity 82 Operation Manual for ACI Single Stage - Chickens

83 14. AIR CELL TOO SMALL Possible causes: Inadequate breeder ration Large eggs Humidity too high, 1 to 19 days 15. AIR CELL TOO LARGE Possible causes: Small eggs Humidity too low, 1 to 19 days 16. CHICKS HATCH EARLY Possible causes: Small eggs Leghorn eggs versus meat-type eggs Incorrect thermometer Temperature too high, 1 to 19 days Humidity too low, 1 to 19 days 17. CHICKS TOO SMALL Possible causes: Eggs produced in hot weather Small eggs Thin, porous eggshells Humidity too low, 1 to 19 days 19. TRAYS NOT UNIFORM IN HATCH OR CHICK QUALITY Possible causes: Eggs from different breeds Eggs of different sizes Eggs of different ages when set Disease or stress in some breeder flocks Inadequate incubation air circulation & heat distribution 20. SOFT CHICKS Possible causes: Unsanitary incubator conditions Temperature too low, 1 to 19 days Humidity too high, 20 to 21 days 21. CHICKS DEHYDRATED Possible causes: Eggs set too early Humidity too low, 20 to 21 days Chicks left in hatcher too long after hatching completed 22. MUSHY CHICKS Possible cause: Unsanitary incubator conditions 18. CHICKS TOO LARGE Possible causes: Large eggs Humidity too high, 1 to 19 days 23. UNHEALED NAVEL, DRY Possible causes: Inadequate breeder ration Temperature too low, 20 to 21 days Wide temperature variation in incubator Humidity too high, 20 to 21 days Humidity not lowered after hatching completed Operation Manual for ACI Single Stage - Chickens 83

84 24. UNHEALED NAVEL, WET AND WITH ODOUR Possible cause: Omphalitis Unsanitary hatchery and incubators 25. CHICKS CANNOT STAND Possible causes: 30. CLOSED EYES Possible causes: Temperature too high, 20 to 21 days Humidity too low, 20 to 21 days Loose down in hatcher Down collectors not adequate Breeder ration inadequate Improper temperature, 1 to 21 days, overheating Humidity too high, 1 to 19 days Inadequate ventilation, 1 to 21 days 26. CRIPPLED CHICKS Possible causes: Inadequate breeder ration Variation in temperature, 1 to 21 days Malpositions 27. CROOKED TOES Possible causes: Inadequate breeder ration Improper temperature, 1 to 19 days 28. SPRADDLE LEGS Possible cause: Hatchery trays too smooth 29. SHORT DOWN Possible causes: Inadequate breeder ration High temperature 84 Operation Manual for ACI Single Stage - Chickens

85 7. Appendices operator s interface panel configuration menu carbon dioxide sensor operating instructions the importance of egg & chick transportation give day old chicks the best start hatchery sanitation concepts, logistics & assessment practical hatchery sanitation guidelines what to do with hatchery waste breakout analyses guide for hatcheries Operation Manual for ACI Single Stage - Chickens 85

86 86 Operation Manual for ACI Single Stage - Chickens

87 APPENDICES APPENDIX I: OPERATOR S INTERFACE PANEL CONFIGURATION MENU If a PTA537 Operator s Interface Panel, which incorporates an LCD display, is used with machine controller software PTA453 version 1.27 or later then the following features are available: Sensor Calibration, Alarm Viewing, and Setpoints Adjustments. TO ACCESS THESE FEATURES 1. Activate the ALARM BYPASS key switch and 2. Simultaneously press down the TURN and ALARM CANCEL button. The display will change to CALIBRATION? on the first line. The second line shows the available menu options. TO SELECT THE AVAILABLE MENU OPTIONS They can be selected using the following three buttons on the panel: TURN - to choose the left item Lights - to choose the centre item ALARM CANCEL - to choose the right item Normal operation of these three buttons is suspended while the menu is active. Pressing the LIGHTS button for example will not turn on the interior light when the menus are active. If the TURN and ALARM CANCEL buttons are pressed with the ALARM BYPASS key deactivated, the display will change to the secondary information screen which shows the machine address, profile day in cycle, and other machine type dependent information. Use the same two buttons to switch to the regular temperature and humidity readout. TO START THE CALIBRATION FUNCTION The first menu function is CALIBRATION? It will show YES EXIT NO as the available menu options. TO START THE CALIBRATION FUNCTION Press the TURN button to select YES, or Press ALARM CANCEL to select NO and view more functions. The ALARMS? function will appear. Choosing NO again will show SETPOINTS?. Choosing NO again will return to the Calibration Menu. Choose EXIT to return to the regular temperature and humidity readout display. Note: The menus can be exited at any time by turning off the ALARM BYPASS key switch. CALIBRATION When the calibration menu is selected, you will be asked to calibrate temperature or humidity. Press TURN to calibrate temperature, or Press ALARM CANCEL to calibrate humidity. In both cases, use the TURN button ( + ) to adjust the reading higher and the ALARM CANCEL ( - ) to adjust it lower. The buttons can be held down to change it more quickly. The readings will also shift higher and lower as the machine s sensor readings change. Once the reading matches the thermometer or electrotherm press the LIGHTS button to continue. TO KEEP THE NEW SETTINGS Press TURN (Yes) to change the offset, or Press ALARM CANCEL (No) to leave the offset unchanged. The ALARM BYPASS could also be turned off to cancel the changes. Operation Manual for ACI Single Stage - Chickens 87

88 Note: Calibration always takes place in units as selected on the master display panel. If the machine uses a relative humidity sensor and it is calibrated in wet bulb units (or vice versa), make sure that the dry bulb temperature has been calibrated at least 5 minutes prior because the conversion routines are affected by the dry bulb temperature. Also the conversion routines may add some error. ALARMS This function allows you to see all active alarms on the machine. The display continually cycles through the alarms until the screen is exited. Note: If the humidity setpoint is changed in degrees wet bulb units, it may not be possible to choose the desired value if this change is to be followed by a large dry bulb change. Change the dry bulb setpoint first, then change the wet bulb setpoint. When the dry bulb setting is changed by a large amount, the current wet bulb setting may be out of range which causes the machine to give a NOVRAM/ RTC FAILURE alarm and use default setpoints. This alarm will go away once the wet bulb setpoint is changed to a valid number. Always check afterwards that the machine is operating with the correct setpoints. The ALARM CANCEL button can be pressed to acknowledge the alarms. You will be asked whether to enable alarm override. Press TURN (Yes) to activate alarm override. Press ALARM CANCEL (No) to acknowledge alarms. Note: Acknowledged alarms will not be shown until they return to the alarming state. The alarm override functionality is available in software version 1.28 or later. SETPOINTS This function allows you to set the temperature, humidity, and damper setpoint. It is equivalent to using the CHANGE SETPOINT function on the Sentry display panel, thus if a profile is active it will be cancelled. TO USE SETPOINTS The procedure to use this function is similar to calibration. Use the TURN button ( + ) to increase the setpoint. Use the ALARM CANCEL ( -) to decrease it. The number will stop when it has reached the maximum or minimum allowed point. 88 Operation Manual for ACI Single Stage - Chickens

89 APPENDIX II: CARBON DIOXIDE SENSOR OPERATING INSTRUCTIONS INSTALLATION The cable from the carbon dioxide sensor is hooked up as shown below: Wire Colour Machine Controller Sensor Board White TB1-28 J2-5 Brown TB1-29 J2-4 Green TB1-30 J2-3 Red TB1-31 J2-1 Black TB1-32 J2-2 MACHINE STATE This screen will display the carbon dioxide reading from the sensor. The reading can be displayed in parts per million (ppm) or % gas concentration, as selected in the display menu. The actual carbon dioxide reading will not go below 0.01% (100 ppm). A reading of 0 indicates there is a problem with the sensor. On ACI machines the damper can be controlled using the carbon dioxide reading. The damper setting item will be replaced by a carbon dioxide setpoint when it is active. The auto damper function is automatically disabled when a carbon dioxide setpoint is in effect. Replace the eprom in the machine controller and Sentry display panels with version 1.30 or greater. In the machine controller the eprom part number is PTA453 and can be found on the PTA410 board. In the display panel the eprom part number is PTA452 and can be found on the PTA411 board. TO REPLACE THE EPROM Remove power from the machine or display panel. Carefully pry the old chip from its socket. Insert the new chip into the socket, with the notch oriented the same as the old chip. When upgrading from a software version lower than 1.30, reconfigure the network for the display panel to recognize the new software. Otherwise you will not be able to use the carbon dioxide setup function. USING THE CARBON DIOXIDE SENSOR The machine controller automatically recognizes the carbon dioxide sensor on any Sentry controlled machine. Remove the protective bottle from the unit for proper sensor operation. Place the protective bottle over the sensor whenever the machine is washed to avoid damage to the sensor. TO CHANGE SETPOINTS On ACI machines you may enter a carbon dioxide value into the damper field. Accepted range is 300 to ppm, or 0.03 to 1.0% CO 2. Once the cursor is moved up or down the value entered is automatically displayed in units selected in the preferences screen. The values entered must be multiples of 100 ppm (0.01%), the program will automatically round down to the closest multiple if necessary. To enter a normal damper setpoint, enter a whole number between 0 and 100. With a carbon dioxide setpoint active the machine will open and close the damper to regulate the CO 2 level. EDIT PROFILE Profiles can also be programmed to control damper using carbon dioxide. If a value in the range shown above is entered into the damper field the machine will control to the selected carbon dioxide value. A profile may contain a mix of regular damper setpoints or carbon dioxide setpoints in any order. The machine controller differentiates automatically between the two depending on what kind of number is entered. Be careful when copying profiles to another machine to make sure that a profile is not copied to a machine which does not have a carbon dioxide sensor installed, a NOVRAM/RTC alarm will be displayed if such a machine encounters a carbon dioxide setpoint. Operation Manual for ACI Single Stage - Chickens 89

90 CARBON DIOXIDE SETUP This function can be found in the machine setup menu. Through the use of a dialog box, you may change any of the parameters listed below. CONCENTRATION OF SPAN GAS When calibrating the sensor, the machine needs to know what concentration of calibration gas is used to calibrate the span (the high point of a two step calibration). This value: Defaults to 0.48% (4800 ppm). Can be changed to any value between 0.10 to 1.00% (1000 to ppm). Use certified calibration gases to calibrate the carbon dioxide sensor. SAFETY DAMPER STARTS AT DAY This parameter determines at what profile day in cycle the minimum safety damper takes effect. The accepted range is 0 to 50 days. This setting has an effect only if the machine is using a carbon dioxide setpoint. SETPOINT CONTROL HYSTERESIS When a machine uses a carbon dioxide setpoint: The damper will start to open when the actual readings goes the specified amount above the setpoint. The damper closes when the actual goes the specified amount below the setpoint. Lower values for this parameter result in more damper activity. The accepted range is 0.01 to 0.10% (100 to 1000 ppm). HIGH CARBON DIOXIDE ALARM This field specifies at what carbon dioxide reading an alarm is generated. The acceptable range is 0.10 to 1.25% (1000 to ppm). This alarm cannot be programmed in the alarm setup screen, it has a fixed delay before alarming delay of one minute. To disable the high carbon dioxide alarm set this value to its maximum. MINIMUM SAFETY DAMPER OPENING This parameter ensures that the machine will not completely close the damper in case of abnormal conditions or sensor failure. The range for this parameter is 0 to 100% open. This setting has an effect only if: The machine is using a carbon dioxide setpoint. The profile day in cycle is greater than or equal to the next parameter below. DAMPER DUTY CYCLE This parameter controls the amount of time the damper is allowed to open or close during a one minute period. It is specified as a percentage of one minute. As an example, if it is set to 25% the damper will operate for 15 seconds, stop for 45 seconds, then start again. This repeats until the carbon dioxide actual returns to the hysteresis window. Increasing this number allows the damper to adjust more quickly to control carbon dioxide levels but tends to cause more instability. Lower numbers keep the carbon dioxide more stable at the expense of slow reaction to large changes in the carbon dioxide. CHANGE CALIBRATION Use this function to calibrate the carbon dioxide sensor. The familiar temperature and humidity calibration screen will appear. Press the Enter key without changing any values. The next screen will contain two new options: To calibrate the zero. 90 Operation Manual for ACI Single Stage - Chickens

91 To calibrate span points of the sensor. TO CALIBRATE THE ZERO POINT Ensure that pure nitrogen gas is flowing into the sensor s calibration hose for approximately 30 seconds with a flow rate of 300 ml/minute. Select CALIBRATE CO 2 ZERO. Press the ENTER key. TO CALIBRATE THE SENSOR SPAN Ensure that the span gas concentration in the Carbon Dioxide screen is correctly programmed. Ensure that certified CO 2 calibration gas is flowing into the sensor s calibration hose. Select CALIBRATE CO 2 SPAN. Press the ENTER button. It is recommended that the sensor calibration be checked at least once a month. Warning: Do not attempt to calibrate the sensors when no calibration gas is flowing into the sensor, readings will be unpredictable until the sensor is properly recalibrated. CARBON DIOXIDE UNITS This function can be found in the display menu, allowing the user to select whether carbon dioxide values are displayed in parts per million (ppm) or % gas concentration. ALARMS There are two new carbon dioxide related alarms: HIGH CARBON DIOXIDE will be displayed when the actual readings exceeds the High carbon dioxide alarm setting in the carbon dioxide setup screen. CARBON DIOXIDE SENSOR is displayed on the machine only if: The machine is using a carbon dioxide setpoint. The sensor is sending an invalid reading to the machine or is not responding. When no setpoint is in effect a reading of 0 ppm on screen indicates a sensor failure. These two alarms cannot be programmed in the alarm setup screen, they have a fixed alarm delay of 1 minute. OPERATOR INTERFACE PANEL DISPLAY The display on the front of the machine displays the current carbon dioxide actual and setpoint. TO ACCESS THIS SCREEN Turn the ALARM BYPASS key to the off position. Press and release both the TURN and ALARM CAN- CEL buttons simultaneously. This will display the secondary screen. Press and release the TURN and ALARM CANCEL buttons again to show the carbon dioxide screen. Press the two buttons once more to return to the normal screen displaying temperature and humidity. TO CALIBRATE THE CARBON DIOXIDE SENSOR Turn on the Alarm Bypass key. Press and release the TURN and ALARM CANCEL buttons. This will bring up the function menu. Select YES in response to CALIBRATION? Press the centre button to calibrate CO 2. The screen will now display the current carbon dioxide reading. Ensure the calibration gas is flowing at a rate of 300 ml/minute. Press ZERO or SPAN as appropriate. Warning: Do not attempt to calibrate the sensors when no calibration gas is flowing into the sensor, readings will be unpredictable until the sensor is properly recalibrated. The new calibrated actual reading will appear approximately 10 seconds later. Operation Manual for ACI Single Stage - Chickens 91

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93 APPENDIX III: THE IMPORTANCE OF EGG AND CHICK TRANSPORTATION by Ron Meijerhof, Centre for Applied Poultry Research, Het Spelderholt, Beerbergen, The Netherlands The necessary task of transporting hatching eggs and chicks to and from the hatchery is a very delicate process. Therefore it is wise to be familiar with the elements which determine optimal transportation conditions. In modern poultry production, transportation is an important issue. It is often associated with conveying broilers to the processing plant, and is viewed as critical. However, the transportation process of both hatching eggs from breeder farms to hatchery and day-old chicks from hatchery to grow-out can also affect technical results. If breeder farms and grow-outs are located far away from the hatchery, transportation conditions are especially important, although transport covering shorter distances should also be given attention. To determine optimal transportation conditions, it is important to know the requirements of eggs or chicks and to understand how they are influenced by climactic conditions. BACTERIAL CONTAMINATION A transportation process with a high impact on technical results occurs directly after lay, in the laying nest. At the moment of lay, an egg is wet, warm and the shell is more or less fragile. After lay, the egg dries, cools down and the shell gets more rigid. Under influence of the cooling process, the egg content shrinks and a vacuum is formed, forcing an air stream into the egg. When microorganisms are present at the surface of the egg at this time, the risk of contamination of the eggs is obvious. Bacterial contamination has a detrimental effect on hatchability and chick quality. For this reason, nest material must be kept as clean as possible and floor eggs should be avoided. TEMPERATURE CONTROL After collection, eggs are stored for several days at the farm and then transported to the hatchery. When eggs are collected twice a week from the breeder farm, storage temperatures of C are often used. During transportation, it is important to keep the temperature as uniform as possible in order to prevent condensation (sweating), which occurs when cold eggs are placed in a warm environment, especially when relative humidity is high. During the summer, sweating can occur when eggs are stored under controlled conditions but transportation trucks are not climactically controlled. It is also sometimes observed while setting the eggs, especially when they are stored on cardboard trays, which cause the eggs to adapt to temperature changes very slowly. This may result in eggs in the centre of the container retaining the temperature of the cold store room, even though the eggs have already been transported and placed at another temperature for several hours. AVOID TEMPERATURE SHOCKS Climactic control is also important during the winter because major temperature shocks should be avoided. It is a common occurrence for transportation vehicles to be temperature controlled, but, during egg loading and unloading, especially at breeder farms, mistakes are made. Eggs adapt to temperature changes very quickly, especially when there is much air movement. Therefore, when eggs are loaded in wintertime, especially when the wind is blowing, the containers should not be placed outside for long periods of time. When weather conditions are bad, it is suggested to cover up the containers with plastic shelters, removing them when transportation is completed so eggs can adapt to the new temperature. However, use of these covers is not advisable in very sunny weather because direct sun radiation on the cover will create a dramatic temperature rise directly under the cover. RELATIVE HUMIDITY Hatching eggs are normally stored under high relative humidity to prevent moisture loss. Under normal conditions, it is not necessary to have high relative humidity during transportation because, with a short transport time, moisture loss is limited. In this situation, a high relative humidity might even be negative because it increases the risk of contamination by sweating when the egg room is colder than the transportation vehicle. Even when eggs are transported over longer distances or by air freight, increasing the humidity is normally unnecessary. Operation Manual for ACI Single Stage - Chickens 93

94 MOTION Theoretically, vibration of the egg due to transport has a negative effect on hatchability. In earlier experiments, a relationship between transportation movements and some embryonic abnormalities were reported. However, in modern transportation vehicles, this influence will be small or non-existent if the driver is skilled and loading and unloading is done with care. Also, the number of cracks will be very limited when eggs are packed and transported correctly. TRANSPORTATION OF DAY-OLD CHICKS After pulling the hatch, the chicks are processed, packed in cardboard or plastic boxes of 50 or 100 each, and transported to the grower. Often, this type of transportation is done in trucks over limited distances. It is obvious that with increasing distances and time of transportation, more demands on the transportation conditions should be made. Although many countries limit chick transportation time to hours, transportation times of 24 hours or more do occur when the parent stock is transported, for example. Under optimal conditions, chicks can withstand transportation of over 48 hours without any significant mortality increase because of energy obtained from the yolk sac. In the first days, the yolk sacs provide chicks with all necessary nutrients. Research has shown that holding chicks for 24 hours without feed and water can even improve performance, probably because the birds have more time to utilise the nutrients from the yolk sac. Holding the chicks for 48 hours or longer resulted in a slightly decreased performance, although mortality was still not significantly altered. The two key factors that will have a negative influence on chick quality during transportation are overheating and dehydration. This indicates that ventilation and climactic conditions such as temperature and humidity should be carefully considered. CONTROL TEMPERATURE AND HUMIDITY The optimal transportation temperature is between 24 and 26 C. Although this is much lower than the temperature in the house, within the chick boxes, between the birds, it is adequate for transportation. Overheating can have especially negative effects on the chicks. As mentioned earlier, it is important to avoid dehydration and, at first glance, increasing humidity in the truck appears to be a practical method of preventing it. In reality, this method is ineffective because humidity in the chick boxes is rather high, due to moisture production of the chicks and limited ventilation, and increasing outside humidity does not improve the situation. Increasing humidity when transporting in cardboard boxes can have an especially negative effect because the boxes get weak and cold and stacks may collapse. So, in practise, humidity is often uncontrolled in transportation trucks. However, dehydration can occur if the ventilation rate is too high. To avoid dehydration, preventing overheating is the first step. When chicks are transported over extended periods of time, an injection of moisture is often given during chick processing. GIVING ENOUGH VENTILATION Probably the biggest problem during transportation is providing the chicks with enough ventilation. Boxes containing 50 or 100 chicks produce a lot of heat and use a lot of oxygen. Placing the stacks of boxes far enough apart will encourage sufficient air flow, leaving only the concern of desired temperature. However, economics forces us to increase the number of chicks per truck and, therefore, place the stacks more tightly. This will result in a more restricted ventilation between and in the stacks and an increased demand for total amount of ventilation. In this situation it is very important to pay enough attention to providing the chicks with adequate ventilation. This begins with choosing boxes that allow enough air flow, but also by ascertaining that the pre-stamped holes of the carton boxes are punched out while packing. Nonoptimal transportation conditions do not always result in an increased number of dead chicks, but will hurt the bird s beginning and, therefore, performance. The transportation truck should be designed to provide all chicks with enough ventilation. This can be achieved by placing ventilation ducts in the truck, providing sufficient air flow at specific places. Also, the orientation of the stacks of boxes in the vehicle should be taken into consideration. To prevent stacks from moving during transportation and disturbing the desired ventilation pattern, stacks must be fixed at the floor position. The truck should also be equipped with an alarm system that warns the driver if the ventilation system is down 94 Operation Manual for ACI Single Stage - Chickens

95 and the temperature rises. If the trucks do not have an adequate ventilation system and outside temperatures are high, the number of chicks per box should be lowered. PREPARING FOR THE FLIGHT Careful packing of the chicks for air transportation is especially important, and utilisation of space is critical. This is a special situation, with very strict ways of stacking the boxes on pallets. Another important aspect of air transportation is timing, because hatchery managers do not want their chicks to wait at the airport for hours and so plan their hatch and transportation as tightly as possible, given an expected departure time. Unexpected strikes, skipped flights, delays and traffic jams are difficult to deal with if you plan your hatch date and hour more than three weeks in advance. It is especially important to plan direct flights, avoiding uncontrolled transfers at airports, where pallets with chicks might be left in the sun or cold. Operation Manual for ACI Single Stage - Chickens 95

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97 APPENDIX IV: GIVE DAY-OLD CHICKS THE BEST START by Dr. V Raghavan, Sin Heng Chan Berhad, Malaysia Optimisation of the hatchery process is vital in producing quality day-old chicks. To maintain the quality the chicks need a good start in life ranging from reception at the farm, stage in brooding, stress control, feeding and management. Aiming for the best results in better economic return and lower production costs. The first few days of a chick s life are very crucial, and they need full attention and maximum care from the farmer. If not, problems will develop at later stages. Giving the chicks the best start in life will help it grow into a best broiler or an efficient layer or breeder. Any slackness or laziness may prove costly as poultry is a timely and expensive operation. Any delay in adopting any of the operations will increase the severity of the problem. Chick quality is the subject of frequent concern to the poultry industry as field performance is often linked to substandard chick quality. There is no national standard for routine assessment of chick quality, and actual causes of problems are often undermined. A chick of good quality must satisfy the following criteria: Clean, dry and free from dirt and contamination. Clear and bright eyes. Free from deformities. Completely sealed navel, clean, and dried up. No yolk sac or dried membranes should protrude from the naval area. Firm body to touch. Absence of any sign of stress - panting respiratory distress. Alert and interested in its environment and responding to sound. Normal conformation of legs, no hock swelling, skin lesions, etc. Well formed beak, not soft. Straight toes. Check dehydration by examining the skin over the shanks and over the back. Dry skin and too loose is a sign of dehydration. Besides physical examination, a microbiological examination on a small number of chicks can also be done. For this test yolk sac cultures are used, and results recorded as either no growth or 1+, 2+. For Aspergilloses the right lung of each chick is removed and deposited in dextrose agar for fungal growth. For Salmonella the intestinal cleo Ceco-Colic- Junction is removed and transferred to tetrathionate brilliant green for culture of Salmonella species. ARRIVAL OF THE CHICKS You have got a date for receiving the chicks from your hatchery. So get ready to receive them. See that the house is properly disinfected and also all the equipment like brooders, feeders, waterers. Make sure that the curtains are in position and the litter material is clean and dry. When the chicks arrive the brooding begins. The term brooding originates from the German word Brod which means to heat. Brooding refers to the rearing of day-old chicks to an age of 6-8 weeks protecting them It all starts with good parent stock management The basis for a quality chick lies in the stage before the hatchery: a good parent stock is important, so that a quality chick can be produced. Parent breeders must be from disease free grandparent stock. They must be grown to recommended body weight, and of good uniformity. All required vaccinations suitable for the area must be given with minimum stress to allow optimum disease resistance development. Do not try to push production onset by increasing feed amounts, only increase feed with production or the birds will be overweight which leads to poor lay persistency. Good breeder nutrition is essential for hatchability and chick quality, and in hot climates, more attention should be paid to the use of a higher level of vitamins. Antibiotics should be used sparingly and only when absolutely necessary during the entire breeder life. Do not have more that 9.5% males in tunnel houses and 11% in open sided houses at 25 weeks of age. Excess males and over mating causes egg yolk peritonitis resulting in chick quality problems. Operation Manual for ACI Single Stage - Chickens 97

98 from all inclement weather, predators and other problems. Baby chicks are homeothermic, which means that their body temperature remains the same (unlike birds which are poikilothermic, their body temperature changes accordingly to environmental temperature). The thermo-regulatory system in chicks has not developed yet, which makes them vulnerable to chilling or wind. They need some system which can provide heat up till the time when they can regulate their body temperature. Thereafter they will be independent. Natural brooding is the system of rearing chicks by a hen and is still very much practised in areas where poultry is kept as a backyard activity. The hen provides warmth to the chicks by keeping them under her wings, and protects them from chilling. This system will not work on a large scale as the hen can brood a limited number of chicks only and if she is sick the disease will be transmitted to the baby chicks, and also the chicks can easily be infested by ectoparasites. So artificial brooding is needed with the help of some sort of heater. The advantages are that a large number of chicks can be reared at one time, temperature can be regulated and it can be done at any time of the year. Various methods are: Hover type brooding, hot air/ gas type brooding and battery brooding. The brooding temperature assists chicks in absorption of the yolk and protects them from chilling. It also regulates the system of the chicks to digest the feed. Brooder houses should be airy and protect the chicks from wind and cold. It should be expected to be ready by 5-7 days before arrival of the chicks. It should be thoroughly disinfected and the required equipment should be installed after thorough disinfection. A thin layer (2.5 to 5 cm) of clean, soft, and dry bedding material is required to cover the floor. It should absorb moisture from the droppings of the chicks. MORTALITY DURING BROODING During brooding not all chicks will survive. There are several reasons why mortality occurs. It can be due to exhaustion (high temperature, poor ventilation, high intensity of light), stress of transportation, impaction (litter eating), pasty vents (chick quality, looseness of gut), or yolk sac infection (check with hatchery). After arrival of the chicks take the chick boxes directly to the brooder house. Open the boxes and put the chicks under the brooder. Check the initial temperature of the brooder, it should be around 90 F or 32 C. Due to transport chicks will be under stress, so only provide them with clean drinking water with electrolytes or glucose. Burn empty chick boxes. According to season and age of the chicks brooding temperature must be maintained. The temperature should be around 95 F or 33 C during the first week, then it should be reduced by 5 F or 2.7 C every week up to 7 weeks of age when temperature remains at F or C. Record the temperature daily by hanging a thermometer at chick level. HYGIENE AND HEALTH The single most important factor in keeping chicks healthy is maintaining good hygiene - it is your insurance policy. Healthy breeders and hygienic hatchery management contribute greatly to disease free chicks. If good hygiene standards are maintained on the farm the chicks can achieve uninterrupted growth and production aided by appropriate vaccination and medication. Hygiene does not mean just a choice of the right disinfectant. It is a total concept dedicated to maintaining the highest and cleanest standards. Over the past 25 years an enormous amount of knowledge has been gained about control of diseases in poultry, and it is essential that emphasis is put first and foremost to disease prevention in chicks rather than treatment. Once a disease has broken out on a farm unit it may be difficult to stop. It is not always easy to recognise the onset of a disease, diagnose the cause or take corrective action. Treatment may be very expensive and mass medication methods inevitably treat healthy as well as diseased flock, adding to the financial burden. When disease does occur it is vital to begin remedial action as soon as possible. Carefully observing the daily routine can provide an early indication of trouble. Keep checking on chick appearance, behaviour and general well being, feed and water consumption and mortality pattern. CONTROL OF WET DROPPINGS Wet droppings are a serious problem, especially in broiler chicks during the first 10 days of their life. It predisposes the chicks to infection by the litter mois- 98 Operation Manual for ACI Single Stage - Chickens

99 ture being too high, presence of ammonia, etc. Farmers often have to change litter. Factors affecting wet droppings are infectious agents, parasites and toxins, nutrition and husbandry. To manage the occurrence of wet litter everything must be done to keep moisture levels down (dry basic material, ventilation, and heating), modify salt levels in the feed, use nipple drinkers, and check water quality. The use of various items like zeolite, bentonite can be considered through the feed, to reduce litter moisture. Having had a quality chick the next point is to control the various forms of stress. Stress factors like boxing, packing, beak trimming, vaccination, transport could be minimised by liaising with the hatchery manager to hold the chicks for a longer time in the hatchery in order to allow them to settle down instead of sending them abruptly to the farm. Care must be taken to transport the chick during the evening or during the cooler parts of the day. WATER BEFORE FEED Do not introduce any feed for the first four hours after arrival of the chicks, just give clean water with electrolytes or specific liquid nutrients. Let the chicks settle down and overcome stress. Introduce either a starter mash or crumble. Each chick should get a minimum of 5 cm linear space of feeding up to 2-3 weeks. The proper feeding of the chicks contributes to a uniform growth. The feed must be properly balanced to contain all the nutrient requirements for growth and production, and should be free of toxins. Pasty vents are due to poor quality chicks or looseness in the gut. Do not pick away the pasted faecal material - it may cause injury and encourage cannibalism. Clean the areas gently with a moist cloth or cotton. Swab and dip in mild antiseptic solutions like potassium permanganate. If the chicks are too small and too pasty, cull them. Operation Manual for ACI Single Stage - Chickens 99

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101 APPENDIX V: HATCHERY SANITATION: CONCEPTS, LOGISTICS AND ASSESSMENT By M.K. Eckman, Ph.D. Professor and Avian Pathologist, ACES Department of Poultry Science, Auburn University, Alabama, USA Variation in sanitation programmes, product selection procedures and implementation is common among modern day broiler hatcheries. However, certain basic concepts, cardinal rules and facility designs characterise the better programmes. It is not uncommon for the hatchery labour force to expend 70 percent of their time on various types of sanitation activities. In contrast, the cost of sanitation chemicals, regardless of form (i.e. sanitizers, disinfectants, detergents, etc.), is estimated to constitute only 5 percent of the total sanitation programme. Therefore, a major consideration should be placed on purchasing the best products available as they are a minor portion of the total programme expenditure. Moreover, the use of sanitation chemicals is but one phase in a comprehensive programme. Equipment, application, surface type, product flow (chicken, eggs) traffic patterns, ventilation, rolling stock (vehicles) and microbiological monitoring impact the selection of sanitation chemicals with regard to their label claims and expected performance (Table 1). Table 1 - Sanitation Chemicals: Significant Factors 1. ph use dilution 2. Water hardness 3. Chemical compatibility 4. Temperature 5. Application method 6. Organic matter 7. Surface and porosity 8. Microbiological load 9. Product flow (hatchery) 10. Activity of area 11. Chemical concentration 12. Contact time 13. Corrosiveness An area of great significance in hatchery sanitation is the quality of the breeder programme. Egg pack cleanliness and shell quality determine the origin and extent of microbiological loads that enter the hatchery on a continual basis. Dirty eggs, marginal shell quality, aging or infected breeder flocks and weather extremes place tremendous pressures on quality at all levels of incubation (setters, hatchers, chick pull). In essence, hatchery sanitation programmes, like all other areas of live production, are expected to produce a quality product (chick) within the economic constraints of the integrated operation. The following material will not detail chemical selection and/or specific procedures, but rather stress concepts, basic biological principles and operational guidelines for developing long-term, sound programmes in hatchery sanitation. QUALITY CONTROL PROGRAMMES As previously mentioned, hatchery sanitation includes more than the simple application of selected chemicals. Operational procedures, facility design and construction, product transport and flow, from the breeder phase through to chick placement must be considered in the total sanitation programme. Additionally, an inclusive quality control programme (QAC) that assesses both the breeder and hatchery phase objectives is mandatory for the implementation of a successful programme (Table 2). Many times, the objective of a programme in different phases (i.e. hatching eggs, egg storage, incubation, hatching, etc.) cannot be limited to the simple application of a sanitation product in a space, on a surface or piece of equipment, but rather involves a blend of product application, management and operational procedures on a continual basis. Table 2 - Basic QAC Programme* 1. Egg Handling and Breakout Twice Monthly a. 7 to 14 days and residue b Egg Sample c. True Fertility d. Embryonic Mortality e. Culls, cracks and pips f. Shell cleanliness g. Internal contamination h. Point-Spread i. Establish standard by flock age. 2. Microbiological Monitoring Twice Monthly a. Open plates (Non-selective agars) b. Swabs (Transport) c. Touch plates (Selective agars) 3. Shell Quality as needed a. 180 egg sample b. Specific gravity 1.075, 1.080, c. Establish standard by flock age. *Detailed Programme Eckman, M.K Operation Manual for ACI Single Stage - Chickens 101

102 The following areas, procedures, principles, concepts and methods of assessment are basic to and will characterize a comprehensive sanitation programme from the hatching egg through chick placement. Breeder Phase: Farm level 1. Egg pack cleanliness 2. Shell quality 3. Egg handling and storage 4. Egg transport 5. Egg sanitation - course spray, foaming, washing. MINIMISE CONTAMINATION Floor and nest litter quality must be maintained in order to limit bacterial and fungal loads on fresh hatching eggs. Automatic nest systems limit exposure to wet faecal material but often result in a fine coat of dust on the eggs. Prior to grading, storage, transport or sanitizing, such eggs must be blown free of dust and debris with a pressurized air source. Plastic covers on egg buggies are optional, however, they limit microbial exposure during storage and transport. Washing, course spraying and foaming are reasonably common practices and are most effective when done immediately upon collection of eggs. A variety of chemicals are available and label directions are best obtained from the suppliers. However, many producers continue to rely on quality management for a clean egg-pack and do not sanitize hatching eggs with chemical application. Proper handling of hatching eggs limits breakage and subsequent penetration with either bacterial or fungal species. Also, the rapid changes in ambient temperatures during storage, transport and hatching must be avoided to prevent sweating or condensation on shell surfaces. The negative impact of condensation on hatching eggs is magnified when shell quality is marginal or below standard. Obviously, once eggs are laid they do not remain sterile. Limiting microbial exposure in combination with shell quality is the key for effective hatching egg sanitation. Hatchery Phase: 1. Egg holding room 2. Incubators (setters) 3. Setter rooms 4. Hatchers 5. Hatcher rooms 6. Chick pull area 7. Chick processing 8. Chick delivery 9. Ventilation systems 10. Wash room 11. Vaccine preparation area 12. Chemical storage PREVENTION THROUGH DESIGN The primary objectives of any hatchery sanitation programme are to limit the entry and/or multiplication of bacterial and/or fungal populations on the premise, in a space, on equipment, in vaccines and ultimately in contact with eggs and chicks. Facility design and materials will impact programme effectiveness. Explosion-proof electrical systems, non-porous surfaces and proper traffic patterns will also impact programme effectiveness. Newer hatcheries have been designed for maximum cleaning and disinfection; in contrast, older facilities may compromise sanitation procedures as a result of both inadequate design and materials. The increased size typical of modern-day hatcheries (i.e. 750,000 to 1,500,000 chick pull/week), and the operational demands for scheduled chick deliveries, likewise pressure sanitation programmes and may limit thoroughness of procedures. Operationally, the ideal flow in any hatchery from egg to chick will correlate from clean to dirty. In other words, the bloom of microorganisms will increase as hatching commences and chick pull and processing proceeds. As opposed to the incubation phase, however, all areas from hatching through chick processing will be eventually emptied of product and thoroughly cleaned. 102 Operation Manual for ACI Single Stage - Chickens

103 With substantial efforts and planning, the egg room can be emptied of eggs and thoroughly cleaned and disinfected. In contrast, most incubators are continually operational and must be sanitized while still containing the egg (ovic embryo). Although hatchers are thoroughly cleaned and disinfected prior to transfer of eggs, they possess the highest microbial bloom during pipping of any location in the hatchery. Therefore, traffic flow through hatcher rooms should be minimized when at all possible during the hatching process. Following clean-up and disinfection, hatchers should be allowed to dry prior to transfer. CHEMICAL CONTROL Most chemical applications for disinfection in the egg room(s), setters, setter rooms, hatchers and hatcher rooms are routine and a variety of active ingredients and products are available (Table 3). However, product choice will be a blend of preferences by the hatchery manager, and factors will include product efficacy, safety, user friendliness and cost. Table 3 - General Disinfectants: Chemical Category 1. Aldehydes 2. Quaternary Ammonium Compounds 3. Phenolics 4. Alcohols 5. Potassium, salts 6. Halogens 7. Peroxide 8. Ozone 9. Imidazoles 10. Others 11. Combinations Information pertinent to product selection will originate as label claims, safety data sheets, technical bulletins and past experience. Product selection, if done properly, should involve a careful review of label claims an information provided in writing by the supplier. Information on product application, disposal and user friendliness should be readily available through the basic supplier or distributor and will be a reflection of product stewardship at the user level. Chemical applications in the chick processing area are usually less stringent as clean-up and disinfection are conducted on an all-in, all-out basis when activities are completed and product (i.e. chick) is not present. Rolling stock (egg trucks, chick buses) must be considered an extension of the hatchery and should be cleaned and disinfected at a level similar to the egg room or incubators. Another area that is often overlooked with regard to sanitation is the water supply. Although water hardness (i.e. mineral deposits) may affect equipment, the primary factor is and thermal fogging, course spraying and fumigation for surface and space disinfection. Broad generalizations regarding safety in application are usually inadequate and may vary among products. It is strongly recommended that safety procedures should be strictly adhered to for each product on the basis of label instructions and safety data sheets. All sanitation programmes should be in writing and revised as necessary. Additional use of pesticides, in most instances, should be by or under the direction of certified pesticide applicators. The assessment of the effectiveness of sanitation programmes involves measuring operational procedures and chemical efficacy in both the breeder and hatchery phases. Standard procedures for assessing shell quality, egg cleanliness, shell breakage and microbiological contamination of space, surface, equipment and vaccines have been published. In summary, an effective sanitation programme is a combination of both chemical application and management practices that limit the entry and magnification of microbial populations in the process of producing day-old broilers. The following factors, procedures and principles should be considered the most significant: 1. Hatching egg quality Shell Cleanliness 2. Facility design and materials 3. Chemical selection 4. Chemical application 5. Chemical safety and product stewardship 6. Labour education - product application 7. Basic programme in-writing 8. QAC programme for assessment Management must support the implementation of comprehensive sanitation programmes and their assessment. Although cost will always be a consideration in Operation Manual for ACI Single Stage - Chickens 103

104 all phases of live production, quality programmes in terms of sanitation will continue to pay dividends in the hatching and delivery of the modern-day broiler chick. The role of the broiler-hatchery phases with regard to food-safety in the processed broiler will increase as microbial reduction and assessment will be expected to commence with the day-old placement of parent breeders and continue through the hatchery phase and broiler grow-out. 104 Operation Manual for ACI Single Stage - Chickens

105 APPENDIX VI: PRACTICAL HATCHERY SANITATION GUIDELINES TO ASSURE QUALITY An effective hatchery sanitation program is the cornerstone to maximising chick quality, performance and hatchability. There are sound financial reasons for maintaining consistent chick quality, and a good sanitation and monitoring program proves this. By Donna Hill, DVM, MAM, Dilplomate ACPV, Maryland, USA. The purpose of the sanitation/disinfection program is to maintain an environment that consistently minimises detrimental bacterial or mould impacts on the egg or the chick. This definition leads to the concept that a sanitation program should include more than just which disinfectant to use and how to use it. In this vein, a sanitation program should: Institute practices that prevent problems from entering or multiplying in the hatchery, such as incoming egg standards. Define an effective program for each facility. This should include not only the types of products used, but also how they are to be used. Routinely monitor the process for consistent efficacy and identify problems before they are evident in the field. Problem solving if the monitoring process indicates a problem. Correlate hatchery baselines with bottom line field performance measures to determine the true results of your sanitation program. PREVENT PROBLEMS FROM ENTERING OR MULTIPLYING The success of a hatchery sanitation program is equally dependent of the sanitation and egg handling program of the hatching egg producer. There is no disinfection program that will return a dirty or sweated egg to the quality that is necessary to hatch a quality chick. Yolk sac infection will be high in chicks hatched from these eggs no matter how good the hatchery sanitation program is. In addition to the impact that these eggs have on the chicks that hatch from them, they are also a source of contamination to the hatchery and all other hatches. Bacteria that are able to penetrate the egg shell, multiply in the last phase of incubation. You can significantly decrease egg borne contamination by instituting hatching egg quality standards. Once the guidelines are established and agreed to by the breeder manager and the hatchery manager, each load of eggs should be inspected before they are set. If they do not meet the agreed upon standard, they are rejected. The hatchery manager should notify the breeder manager immediately so that action can be taken at the flock level. The specific egg pack guidelines that are agreed to are not as critical as communication is to the success of this program. A program that provides an assessment of the quality of all egg lots, both good and bad, will over time, prevent incoming egg quality from compromising the hatchery sanitation program. Since cracked eggs are an ideal environment for bacterial and mould growth, they need to be removed at set and transfer. Institute programs that monitor cracked eggs. A cracked egg is much more of a problem than just a decrease in hatch. Site selection is another area of outside influence on the bacteria and mould levels within a hatchery. A hatchery that is near a feed mill or a processing plant will always have a more difficult time controlling bacterial and mould challenges. Hatcheries should not be sited near these facilities. Since incoming air is a source of contamination in any facility, proper cleaning and disinfection of any air handling equipment is critical to any hatchery sanitation program. These areas are often the source of a bacterial and mould bloom when they are not properly cleaned before utilization with seasonal changes. Another common problem in hatchery design is a dirty area exhaust that is not adequately isolated from a clean area air intake. These problems must be rectified to prevent recontamination of clean areas. DEFINE AN EFFECTIVE PROGRAM FOR EACH FACILITY There are many effective sanitisers and disinfectants on the market today. The choice of sanitising/ disin- Operation Manual for ACI Single Stage - Chickens 105

106 fecting products is based on matching the job that must be done and the properties of the products available. A knowledgeable salesperson can provide products that fit your sanitation program and are compatible with each other. The effectiveness of the disinfectant/sanitiser is dependent on a number of factors: Absence of organic matter from the area to be sanitised. The type of surface that the sanitiser is applied to. The diluent properties that the sanitiser/disinfectant is diluted to in working strength The length of time that the sanitiser/disinfectant is in contact with the surface to be sanitised The temperature of the disinfectant solution and surface to be cleaned. Use of an effective concentration of disinfectant/ sanitiser to insure proper killing action. Compatibility between the cleaners and disinfectants which are used. The hardest part of any sanitation program is to consistently remove all organic matter from the surfaces to allow exposure of microorganisms to the disinfectant and sanitiser. Organic matter, such as fluff, blood, shells, meconium, and dirt render disinfectants inactive. To have a consistent sanitation program, establish very specific standard operating practices for all cleaning, sanitising, and disinfecting activities in each facility. When exact procedures and time schedules are outlined, people will not need to interpret what they think is the best method. The ideas of the associates actually performing the job should be used to develop the operating procedures. Take the ideas that have been offered and test them in the facility. Are they the best way to get an effective job done? Provide rodac plates and swabs to associates to test the effectiveness of their procedures. This way you develop in the associate a confidence and an understanding of the process. THE EFFECTIVENESS OF A SANITISER AND DISIN- FECTANT The method of disinfection application is critical. Always follow manufacturer s recommendations. This ensures efficacy and safety during use. Many hatcheries are using foaming techniques to increase the exposure time. Not all disinfectants have been formulated to be used with a foamer. The effectiveness of a sanitiser and disinfectant is influenced by the compatibility of the cleaner used with it. This is critical when the surface is not completely rinsed prior to application of the sanitiser. For best results there should be ionic compatibility between the detergent or cleaner and the sanitiser. If they are not compatible, the sanitiser is ineffective. Many hatcheries will spray disinfectants into hatchers during hatch. This should only be done if it doesn t add excess humidity to the machine. With the decreased shell conductance in today s high yielding breeds, anything that adds extra humidity during hatch or disrupts air flow negatively impacts chick quality. A better solution is to fog the room and allow the machines to pull the disinfectant in as normal airflow. There is some work demonstrating the need for a sanitation program to incorporate a system of rotational sanitisers to prevent the development of resistant microbes. They demonstrated that microorganisms become resistant over time when exposed to the same disinfectant continually. When different compounds (acidic and alkaline) which were chemically compatible were rotated, less resistance developed. This research also showed that this strategy may be more effective in combating biofilms. Standard operating procedures for vaccine mixing, administration, and equipment sanitation must be instituted to prevent contamination of the chick via vaccine administration. ROUTINELY MONITOR THE PROCESS A routine monitoring program is necessary to ensure that the sanitation program is consistently effective. Monitoring should be done on a monthly basis at a minimum. A monitoring program should: Not be complicated. Be objective. Quick. Easy to evaluate, understand and track over time. 106 Operation Manual for ACI Single Stage - Chickens

107 Be random within a system of priortization. Have clear goals Able to be carried out in a hatchery by hatchery personnel. Be done at the appropriate time in the cycle to check cleaning and disinfection. There are many different suggestions for sanitation monitoring programs in the literature. I have adopted many of these ideas and developed a sanitation index that can be applied in an objective manner. This allows hatcheries to compare their performance with other hatcheries in the same company system. It also allows them over time to develop a pass/fail performance standard within their system. In conjunction with field chick mortality surveys and one-week mortality over time, you can determine the scores that will insure that hatchery sanitation is not a part of a chick mortality or performance problem. HATCHERY MONITORING PROGRAM The sanitation index includes a microbiological sampling of fifty critical control points in the hatchery (Figure 1). The sampling includes twenty-five air samples, ten vaccine samples (1cc), and fifteen contact samples. Air samples are done with TSA plates ex- Figure 1: Sanitation index of 50 bacteria and mould sampling points Three Marek s vaccine at mix samples. One spray vaccine at mix sample. Six Marek s vaccines at injection samples. Two setter hall air samples. Nine setter air samples. One hatcher hall air sample. Nine hatcher air samples. Five hatching tray contact samples. One hatcher wall contact sample. One hatcher door contact sample. One hatcher ceiling contact sample. One hatcher nozzle contact sample. One hatcher fan contact sample. One vaccine room air sample. Two chick room air samples. Three chick belt samples. Two chick slide samples. One egg room air sample. posed for ten minutes. Vaccine sampling is done with TSA plates and 1 cc of vaccine. Contact sampling is done with Rodac Deneutralizing agar plates exposed to the surface being tested for 15 seconds. Incubate all plates for 48 hours at 100 F for total bacterial colony counts. Then leave all plates at room temperature for an additional 24 hours for total mould colony counts. All plates are counted for total plate count and mould numbers (see Table 1). The total score is based 50/50 on mould and bacteria counts. The total number of plates ranked as heavy growth are weighted with a factor of four, moderate growth with a factor of three, light growth with a factor of two and no growth with a factor of one. With this scoring system, a perfect score would be a sum total of 100 since there are 100 plate assessments and no growth has a weight of one. A perfect score would mean that there was no bacterial or mould growth in any critical control point sampled in the hatchery. THE 50 CRITICAL SAMPLING POINTS By using 50 critical control points a generic monitoring program could be developed that has worked well in a field situation. You will probably want to customise your own system to emphasise critical points that you have identified in your program. With a system that uses a weighted index, a simple line graph can be used to share the results with associates on a monthly basis. When you begin a monitoring program, you will probably find that there is fairly large spread between the top and the bottom hatcheries. With time on the program, the hatcheries on the bottom will learn how to use the system to improve their sanitation program. The program is a success when there is a very small spread between all hatcheries on the program and yolk sac infection is not a significant cause of mortality in the chicks. With the movement away from formaldehyde disinfection, Pseudomonas spp. have emerged as the most challenging of bacterial microorganisms to control. Since this is primarily a water borne problem, it is prudent to monitor water sources independently of your normal hatchery sanitation program. Since finding pseudomonas in a water source is a significant finding in a hatchery, the objective of this program is to identify it before it becomes a problem and the hatchery is forced to resume using formaldehyde. At least Operation Manual for ACI Single Stage - Chickens 107

108 once a month all humidifiers, the incoming water supply, evaporative coolers, and a representative sampling of the hatcher and setter spray nozzles and moisture pans in the incubators should be sampled for pseudomonas. Any finding of pseudomonas in the water testing or the routine hatchery monitoring should be investigated as a problem. PROBLEM SOLVING IF THERE IS ONE If there is a deviation to the normal seasonal baseline or a problem area is noted in the routine monitoring program, the program needs to be expanded to investigate the problem. Key diagnostic questions are: Is the program effective? Is the program being applied consistently? Is there a problem in the process such as the tray washer or the correct mixing of disinfectant? Are the associates adequately removing organic debris in all areas consistently? * Has the incoming egg quality changed? Is there a sweating egg problem? Has the water supply become contaminated? Is the problem recontamination? A good monitoring program can be expanded to answer these questions, it is usually just an expansion in sample numbers over time that is needed. DETERMINE THE TRUE RESULTS The ultimate measure of your process is in the chicks in the field. A chick mortality survey will give you an unbiased assessment of your performance. In a chick mortality survey, a representative sample of the mortality in chicks from 1 to 7 days is evaluated. In general, causes of mortality are yolk sac infection, dehydration, trauma, bacteria other than yolk sac infection, and leg problems. This mortality profile needs to be done seasonally to establish a baseline of performance as it relates to your hatchery scores. If the one week mortality is high and yolk sac is a large percentage of the mortality, then the hatchery or egg sanitation needs to be improved. If dehydration is the primary cause of mortality, then set/pull times and hatchery ventilation need to be investigated, not sanitation. Culturing the yolk sacs of field mortality can also be a very good problem solving tool in a hatchery sanitation investigation. In some cases, such as pseudomonas, the hatchery and the chick cultures will be the same. Maintaining chick quality is an investment that pays off in performance. Commonly hatcheries are not thought of a profit centers, but rather cost centers, in integrated broiler production. Despite the fact that the return on investment is not as directly measurable as in a processing plant, there is a handsome pay-back in maintaining consistent chick quality. To do this requires an investment in monitoring and effective sanitation programs. Chick quality pays, it doesn t cost. A good sanitation and monitoring program proves this. Table 1: Determining the final sanitation index score Colony ranking: Bacteria Mould Weight Factor None 0 colonies 0 colonies 1 Light 1-10 colonies 1-2 colonies 2 Moderate colonies 3-5 colonies 3 Heavy >50 colonies >5 colonies Operation Manual for ACI Single Stage - Chickens

109 Hatchery Audit Hatchery Day Date Time Bacterial Growth # Plates % Weight Factor H eavy x4= M edium x3= L ight x2= N one x1= Total Tota l Colony Ranking 0 = None 1-10 = light = Moderate >50 = Heavy Mould Growth # Plates % Weight Factor Tota l H eavy x4= M edium x3= L ight x2= N one x1= Colony Ranking 1-2 = light 3-5 = Moderate >5 = Heavy Total Score B acteria Score = x.50= M ould Score = x.50= Total Score Example Worksheet for Hatchery Sanitation Audit Operation Manual for ACI Single Stage - Chickens 109

110 110 Operation Manual for ACI Single Stage - Chickens

111 APPENDIX VII: WHAT TO DO WITH HATCHERY WASTE By Eddie Loftin, Division Manager and Anthony DeLee, Breeder/Hatchery Manager, Sanderson Farms, Inc., McComb, Mississippi, USA The beauty of hatching eggs is that, after awhile, many tiny, yellow, fluffy birds emerge from their shells. A significant drawback is the waste they leave behind. How can waste be processed and what can be done with it? Handling and disposal of hatchery waste continues to be a problem for the hatchery manager. One problem is the large volume of waste accumulation - one pound of hatchery waste (egg shell, unhatched eggs, cull chicks) results from each 38 chicks placed in the field. In today s huge hatcheries, there is consistently 10,000 to 12,000 pounds of hatchery waste per pull. Of this weight, approximately 60% is liquid and 40% solid. Another problem with hatchery waste is its obviously odorous and unsanitary qualities. It needs to be removed from the hatchery as quickly as possible, stored with minimal leakage and spreading of odour, and dumped into a transport vehicle quickly and with minimal human contact. SYSTEMS TO REMOVE WASTE The systems used to remove hatchery waste from the hatchery to some type of holding container can be broadly grouped into three categories: manual system, auger system, and vacuum system. In using the manual system, chicks are removed from the tray, and the waste is dumped into a trash can, bucket, rolling bin, etc. When this container is full, it is manually moved into the holding container. This dumpster is then either picked up and dumped into a transport vehicle or augered into it. This system is necessarily labour intensive and not very efficient. The only hatcheries that are still using this system are those which hatch out a small number of birds. They cannot justify the costs of upgrading their disposal systems due to the small numbers of birds they hatch. The auger system utilizes dump hoppers at the transfer window. After the chicks are taken off and thrown through the window, the hatchery waste is dumped into the dump hopper immediately below the window. The hatchery waste then runs through the pipe and auger at the bottom of the dump hopper into the holding container outside the hatchery. While much better than the manual system, the auger system requires more maintenance than the vacuum system and, because of this, more and more people are going to the vacuum system for waste removal. VACUUM DISPOSAL The best system for hatchery waste removal and storage is vacuum waste removal. The main components of such a vacuum disposal system are as follows: Dump hopper with gate valve (air operated) at each transfer window. Stainless steel transport pipe (4-1/2 inch O.D.) to carry waste from dump hopper to holding container. Outdoor holding container. 6 inch PVC pipe running from the holding container to the vacuum pump. 20 HP vacuum pump. After the chicks are thrown through the take-off window, the hatchery waste is dumped into the dump hopper. With two or more take-off stations, the gate valves at the bottom of the hopper alternately open and close to remove waste from each hopper. This waste travels to the holding container where it is stored. The transport air travels out of the holding tank, through the 6" PVC tubing and into the vacuum pump, which creates the vacuum. As long as paper and other foreign objects are kept out of the dump hopper, the system will transport the hatchery waste to the holding container relatively trouble-free. There can, however, be some problems in emptying the holding container after it is full. It is important that the holding container be emptied completely each day. Any eggshells or yolk left adhering to the side of the container will continue to trap waste product on each successive day. In order to prevent this occurrence, whoever is responsible for emptying the holding container must closely observe for sticking material. If sticking does occur, the hatchery waste must be removed and the holding container washed down to prevent sticking next time. Some Operation Manual for ACI Single Stage - Chickens 111

112 hatcheries utilize an automatic washing system so that a person does not have to climb to the top of the holding container and manually wash down the container. WHAT TO DO WITH WASTE The decision of what to do with hatchery waste - either landfill dumping or rendering - is an economic or regulatory decision. In most cases, rendering the hatchery waste will be the most economical if a rendering operation is available for the hatchery to utilize. Using a rendering process will require a hatchery manager to take better care of his hatchery waste than if he was dumping in a landfill. The biggest problem for the hatchery waste renderer is heat, which causes explosive bacterial growth and coagulation of waste liquids. The problem is not in the bacteria themselves (the product undergoes a Pasteurization process during rendering), but the liquid coagulation, which interferes with the filtering that is necessary during processing. To keep this spoilage to a minimum, hatchery waste should be collected as quickly as possible after chicks are pulled. In addition, any hatchery waste generated on days that chicks aren t pulled (transfer cracks, eggs broken during traying, dropped cases) should be stored in a sealed container and kept under refrigeration, not to be put into the hatchery waste system until just before collection of hatchery waste for rendering. Hatchery management must also keep all paper and foreign objects out of the hatchery waste in order to utilize rendering. PREMIUM PET FOOD The rendered hatchery waste products are utilized in premium pet foods. This market will remain healthy and rendering will continue to be an outlet for hatchery waste. The question of hatchery waste disposal need not be a dilemma for hatchery management. If the hatchery is equipped to remove hatchery waste quickly and efficiently to the outside; if it is stored outside in a container preventing leakage and spread of odour; and if it is transported from the hatchery in a timely manner, then hatchery waste disposal will not be a tremendous burden on hatchery management. 112 Operation Manual for ACI Single Stage - Chickens

113 APPENDIX VIII: BREAKOUT ANALYSIS GUIDE FOR HATCHERIES By Dr. Joseph M. Mauldin, University of Georgia, Cooperative Extension Service, Athens, USA Breakout analyses are useful hatchery management procedures that provide valuable information in isolating problems in the breeder and hatchery program. The brief amount of time involved in performing breakouts will pay large dividends by increasing reproductive efficiency. There are three procedures for breakout analysis which can easily be implemented by a quality control person to trouble shoot hatchery or breeder flock problems. Each method has advantages and disadvantages when compared to other methods. Problems in the breeder and hatchery program can be isolated by using breakout analyses from the hatchery. There are three types of breakout analyses that can be performed on hatching eggs. The first opportunity for a breakout analysis is with fresh hatching eggs. The second opportunity occurs with candling eggs at 7 to 12 days of incubation. The final breakout comes at hatch time. All three methods are fairly simple, and each one provides a powerful means of problem solving that can strengthen a hatchery-breeder quality control program. The most serious disadvantage of a fresh egg breakout is that it only provides information on fertility estimates. A company relying on the fresh egg breakout analysis will not gain valuable information on other important sources of reproductive failure such as embryonic mortality, contamination, pips, hatch of fertiles, and many others. A second disadvantage is the loss of valuable hatching eggs due to the procedure. However, a relatively small sample size is normally used for fresh egg breakouts. Because valuable hatching eggs must be used, the sample size rarely exceeds 100 eggs, resulting in the third disadvantage, errors of prediction. Rarely are samples of fresh eggs large enough to provide an adequate sample size, leading to sampling error. The other two methods of breakout require the evaluation of several hundred eggs, but only problem eggs in a sample are evaluated. A fourth disadvantage of a fresh egg breakout is that it is more difficult to distinguish between fertility and infertility in fresh eggs than when eggs have been incubated for several days. Distinguishing fertiles from infertiles is certainly not impossible after a little practice. To correctly distinguish the differences in fertile and infertile eggs, the egg contents must be poured out and the germinal disc must be found. The germinal disc in an infertile egg will contain a white, opaque area inside the circular disc. The opaque area may or may not be in the centre of the disc. Refer to illustration below. FRESH EGG BREAKOUT The fresh egg breakout has the advantage of being the quickest way to estimate fertility in the breeder flock. It is useful when a flock begins to lay eggs or if a flock has been treated for a disease or fertility problem. Fertility can t be determined on the day the eggs are laid rather than having to wait until after the egg storage time and the incubation time for the opportunity for candling or hatch day breakout. For example, if there is a storage time of one week and fertility is determined by hatch day breakout analysis, then the information regarding flock fertility is four weeks behind the flock performance. Management changes, in this case, will take a long time to incorporate. However, there are numerous disadvantages associated with the fresh egg breakout. Infertile egg - arrow denotes germinal disc which appears white and opaque. Sometimes the white, opaque area is granulated. The germinal disc of a fertile egg will appear as a doughnut with a thick, white circle around the outer perimeter of the disc. Although this thick circle is white, it is never as bright as the white, opaque material found in the germinal disc of an infertile egg. During a fresh Operation Manual for ACI Single Stage - Chickens 113

114 egg breakout, it is important to have a sample size of at least 100 eggs per flock. Because of the disadvantages involved in the fresh egg breakout, use of this procedure is not recommended unless a quick fertility check is desired. Candling and/or hatch day breakouts should be done more routinely (every one or two weeks). Fertile egg - arrow denotes germinal disc which appears as a donut with an opaque outer circle. CANDLING BREAKOUT ANALYSIS The candling breakout analysis offers the most accuracy in determining fertility. It is also useful in determining other sources of breeder flock or hatchery failures, such as percentages of eggs set upside down, cracked, and embryos that have died early. Many hatchery managers incorporate the candling breakout procedure into their quality control program to monitor the week-to-week status of their breeders throughout the life of the flocks. Candling can be done as early as five days of incubation, but errors in candling often occur at this time. Because of the rapid growth rate of the embryos during the second week of incubation, very few, if any, candling errors are made on the ninth or tenth day of incubation. There are two methods of candling that may be used. The fastest method involves the use of a table or mass candler. An entire tray of hatching eggs may be placed on the mass candler and examined with one observation. Clear eggs consist of infertiles and eggs with early dead embryos and emit more light than eggs with viable embryos. Clear eggs are removed from the tray to be broken out. Candling with a spot candler is a little slower, but it is more accurate for several reasons. By examining each egg individually with a spot candler, less errors are com- mitted, and eggs set upside down or cracked are much easier to distinguish than with the mass candler. It is important to record the information of eggs set upside down, farm cracks and cull eggs. All companies have varying qualities of hatching egg producers. The producers that are not careful about sending the hatching eggs to the hatchery with the blunt end up cost the company a lot of money in lost hatchability and chick quality. It is important to identify these individuals with a candling breakout analysis so that they can be encouraged to be more careful. The knowledge that a hatchery is enumerating upside down eggs will, in many cases, be enough to justify more careful egg collection. For the candling and breakout procedure to be accurate, a sufficient sample size of eggs must be used for candling. A minimum of four trays per breeder flock is needed to ensure that estimates for fertility, eggs set upside down, farm cracks, and cull eggs are meaningful. Also, it is often suggested that candling estimates of fertility are the true fertility. This is not correct. Candling samples of eggs only provides an estimate of true fertility. The only way to obtain the information of true fertility would be to candle every tray in a setting of a breeder flock. To do this would not be time efficient. Table 1 is an example form that may be used for the candling procedure. Included is an example of a candling breakout analysis. Examining these data it is revealed that fertility was excellent at percent and that early embryonic mortality was good at 2.47 percent. However, egg collection and selection on the breeder farm appeared to be a little sloppy because farm cracks, upside down and cull egg percentages were all greater than 0.50 percent. HATCH DAY BREAKOUT The hatch day breakout analysis involves sampling unhatched eggs from breeder flocks, and classifying them into the various causes of reproductive failure. The procedures for this valuable management tool are described below. The hatch day breakout analysis should be performed at least once every two weeks on samples of eggs from all breeder flocks, regardless of hatchability performance or flock age. Even good hatching flocks should be monitored to get a true picture of hatchery and re- 114 Operation Manual for ACI Single Stage - Chickens

115 productive efficiency. Breakout analysis on all breeder flocks is critical in pinpointing problems in setters and hatchers; comparing breeder companies; evaluating flock or farm management; and compiling flock histories for production, fertility, hatchability and reproductive failure. Breakouts are also beneficial for trouble-shooting problems in production, egg handling and storage. For example, high numbers of early deads may indicate prolonged storage or storage at elevated temperatures, or inadequate egg collection procedures. In most hatcheries, the breakout should be performed on two consecutive hatch days to ensure that all breeder flocks are sampled. Table Day Candling and Breakdown Analysis Form Date: 10/14/96 Company: Big Bird Hatchery Location: Athens Breeder Flock Flock #: 24 Test: No Test Hatch Date: 12/27/95 Male Female Breed: X Y Age (wks): 38 Tray # eggs/tray infertile early dead farm racks upside down BREAKOUT PROCEDURE: 1. Immediately after the chicks are pulled, collect a minimum of four trays of eggs per breeder flock from different parts of a single setter. 2. Remove all unhatched eggs, including pips, from the hatching tray. Place them in filler flats with the large end up and record the flock number. 3. Record the number of cull and dead chicks left in the tray. 4. Break out the eggs and classify them into the appropriate categories of reproductive failure listed in Table 2 and Table 5. The best procedure is to break and peel the large end of the eggs since embryonic development will most often be located cull eggs there. The alternative method of cracking the eggs over a pan is not as accurate because the embryo or germinal disc often rotates beneath the yolk and is difficult to locate. Cracking eggs also increases the likelihood of rupturing the yolk membrane (these membranes are weak after 21 days of incubation). When the yolk membrane ruptures, it is difficult to know if that egg contained an early dead embryo or was infertile Totals: Persents: Fertility = % infertile = 97.69% Other Observations EMBRYO MORTALITY DETERMINA- TION There are some cases when the embryo or the blastodisc will not appear on the top of the yolk. When this occurs, rotate the egg and pour off some albumen so that the germinal disc (fertile or infertile) will appear at the top. If the embryonic development is still not found, the yolk may then be poured into an empty pan and examined. The classifications of embryonic death may be as detailed as the hatchery manager wishes. It must be kept in mind when starting a Operation Manual for ACI Single Stage - Chickens 115

116 Table 2 - Data Collection Hatch Day Breakout General Reproductive Failures Flock number Infertiles Flock age Embryo mortality Male breed Pipped, unhatched Female breed Cull eggs Sample size, sample index Farm and transfer cracks Setter number Contaminated eggs Management type (test) Cull chicks Hatchability Upside down Although these statements are correct, there may be instances when they are not fail safe. To accurately classify the egg, the presence or absence of early embryonic development must be established. Most eggs can be classified as soon as the tops of the shells are peeled back. Others require closer inspection. Be careful not to let blood spots, meat spots, or yolk mottling result in classifying an infertile egg as fertile. Table 3 - Signs of Embryonic Development breakout program that the quality control person need not be an embryologist. In most cases, sufficient information is obtained by classifying the dead embryos by the week that death occurred (i.e., first, second, or third). This is easily done after a few practice runs. The clarity of the development is not as good in eggs broken after 21 days of incubation as when eggs are broken while the embryos are still alive. However, with practice one can conduct an accurate breakout analysis by judging the embryos according to size and looking for some of the obvious changes in the developmental sequence (Table 3). A good training technique for someone not previously involved in breakout analyses would be to examine live embryos at different stages of development and compare them to the dead embryos obtained from unhatched 21-day incubated eggs, or embryos pictured in poster publications. IDENTIFYING FERTILITY Fertility of a 21- day incubated egg can be identified by looking for signs of development, and by examining yolk colour and albumen consistency. The two statements that follow relate to the identification of very early deads, positive development, and infertile eggs after 21 days of incubation. Generally speaking, an infertile yolk will be a brighter yellow than a fertile yolk. The albumen of infertile eggs is thicker than the albumen of fertile eggs. An infertile yolk is held in the centre of the egg while a fertile yolk will sink near the point end. Day Signs 1. Appearance of primitive streak and first somite. 2. Appearance of amniotic folds; heart beats; blood circulation. 3. Amnion completely encircles embryo; embryo rotates to lest side. 4. Eye pigment; leg buds larger than wing. 5. Appearance of elbows and knees. 6. Appearance of beak; voluntary movement; demarcation of digits and toes. 7. Comb growth begins; appearance of egg tooth. 8. Feather tracts prominent; upper and lower beak equal in length. 9. Bird-like appearance; mouth opening appears. 10. Digits completely separated; toe nails. 11. Comb serrated clearly; tail feathers apparent; eye lid oval. 12. Eyelids almost closed and elliptical. 13. Appearance of overlapping scales; embryo covered with down; eye lid slit opening. 14. Embryo aligned with long axis. 15. Small intestines taken into abdomen. 16. Feathers cover body. 17. Head between legs. 18. Head under right wing. 19. Amniotic fluid disappears (embryo swallows it); yolk sac half withdrawn. 20. Yolk sac completely drawn into body; beak pips into air cell. 21. Shell pipping; normal hatching. 116 Operation Manual for ACI Single Stage - Chickens

117 Another pitfall is that most embryos that die during the second week of incubation look dark and are often mistaken for contaminated eggs. The dark appearance results from the breakdown of the blood in the tremendous vascular system of the extraembryonic membranes. Most contaminated eggs will be malodorous which will help to classify them. Second week embryonic mortality may look contaminated; however, they should only be classified as contaminated when they emit an odour. KEEP ACCURATE RECORDS It is necessary to collect general and reproductive failure data to provide a basis for analysis. Building a data base of information enables the evaluation of reproductive efficiency by flock and breeder, and it is an excellent diagnostic tool when problems arise in the hatchery or breeder flocks. Also, the influences of flock management, field and incubation equipment can be measured by studying their effects on fertility, hatchability, and reproductive failure. The Hatch Day Breakout Analysis form is basic for the evaluation of reproductive performance (Table 4). In this data collection form all the reproductive failures are enumerated, totalled and the percentages are calculated. From these data reproductive efficiency measures such as fertility, percent hatch of fertiles, spread, estimated hatchability, and the sample index Table 4 - Hatch Day Breakout Analysis Form Date: 10/14/96 Company: Big Bird Flock #: 42 Test: no test Male Female % Egg Hatchery Production 73.8 Location: Athens Breed: X Y Age (wks): 38 Breeder Flock Actual Hatch date: #Set: 28,600 Hatch %: Setter #: 16 # eggs/trayup infertile dead embryos 1-7 dead embryos 8-14 dead embryos pipped unhatched cull chicks cracks farm cracks transport cont cull eggs small end Totals: Percents: Other Observations Fertility: Estimated Hatch: Malformations: None Sample Index: 0.87% Hatch of Fertiles: Spread: Shell Quality: OK Operation Manual for ACI Single Stage - Chickens 117

118 can be generated (Table 5). The example calculations generated in Table 5 were taken from the example data provided in Table 4. By examining the results of the example provided, an analysis of the problem areas of Flock #42 can be understood. This 38 week old flock should have hatched considerably higher than percent. First, the fertility of percent should be about 4 percent higher for this age flock. Also, the percent hatch of fertiles was too low at percent. This was caused by the elevated percentages noted for early deads (4.17 percent); contaminated (0.74 percent); and cull eggs (0.74 percent). It is obvious that the problems of low hatchability of Flock #42 stem from both breeder flock and hatchery. The low sample index of 0.87 reveals Table 5 - Examples for Calculating Reproductive Efficiency Values Formula: % Fertility = 100 (# infertiles sample size) x 100 Example: 100 (50 672) x 100 = 92.56% that the sample was reliable in providing an estimate of true performance. The sample index listed in Table 5 is a valuable measure of how representative your sample is of the true reproductive performance of the entire setting of eggs. A large sample index (greater than 3.0) would indicate that the sample was not a good representation of actual performance. Small sample sizes will result in greater variation in the sample index. Calculating these measures is necessary in interpreting results and taking corrective action. Figures 1 and 2 depict how building a data base on the life of the flock can be useful in evaluating reproductive efficiency. Notice how the age of a flock causes considerable variation in fertility, hatchability and embryonic mortality. Plotting these data enables flock evaluations over time, and enables a manager to determine the genetic potential of breeding stock by using the best hatching flocks as examples. Formula: % Hatchability = (# Hatched # Set) x 100 Example: (23,160 28,600) x 100 = 80.98% Formula: % Hatch of Fertiles = (Hatchability Fertility) x 100 Example: ( ) x 100 = Formula: Spread = Fertility - Hatchability Example: = Figure 1: Influence of flock age on reproductive performance Formula: % Estimated Hatchability = % Reproductive Failures Example: 100 ( ) = 81.85% Formula: Sample Index = % Estimated Hatchability - % Hatchability Example: = 0.87 Figure 2: Influence of flock age on embryo mortality 118 Operation Manual for ACI Single Stage - Chickens