Chicken Operations Manual - Multi Stage.pdf

Jamesway Incubation Systems Systems

Chicken Operation Manual forr Multi-Stage Systems fo

MANOPSC Revision D1

Jamesway Incubator Company Inc. 30 High Ridge Court Cambridge, Ont., Canada N1R 7L3 tel: (519) 624-4646 fax: (519) 624-5803 email for customer service: [email protected]

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. © 2002 Jamesway Incubator Compa ny Inc.

Table of Contents Chapter 1 - Introduction Multi-Stage Incubation ............. ............................ ............................... ............................... .............................. .............................. .............................. ................................. ....................... ..... 15 Air Flow ................ ................................ ................................ ................................ ................................ ................................ ................................ ................................. ................................. ................16 16 The Laminar Air Flow Pattern ............... ............................... ............................... ............................... ............................... ............................... ............................. .............16 16 Air Flow within an Incubator .............. ............................. ............................. ............................. .............................. .............................. .................................. ..................... .. 16 Air Flow within a Hatcher ............... .............................. .............................. .............................. .............................. ............................... ................................ ...................... ...... 17 Specifications for Jamesway Jamesway Incubation Systems ............. ........................... ............................. ............................. ............................ ......................... ........... 17 Size and Capacity Options for Multi-Stage Incubators ............. ........................... ............................ ............................. ............................. ....................... ......... 18 Size and Capacity Options for Multi-Stage Hatchers ............. ........................... ............................ ............................. ............................. ......................... ........... 19 Cabinet, Basic ............... .............................. ............................... ............................... .............................. ............................... ............................... ................................. ............................ .......... 20 Component Identification ................ ............................... .............................. .............................. .............................. .............................. ............................... ................................ ................20 20 Cabinet, Entrance .............. .............................. ............................... .............................. ............................... ............................... ............................... ................................. ...................... ..... 20 PT100 Controls .............. ............................. ............................... ............................... ............................... ............................... ............................... .................................. .......................... ........ 21 Display Panel ............... .............................. ............................... ............................... .............................. ............................... ............................... ................................. ........................ ...... 21 Machine Controller .............. .............................. ............................... ............................... ............................... ............................... ............................... ............................... ................21 21 Temperature and Humidity Sensor ............... .............................. .............................. ............................. ............................. .............................. ........................ ......... 22 Multi-Stage Incubator with PT100 Controls ............... ............................. ............................ ............................. ............................. ............................... ................... .. 22 2-Door Hatcher with PT100 Controls ....................................... ..................................................... ............................. .............................. ................................ .................23 23 PX Hatcher with PT100 Controls ............... .............................. .............................. .............................. .............................. .............................. ............................... ................23 23 Electro-Mechanical Controls .............. ............................. .............................. .............................. .............................. .............................. .............................. ........................ ......... 24 Incubator Information Panel .............. ............................. .............................. .............................. .............................. ............................... ................................. ................... .. 24 Incubator Control Box .............. ............................. ............................... ............................... ............................... ............................... ................................ ........................... .......... 24 Incubator Thermostat Board ............... ............................... ............................... .............................. .............................. .............................. ................................ .................24 24 Hatcher Control Box and Information Panel ............. ............................ ............................. ............................. ............................. ............................ ..............25 25 Hatcher Thermostat Board ............. ............................ ............................... ............................... .............................. .............................. ................................ ...................... ..... 25 Multi-Stage Systems with E/M Controls ............. ............................ ............................. ............................. .............................. ............................. ................... ..... 25 Ventilation System .............. ............................. ............................... ............................... ............................... ............................... .............................. ................................. ....................... ..... 26 Incubators ............... ............................... ................................ ................................. ................................. ................................. ................................. .................................. ....................... ..... 26 PX Hatcher ................ ................................ ................................ ............................... ............................... ................................ ................................ ................................. ....................... ...... 27 2-Door Hatcher .............. ............................. ............................... ................................ ................................ ............................... ............................... ................................. .................... ... 28 Hatcher Exhaust Plenums ............. ............................. ............................... .............................. .............................. .............................. ................................ ...................... ..... 29 Compressed Air Supply ............... .............................. .............................. .............................. ............................... ............................... ............................... ........................ ........ 29 Farm, Incubator and Hatcher Racks ............... ............................... ............................... .............................. .............................. .............................. ......................... .......... 30 Farm Racks.............................. Racks............................................... ................................. ................................ ................................. ................................. ................................ ...................... ...... 30 SST Egg Transport System ............. ............................ .............................. ............................... ............................... .............................. ................................. ..................... ... 30 The Automatic Incubator Rack Loader ............... .............................. .............................. .............................. .............................. ............................. .................. .... 30 Incubator Racks ................ ............................... ............................... ................................ ................................ ............................... ............................... ................................. .................31 31 Hatcher Racks ............... ............................... ................................ ............................... ............................... ................................ ................................ ................................. ................... .. 31 Rack Specifications ............... .............................. .............................. .............................. .............................. ............................... ............................... .............................. ...............31 31 Hatcher Dollies Dolli es and Plastic Baskets ......................................... ....................................................... ............................ ............................. ........................... ............ 32 Egg Flats ............... ............................... ................................ ............................... ............................... ................................ ................................ .................................. ............................ .......... 33 Accessories ............... ................................ ................................. ................................ ................................. ................................. ................................. ..................................... .............................. .......... 34 Back-up Alarm System ................ ............................... .............................. ............................... ............................... ............................... .................................. ............................ .......... 34 Egg Flat Cabinet ............... ............................... ............................... ............................... ............................... ............................... ............................... ................................ ....................... ...... 35 Egg Flat Storage ............... .............................. ............................... ............................... ............................... ............................... ............................... ................................. ....................... ...... 35 Battery Operated Circuit Tester, Tester, PB3040 ............. ............................ ............................. ............................. ............................. ............................. ....................... ........ 35 Digital Thermometer, HA1070 ............... .............................. .............................. ............................. ............................. .............................. ................................ ...................... ..... 35 Velometer Air flow Meter, HA1061 .............. ............................. .............................. .............................. .............................. ............................. .............................. ................35 35 Incubator Rack Tester, HA1145 ............. ............................ .............................. .............................. .............................. ............................. ................................. ..................... .. 35

Chapter 2 - Multi-Stage Requirements Ventilation ................................................................................................................................................... 39 The Importance of the Heating, Ventilation and Air Conditioning System .................................................. 39 Measurements that Define Air Properties ............................................................................................. 39 Dry Bulb Temperature ...................................................................................................................... 39 Wet Bulb Temperature ..................................................................................................................... 39 Dewpoint Temperature ..................................................................................................................... 39 Relative Humidity ............................................................................................................................. 40 Specific Room Considerations .............................................................................................................. 40 Egg Room ........................................................................................................................................ 40 Incubator Room ............................................................................................................................... 40 Hatcher Room .................................................................................................................................. 41 Chick Room ..................................................................................................................................... 41 Wash/Pull Room .............................................................................................................................. 41 Clean Room ..................................................................................................................................... 42 Water Requirements .................................................................................................................................. 42 Water Quality for Spray Nozzles and Humidity .....................................................................................42 Recommendations ........................................................................................................................... 42 Incubator Electrical Specifications ............................................................................................................. 43 PX and 2-Door Hatcher Electrical Specifications ....................................................................................... 43 Air Requirements ....................................................................................................................................... 44 Compressed Air .................................................................................................................................... 44 Compressor .....................................................................................................................................44 Tank .................................................................................................................................................44 Auxiliary Air Needs ................................................................................................................................ 44 Air Line Drops .................................................................................................................................. 44 Chapter 3 - Temperature and Humidity Specifications Systems Using PT100 Controls ................................................................................................................. 47 Systems Using Electro-Mechanical Controls ............................................................................................. 48 Chapter 4 - Operational Procedures Conventional Incubators versus the Hatch Commander ............................................................................ 51 Egg Handling Basics .................................................................................................................................. 51 Obtaining and Storing Eggs .......................................................................................................................51 Transferring the Eggs to the Incubator Racks ............................................................................................ 52 Methods for Loading Eggs into the Incubator Rack ................................................................................... 52 Preparation ........................................................................................................................................... 52 Method 1: from Farm Rack to Incubator Rack .......................................................................................53 Method 2: Traying Up by Hand .............................................................................................................. 53 Method 3: Automated ............................................................................................................................54 Loading a Full Set ................................................................................................................................. 54 Loading a Partial Set .............................................................................................................................54 Final Inspection of Loaded Racks ..............................................................................................................55 Clean up ..................................................................................................................................................... 55 Preparing to Start the Incubator ................................................................................................................. 56 Left or Right Hand? ............................................................................................................................... 56 Pre Start Check..................................................................................................................................... 56 Pre Start ..................................................................................................................................................... 56 Incubators with PT100 or PT100SMT Controls .....................................................................................56 Control Box ...................................................................................................................................... 56 Temperature and Humidity Sensor .................................................................................................. 57 To Install a Wick ..........................................................................................................................57 Temperature and Humidity Settings ................................................................................................. 57

Incubators with Electro-Mechanical Controls ........................................................................................ 58 To Install a Thermostat ..................................................................................................................... 58 To Install Wicking ............................................................................................................................. 58 Start Up and 24-Hour Monitoring ............................................................................................................... 59 Loading Empty Racks into the Incubator .............................................................................................. 59 Connecting Air Lines ............................................................................................................................. 60 Connecting Turn Alarm Cables ............................................................................................................. 61 Installing Curtains ................................................................................................................................. 62 Preheating the Incubator ....................................................................................................................... 63 24-Hour Monitoring Prior to Loading ..........................................................................................................63 Checking the Egg Turning Mechanism and the Egg Turn Alarm ........................................................... 63 If Using PT100 Controls ................................................................................................................... 63 If Using Electro-Mechanical Controls ............................................................................................... 64 Loading Eggs into the Incubator ................................................................................................................ 66 Preparing for the First Egg Setting ........................................................................................................66 Loading a Tunnel Incubator ................................................................................................................... 66 After Loading Racks ..............................................................................................................................67 Additional Loading Instructions for Super J Incubators ......................................................................... 67 Charting Egg Settings ................................................................................................................................ 67 Loading the First Set into the Incubator ................................................................................................68 Loading the Second Set into the Incubator ........................................................................................... 68 Loading the Third to the Sixth Set into the Incubator ............................................................................ 69 Transferring the First Set Out of the Incubator ...................................................................................... 70 Coordinating Set, Transfer and Pull on a Calendar Basis ..................................................................... 70 Hatchers with PT100 or PT100SMT Controls ....................................................................................... 71 Control Box ...................................................................................................................................... 71 Preparing for Egg Transfer ......................................................................................................................... 71 Temperature and Humidity Sensor .................................................................................................. 72 To Install a Wick .......................................................................................................................... 72 Temperature and Humidity Settings ................................................................................................. 72 Hatchers with Electro-Mechanical Controls .......................................................................................... 73 To Install a Thermostat ..................................................................................................................... 73 To Install Wicking ............................................................................................................................. 73 Additional Hatcher Preparations ........................................................................................................... 74 Preparing the PX Hatcher for Egg Transfer ...................................................................................... 74 Preparing the 2-Door Hatcher for Egg Transfer................................................................................ 75 Pre-Heating a Hatcher with PT100 Controls ....................................................................................76 Preheating a Hatcher with Electro-Mechanical Controls ..................................................................77 Transferring Eggs from Incubator to Hatcher ............................................................................................. 77 Big J Incubators .................................................................................................................................... 78 Big J and Super J Incubators ................................................................................................................ 78 Transfer Patterns ........................................................................................................................................ 79 Placement of Eggs within a Given Column ...........................................................................................79 Placement of Columns in a Rack or on a Dolly .....................................................................................79 Transferring a Full Set ...................................................................................................................... 79 Transferring Partial Set .................................................................................................................... 79 Placement of the Rack or Dolly within the Hatcher ...............................................................................79 Transfer Pattern for the PX Hatcher ...................................................................................................... 80 Transfer Pattern for the 2-Door Hatcher ................................................................................................ 80 Method 1: Manual Transfer .................................................................................................................... 81 PX Hatcher ...................................................................................................................................... 81 2-Door Hatcher ................................................................................................................................ 83 Method 2: Mechanical Transfer ............................................................................................................. 85

Washing and Sanitizing the Incubator ........................................................................................................86 Hatching the Eggs ...................................................................................................................................... 86 Taking Off the Hatch ................................................................................................................................... 87 Method 1: Manual Method .................................................................................................................... 87 PX Hatcher - Using Plastic Hatcher Baskets and Dollies ................................................................. 87 2-Door Hatcher - Using Metal Hatcher Baskets and Racks .............................................................88 Method 2 and 3: Semi-Automated Method or Fully Automated ............................................................. 88 Guidelines to Minimize Chick Loss ............................................................................................................. 89 Incubator ...............................................................................................................................................89 Hatcher .................................................................................................................................................89 Transferring Eggs from Incubator to Hatcher ........................................................................................89 Egg Transfer .......................................................................................................................................... 90 Chapter 5 - Cleaning Procedures General Guidelines for Cleaning Practices ................................................................................................ 93 For Personnel ........................................................................................................................................ 93 Specific Cleaning Practices for Incubators ................................................................................................. 93 Complete Clean-Out and Sanitation of Incubators .....................................................................................94 Specific Cleaning Practices for Hatchers ...................................................................................................94 PX Hatcher ............................................................................................................................................94 2-Door Hatcher ..................................................................................................................................... 96 Chapter 6 - Routine Monitoring and Maintenance Basic Guidelines for Monitoring Equipment ............................................................................................. 101 Monitoring Incubators .............................................................................................................................. 101 Temperature and Humidity Readings .................................................................................................. 101 Space Saver Intake Duct .................................................................................................................... 101 Monitoring Hatchers ................................................................................................................................. 102 Temperature and Humidity .................................................................................................................. 102 Monitoring Ventilation Equipment ............................................................................................................. 102 Environmental Conditions ................................................................................................................... 102 Routine Maintenance for Incubator PT100 Controls ................................................................................106 Weekly ................................................................................................................................................ 106 Reservoir ....................................................................................................................................... 106 Wick ............................................................................................................................................... 106 To Install a Wick ........................................................................................................................ 106 Every Three Months ............................................................................................................................106 Probes ........................................................................................................................................... 106 Calibration ...................................................................................................................................... 106 Display Panel ................................................................................................................................. 106 High Humidity ........................................................................................................................... 106 Low Humidity ............................................................................................................................106 High Temperature ..................................................................................................................... 106 Low Temperature ...................................................................................................................... 107 Fan Motor Off Switch ................................................................................................................107 Turn Failure ...............................................................................................................................107 Power Off ..................................................................................................................................107 Alarms ...................................................................................................................................... 107 Display Panel LEDs .................................................................................................................. 107 Control Box .................................................................................................................................... 107 Routine Maintenance for Incubator Electro-Mechanical Controls ............................................................108 Weekly ................................................................................................................................................ 108 Reservoir ....................................................................................................................................... 108 Wick ............................................................................................................................................... 108

To Install a Wick ........................................................................................................................ 108 Every Three Months ............................................................................................................................108 Thermostats ...................................................................................................................................108 Information Panel ...........................................................................................................................108 Control Box .................................................................................................................................... 108 Wires, Connections and Bulbs .................................................................................................. 108 High Temperature Circuit ..........................................................................................................109 Heat Circuit ...............................................................................................................................109 Low Temperature Circuit. ..........................................................................................................109 Humidity Circuit .........................................................................................................................109 Motor Off Circuit ........................................................................................................................ 109 Power Off Check ....................................................................................................................... 109 Routine Maintenance for Incubators ........................................................................................................110 Before Every Set .................................................................................................................................110 Egg Tray Frames ............................................................................................................................110 Space Saver Intake Duct ............................................................................................................... 110 After Every Transfer.............................................................................................................................110 Incubator Racks .............................................................................................................................110 Weekly ................................................................................................................................................ 110 Spray Nozzles ................................................................................................................................110 Spray Nozzle Condition ............................................................................................................110 To Clean Spray Nozzles ...........................................................................................................110 To Check the Water Pressure ................................................................................................... 111 Water Pan ...................................................................................................................................... 111 Door Seals ..................................................................................................................................... 111 Threshold Gaskets .........................................................................................................................111 Curtains ......................................................................................................................................... 111 Rubber Gaskets .............................................................................................................................111 Compressor ...................................................................................................................................111 Monthly ............................................................................................................................................... 112 Heat Rods ...................................................................................................................................... 112 Fans ............................................................................................................................................... 112 Every Three Months ............................................................................................................................112 Wash and Sanitize ......................................................................................................................... 112 Damper System .............................................................................................................................112 Fan Motors, Switches and Blades .................................................................................................. 113 Fan Blade Spacing and Motor RPM ............................................................................................... 113 Procedure for Checking RPM ................................................................................................... 113 Every Six Months ................................................................................................................................ 113 Water Line Strainer ........................................................................................................................ 113 V-Groove Tracks ............................................................................................................................. 113 To Level Tracking ...................................................................................................................... 114 Switch Plates ................................................................................................................................. 114 Hatchers ................................................................................................................................................... 119 Routine Maintenance for PT100 Hatcher Controls ................................................................................... 119 Twice-Weekly ...................................................................................................................................... 119 Water Reservoir .............................................................................................................................119 Wick ............................................................................................................................................... 119 To Install a Wick ........................................................................................................................ 119 Every Three Months ............................................................................................................................119 Probes ........................................................................................................................................... 119 Calibration ...................................................................................................................................... 119 Display Panel ................................................................................................................................. 119 High Humidity ...........................................................................................................................119 Low Humidity ............................................................................................................................120

High Temperature ..................................................................................................................... 120 Low Temperature ...................................................................................................................... 120 Power Off Alarms ...................................................................................................................... 120 Fan Motor Off and Door Open Alarms ........................................................................................... 120 For PX Hatchers ............................................................................................................................ 120 Air Cylinder ...............................................................................................................................120 For 2-Door Hatchers ...................................................................................................................... 120 Blowers .....................................................................................................................................120 Auxiliary Damper ...................................................................................................................... 120 Control Box .................................................................................................................................... 121 Routine Maintenance for Electro-Mechanical Hatcher Controls ............................................................... 122 After Every Hatch ................................................................................................................................122 Thermostat Board .......................................................................................................................... 122 Twice Weekly ...................................................................................................................................... 122 Water Reservoir ............................................................................................................................. 122 Wick ............................................................................................................................................... 122 To Install a Wick ........................................................................................................................ 122 Every Three Months ............................................................................................................................122 Thermostats ...................................................................................................................................122 Control Box .................................................................................................................................... 122 Wires, Connections and Bulbs .................................................................................................. 123 High Temperature Circuit ..........................................................................................................123 Blower Circuit ............................................................................................................................ 123 Heat Circuit ...............................................................................................................................123 Humidity Circuit ......................................................................................................................... 123 Motor Off Circuit ........................................................................................................................ 123 Power Off Check ....................................................................................................................... 123 Routine Maintenance for Hatchers ........................................................................................................... 124 After Every Hatch ................................................................................................................................124 Wash and Sanitize ......................................................................................................................... 124 Twice-Weekly ...................................................................................................................................... 124 Spray Nozzles ................................................................................................................................ 124 Spray Nozzle Condition ................................................................................................................. 124 To Clean the Spray Nozzles ...................................................................................................... 124 To Check the Water Pressure ................................................................................................... 124 Exhaust Duct ................................................................................................................................. 124 Door Seals ..................................................................................................................................... 124 Threshold Gaskets ......................................................................................................................... 125 Weekly ................................................................................................................................................ 125 All Joints ........................................................................................................................................ 125 Hatcher Racks ...............................................................................................................................125 For 2-Door Hatchers ...................................................................................................................... 125 Blower ....................................................................................................................................... 125 Monthly ............................................................................................................................................... 126 Fans ............................................................................................................................................... 126 Heat Rings ..................................................................................................................................... 126 Cabinet .......................................................................................................................................... 126 For PX Hatchers ............................................................................................................................ 126 Air Cylinder Control Assembly .................................................................................................. 126 Every Three Months ............................................................................................................................127 Fan Motors and Blades .................................................................................................................. 127 Fan Blade Spacing and Motor RPM ............................................................................................... 127 Procedure for Checking RPM ................................................................................................... 127 Damper System ............................................................................................................................. 127 For 2-Door Hatchers ................................................................................................................. 128

Water Line Strainer ........................................................................................................................ 128 Routine Maintenance for Ventilation Equipment ....................................................................................... 133 As Required ........................................................................................................................................ 133 Humidifiers ..................................................................................................................................... 133 Furnaces ........................................................................................................................................ 133 Cooling Units .................................................................................................................................133 Weekly ................................................................................................................................................ 133 Furnaces ........................................................................................................................................ 133 Cooling Units .................................................................................................................................133 Evaporative Coolers ....................................................................................................................... 133 Exhaust Fans .................................................................................................................................133 Monthly ............................................................................................................................................... 133 Furnaces ........................................................................................................................................ 133 Cooling Units .................................................................................................................................133 Evaporative Coolers ....................................................................................................................... 133 Exhaust Fans .................................................................................................................................133 Every Six Months ................................................................................................................................133 Furnaces ........................................................................................................................................ 133 Cooling Units .................................................................................................................................133 Evaporative Coolers ....................................................................................................................... 133 Exhaust Fans .................................................................................................................................133 Specifications for Ventilation Components ...............................................................................................136 Incubator Damper Positions ................................................................................................................136 Positioning of Spray Nozzles ...............................................................................................................136 Space Saver Intake Duct .................................................................................................................... 136 Hatcher Damper Positions ..................................................................................................................137 PX Hatcher .................................................................................................................................... 137 2-Door Hatcher ..............................................................................................................................137 General Considerations for Fan Blade Spacing ....................................................................................... 138 Fan Blade Spacing for 50 Hz Area - Older Motor Mount ..................................................................... 139 Fan Blade Spacing for 60 Hz Area - Older Motor Mount ..................................................................... 140 Fan Blade Spacing for 60 Hz Area - New Motor Mount ...................................................................... 141 Fan Blade Spacing for 50 Hz Area - New Motor Mount ...................................................................... 141 Fan Blade Spacing for Hatchers ......................................................................................................... 142 Chapter 7 - Optimizing Performance Entrance End Temperature ...................................................................................................................... 145 Procedure to Measure Entrance End Temperature .............................................................................146 Exit End Temperature ............................................................................................................................... 147 Procedure to Measure Exit End Temperature ..................................................................................... 147 Internal Incubator Pressure ...................................................................................................................... 148 Procedure to Measure Internal Incubator Pressure ............................................................................ 148 Damper Performance ............................................................................................................................... 149 Incubator Damper Position at Set ....................................................................................................... 149 Incubator Damper Position at Transfer ................................................................................................149 Electro-Mechanical Incubators ............................................................................................................ 149 Time of Transfer ....................................................................................................................................... 151 Monitoring the Hatch ................................................................................................................................152 Controlling Other Variables to Improve Performance ............................................................................... 152 Grouping of Eggs—Flock Age and Egg Size ...................................................................................... 152 Problems Caused by Incorrectly Grouping Eggs ................................................................................ 152 Optimum Grouping of Eggs ................................................................................................................ 152 Pre-incubation and Pre-warming of Eggs ........................................................................................... 153

Partial and Skipped Set ...................................................................................................................... 153 Skipped Set ......................................................................................................................................... 153 Partial Set ........................................................................................................................................... 153 General Rules for Adjusting Set Times .................................................................................................... 154 Analysing Overall Performance ................................................................................................................ 154 Variation of Air Cell Size ...................................................................................................................... 154 Hatcher Residue Breakout .................................................................................................................. 154 Fresh Egg Breakout ............................................................................................................................155 Troubleshooting Performance .................................................................................................................. 155 1. Uneven Temperature, Side to Side .................................................................................................. 155 2. Uneven Temperature, Top to Bottom ............................................................................................... 155 3. Dampers Not in Range .................................................................................................................... 155 4. High Early Embryo Mortality ............................................................................................................156 5. High Late Embryo Mortality .............................................................................................................156 6. Differential Pressure Out of Range ................................................................................................. 156 Chapter 8 - Chick Development and Troubleshooting Hatchability Chicken Embryology, The Timing of Major Embryonic Developments ..................................................... 161 Before Egg Laying ...............................................................................................................................161 Between Laying and Incubation .......................................................................................................... 161 During Incubation ................................................................................................................................ 161 Analysing Hatch Residue .........................................................................................................................162 1. Chicks Hatch Late ........................................................................................................................... 162 2. Fully Developed Embryo with Beak not in Air Cell .......................................................................... 163 3. Fully Developed Embryo with Beak in Air Cell ................................................................................ 163 4. Chicks Pipping Early ....................................................................................................................... 163 6. Malpositions .................................................................................................................................... 163 7. Sticky Chicks (albumen sticking to chicks) ......................................................................................163 8. Sticky Chicks (albumen sticking to down) .......................................................................................163 9. Chicks Covered with Egg Remnants ............................................................................................... 163 10. Eggs Exploding .............................................................................................................................164 11. Clear Eggs .................................................................................................................................... 164 12. Blood Ring (embryonic death 2 to 4 days) .................................................................................... 164 13. Dead Embryos, 2nd Week of Incubation ....................................................................................... 164 14. Air Cell Too Small .......................................................................................................................... 164 15. Air Cell Too Large .......................................................................................................................... 164 16. Chicks Hatch Early ........................................................................................................................ 165 17. Chicks Too Small ........................................................................................................................... 165 18. Chicks Too Large ........................................................................................................................... 165 19. Trays Not Uniform in Hatch or Chick Quality ................................................................................. 165 20. Soft Chicks .................................................................................................................................... 165 21. Chicks Dehydrated ........................................................................................................................ 165 22. Mushy Chicks ................................................................................................................................165 23. Unhealed Navel, Dry ..................................................................................................................... 165 24. Unhealed Navel, Wet and with Odour ........................................................................................... 165 25. Chicks Cannot Stand .................................................................................................................... 166 26. Crippled Chicks .............................................................................................................................166 27. Crooked Toes ................................................................................................................................ 166 28. Spraddle Legs ...............................................................................................................................166 29. Short Down ................................................................................................................................... 166 30. Closed Eyes ..................................................................................................................................166

Chapter 9 - Appendices Appendix I - The Importance of Egg and Chick Transportation ..................................................................... 169 Bacterial Contamination .................................................................................................................169 Temperature Control ...................................................................................................................... 169 Avoid Temperature Shocks ............................................................................................................ 169 Relative Humidity ........................................................................................................................... 169 Motion ............................................................................................................................................ 170 Transportation of Day-Old Chicks .................................................................................................. 170 Control Temperature and Humidity ................................................................................................ 170 Giving Enough Ventilation .............................................................................................................. 170 Preparing for the Flight ..................................................................................................................171 Appendix II - Give Day-Old Chicks the Best Start .......................................................................... 173 Arrival of the Chicks ....................................................................................................................... 173 Mortality during Brooding ...............................................................................................................174 Hygiene and Health ....................................................................................................................... 174 Control of Wet Droppings ...............................................................................................................174 Water before Feed ......................................................................................................................... 175 Appendix III - Hatchery Sanitation: Concepts, Logistics and Assessment .......................................... 177 Quality Control Programmes.......................................................................................................... 177 Minimise Contamination ................................................................................................................178 Prevention through Design ............................................................................................................ 178 Chemical Control ........................................................................................................................... 179 Airborne Contaminants ..................................................................................................................179 Applying Sanitation Programmes ................................................................................................... 179 Appendix IV - Practical Hatchery Sanitation Guidelines to Assure Quality .........................................181 Prevent Problems from Entering or Multiplying ..............................................................................181 Define an Effective Program for Each Facility ................................................................................181 The Effectiveness of a Sanitiser and Disinfectant .......................................................................... 182 Routinely Monitor the Process ....................................................................................................... 182 Hatchery Monitoring Program ........................................................................................................ 183 The 50 Critical Sampling Points ..................................................................................................... 183 Problem Solving if There is One .................................................................................................... 184 Determine the True Results ........................................................................................................... 184 Appendix V - What to Do with Hatchery Waste ...................................................................................187 Systems to Remove Waste ............................................................................................................187 Vacuum Disposal ........................................................................................................................... 187 What to Do with Waste ................................................................................................................... 188 Premium Pet Food ......................................................................................................................... 188 Appendix VI - Breakout Analysis Guide for Hatcheries .......................................................................189 Fresh Egg Breakout ....................................................................................................................... 189 Candling Breakout Analysis ........................................................................................................... 190 Hatch Day Breakout ....................................................................................................................... 190 Breakout Procedure: ...................................................................................................................... 191 Embryo Mortality Determination .................................................................................................... 191 Identifying Fertility ..........................................................................................................................192 Keep Accurate Records ................................................................................................................. 193 Glossary ...................................................................................................................................................195

1. Introduction 

overview

• air flow • sizes and capacities • component identification

Operation Manual for Multi-Stage - Chickens

13

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MULTI-STAGE INCUBATION Jamesway Multi-Stage Incubators are precisely controlled environments for efficient chick production. Eggs, organized in individual block settings of two incubator racks, move progressively through the incubator cabinet as the embr yos develop.

Note: Racks (total of six) in the Hatch Commander incubator are moved once per week. Racks (total of twelve) in all other Jamesway tunnel incubators are moved twice per week.

Jamesway Multi-Stage incubator cabinets are designed to hold six or twelve racks. When two racks of fresh eggs are introduced into the incubator, they are set at the entrance, in position 1. This block of eggs will be pushed along either once or twice weekly (six or twelve rack machines respectively) until they arrive at the exit end (position 3 or 6 respectively). The process, in the incubator, takes 18 days for chicken eggs.

A distinctive feature of the Jam esway Multi-Stage Incubator is its Laminar Air Flow Pattern. This unique air flow pattern enables hatchery managers to make the most efficient use of energy sources. It also provides an ideal environment for eggs in each stage of embryonic growth.


15

AIR FLOW The Laminar Air Flow Pattern Laminar Air Flow, as opposed to turbulent air flow, requires only one sensing point to maintain ambient environmental conditions for heat, humidity, fresh air and carbon dioxide. This air flow, combined with high speed fans and water atomization, provides the necessary humidification and cooling. As a result, the need for cooling coils is eliminated. Furthermore, the Laminar Air Flow Pattern, combined with the conditioned air inside the incubator, maximizes the use of heat and carbon dioxide produced by embryonic development.

Air Flow within an Incubator Within the Jamesway Multi-Stage Incubator, heat is drawn from two sources: heat elements near the incu bator fans, and the natural heat which radiates from the eggs with the most embr yological development. As embryos develop, they require additional oxygen and give off carbon dioxide in ever-increasing amounts. The changing colour in the illustration shows the increasing production and release of heat by embr yos as they develop. The yellow coloured racks at the left rep-

resent the least developed embryos. These eggs produce the least amount of heat and, therefore, are the coolest eggs in the incubator. The red coloured racks at the right represent the most embryologically advanced eggs and, therefore, the warmest. The red and blue arrows depict the air flow pattern within Jamesway incubators. Fresh air enters through the intake at the entrance to the incubator. The air blends with conditioned air already in the incubator. At the same time, humidity is added, as required, by four spray nozzles, operated by an electronically controlled solenoid valve. The relative humidity of incubator air is important. It controls egg moisture loss, which can significantly affect hatchability and chick quality. Ideally, eggs should lose 12 to 15 percent of their weight prior to pipping. Any less could cause edema in the chicks. Too much water loss causes dehydration. Six energy saver fans positioned at the entrance to the incubator force fresh, moistened air (blue arrows) over the closed top of the incubator racks toward the exit end to cool the oldest eggs. Warm air and carbon dioxide produced by the most developed eggs are picked up by the fresh air and circulated back (red arrows) through the racks, over and around each of the newer eggs, surrounding them with warmth and extra carbon dioxide.

Intake Exhaust

The Laminar Air Flow Pattern in the incubator

16


Air Flow within a Hatcher The Jamesway PX Hatcher is also designed with the same Laminar Air Flow Pattern. The Laminar Air Flow in the Jamesway PX Hatcher (illustration) works in conjunction with a patented, pressurized exhaust system, thus the name PX. The PX system provides uniformity in temperature, humidity, and consistency in air velocity that results in increased hatchability and improved day-old chick quality. Furthermore, this system eliminates the need for a blower and auxiliary damper motor reducing electrical consumption.

SPECIFICATIONS FOR JAMESWAY INCUBATION SYSTEMS Parameters for temperature, humidity and component tolerances have been established for Jamesway MultiStage Systems and can be found in this manual. They should be followed in order to achieve maximum results. Any variation from these standards will have adverse and questionable results.

As fresh air is added to the hatcher (represented by the blue arrows) it circulates throughout the hatcher, and warm air (represented by the red arrows) is exhausted. This air flow design provides an environment that is as close to natural conditions as possible within multistage incubation systems.

Exhaust Intake

The Laminar Air Flow Pattern in the hatcher


17

SIZE AND CAPACITY OPTIONS FOR MULTI-STAGE INCUBATORS Space Saver Length: 24 ft. 9-3/8 in. (7553 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 10 ft. 0-1/4 in. (3054 mm) SAO Width: 9 ft. 10-1/4 in. (3004 mm) Big J Capacity: 77,760 eggs Super J Capacity: 90,720 eggs

Conventional Tunnel Length: 27 ft. 8-1/4 in. (8429 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 10 ft. 0-1/4 in. (3054 mm) SAO Width: 9 ft. 10-1/4 in. (3004 mm) Big J Capacity: 77,760 eggs Super J Capacity: 90,720 eggs

Side Door Length: 27 ft. 4-1/4 in. (8338 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 10 ft. 0-1/4 in. (3054 mm) SAO Width: 9 ft. 10-1/4 in. (3004 mm) Big J Capacity: 77,760 eggs Super J Capacity: 90,720 eggs

Hatch Commander Length: 14 ft. 9-3/8 in. (4505 mm) Height: 8 ft. 3 in. (2515 mm) Basic Width: 10 ft. 0-1/4 in. (3054 mm) SAO Width: 9 ft. 10-1/4 in. (3004 mm) Big J Capacity: 38,880 eggs Super J Capacity: 45,360 eggs

18


SIZE AND CAPACITY OPTIONS FOR MULTI-STAGE HATCHERS PX Hatcher Depth: 6 ft. 11-7/8 in. (2130 mm) Height: 6 ft. 1-3/4 in. (1873 mm) Basic Width: 9 ft. 9-3/4 in. (2991 mm) SAO Width: 9 ft. 7-3/4 in. (2940 mm) Big J Capacity: 12,960 eggs Super J Capacity: 15,120 eggs

2-Door Depth: 6 ft. 2-1/4 in. (1886 mm) Height: 6 ft. 1-3/4 in. (1873 mm) Basic Width: 9 ft. 0-1/4 in. (2750 mm) SAO Width: 8 ft. 10-1/4 in. (2699 mm) Big J Capacity: 12,960 eggs Super J Capacity: 15,120 eggs


19

COMPONENT IDENTIFICATION CABINET, BASIC Controls on the roof — eliminates interior wires and conduits which collect dirt and bacteria.

Walls and ceiling — smooth fibre-glass reinforced plastic for ease of cleaning Joints sealed to eliminate dirt.

CABINET, ENTRANCE Intake Duct

Fans force fresh, moistened air over the closed top of the incubator racks toward the exit end to cool the oldest eggs.

Rack curtains are necessary for proper air circulation.

Centre Aisle Door Incubator Rack

Tracking

Threshold

20


Rack Baffle

PT100 CONTROLS The PT100 Control System provides an accurate means of regulating temperature and humidity as well as a complete indication of the status of all systems and alarms.

Display Panel Mounted externally for easy visibility and use.

Alarm status displays high and low temperature and high and low humidity.

Temperature and Alarm Light warns of possible problems.

Status of Heaters, Sprayer and Damper Control

Current Temperature and Humidity

Temperature and Humidity Setpoints

Machine Controller A Machine Controller is located on top of each machine. This unit performs both the environmental control and monitoring of the incubator or hatcher. All instrumentation and control devices are connected to the machine controller.

In older models, make sure boards are firmly seated.

Newer control boxes contain one main board.

Guards in place Operation Manual for Multi-Stage - Chickens

21

Temperature and Humidity Sensor Platinum probes accurately evaluate the machine’s environment. This information is transmitted to the control box.

Probe Wick (PB4077)

Plug Distilled Water Reservoir

MULTI-STAGE INCUBATOR WITH PT100 CONTROLS Venturi Centre Aisle Door Air Intake

Fans Spray Nozzles Water Pan

Control Box Damper Drive Box

Entrance End

Exhaust Damper Temperature and Humidity Sensor (inside)

Heat Elements Intake Duct

PT100 Display Panel

Wall Gasket Threshold Rack Baffle Exit End

Centre Aisle Doors Incubator Racks with Curtains V-Groove or U-Channel

22


Rack Stop

PX HATCHER WITH PT100 CONTROLS Control Box

PT100 Display Panel

Damper Drive Box Air Cylinder Control

Temperature and Humidity Sensor (inside)

Exhaust Duct

Intake Duct Door Alarm Switch (1 of 3 mounted in front)

Baskets Threshold Rack Guide Fans and Dolly Assembly

2-DOOR HATCHER WITH PT100 CONTROLS

Control Box Blower Motors Intake Box

Exhaust Duct

PT100 Display Panel Temperature and Humidity Sensor (inside)

Tracking Motor Fan Assembly

Rack and Metal Baskets

Threshold Rack Guide Operation Manual for Multi-Stage - Chickens

23

ELECTRO-MECHANICAL CONTROLS

Incubator Information Panel The Information Panel provides a complete visual assessment of machine status and alarms.

Incubator Control Box The Control Box is located on the he ader panel at the exit end of the incubator. (On older models, the control box may be found inside the machine at the exit end.) This unit performs both environmental control and monitoring of the incubator. All instrumentation and control devices are connected to the control box.

Incubator Thermostat Board

Low Temp. Thermostat

Thermostats and humidistat accurately evaluate the machine’s environment. This infor mation is transmitted to the control box.

High Temp. Thermostat Aux. Heat Thermostat

Humidistat with Wick (P1507)

Main Heat Thermostat

Plug Distilled Water Reservoir

24


Hatcher Control Box and Information Panel The Control Box is located centrally on the front of the header panel. This unit performs both environmental control and monitoring of the hatcher. All instrumentation and control devices are connected to the control box and a complete visual assessment of machine status and alarms is provided.

Hatcher Thermostat Board

High Temp.Thermostat Thermostats and humidistats accurately evaluate Blower Thermostat the machine’s environment. This information is transmitted to the control box. Heat Thermostat Reading Thermometer Reading Thermometer with Wick (P1507) Plug Reading Humidistat with Wick (P1507)

Distilled Water Reservoir

Multi-Stage Systems with E/M Controls Control Box and Information Panel Control Box

Thermostat Board located on right side

Thermostat Board Reservoir


25

VENTILATION SYSTEM Incubators The Damper Assembly is regulated by the temperature input to the control box. Components include the motor assembly and the drive box which control the position of both the intake and exhaust damper baffles. The status of the following damper positions are indicated on the PT100 display panel: damper opening, damper closing, damper open (fully open) and damper closed (fully closed).

Damper Drive Box

PT100 Controls

EM Controls

Incubator damper slides shown in fully closed position

Venturi Fans Air Intake Entrance End

Damper Slide

Spray Nozzles Water Pan

Exhaust Damper Drive Box

Intake Duct Heat Elements

Exit End Incubator Ventilation Components

26


PX Hatcher The Damper Assembly is regulated by the temperature input to the control box. Components include the motor assembly and the drive box which control the exhaust damper slide position. The status of the following damper positions are indicated on the PT100 display panel: damper opening, damper closing, damper open (fully open) and damper closed (fully closed).

Damper Assembly Spray Nozzle Exhaust Duct

Damper Rod, Collar & Set Screw Spray Nozzle Connection Junction Box Assembly connects to Umbilical Cable.

Damper Slide Latch (1 of 6)

Fan and Motor Intake Duct

Note: When the damper slide is fully closed, there is a spatial opening of 1/8 in. (3 mm).

Fan Dolly Kickstand

Exhaust Duct and Fans


27

2-Door Hatcher Motors

Blower Box

Intake Box for Big J - one motor

Air Intake

Intake Box for Super J.

Damper Assembly Fan Stand Spray nozzles are mounted through the exhaust holes in the rear wall. They are directed at the centre of each fan blade. Exhaust Openings

Heat Ring

Fan Assembly

28


Fan and Motor

Fan and Heater Connections to Control Box

Hatcher Exhaust Plenums Tower Plenum Flush Plenum

Entrance Door Trough in plenum floor slopes towards drain and external exhaust.

In the plenum room, the floor should slope towards a common trough that runs along the length of the back wall. This trough should slope 1/2 in. per 10 ft. (4mm/m) towards the drain located at the end opposite the entrance door. These slopes 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 Multi-Stage or contact your Jamesway representative.

Air Regulator

Compressed Air Supply Drain Plug Optional valve for extension, capped

Optional valve to each machine for maintenance

Air Regulator and Filter Assembly

Valve


29

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. They are 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.

30


Incubator Racks Jamesway Incubator Racks are constructed of 30 percent zinc electroplated and 70 percent hot-dipped galvanized steel. Each rack is equipped with pneumatic egg turning cylinders, polyurethane (non-kink) air lines, mercury switch-activated turning sensors, and four injection-moulded plastic wheels. Unlike other incubation equipment, Jamesway Incubator Racks also have top, bottom and side panels, and individual plastic curtains to assist the air circulation pattern. The capacity of each incubator rack varies with the size of the egg flat. Egg Flat Part Number

Number of Eggs / Flat

Number of Flats / Rack

Total Egg Capacity / Rack

PB4509

36

180

6,480

PB4215

42

180

7,560

PB4478

77

90

6,930

PB3179B

84

90

7,560

PB5077

84

90

7,560

PB5046

168

45

7,560

Hatcher Racks Galvanized steel hatcher racks along with galvanized steel hatcher baskets are for use in 2-Door Hatchers.

Rack Specifications Type of Rack Farm Rack Incubator Big J Hatcher Super J Hatcher

Maximum Outer Dimensions Depth

Width

Height*

46.1 in.

26.9 in.

74.5 in.

1172 mm

683 mm

1892 mm

49.4 in.

39.3 in.

79.9 in.

1254 mm

997 mm

2029 mm

46.6 in.

40.5 in.

64.5 in.

1184 mm

1029 mm

1638 mm

49.6 in.

43.5 in.

70.9 in.

1259 mm

1105 mm

1800 mm

Trays 30 trays 45 trays 45 trays 45 trays

Note: Dimensions given are for metal or glass impregnated nylon V-groove wheels. *Add 1 in. (25 mm) for racks with polyolefin wheels.


31

Hatcher Dollies and Plastic Baskets Hatcher Dollies and plastic hatcher baskets are standard equipment for the PX Hatcher. All dollies have durable polyolefin wheels and are zinc electroplated. These features resist cor rosion 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. For existing 2-Door Hatchers, Jamesway offers hatcher dolly/plastic basket conversion kits. (Conversion kits CK1127 and CK1128.) Contact a Jamesway representative for details.

Baskets may be stacked 15-high. This allows 30 baskets in total.

Type of Dolly

Maximum Outer Dimensions Depth Width* Height

Baskets

PX Hatcher, Double Dolly

50 in.

32 in.

70 in.

30 baskets

1270 mm

813 mm

1778 mm

* Note: Width measurement includes baskets. The above measurements also apply for 2-Door Hatcher conversion kits.

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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.


33

ACCESSORIES BACK-UP ALARM SYSTEM This alarm utilizes a regular mercury thermostat. It provides a second independent monitoring system for incubators and hatchers in case of overheating or failure of the regular alarm system.

Green & red LEDs indicate the state of the circuit. Test switch verifies proper functioning of the LEDs and alarm relay. It does not test circuit operation.

Control Box 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.

34


Mercury thermostats are used as the temperature sensing devices. Recommended thermostats: for incubators 101˚F • for hatchers — 100˚F. •

—

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 PB3040

VELOMETER AIR FLOW METER HA1061

DIGITAL THERMOMETER HA1070

INCUBATOR RACK TESTER HA1145


35

36


2. Multi-Stage Requirements •

ventilation requirements

• water requirements • electrical requirements • air requirements


37

38


VENTILATION

THE IMPORTANCE OF THE HEATING, VENTILATION AND AIR CONDITIONING SYSTEM A well-designed Heating, Ventilation and Air Conditioning (HVAC) System reduces energy costs as well as boosts both incubator and hatcher operation and performance. It also improves hatchery sanitation, and provides the proper environment for embryo development and quality day-old chicks. For optimal hatchability and normal embryo growth, the HVAC system should successfully provide incubator and hatcher rooms with fresh air of the proper temperature, humidity and pressure. This conditioned air enters the machine through a dampered air intake located on the top of the machine. Normally, the stale air from the incubators exhausts directly to the outside atmosphere through an exhaust in the rear roof of the hatchery, but it is equally feasi ble to connect the machines to a common powered exhaust, or to provide a non-powered common exhaust through the roof of the building. Hatchers should be allowed to vent into a plenum behind the machines. This plenum or dust corridor can be exhausted naturally or power-assisted. A sloping floor with an open drain at the far end f acilitates cleaning. Additionally, a spray system with a timer helps to keep the fluff wet and contained within the plenum. If this system is not used, each hatcher can be individually exhausted to the outside of the building. Exhaust ducts must be provided with clean-outs at convenient locations. See page 29. It is also important to provide a well distributed air supply to all rooms in the hatchery. Ideally, each room should have its own ventilation system and there should be as little air passage between rooms as possible. The HVAC system should be designed to create pressure differentials, where desired, between intake and exhaust systems for any single area.

Note: Exhaust systems for the incubators and hatchers should not be equipped with dampers of any kind. All fresh air intakes and air-cooled mechanical equipment should be at least 25 ft. (7.6 m) from the nearest hatcher exhaust if at all possible.

Most modern hatcheries in use today will implement an HVAC system. The sophistication and type of system will depend largely on the climate as well as the economic conditions.

MEASUREMENTS THAT DEFINE AIR PROPERTIES Because air has water absorption and holding properties, these are the key variables to consider when ventilating hatcheries. They are measured by dry bulb temperature, wet bulb temperature, dewpoint temperature and relative humidity. Jamesway Multi-Stage Incubators and Hatchers have specific dry bulb and wet bulb temperatures for proper embr yonic development. (See page 47, Chapter 3 - Temperature and Humidity Specifications for Incubators and Hatchers.)

Dry Bulb Temperature Dry bulb temperature is measured using an ordinary thermometer.

Wet Bulb Temperature Wet bulb temperature is measured using a thermometer where the bulb is covered with a wet wick. The difference in the dry bulb and wet bulb temperature readings is a measure of the dryness of the air.

Dewpoint Temperature Dewpoint temperature is the temperature at which moisture leaves the air and condenses on objects. This typically occurs when the dry bulb, wet bulb and dewpoint temperatures are the same.


39

Relative Humidity Relative humidity is a comparison of the amount of moisture within the air to the amount of moisture the same air at the same dry bulb temperature could hold if it were saturated.

SPECIFIC ROOM CONSIDERATIONS Egg Room Avoid all direct blasts of air on 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 seven (7) days, lower temperatures are recommended. See Obtaining and Storing Eggs on page 51. Egg Room Optimum Temperature, dry bulb

General Conditions 64–68°F 18–20°C

Relative Humidity, % RH

75–80%

75–80%

Incubator Room The space containing the incubator or the space above the incubators (from top of the incubator to ceiling or roof) should be a separate area. Continuously operating fans on the heaters and cooling units (if located in this space) or other fans located here should continually circulate and mix the air supply. Doors into this area should be kept closed.

Note: Fresh Air Supply and Room Pressure given are not valid when evaporative cooling is used. Consult your Jamesway representative for additional information.

Incubator Room Minimum Temperature, dry bulb

General Conditions 73°F 23°C

Maximum Temperature, dry bulb

85°F

29°C

Optimum Temperature, dry bulb

80°F

27°C


50-60%

50-60%

Fresh Air Supply (Super J), per incubator 375 cfm*

640 m3 /h

Room Pressure Differential to outside

1.0–3.0 Pa*

0.005–0.015 in. w.g.*

* cfm (cubic feet per minute), in. w. g. (inches water gauge), Pa (Pascals)

40


Hatcher Room Continuously operating fans on the heaters and cooling units (if located in this space) or other fans located in the hatcher room should continually circulate and mix the air supply. Doors into this area should be kept closed.

Note: Fresh Air Supply and Room Pressure given are not valid when evaporative cooling is used. Consult your Jamesway representative for additional information.

Hatcher Room Minimum Temperature, dry bulb

General Conditions 73°F 23°C

Maximum Temperature, dry bulb

85°F

29°C

Optimum Temperature, dry bulb

80°F

27°C


50–60%

50–60%

Fresh Air Supply (Super J), per incubator

375 cfm

640 m3 /h

Room Pressure Differential to outside

0.005-0.015 in. w.g.*

1.0–3.0 Pa*

* cfm (cubic feet per minute), in.w. g. (inches water gauge), Pa (Pascals)

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 and thus a necessary supply of oxygen.

Chick Room Optimum Temperature, dry bulb



40–50%

40–50%

Fresh Air Supply per 10,000 chicks

300 cfm

510 m3 /h

Wash/Pull Room This room should have a controlled environment for both worker and chick comfort. It is also one of the dirtiest rooms in the hatchery and therefore should have a negative pressure to the rest of the hatchery. This is achieved by using an exhaust fan and an adequate fresh air supply. Pull/Wash Optimum Temperature, dry bulb



41

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 to the rest of the hatcher y and an adequate fresh air supply. It is important to provide air exchange with outside air to allow drying of the equipment. Clean Optimum Temperature, dry bulb


WATER REQUIREMENTS WATER QUALITY FOR SPRAY NOZZLES AND HUMIDITY The spray nozzles in the Jamesway incubator provide both humidity and cooling. A system that uses spray nozzles to atomize water requires a good clea n source of water (sediment free and minimal mineral content) to avoid excessive scale build up.

Recommendations 1. Since most hatchery water supplies do not meet the criteria listed below, treat the water supply to the machines, using a reverse osmosis (RO) or other suitable water treatment system. 2. Separate the water supply to the incubators and hatchers from the water supply to the rest of the hatchery. 3. The pressure at the spray nozzle must be a minimum of 65 psig (4.5 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 with 2.7 gal. (10 L) of water per hour, and each hatcher with 1.5 gal. (6 L) of water per hour.

42


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 to 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. 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.

INCUBATOR ELECTRICAL SPECIFICATIONS Total connected load at 230 V is 42 A. Power supplied to the incubators may be in any of the following configurations: 1. 230 V, single phase, 3 wire, 60 Hz,

Note: The start-up load* is calculated using a fresh set of eggs and bringing the incubator up to temperature. Recommended voltage is 230, but can range from 208 to 240 volts. If specifications outside of this range are required, please contact Jamesway.

2. 230 V, single phase, 2 wire, 50 Hz, or 3. 230 V, single phase, 2 wire, 60 Hz. Each incubator also requires: 1. One non-fused grounded neutral lead. 2. One 50 A (for 230 V operation), or 60 A (for 115 V operation) circuit breaker protecting ungrounded load carrying conductors. With 230 V motors, the start-up load* is 42 A, running load is 27 A. With 115 V motors, the start-up load* is 53 A, running load is 38 A.

PX AND 2-DOOR HATCHER ELECTRICAL SPECIFICATIONS Total operating load at 230 V is 13 A.

Note: Recommended voltage is 230, but can range from 208 to 240 volts. If specifications outside of this range are required, please contact Jamesway.

Power supplies to the hatcher may be in any of the following configurations: 1. 230 V, single phase, 3 wire, 60 Hz, 2. 230 V, single phase, 2 wire, 50 Hz,or 3. 230 V, single phase, 2 wire, 60 Hz. Each hatcher requires the following: 1. One non-fused grounded neutral lead. 2. One 20 A circuit breaker protecting the ungrounded load carrying conductor. With 230 V motors, the running load is 13 A. With 115 V motors, the running load is 17 A.


43

AIR REQUIREMENTS COMPRESSED AIR A large compressor centrally located with piping to the appropriate equipment is recommended. Air dryers are endorsed. Air consumption for four Jamesway incubators (48 cylinders) at 60 psig (4 bars) would be 2.44 cfm (4.15 m3/h) once/hour. Air consumption for four Jamesway PX Hatchers (8 cylinders) at 20 psig (1.5 bars) would be 0.02 cfm (0.03 m3/h). The requirements for an air tank motor-compressor outfit to handle a specific number of Jamesway incu bators and hatchers would be as follows: 1. 1 to 4 incubators and hatchers 1 hp (0.75 kW) 2. 5 to 9 incubators and hatchers 3 hp (2.2 kW) 3. Over ten (10) incubators and hatchers, use a 5 hp (3.7 kW) motor for each set of ten (10).

Compressor The requirements for a compressor are as follows: 1. Must be oil-less type. 2. Have a displacement of 2.7 cfm (4.6 m3/h) at 1725 rpm. 3. Have a pressure switch set to cut in at 150 psig (10 bars) and out at 175 psig (12 bars).

Tank The air tank must be built to ASME (The American Society of Mechanical Engineers) code requirements and tested at 300 lb. (136 kg). It may be either horizontal or vertical. The capacity should be 44 cu. ft. (1.25 m3) at 160 psig (11 bars). Other requirements are a pressure gauge and shut off valve on the tank outlet, a tank drain, a tank safety valve and tank legs.

44


AUXILIARY AIR NEEDS When using an air system to the above specifications, air must not be taken for auxiliary equipment. A separate air source must be employed or a central system of a proportionally larger capacity must be used. The air system for incubators must not be allowed to fall below the above specifications.

Air Line Drops One air line is required for each Jamesway air filterregulator assembly. Each air line drop requires a shut-off valve and an adapter to accept plastic tubing with an outside diameter (O.D.) of 3/8 in. (9.5 mm). A Jamesway air filter-regulator assembly can supply seven (7) incubators or portion thereof when used with PT100 or Sentry Controls. With Electro-Mechanical controls, one air line drop and one air filter-regulator assembly is required for every four (4) incubators or portion thereof. Jamesway air filter-regulator assem blies work well for small installations. Large hatcheries should consider using one or two large compressors to supply air throughout the hatchery. Generally the required line is installed above a row of incubators. Each row can be comprised of 15 to 20 machines. Each machine is fitted with a drop that tees off the main line and is fitted with a shut-off valve and a 3/8 in. (9.5 mm) tube adapter as described above. The line diameter quoted is the minimum recommended.

3. Temperature and Humidity Specifications •

for systems using PT100 controls

• for systems using electromechanical controls


45

46


Variable environments allow for improved performance in different flocks. Multi-Stage machines can be programmed to specific settings, which in turn allows for flexibility in the environment. The specifications shown below are for an average flock and should be used as a guideline when considering your particular situation (breed, age of flock, age of eggs, etc.).

Note: If the incubator is continually full, temperature settings should not be changed. When new settings of eggs are skipped, temperature settings are based on days of incubation for the oldest eggs in the incubator.

SYSTEMS USING PT100 CONTROLS Table 1: Big J Incubator Set Points Stage of Incubation Temperature

Humidity

Days 1–10

99.9°F (37.72°C)

88.0°F (31.11°C)

Days 10 and 11

99.6°F (37.56°C)

86.0°F (30.00°C)

Days 12 and 13

99.3°F (37.39°C)

86.0°F (30.00°C)

Day 14

99.0°F (37.22°C) (winter)

86.0°F (30.00°C) (winter)

Normal Run

99.0°F (37.22°C) (summer)

86.0°F (30.00°C) (summer)

Table 2: Super J Incubation Set Points Stage of Incubation Temperature

Humidity

Days 1–10

99.9°F (37.72°C)

88.0°F (31.11°C)

Days 10 and 11

99.6°F (37.56°C)

86.0°F (30.00°C)

Days 12 and 13

99.2°F (37.33°C)

86.0°F (30.00°C)

Day 14

98.8°F (37.11°C) (winter)

86.0°F (30.00°C) (winter)

Normal Run

98.8°F (37.11°C) (summer)

86.0°F (30.00°C) (summer)

Table 3: Super J with SST Incubation Set Points Stage of Incubation Temperature

Humidity

Days 1–10

99.9°F (37.72°C)

88.0°F (31.11°C)

Days 10 and 11

99.6°F (37.56°C)

86.0°F (30.00°C)

Days 12 and 13

99.2°F (37.33°C)

86.0°F (30.00°C)

Day 14

98.6°F (37.11°C) (winter)

86.0°F (30.00°C) (winter)

Normal Run

98.6°F (37.11°C) (summer)

86.0°F (30.00°C) (summer)

Table 4: Big J/Super J Hatcher Set Points Stage of Incubation Temperature

Humidity

Big J at Transfer

98.5°F (36.94°C)

86.0°F (30.00°C)

Super J at Transfer

98.5°F (36.94°C)

86.0°F (30.00°C)


47

SYSTEMS USING ELECTROMECHANICAL CONTROLS

Note: Use start-up thermostats whenever the oldest eggs in the incubator have 14 days or less of incubation.

Table 5: Big J Incubator Thermostat Settings Stage of Incubation Humidity Low Temp.

High Temp.

Aux. Heat

Main Heat

Start-up

84–86-88°F

97.0°F

100.5°F

99.75°F

100.0°F

Day 1–14

29-30-31°C

36.11°C

38.06°C

37.64°C

37.78°C

PB1809

PB1812

PB1437

PB1435

PB1436

Normal Run

84–86-88°F

97.0°F

100.0°F

98.8°F

99.0 °F

Day 15–18

29–30-31°C

36.11°C

37.78°C

37.11°C

37.22°C

PB1809

PB1812

PB1436

PB1433

PB1434

Table 6: Super J Incubator Thermostat Settings Stage of Incubation Humidity Low Temp.

High Temp.

Aux. Heat

Main Heat

Start-up

84-86-88°F

97.0°F

100.5°F

99.75°F

100.0°F

Day 1–14

29-30-31°C

36.11°C

38.06°C

37.64°C

37.78°C

PB1809

PB1812

PB1437

PB1435

PB1436

Normal Run

84–86–88°F

97.0°F

100.0°F

98.6°F

98.8°F

Day 15–18

29–30–31°C

36.11°C

37.78°C

37.0°C

37.11°C

PB1809

PB1812

PB1436

PB3759

PB1433

Table 7: Super J with SST Thermostat Settings Day in Cycle Humidity Low Temp.

High Temp.

Aux.Heat

Main Heat

Start-up

Normal Run

84–86–88°F

97.0°F

100.5°F

99.75°F

100.0°F

29–30–31°C

36.11°C

38.06°C

37.64°C

36.67°C

PB1809

PB1812

PB1437

PB1435

PB1436

84–86–88°F

97.0°F

100.0°F

98.4°F

98.6°F

29–30–31°C

36.11°C

36.67°C

36.89°C

37.0°C

PB1809

PB1812

PB1436

PB3760

PB3759

Table 8: Big J/Super J Hatcher Thermostat Settings Day in Cycle High Temp. Blower Heat

Temp. Read.

Humidity

Hum. Read.

Big J

99.5°F

99.0°F

98.8°F

98–100°F

86.0°F

84–88°F

Day 18–21

37.5°C

37.22°C

37.11°C

36.67–37.78°C

30°C

29–31°C

PB1925

PB1434

PB1433

PB1923

PB1926

PB1924

Super J

99.5°F

98.8°F

98.6°F

98–100°F

86.0°F

84–88°F

Day 18–21

37.5°C

37.11°C

37°C

36.67–37.78°C

30°C

29–31°C

PB1925

PB1433

PB3759

PB1923

PB1926

PB1924

48


4. Operational Procedures •

egg handling basics

• obtaining and storing eggs • transferring eggs from farm rack to incubator racks • start-up • setting procedures • guidelines for setting and transfer procedures • transferring eggs from incubator racks to hatcher baskets • hatching eggs


49

50


Poultry hatcheries should produce the greatest possi ble number of healthy chicks from fertile eggs. Proper handling of eggs and the operation of incubating and hatching equipment contribute to this goal.

CONVENTIONAL INCUBATORS VERSUS THE HATCH COMMANDER The following text and illustrations refer to conventional incubators that contain a total of twelve racks, six on each side. If you are using a Hatch Commander incubator, there will be only six racks in total, three on each side.

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 tem perature shocks. Pay particular attention during loading and unloading.

Moving the farm rack. Watch where you are going!

OBTAINING AND STORING 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.

Note: The egg storeroom should be designed to hold a one-week supply of eggs.

Egg rooms, including the HVAC system, should be cleaned and sanitized every day.

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.


51

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 two Jamesway incubator racks from the wash room to the egg work room. If farm racks were used, push the egg flats through into the incubator racks. For further 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 further explanation, see Method 2: Traying Up by Hand on the following page.

METHODS FOR LOADING EGGS INTO THE INCUBATOR RACK PREPARATION The incubator should be operational or in the process of being preheated and monitored. Prepare two incu bator racks for the eggs by thoroughly cleaning and sanitizing. At a testing station, connect rack air lines to check that the egg turn is functioning properly. A regulated air pressure of 35 to 40 psig (240 to 275 kPa) should be available. The transfer of the eggs should take place in the egg room where the temperature should be between 65 °F and 68°F (18°C and 20°C).

52


Transferring eggs from farm rack to incubator rack

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 two of the three 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 frame, at one time, into the incubator rack. Start at the top left c orner and work down.

Farm racks are unloaded bottom to top, alternating one tier with the other.

Make sure that the egg flats are pushed completely into the tray frames and do not protrude.

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.

Transferring eggs from farm rack to incubator rack

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. 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. Make sure that the egg flats are pushed completely into the tray frames and do not protrude. When traying by hand, start at the top and fill one column before filling the next. Operation Manual for Multi-Stage - Chickens

53

METHOD 3: AUTOMATED If eggs are delivered in paper Keyes trays a vacuum lift may be used to load eggs into the plastic egg flats. Refer to equipment manufacturer ’s instructions for proper operation.

LOADING A FULL SET Place two racks side by side. Start with the f irst tray at the top left tier of the incubator rack. Load eggs working downward until the f irst tier is full. Continue loading eggs, starting at the top of the centre tier of the same rack. Work top to bottom. Load the right tier. Again, work top to bottom.

Fill one column at a time. Start with the left-hand tier and work downwards.

After completely loading the first rack, repeat this process to fill the second incubator rack.

LOADING A PARTIAL SET If the number of eggs to be loaded will not completely fill two racks, the following procedure should be followed. Place two racks side by side. Start with the first tray at the top right tier of the lefthand rack. Load the eggs working downward until the first column is full. Continue loading the centre column top to bottom until one half of the total available eggs are loaded. With the remaining eggs, load the right-hand rack starting at the top left tier. Work downward and continue with the centre column until all of the eggs are loaded. When these racks are positioned side by side in the incubator, the loading patterns will mir ror each other. The empty tray frames will be directly beneath the fans, while the loaded trays will be next to the fully loaded racks. This method of loading partial sets ensures an even airflow through the egg mass.

54


Partial set. Racks will mirror each other when positioned side by side. When loading in the incubator, empty frames will be directly beneath the fans.

FINAL INSPECTION OF LOADED RACKS After the racks have been loaded with eggs, check all egg trays for proper positioning in the egg tray frames. Push the flats as far to the back of the incubator rack as possible to ensure proper egg turning. At a testing station, connect rack air lines to check that the egg turn is functioning properly. A regulated air pressure of 35 to 40 psig (240 to 275 kPa) should be available. Level the eggs. This can be done by reversing the air line connection for a short duration or by hand.

Check the position of all egg trays. Push them firmly towards the back.

CLEAN UP After loading incubator racks, take the farm racks to the equipment wash room. Thoroughly clean and sanitize. Move clean farm racks to the loading dock for return to the farm. If eggs were trayed up by hand, discard cartons. Note: Farm racks may be returned to the farm loaded with, or without clean empty plastic egg flats.

Test for correct turning

Egg frame positions


55

PREPARING TO START THE INCUBATOR After every new installation of a Jamesway incubator or hatcher, a Jamesway technician will start each incu bator to ensure it functions correctly. Follow this procedure after every complete clean-out and sanitation of the incubator or if the incubator has been idle. See Chapter 5 for complete clean out and sanitation and Chapter 6 for maintenance schedules.

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. (If you are not sure which doors are at the entrance, remember that the fans are located at the entrance end.)

Stand at the front entrance, facing the fans to determine the left and right sides.

PRE START CHECK Check that all equipment has been thoroughly washed and sanitized.

PRE START INCUBATORS WITH PT100 OR PT100SMT CONTROLS

Locate the fan switch on the PT100 display. Turn off.

Turn the fan switch off. (The fan switch is located on the PT100 Display.)

Control Box Turn the power off - CB1, CB2 and CB3.

CB3 CB2 CB1

Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 Vac. They will cause serious shocks, injury or death if touched. Turn CB1, CB2 and CB3 off. CB1, CB2 and CB3 are located behind the panel door on the front of the control box.

56


Open the control box. Ensure that the interior of the control box is clean and free of debris, especially metal shavings. If you are using PT100 Controls, check all circuit boards for proper seating in the main board. Turn the power back on. Turn the fans back on.

Temperature and Humidity Sensor Fill the humidity water reservoir with distilled water. Using distilled water will prevent mineral build up.

PT100 Controls. Make sure the boards are firmly seated.

Replace the stopper to reduce evaporation and contamination through the reservoir hole. Install wicking (PB4077) on the humidity probe. Ensure it is completely covered. To Install a Wick

Hold the top of the wicking with one hand. Gently slide over the extended end of the probe. Seat the wicking firmly around the probe. Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking.

Temperature and Humidity Sensor with wicking PB4077

The wicking (PB4077) should be 12 in. (30 cm) in length. Warning: Incorrectly sized wicking may give inaccurate wet bulb readings.

Temperature and Humidity Settings Determine the incubator capacity - Big J, Super J or SST. Set the temperature and humidity thumbwheels located on the display panel. Specifications for each machine can be found on page 47.

Thumbwheels on the PT100 Display Operation Manual for Multi-Stage - Chickens

57

INCUBATORS WITH ELECTRO-MECHANICAL CONTROLS Turn the fan switch off. Determine the incubator capacity - Big J, Super J or SST. Ensure that the correct thermostats are installed. Start up thermostats should be used whenever eggs in the incubator are 14 days or less. This normally occurs when the incubator is new and the initial set of eggs are loaded, or when the incubator is restarted after being emptied and left idle for a time, e.g., during periods of low production. For start up thermostats see page 48.

The fan switch is located on in the centre of the fan assembly.

Fill the humidity water reservoir with distilled water to prevent mineral build up. Replace the stopper to reduce evaporation and contamination through the reservoir hole. Install wicking (P1507) on the humidistat bulb.

To Install a Thermostat The thermostat board is located on the right side of the incubator above the 4th rack. See page 25 for location. Insert thermostat into the clips.

Warning: The thermostat contacts are electrically live. Therefore, open the control panel to disconnect the power to the thermostats before removing. Failure to do so could result in injury.

To Install Wicking Hold the top of the wicking with one hand. Gently slide over the bottom of the bulb. Seat the wicking firmly around the bulb. Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking (P1507) should be 12 in. (30 cm) in length.

58


Incubator thermostat board for electro-mechanical controls with wicking P1507

Warning: Incorrectly sized wicking may give inaccurate wet bulb readings.

START UP AND 24-HOUR MONITORING You should monitor all systems for at least 24 hours before loading eggs into the incubator. This will ensure proper functioning. Load the empty racks, connect the air lines and turn alarm cables, install the curtains as described on the following pages. At this point, you will start the incu bator and monitor the systems. A checklist for both PT100 and EM controls is provided on page 65. Note: If racks are not loaded into the incubator and air lines and turn cables not connected, you will not be able to check egg turning. Doing a 24 hour check without incubator racks, should only be considered if the machine was out of operation for a short period of time, e.g., during complete clean-out and sanitation of incubators. See page 94 for details.

LOADING EMPTY RACKS INTO THE INCUBATOR Open the incubator door. Turn the fans off by depressing the fan switch located at the entrance of the incubator. Note: The location of the fan switch varies. For incubators with PT100 Controls, there are two fan switches. One is located on the display panel and the other inside the incubator at the entrance end. Use the internal entrance end fan switch. This switch puts the machine into maintenance mode– fans are off and the fan failure alarm is disabled. For incubators with electro-mechanical controls, the switch is located in the centre of the fan assembly. See illustration below.

Before loading the rack s into the incubator, remove the threshold.

Remove the threshold. Push the empty racks in one at a time. Fill positions 1 through 5 on both sides of the incubator. (Two racks are to remain outside so they can be loaded with eggs.) When loading a new rack, push the new rack against the rack presently in position 1. Gently pushing all racks forward until the new rack is pushed through, but not beyond, the gaskets. This will ensure that the new rack, which is beneath the fans, has an effective seal with the gaskets on all sides. Note: If the rack, in position 1, is pushed beyond the gaskets, remove the rack in position 5 from the exit end and relocate it to position 1. Again, make sure the rack does not pass beyond the gaskets and that there are no gaps between the racks.

PT100 Internal Fan Switch EM Fan Switch located centrally

Loading empty racks during start-up Operation Manual for Multi-Stage - Chickens

59

Later, when the egg-filled rack is loaded, and all 6 positions are filled, the same air-tight instructions will apply. The rack stop at the incubator exit provides a proper location for all racks so that the rack in position 1 is fitted against the gasket.

CONNECTING AIR LINES Locate, on the bearing panel of each incubator rack, the clear and black plastic hoses. These air lines are part of the tray frame turning mechanism. At the end of each air line is a male insert that f its into a female disconnect on the rack directly next to it. The black air line connects into the black air line of the adjoining rack, while the clear air line connects into the clear air line.

Important: Careful positioning of the rack in position 1 is critical to the operation of the incubator. Do not push the rack in position 1 beyond the gaskets located below the fans and down the walls. The rack must pass through, but not beyond, these gaskets. This creates a separation between the entrance and incubation chamber.

Racks in position 1 must fit against the gasket.

Connect clear to clear and black to black.

Position of air line connections

60


At the exit end, connect the air lines from the ceiling to the nearest rack in the right bank of racks. Again, connect black with black and clear with clear. At the entrance end, connect the air lines from the ceiling to the rack in position 1 on the left bank of racks. The black air line connects with black and the clear air line connects with clear.

CONNECTING TURN ALARM CABLES Located, on the bearing panel of each rack, are male and female connections for the egg turning signals. When connected, signals for egg turning status are transmitted to the egg turn display of the PT100 dis pl ay pa ne l or th e in fo rma ti on pa ne l of th e electro-mechanical controls. Connect the male plug into the female plug of each adjoining rack.

Connect the ends to the ceiling air lines.

Warning: The tray frames will turn when air lines are connected, possibly causing injury. Therefore, ensure that no one is working within the tray frames or any other component of the incubator racks when you are connecting the air lines.

The rack below the fans in the left bank of racks is connected to the same rack in the right bank of racks. The male and female connections of the turn indicator ceiling lines are connected at the exit end. Check for proper functioning. Disconnect one plug to simulate a failure. On PT100 systems, a light emitting diode (LED) will flash to indicate a failure. On electromechanical controls, a failure will register on the egg turn display light on the information panel.

Connect the turn alarm cables.

Position of turn alarm cables Operation Manual for Multi-Stage - Chickens

61

INSTALLING CURTAINS The purpose of the curtains is to create a tunnel that forces air to flow through the egg mass. With the exception of the curtains for position 1 racks, place each curtain so that the two curtain hanger brackets of each rack protrude through the slots in the hangers of the curtain. The curtain hangers, on the curtains of the racks in position 1, sit on top of the brackets. If you have a newer version with no rubber gaskets, the curtains of the incubator racks in position 1 must overlap the curtain angle of the centre aisle door. When you hang the curtain, in position 1, leave a clearance of 1/4 in. (6 mm) to allow the centre aisle door to open without damaging or curling the edges of these curtains.

With the exception of the rack in position 1, the brackets should protrude through the slots in the curtain hanger. Curtains on racks in position 1 sit on top of the brackets.

Important: Do not load incubator racks into, or remove racks from the machine with the curtains in place. Overlap each curtain correctly as you install it. Curtains on the position 1 racks are tucked under the edge of curtains on the position 2 racks. Curtains on the position 2 racks are tucked under the curtains on the position 3 racks, and so on. Determine whether you have an older version of the curtain angle, which has rubber gaskets, or the newer version, which has no gaskets. After the racks are in position, hang the curtains.

Tuck the curtains in position 1 under the curtains in position 2 and so on.

62


No rubber gaskets? Make sure the curtain overlaps the centre aisle door.

PREHEATING THE INCUBATOR Switch the fans on. Check for counter-clockwise rotation. Replace the thresholds at the entrance and close the doors.

24-HOUR MONITORING PRIOR TO LOADING Use the appropriate checklist (depending on whether the controls are PT100 or EM), located on page 65, to visually monitor the incubator.

Replace the thresholds.

To check the egg turning mechanism, refer to the following text.

CHECKING THE EGG TURNING MECHANISM AND THE EGG TURN ALARM After the incubator has been star ted, give the egg turning mechanism a final check. When the racks are f irst loaded into the incubator, they should be level. After the air lines are connected, the racks will turn to the left or right. (The racks will tur n in the opposite direction following a manual egg turn.)

If Using PT100 Controls Press the manual egg turn button on the display panel to activate the air valve located on the incubator roof. The racks in all incubator racks should turn each time this switch is depressed. Wait approximately five (5) minutes for the turn sequence to finish.

PT100 Manual Egg Turn

If after f ive (5) minutes all racks have not completely turned, the egg turn alarm should sound. Also, the visual alarm lamp should flash.


63

If Using Electro-Mechanical Controls Locate the time clock above the entrance end doors of the incubator.

F K N N R O U

B

Turn the dial clockwise one (1) hour on the time clock. The time clock should activate a manual egg turn sequence for up to four (4) incubators. Note: If an EM incubator is equipped with a timer board, there is audible and visual warning of a turn failure. The alarm should sound and the turn light on the information panel should also flash.

T

B

T

R N K N O

U

2

N

4

1 3

X

If using EM controls, dial the clock clockwise 1 hour to check the Egg Turn Alarm.

64


Note: To ensure proper functioning of the incubator, you should monitor all systems for at least 24 hours before loading eggs into the incubator. The following checklist has been developed to assist you in determining proper function. Checklist for Incubators with PT100 Controls Check the following: 1

2

Incubator Number 3 4 5 6

7

8

7

8

Alarm System Display Panel

Temperature Setting Humidity Setting

LEDs Amperage on Heaters

Main Auxiliary

Damper Opening* Water Reservoir Water Line Pressure (65 psig at nozzle) Spray Nozzles (Position and Pattern) Fan Operation and Blade Spacing Air Line Pressure Egg Turning *Note: Both dampers should be open 1/2 in. (13 mm) in the fully closed position.

Checklist for Incubators with EM Controls Check the following: 1

2

Incubator Number 3 4 5 6

Alarm System Control Box Pilot Lights

Main Heat Auxiliary Heat

Amperage on Heaters

Humidity Main Auxiliary

Damper Opening* Water Reservoir Water Line Pressure (65 psig at nozzle) Spray Nozzles (Position and Pattern) Fan Operation and Blade Spacing Air Line Pressure Egg Turning Motor Off Switch *Note: Both dampers should be open 1/2 in. (13 mm) in the fully closed position. Operation Manual for Multi-Stage - Chickens

65

LOADING EGGS INTO THE INCUBATOR The incubator has now been preheated and has been functioning properly for at least 24 hours. Load the eggs into clean, sanitized incubator racks. At a testing station, connect rack air lines to check that the egg turn is functioning properly. A regulated air pressure of 35 to 40 psig (240 to 275 kPa) should be available.

PREPARING FOR THE FIRST EGG SETTING Open the incubator door. Turn the fans off by depressing the fan switch located at the entrance of the incubator. Disconnect the master air line of the first rack in the left-hand row and the turn alarm cables that connect the left bank to the right bank of racks.

When pushing the racks, grip the side frame close to the ends. Watch where you are going!

Note: The location of the fan switch varies. For incubators with PT100 Controls, there are two fan switches. One is located on the display panel and the other inside the incubator at the entrance end. See illustration below. Use the internal entrance end fan switch. This switch puts the machine into maintenance mode–fans are off and the fan failure alarm is disabled. For incubators with electro-mechanical controls, the switch is located in the centre of the fan assembly. See page 59.

Roll each row of five racks forward one rack space to allow room for new racks. When pushing the racks, grip the side frame close to the ends (not near the centre). Failure to do so may result in an inward-bent cross bar that could damage eggs.

LOADING A TUNNEL INCUBATOR Gently swing back the left entrance door as far as possible. Remove the threshold. Using a team of two people roll an egg-filled rack into the incubator. The back of the rack must face the side wall of the incubator. Make sure the rubber gasket fits around the rack after it is in position. See page 60.

Use two people to load the rack. Push on the side frame. The back of the rack faces the outside wall.

The right side of the rack in position 6 will now come in contact with the rack stop. Close the left door and gently swing back the right door as far as possible. Load an egg-filled incubator rack into the right-hand bank following the same instructions.

66


Rack Stops for V-groove (right) and U-channel (left)

AFTER LOADING RACKS After the egg-filled incubator racks are loaded into the incubator: Check all egg trays for correct positioning. Check that the gasket and rack in position 1 create an air-tight seal. Connect the turn alarm cables of the position 1 racks to the position 2 racks. Connect the turn alarm cables for the left and right banks. Connect the air lines from the position 1 racks to the position 2 racks (black to black and clear to clear). Connect the air line drops from the ceiling to the left bank of racks (black to black and clear to clear). Warning: Be sure fingers, clothing and cables are clear of the rack, as turning will occur when the pressurized line is connected.

Install curtains on the newly set racks. Check all curtains for correct overlapping. Switch on the fans and check for counter-clockwise rotation. Replace the thresholds and close the incubator doors. Note: Refer to page 59 for a more in depth description of the above procedure.

ADDITIONAL LOADING INSTRUCTIONS FOR SUPER J INCUBATORS When egg-filled racks are pushed into position 6, disconnect the air lines and turn alarm cables to the incubator racks in position 6. Level the egg tray frames of the position 6 incubator racks. This will create greater air movement, thereby dissipating the heat build-up generated by the most developed embryos. However, do not remove the curtains from the racks until the racks are removed from the incubator at transfer. Connect the air lines and turn alarm cables to racks in position 5.

CHARTING EGG SETTINGS Three days after the first eggs are set, a new batch of eggs can be set in the incubator. For example, assuming the first racks were placed in the incubator on Monday, the second pair of incubator racks could be put in the incubator on Thursday. Again, fresh eggs are set into position at the entrance, and the previously set racks of eggs are pushed forward into the second position. Continue to set racks of eggs twice per week, every third or fourth day, until the incubator is filled. See pages 68 to 70. The following illustrations show how egg settings should be coordinated on a calendar basis. On the eighteenth (18th) day of incubation, eggs in position 6 are ready for transfer. See page 70 for further coordination of transfer and pull times. Note: Under no circumstances should the eggs be held in the incubator past 18-½ days (444 hours). Excessive heat is generated by these embryos shortly after this time. This heat can be harmful to the developing embryos in nearby racks.


67

LOADING THE FIRST SET INTO THE INCUBATOR

Entrance End

Exit End

Set 1

Set 1

LOADING THE SECOND SET INTO THE INCUBATOR

Entrance End

68


Exit End

Set 2

Set 1

Set 2

Set 1

LOADING THE THIRD TO THE SIXTH SET INTO THE INCUBATOR

Entrance End

Exit End

Set 3

Set 2

Set 1

Set 3

Set 2

Set 1

Entrance End

Exit End

Set 4

Set 3

Set 2

Set 1

Set 4

Set 3

Set 2

Set 1

Entrance End

Exit End

Set 5

Set 4

Set 3

Set 2

Set 1

Set 5

Set 4

Set 3

Set 2

Set 1

Entrance End

Exit End

Set 6

Set 5

Set 4

Set 3

Set 2

Set 1

Set 6

Set 5

Set 4

Set 3

Set 2

Set 1


69

TRANSFERRING THE FIRST SET OUT OF THE INCUBATOR

Entrance End

Exit End

Set 6

Set 5

Set 4

Set 3

Set 2

Set 1

Set 6

Set 5

Set 4

Set 3

Set 2

Set 1

COORDINATING SET, TRANSFER AND PULL ON A CALENDAR BASIS

SUN

70

MON

Legend Eggs to incubator Transfer to hatcher Pull chicks from hatcher Set on Monday Set on Thursday

TUE

WED

THU

FRI

WEEK 0

1

2

WEEK 1

3

4

WEEK 2

5

WEEK 3

7

1

2

8

2

3

WEEK 4

9

3

4

10

4

5

WEEK 5

11

5

WEEK 6

13

7

8

14

8

9

WEEK 7

15

9

10

16

10

11

WEEK 8

17

11

WEEK 9

19

13

1


7

13 14

20

14

15

SAT

PREPARING FOR EGG TRANSFER Before eggs can be transferred from the incubator to the hatcher, prepare and start the hatcher. Thoroughly wash and sanitize all equipment. Place hatcher baskets in the rack. When the hatcher is turned on, the operating temperature will rise, drying the racks and baskets. Note: Placing the metal hatcher baskets upside down will assist drainage and drying.

HATCHERS WITH PT100 OR PT100SMT CONTROLS

The fan switch is located o n the PT100 Display Panel.

Turn the fans off. The fan switch is located on the PT100 Control Dis play.

Control Box

CB3 CB2 CB1

Turn the power off. Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 Vac. They will cause serious shocks, injury or death if touched. Before servicing the control box, turn CB1, CB2 and CB3 off. CB1, CB2 and CB3 are located behind the panel on the front of the control box.

Open the control box. Ensure that the interior of the control box is clean and free of debris, especially metal shavings. If you are using an earlier PT100 control system, check all circuit boards for proper seating in the main board. Turn the power back on. Turn the fans back on.

PT100 Controls. Firmly seat boards. Operation Manual for Multi-Stage - Chickens

71

Temperature and Humidity Sensor Fill the humidity water reservoir with distilled water. Using distilled water will prevent mineral build up. Replace the stopper to reduce evaporation and contamination through the reservoir hole. Install wicking on the humidity probe. Ensure it is completely covered. To Install a Wick

Hold the top of the wicking with one hand. Gently slide over the extended end of the probe. Seat the wicking firmly around the probe.

Temperature and Humidity Sensor with wicking PB4077

Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking (PB4077) should be 12 in. (30 cm) in length.

Temperature and Humidity Settings Determine the hatcher capacity - Big J or Super J. Set the temperature and humidity thumbwheels located on the display panel. The set point specifications for each machine can be found on pages 47.

Thumbwheels on the PT100 Display

72


HATCHERS WITH ELECTRO-MECHANICAL CONTROLS Check the gasket on the thermostat board for possible damage. Repair or replace if required. Determine the hatcher capacity - Big J or Super J. Ensure that the correct thermostats are installed. For specifications see page 48. Fill the humidity water reservoir with distilled water to prevent mineral build up. Replace the stopper to reduce evaporation and contamination through the reservoir hole. Install wicking (P1507) on the humidistat bulb.

Thermostat Board for EM Controls with wicking P1507

To Install a Thermostat The thermostat board is located on the centre post of the hatcher. See page 25. If you are working with an older machine, first remove the cover that encloses the thermometers. Remove wicks, unplug and carefully remove the thermostat board from the centre post. Gently insert the thermostat(s) into the clips. Reinstall the thermostat board and plug into socket on the Control box. Reinsatll wicking after the board has been plugged into the socket. On older machines, replace the cover.

To Install Wicking Hold the top of the wicking with one hand. Gently slide over the bottom of the bulb. Seat the wicking firmly around the bulb. Place the free end of the wicking into the reservoir. Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking (P1507) should be 12 in. (30 cm) in length.


73

ADDITIONAL HATCHER PREPARATIONS In addition, specific hatcher preparations must be made depending on whether the hatcher is PX or 2-Door.

Preparing the PX Hatcher for Egg Transfer Check that the fan switch is in the “off ” position. Ensure the exhaust duct assembly and both duct panels are correctly latched. Check that the damper rod is held in the block by the pin. Wheel in the fan dolly and locate the front angle guides of the dolly in the roller bracket assembly. Tilt the dolly forward into position, then drop the kickstands to the floor.

Wheel in the fan dolly and locate the front angle guides of the dolly in the roller bracket assembly.

Plug in the fans and heat ring. Plug in the fan dolly. The umbilical cord from the hatcher ceiling plugs into the socket of the junction box located on the fan dolly. Once the umbilical cord is plugged into the junction box, lock it into position. Insert the spray assembly Kwik Connect into the water line. Switch the fans on, momentarily, to check for proper functioning. Fan dolly in position

Inside the PX hatcher

Insert the spray assembly Kwik Connect into the water line.

74


Install the rack guides, locating them on the anchor bolts of the hatcher floor. The short rack guide should should be located in the centre position. Roll in the dollies loaded with empty plastic baskets, and centre the dollies on the angle guides. Note: The baskets must be located against the Note: rack stop. Failure to do so will result in poor air flow.

PX Hatcher back stop

Replace the thresholds. Make sure they are properly located against the brackets. Close the doors gently, applying pressure to the door handle until the latch engages. Turn on the fans.

Preparing the 2-Door Hatcher for Egg Transfer Turn fans off. Check all spray nozzles to ensure they are centred. Check that the exhaust duct on the back of the hatcher is latched correctly. Ensure that the fans and heat ring are plugged in correctly.. Momentarily switch on the fans to verify proper rectly operation. Remember Reme mber to stand clear of the fans to avoid avoid injury.

Inside the 2-Door Hatcher

Remove the thresholds from the hatcher doorway. doorway. Swing out the entrance guides. Roll in the empty racks. Reposition the entrance guides inside the hatcher. Replace the thresholds. Make sure they are properly located in the brackets. Gently close the doors, applying pressure on the door handle until the latch engages. Turn the fans f ans on.

Properly latch the exhaust duct on the back of the hatcher.


75

Note: With U-channel tracking, the rear wheels Note: should be as far back as possible, over the roll back hump and against the stop. With V-groove tracking, the rear wheels should be located as far back as possible to the wheel tab and past the stop bolt. Incorrect positioning of hatcher racks will result in poor air flow.

Make sure the rack rea r wheels are over the bump in the U-channel rack stop (left) or the stop bolt bo lt in the V-groove V-groove rack stop (right).

Pre-Heating a Hatcher with PT100 Controls As the hatcher is heating, check the display panel for the following: 1. Flashi Flashing ng syste system m alarm LEDs LEDs for for low low tempera temperatur turee and low humidity. 2. Activ Activate ated d system system stat status us LEDs LEDs for for heat heat on and and damper closed. 3. Temperat emperature ure and and humidi humidity ty read read belo below w set point point.. 4. A flas flashi hing ng al alarm arm la lamp mp.. 5. Temper emperature ature shou should ld reach reach set set point, point, 98.5 98.5°° F (36.94°°C). (36.94 6. Hum Humidi idity ty shou should ld reac reach h set set point point,, 86.0 86.0°°F (30° (30°C). 7. The hatc hatcher her is is now now ready ready for for trans transfer fer..

PT100 Display Panel

76


Preheating a Hatcher with Electro-Mechanical Controls Switch on the fans and let the machine preheat. Verify that the heat light on the control panel and the light on the thermostat board are on. The hatcher is now ready for f or transfer. Is the heat light on the control panel on?

Is the light on the thermostat board on?

TRANSFERRING EGGS FROM INCUBATOR TO HATCHER The hatcher is preheated and a work-place has been prepared for transferring eggs. The transferring of eggs from the incubator to the hatcher can be accomplished in two ways: by manual transfer or by mechanical transfer. Each requires a different preparation. Remove incubator racks from position 6 by entering the incubator from the exit end. Note: Under no circumstance should eggs be held Note: Under in the incubator for more than 18-1/2 days (444 hours).

Set up a convenient work-place.


77

BIG J INCUBAT INCUBATORS ORS Note: Start and complete the procedure, on this Note: Start page, for one rack (either left or right) before proceeding to the remaining rack in position 6.

If eggs in position 6 racks have not been levelled already,, use the ceiling air line to do so. Disconnect the ready ceiling air line from racks in position 6. Disconnect the air lines between the racks in positions 5 and 6. Disconnect the turn alarm cables between racks in positions 5 and 6.

Level the eggs in position 6.

Connect the turn alarm alar m cables to the racks in position 5. Connect the ceiling air lines to racks in position 5.

BIG J AND SUPER J INCUBATORS Remove the curtains from only one of the position 6 racks. Swing back the rack stop (if U-channel). Open the door and remove the threshold. Depress the rack stop (if V-groove). V-groove). Move the rack from the incubator to the transfer area. Replace the threshold, rack stop (if U-channel) and close the door. Repeat the process for the remaining position 6 rack.

Work on one side only. only. Disconnect the airlines a irlines and turn alarm cables between positions 5 and 6. Connect both the ceiling turn alarm cable and the airline to the position 5 rack.

78


Disconnect the airlines between positions 5 and 6.

TRANSFER PATTERNS There are three components to the transfer pattern: 1. Pla Placeme cement nt of of eggs eggs with within in a giv given en colum column. n. 2. Pla Placeme cement nt of colu columns mns in in a rack or or on a doll dolly y. 3. Pla Placeme cement nt of the the rack or or dolly dolly withi within n the hatch hatcher er..

PLACEMENT OF EGGS WITHIN A GIVEN COLUMN Regardless of whether you are transferring the eggs to metal baskets or plastic baskets, or working on the left or right side, the following pattern for removing eggs from the incubator rack applies. Start with frame 7 and move up to frame 1.

Destacking the incubator rack. Start with frame 7 and move up to frame 1. Go to frame 15 and move up to frame 8.

Next, go to frame 15 and move move up to frame 8. All the eggs that were from this one column, will be stacked in baskets, in one column, one on top of the other.

PLACEMENT OF COLUMNS IN A RACK OR ON A DOLLY Transferring a Full Set Eggs transferred from a full set in an incubator rack will occupy identical columns in the hatcher rack or dolly.

Plastic baskets for the PX Hatcher. When emptying one column of the incubator rack, hatcher baskets will be stacked one on top of the other.

Transferring Partial Set Eggs transferred from a partial set in an incubator rack will occupy identical columns in the hatcher rack or dolly.. Empty baskets will be on the left column of the dolly left hatcher rack or dolly and the right column of the right hatcher rack or dolly dolly..

PLACEMENT OF THE RACK OR DOLL DOLLY Y WITHIN THE HATCHER Eggs that were located in the column closest to the exit end of the incubator will now be located in the middle of the hatcher. Eggs that were located in the middle column of the incubator will now be located adjacent to the eggs nearnea rest the side walls of the hatcher.

Metal baskets for the 2-Door Hatcher. When emptying one column of the incubator rack, hatcher baskets will be stacked one on top of the other. Operation Manual for Multi-Stage - Chickens

79

Eggs that were located in the column furthest from the exit end of the incubator will now be located near the side walls of the hatcher. Refer to the following illustrations for PX and 2-Door transfer patterns.

TRANSFER PATTERN FOR THE PX HATCHER

Left-hand Side

Exit Door

Position 4

Position 5 Position 6

Right-hand Side

Exit Door

PX Hatcher

TRANSFER PATTERN FOR THE 2-DOOR HATCHER

Left-hand Side

Exit Door

Position 4

Position 5 Position 6

Right-hand Side

Exit Door

2-Door Hatcher

80


METHOD 1: MANUAL TRANSFER PX Hatcher The manual method of transfer requires two people and must be completed within a reasonable length of time so that the eggs do not cool excessively. Place a work table in front of the hatcher. Position one empty egg flat cabinet in the work area. Place a bucket of water and disinfectant under or to the side of the work table for discarded eggs. Remove the rack of eggs from the left-hand side of the incubator. Position it in front of the hatcher. Allow easy access to both the incubator rack and hatcher dolly by both peo ple doing the transfer.

Start by sliding the transfer pallet under the eggs in frame 7, column 1 (left-hand side of the incubator rack). Move to column 2 through 6.

Open the right-hand hatcher door. Remove the threshold and the dolly with hatcher baskets. Close the door. Remove the baskets from the dolly and stack conveniently in the work area. Person A: stand between the incubator rack and work table. Person B: stand between the hatcher and work table. Person A: slide the transfer pallet into the left column, frame 7 and remove the eggs from the incubator rack. Place the pallet of eggs on the work table. At the same time, Person B: remove an empty hatcher basket from the stack, and place the basket on the work table. Inspect and discard cracked eggs.

Gently place the pallet on the work table.

Inspect the eggs for cracks. Discard cracked eggs.


81

Person A and B: working together, place the hatcher basket over the flats and pallet. With one hand on the hatcher basket and the other under the pallet, 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. Once the eggs have been inverted, place the basket gently on the table. To avoid breakage, do not bang the basket on the table. Person A: remove the pallet. At the same time, Person B: remove the egg flats and place them in the storage cabinet or cart.

Place the basket over the flats and pallet.

Person A: pick up the hatcher basket filled with eggs and place it on the right-hand side of the dolly. Use extreme care. Avoid slamming the basket of eggs. Person A: remove the next basket and place it on the table. You should continue removing trays of eggs from the left column in an upward direction, and placing egg-filled hatcher baskets on the right-hand side of this dolly. The middle column of the incubator rack will be transferred to the left-hand side of the dolly. Always follow the same sequence for removing eggs from the incubator rack. Start with frames 7 to 1 and then 15 to 8.

Gently turn the basket, eggs and pallet in a smooth rotating motion.

When this dolly is full, place this dolly in right-hand side of hatcher. Replace the threshold and gently close the door. Open the middle door, remove threshold, remove dolly, replace threshold and close the door. The right-hand column of the incubator rack will be transferred to the right-hand side of the second dolly. When the incubator rack is empty, remove it from the work area. Return to the incubator for the rack that is positioned on the right-hand side. Place it conveniently in front of the hatcher and repeating the process this time starting with the left-hand column (frame 7) and placing egg-filled baskets on the left-hand side of the dolly occupying the middle position. When this dolly is full, place this dolly in the middle of hatcher. Replace the threshold and gently close the door.

82


Remove that flats and pallet.

The middle column of the incubator rack will be transferred to the right-hand side of a third dolly. This dolly will occupy the left-hand side of the hatcher. The righthand column of the incubator rack will be transferred to the l eft-hand side of this same dolly. When the last dolly is loaded, place in hatcher, replace the thresholds, and gently close the doors. To ensure the alarm is functioning properly, momentarily switch off the fans. This will cause the alarm to ring. If the alarm does not ring, locate the problem and correct it immediately. The transfer is now complete.

Transferring eggs to the PX Hatcher dolly

Return the two empty incubator racks to the wash room for complete cleaning and sanitization.

2-Door Hatc her The manual method of transfer requires two people and must be completed within a reasonable length of time so that the eggs do not cool excessively. Place a work table in front of the hatcher. Position one empty egg flat cabinet in the work area. Place a bucket of water and disinfectant under or to the side of the work table for discarded eggs. Remove the rack of eggs from the left-hand side of the incubator. Position it in front of the hatcher. Allow easy access to both the incubator and hatcher racks by both people doing the transfer.

Start by sliding the transfer pallet under the eggs in frame 7, column 1 (right-hand side of the incubator rack). Move to column 2 through 6.

Open the left-hand hatcher door and turn off the f ans. Person A: stand between the incubator rack and work table. Person B: stand between the hatcher and work table. Person A: slide the transfer pallet into the right-hand column, frame 7 and remove the eggs from the incu bator rack. Place the pallet of eggs on the work table. At the same time, Person B: remove a metal hatcher basket from the bottom right-hand column of the metal hatcher rack, and place the basket on the work table. Gently place the pallet on the work table. Operation Manual for Multi-Stage - Chickens

83

Inspect and discard cracked eggs. Person A and B: working together, place the hatcher basket over the flats and pallet. With one hand on the hatcher basket and the other under the pallet, 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. Once the eggs have been inverted, place the basket gently on the table. To avoid breakage, do not bang the basket on the table.

Inspect the eggs for cracks. Discard cracked eggs.

Person A: remove the pallet. At the same time, Person B: remove the egg flats and place them in the storage cabinet or cart. Person A: pick up the hatcher basket filled with eggs and place it into the bottom right-hand tray position of the rack. Use extreme care. Avoid slamming the basket of eggs Person A: remove the next basket and place it on the table. You should continue removing trays of eggs from the right-hand column in an upward direction, and placing egg-filled hatcher baskets in the right-hand hatcher rack column from the bottom to top.

Place the basket over the flats and pallet.

Always follow the same sequence for removing eggs from the incubator rack. Start with frames 7 to 1 and then 15 to 8. The middle column of the incubator rack will be transferred into the middle column of the hatcher rack. The left-hand column of the incubator rack will be transferred into the left-hand column of the hatcher rack. When the incubator rack is empty, remove it from the work area. Return to the incubator for the rack that is positioned on the right-hand side. Place it in front of the hatcher and repeating the process this time starting with the left-hand column (frame 7) and placing eggfilled baskets in the bottom left-hand tray position. When the hatcher racks are full, close the doors gently, and switch on the hatcher fans.

84


Gently turn the basket, eggs and pallet in a smooth rotating motion.

To ensure the alarm is functioning properly, momentarily switch off the fans. This will cause the alarm to ring. If the alarm does not ring, locate the problem and correct it immediately. The transfer is now complete. Return the two empty incubator racks to the wash room for complete cleaning and sanitization.

METHOD 2: MECHANICAL TRANSFER Refer to the manufacturer ’s instructions.

Remove that flats and pallet.

Transferring the eggs into the metal hatcher racks. Start at the bottom and move up.


85

WASHING AND SANITIZING THE INCUBATOR Refer to Chapter 5 for washing and sanitizing instructions. Refer to Chapter 6 for maintenance that coincides with washing and sanitizing.

HATCHING THE EGGS During the three days eggs are in the hatcher, record the temperature and humidity twice per day. Monitor the hatch closely for the 12 hours prior to pull time. No more than 50 to 60 percent of the chicks should be hatched at this time. Ten percent of those chicks should be wet or just hatched. To avoid excessive dehydration of chicks, remove the chicks from the hatcher six (6) hours after hatching has been completed.

During the three days eggs are in the hatcher, record the temperature and humidity twice per day.

Once most of the chicks have pipped out, the hatcher temperature may be lowered gradually, but no more than 1°F (0.56°C) every four (4) hours, to a minimum of 95°F (35°C). For each 2°F (1.1°C) the temperature is lowered, the humidity should be lowered 1 °F (0.56°C).

Warning: Do not begin to lower the temperature in the hatcher until most of the chicks have pipped out.

Monitor the hatch closely for the 12 hours prior to pull time.

86


TAKING OFF THE HATCH There are various methods used to pull a hatch, ranging from the traditional manual method to semi-automated and fully automated method.

METHOD 1: MANUAL METHOD PX Hatcher - Using Plastic Hatcher Baskets and Dollies Switch off the fans, open the doors, re move the thresholds and take the dollies out from machine. Close the doors. Place the dollies in front of machine or move to takeoff area. Remove the lid from one plastic basket. Remove the top basket from one column and place on the work table. Transfer the chicks from the hatcher basket to the chick box.

When taking off the hatch, remove the lid from one column. Destack that column before going onto the next.

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 dolly, move on to another and repeat the process. After chicks have been removed from the third dolly, move on to another hatcher. Dispose of the waste, thoroughly clean and sanitize the baskets and dollies.

Carefully transfer chicks.


87

2-Door Hatcher - Using Metal Hatcher Baskets and Racks Place a work table in front of the hatcher with a supply of chick boxes near at hand. Open one door of the hatcher. Swing it gently back out of the way. Leave the fans on. Remove the bottom right-hand basket of chicks and place on the work table. Transfer the chicks, by hand, from the hatcher basket to the chick box. When all chicks have been removed from the tray, place the basket containing shells and unhatched eggs bac k into the hatcher rack. Continue to be remove hatcher baskets from the rack working in an upward direction.

Continue to be remove hatcher baskets from the rack working in an upward direction.

When all of the chicks have been removed from the baskets in the f irst rack, transfer chicks from the second rack. After chicks are transferred from the second rack, switch off the hatcher. Remove the thresholds from the doorways, take the racks out and roll them to the wash room. Dispose of the waste, thoroughly clean and sanitize the baskets and racks.

METHOD 2 AND 3: SEMI-AUTOMATED METHOD OR FULLY AUTOMATED Empty the entire hatcher and take dollies to chick takeoff area. Refer to the manufacturer ’s instructions.

88


Carefully transfer chicks.

GUIDELINES TO MINIMIZE CHICK LOSS INCUBATOR 1. Use the exit doors, not the entrance doors, when entering the incubator during daily checks. Too much cool air is drawn into the incubator when using the entrance doors. Use the entrance doors only when loading eggs into the incubator. 2. While the incubator is operating, never open both entrance and exit doors at the same time. Air movement will cause the doors to slam shut. 3. Be sure the lower duct of Space Saver Incubators is in its correct vertical position at all times. The duct requires 5/8 in. (16 mm) space between the centre post and the edge of the duct. See page 101. 4. Always switch the lights off when exiting the incubator. 5. Do not allow film and dirt build-up on the leading edge of the fan blades to exceed 1/16 in. (2 mm). 6. In the event of a power outage, open all incubator doors, both exit and entrance, 6 to 8 in. (15 to 20 cm). This will prevent overheating of the eggs.

HATCHER In the event of a power outage, open all hatcher doors. Use your judgement. How long do you expect the power outage to last? The amount you open the doors varies directly to the development of the embryos. Open the doors from a crack to halfway. If necessary, you may elect to pull the racks out. 1. Do not slam the hatcher doors. 2. Check the alarms of all hatchers daily. 3. Position the racks so their rear wheels are against the rack stop of the tracking. 4. Turn eggs in a smooth, gentle, rotating motion during transfer. Do not flip eggs quickly. 5. Carefully place the hatcher basket on the table after inverting eggs during the transfer process. Avoid banging the basket onto the table.

6. Do not slam baskets into the racks.

TRANSFERRING EGGS FROM INCUBATOR TO HATCHER A variety of methods can be used with success as long as some guidelines are followed. 1. 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. 2. 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. 3. 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 hatcher racks or onto dollies their location and identity must be recorded for the chick processing. Note: 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 incubator racks from position 6 and hold inside the incubator when preparing for transfer. This may cause air flow disruption and overheating.

4. While the incubator is operating, never open both entrance and exit doors at the same time. Air movement will cause the doors to slam shut. 5. Always turn the lights off when exiting the incubator. 6. Remove the curtains from the incubator racks only when you are ready to remove the rack from the incubator. 7. Make sure the incubator fans continue to run during the transfer process.


89

EGG TRANSFER 1. Do not remove the curtain from the incubator rack until the rack is ready to be removed from the incubator. 2. Do not remove incubator racks from position 6 and hold inside the incubator when preparing for transfer. 3. Level eggs prior to removing incubator racks from the machine. 4. After removing racks from position 6, always check for proper egg turning. 5. During transfer, handle eggs with care. 6. Do not transfer eggs into wet hatcher baskets. 7. Do not slam or tilt baskets in the racks. 8. Transfer eggs after 18 days of incubation. Do not transfer on the 17 th or 19th days of incubation. 9. Once transfer has started, make sure both racks are completed. 10. Do not allow eggs to cool excessively during transfer. 11. Do position all racks and/or dollies properly in the hatchers.

90


5. Cleaning Procedures •

general guidelines

• complete clean-out and sanitation of incubators • specific cleaning practices for hatchers


91

92


Diseases and infections always have have been a major m ajor concern of the poultry industry industry,, especially in the hatchery. Fortunately Fortunatel y, microbial contamination can be prevented and controlled through a highly disciplined, disciplined, self-regulated sanitation program. Jamesway incubators and hatchers are designed and constructed with ease of cleaning in mind. The walls and ceilings are constructed of fibreglass-reinforced plastic, while joints are sealed to eliminate trapped dirt. In addition, roof mounted controls eliminate interior wires and conduits that collect dirt and interfere with cleaning.

GENERAL GUIDELINES FOR CLEANING PRACTICES Follow the sequence listed below. Each step as well as the sequence of steps is important if disease and infections are going to be controlled. Also, follow the specific cleaning c leaning practices listed below for incubators and hatchers. Complete cleaning must proceed disinfecting. This includes floors, walls, incubators, hatchers, trays, chick processing equipment, and so on. Warning: Before commencing clean-out, turn off the fan switch. Turn Turn the power switch off.

SPECIFIC CLEANING PRACTICES FOR INCUBATORS Before each new setting of eggs, sweep or vacuum the entrance of the incubator and the area under the position 1 rack. Wipe down with disinfectant. This is where most foreign material, such as nest material, will accumulate as a result of the incubator ’ incubator ’s air flow pattern. After each transfer of eggs, sweep or vacuum the exit end of the incubator. Wipe Wipe down with disinfectant.

Remove as much organic matter and debris — debris — includincluding down, egg shells, droppings and tissue residue residue — — as as possible from all surfaces to be disinfected. Thoroughly clean all surfaces with warm water and appropriate cleaning aids. Thoroughly rinse all surfaces with abundant quantities of clean, sanitized water. This will remove most lingering detergent residue, organic matter or micro bial organisms. Apply disinfectants.

FOR PERSONNEL Follow your hatchery’ hatchery ’s bio-security procedures. This will include appropriate laundering and disinfecting of work clothes.

After a transfer and before a new set, clean and disinfect the entrance and exit end of the incubator.


93

COMPLETE CLEAN-OUT AND SANITATION OF INCUBATORS

transport of disease organisms. Re-contamination may occur if water remains on the surface.

Once the incubator has reached the appropriate tem perature and humidity humidity,, return re turn the egg-filled racks, in the correct order, to the incubator. Employees should Follow General Guidelines for Cleaning Practices follow all safety procedures when reloading the incu bator. See Chapter 4, Operational Procedures . found on the preceding page. The best time to sanitize an incubator is after egg transfer and should be done every three months.

Remove all racks from one incubator. Relocating two racks to position 6 in each of f ive adjacent incubators. This will cause no interruption inter ruption of embryonic development, and the eggs will turn routinely. routinely. Note: Egg-filled racks placed in warm passageNote: Egg-filled ways instead of incubators should not remain outside of an incubator for more than 1 hour.

SPECIFIC CLEANING PRACTICES FOR HATCHERS After each hatch is pulled, clean and sanitize the entire inner cabinet of the hatcher.

PX HATCHER Alternatively, move the racks from the incubator and place them together in a warm passageway to reduce egg cooling. To ensure each rack is returned to its proper position, number each rack according to its original position. Use a team of three or four people for this procedure. Properly organized, it should take no longer than 45 minutes to one hour to complete. When washing the incubator, do not use a high pressure washer on the motors. Do not allow water to splash on motors and electrical connections. Remove any excess water from the interior of the incubator using squeegees. Clean fan motor off switches. Remove the switches from the guards, and disconnect the terminals. Wipe any dirt off the switches with a damp cloth. Reconnect the terminals and replace the switches, ensuring they are located correctly correctly.. Clean the blades and motors with a damp sanitized cloth or brush if required. Do not use a high pressure washer on the motors.

Adhere to General Guidelines for Cleaning Practices on page 93. Use the following procedures when cleaning and sanitizing a PX Hatcher. Remove hatcher dolly guides and place with the threshthre sholds (already removed) in a convenient location for washing. Disconnect the umbilical cord from the motor frame and dolly assembly. assembly. Plug the female fem ale insert into the receptacle mounted on the rear rea r wall. Disconnect the spray assembly Kwik connect insert from the body. body. Tilt the frame and dolly assembly forward and lift the kickstands. Tilt Tilt the dolly back and pull slightly to disengage it from the support bracket. The motor frame and dolly assembly can then be rolled out of the hatcher hat cher “wheel-barrow style” style ” for cleaning. Remove the pin from the block and lift off the damper rod. Unlatch the two duct panels and open. Slide the wicking off the humidity probe. R emove the water reservoir for cleaning. Vacuum or sweep the fluff from the hatcher floor.

Ensure that all motors and electrical connections are dry before reconnecting. This will prevent damage to the equipment when the incubator is started.

Unlatch and lower the exhaust duct assembly to the floor for cleaning.

Allow all surfaces to dry thoroughly prior to reuse. Dryness helps prevent the reproduction, spread and

Thoroughly soak the roof, walls and floor to soften dirt.

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Using a high pressure washer, clean the exhaust duct and hatcher cabinet. Remove all dirt, egg shells and other debris. If deposits have built up on the roof or walls, remove them with a scrubbing br ush. Rinse the interior of the cabinet thoroughly before ap plying disinfectants. disinfectants. Check the female insert of the umbilical cord for dryness before reconnecting with the junction box. Connecting the cord into a wet junction box receptacle may cause damage to the unit. Fill the water reservoir with distilled water. Locate it on its support, and install new wicking.

Disconnect and remove the fan dolly do lly..

To attach the damper rod, hold the bushing with the Allen head screws facing you. Insert the damper rod into the bushing slot with the upright part of the rod in contact with the two self-locking pins and the rod hook protruding tow toward ard you. Insert I nsert the safety pin into the hole. Lock the pin into position with the arm over the rod hook — not not under it. Wash and sanitize the motor frame and dolly assem bly.. Return them to the hatcher, making sure to locate bly locate the front angle guide correctly. Tilt the assembly forward,, dropping the kickstands into position. The angle ward guides can be re-installed as described in the section Preparing the PX Hatcher for Egg Transfer . Reconnect the motor frame f rame and dolly. dolly. Reconnect the spray nozzle assembly. assembly. Switch the fans on momentarily to check for proper function.

With a high pressure hose, wash the exhaust duct assembly.

Place the clean dollies and hatcher baskets in the hatcher. Locate them on the angle guides and push them to the rear against the stops. Replace the thresholds and close the doors.

Using a high pressure washer, wash the exhaust duct and cabinet. Do not allow water to splash on motors or electrical connections. Operation Manual for Multi-Stage - Chickens

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2-DOOR HATCHER Adhere to General Guidelines for Cleaning Practices on page 93. Use the following procedures when cleaning and sanitizing a 2-Door Hatcher. Remove the tracking and entrance guides from the hatcher. Place them with the thresholds (already removed) in a convenient location for washing. Disconnect the hatcher-moulded cords from the fan motors and the heater. Take the spring off the latch bar at the top of the motor frame assembly, lift the latch bar, and tilt the frame back. The frame can then be removed from the floor support bracket and hatcher. Place it against the hatcher room wall for cleaning.

Remove the motor frame assembly.

Slide the wicking off the humidity probe. Remove the water reservoir for cleaning. Remove the exhaust duct from the rear of the machine. Disconnect the water line from the spray nozzles by loosening the two wing nuts on the back-up assembly. Remove the nozzles for cleaning. Place the duct and nozzle assembly in a handy location for washing. Vacuum or sweep the fluff from the hatcher floor. Thoroughly soak the interior roof, walls and floor to soften dirt. Using a high pressure washer, wash the exhaust duct and cabinet. Remove all dirt, egg shells and other de bris. If deposits have built up on the roof or walls, remove them with a scrubbing brush. Rinse the interior of the cabinet thoroughly before ap plying disinfectants. Blow dry, or wipe dry with a clean cloth, the moulded cord plug sockets. Do not connect the fans and heater to wet sockets as this may cause damage. Wash and sanitize the fans and floor tracks. Re-install them in the hatcher, locating the pins correctly. Reconnect the fans and heater. Switch on the fans momentarily to check for proper function.

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Disconnect the water line by removing the Kwik connect from the nozzle assembly.

Thoroughly clean the water reser voir. Fill it with distilled water, remount it on its support, and install a new wicking. Clean and replace spray nozzle and exhaust duct. Place clean racks and hatcher baskets in the hatcher, locating the rear wheels as far back as possible. Replace the thresholds and close the doors.

Using a high pressure washer, wash the exhaust duct and cabinet. Do not allow water to splash on motors and electrical connections.


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98


6. Routine Monitoring and Maintenance •

PT100 and EM controls

• incubators and hatchers • ventilation • checklists • specifications for ventilation and fan blade spacing


99

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The Jamesway multi-stage incubator system is an efficient material handling and incubation system, producing strong, healthy, active chicks. Nevertheless, in order to obtain optimal production, management should establish and implement regular monitoring and regular maintenance schedules. Maximum benefit will not be obtained if one is implemented without the other. Adapt a monitoring and maintenance program tailored to your specific needs using this manual and the manual for your control system. Note: The monitoring and maintenance information contained with this chapter is the basic requirement for good performance. To further enhance performance, refer to Chapter 7, Optimizing Performance on page 143.

Spacing between the intake duct and the centre post must be maintained at 5/8" (15.5 mm).

BASIC GUIDELINES FOR MONITORING EQUIPMENT Jamesway recommends that personnel from maintenance take and record the following readings using a checklist and the time schedule as suggested below. Assess each item. Is it operating satisfactorily? Unsatisfactory would include variance between set points and actual readings, equipment not functioning or showing excessive wear, dirt build up or any other potential problem. All problems should be investigated and corrected prior to further use.

Check Space Saver Intake Duct after each s et.

TEMPERATURE AND HUMIDITY READINGS Record the temperature and humidity readings. Note any variance between actual and set points. Make necessary corrections.

SPACE SAVER INTAKE DUCT

MONITORING INCUBATORS It is important to assess the general m achine condition as well as the temperature and humidity at prescribed times. This time schedule varies. General machine condition which includes such items as the position of the eggs rack, baffles, curtains, etc. should be checked immediately after every set. Spray nozzles and audible alarms should be checked daily. Also, temperature and humidity should be read, recorded and compared on a twice daily basis. Check the egg turn mechanism every three hours. A table for monitoring incubators, including items and time schedules, is on page 103. Use this table, to pre pare and follow a checklist suited to your hatchery.

Mixing of incoming fresh air with re-circulating air is important to proper machine function. To ensure that fresh air is correctly mixed, an intake duct has been installed on the centre post between the entrance end doors. The duct includes an upper section attached to the roof and a lower section attached to the centre post. The lower portion is easily removable for cleaning pur poses. Since the duct is not permanently attached and protrudes into the entrance end slightly, care must be taken when loading eggs. Check the intake duct after each set. Make sure it is in the proper position and if required, reposition. The correct spacing is 5/8 inches (15.5 mm) and the duct should be parallel with the centre post on both sides. Operation Manual for Multi-Stage - Chickens

101

MONITORING HATCHERS It is equally important to monitor hatchers. Assess the general machine condition as well as the temperature and humidity at prescribed times. This time schedule varies. General machine condition which includes such items as fan blades, heat elements, etc. should be checked prior to transfer. Spray nozzles should be checked daily. Also, temperature and humidity should be read, recorded and compared on a twice daily basis. A table for monitoring hatchers, including items and time schedules, is on page 104. Use this table, to pre pare and follow a checklist suited to your hatchery.

TEMPERATURE AND HUMIDITY Record the temperature and humidity readings. Note any variance between actual and set points. Make necessary corrections.

MONITORING VENTILATION EQUIPMENT ENVIRONMENTAL CONDITIONS Install magnehelic gauges to assist you in m onitoring the incubator and hatcher environments. Mount them in a stationary position in the vicinity of the pressure controllers, making sure they are level. Install a tee on the tube running from the exterior to the controller low pressure port. Connect a tube from the low pressure port of the magnehelic gauge to the tee. Both the controller and magnehelic should have similar readings. Establish a program to monitor and record their readings, as well as the temperature and humidity readings of each room. Readings should be recorded twice daily and twice nightly. With this type of program, you should be able to pick up any malfunction of the ventilation equipment. A table for monitoring the ventilation system is on page 105. Jamesway recommends all hatcheries maintain a catalogue of the ventilation equipment, as well as the components of that equipment, including motor size, pulley and belt size, etc. It is also important to become familiar with the operations of the ventilation equipment. From this information, you can establish both a spare parts list and a routine preventive maintenance program. Note: In some instances the pressure controller may be mounted externally to the room. In these cases the monitoring instrument must be connected to the low pressure (external reference) and room high pressure tubes. A tee on both lines is required.

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Monitoring Schedule for Incubators All of the items mentioned below should be checked, as scheduled. Refer to page 101 for additional notes. 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 Immediately After Every Set

Every 3 Hours After Set

Twice Daily

Daily

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. Display reading

RH °FWB or °CWB

2. Check reading

RH °FWB or °CWB

3. Set point

RH °FWB or °CWB

C) General Machine 1. Position of egg rack against the venturi 2. Rubber baffle condition 3. Curtain condition 4. Curtain position 5. Heat rods 6. Fan rotation 7. Motor off switches 8. Doors seal properly 9. Doors latch properly 10. Door gasket condition 11. Threshold gasket condition 12. Threshold position 13. Space Saver intake duct position 14. Egg turning mechanism 15. Audible alarms 16. Spray nozzles, no excessive dripping 17. Spray nozzle pattern 60°


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Monitoring Schedule for Hatchers All of the items mentioned below should be checked, as scheduled. Refer to page 102 for additional notes. 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 Pre-Transfer

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. Display reading

RH °FWB or °CWB

2. Check reading

RH °FWB or °CWB

3. Set point

RH °FWB or °CWB

C) General Machine 1. Fan blade condition 2. Fan blade spacing 3. Fan rotation 5. Heat rings 6. Hatcher rack track condition 7. Hatcher rack track position 8. Doors seal properly 9. Doors latch properly 10. Door gasket condition 11. Threshold gasket condition 12. Threshold position 13. Spray nozzles, no excessive dripping 14. Spray nozzle pattern 60°

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Twice Daily

Daily

Monitoring Schedule for Ventilation All of the items mentioned below should be checked, as scheduled. Refer to page 102 for additional notes. Actual readings should be recorded and compared with the optimum. Investigate any inconsistent readings. Items to be Checked

Time Schedule Twice Daily and Twice Nightly

Record in each plenum A) Magnehelic Gauge 1. Display reading

in.w.g or Pa

2. Check reading

in.w.g or Pa

3. Optimum pressure

in.w.g or Pa

B) Temperature 1. Display reading

°F or °C

2. Check reading

°F or °C

3. Optimum temperature

°F or °C

C) Humidity 1. Display reading

RH °FWB or °CWB

2. Check reading

RH °FWB or °CWB

3. Optimum humidity

RH °FWB or °CWB


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ROUTINE MAINTENANCE FOR INCUBATOR PT100 CONTROLS Refer to the checklist on page 115.

WEEKLY Reservoir

Calibration Check the accuracy of the temperature and readings. It is important that the electro-therm (HA1071) be positioned correctly next to the PT100 probe. Allow the shaft of the electro-therm to bend. Fit the tip of the shaft into the plastic sleeve and as close to the PT100 sensor as possible. They should not touch. For the testing procedure and calibration refer to The PT100SMT Controls and System Manual , page 85.

Clean the water reservoir with detergent and a bottle brush to minimize the build-up of mineral deposits. If necessary, add distilled water to the reservoir. (Filling the reservoir with distilled water may also be required between weekly cleaning.) Temperature Sensor Electro-therm Shaft

Wick Replace the wick every seven (7) days or more frequently, depending upon the mineral content of the water. Mineral deposits can build up in the wick, resulting in false readings. To Install a Wick

Hold the top of the wicking with one hand. Gently slide over the extended end of the probe. Seat the wicking firmly around the probe. Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking should be 12 in. (30 cm) in length.

1/4 in (6.4 mm) Plastic Tubing Tape holds tubing together 3/8 in. (9.5 mm) Plastic Tubing

Calibration - placement of the electro-therm (HA1071) next to the PT100 sensor

Display Panel Check the PT100 display panel during normal incubator operation. Dial the temperature or humidity thumbwheel switches up or down to simulate various machine conditions. High Humidity

EVERY THREE MONTHS Probes Hard water causes the probes to develop lime and calcium deposits. To clean the probes remove the probe baffle. Wash the probes in white vinegar or other mild acid solvent; rinse thoroughly with water. Failure to do so may result in probe deterioration. If water quality is poor, probes may require more frequent cleaning. Make sure that the temperature probe baffle is not out of position or damaged. The baffle should be on a horizontal plane to protect the probe from coming into direct contact with the spray or stray water particles.

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Dial the humidity thumbwheel down 2 degrees or more. The high humidity LED and alarm lamp should flash. Alternatively, remove the wick from the probe; remem ber to replace the wick after testing. Low Humidity

Dial the humidity thumbwheel up 2 degrees or more. The low humidity LED should flash. High Temperature

Dial the temperature thumbwheel down 1 degree. The high temperature LED and alarm should flash, the damper should start opening, water should spray, and the audible alarm should ring. Alternatively, press and hold the Test button on the display panel until a “1” appears. This will activate the audible alarm.

Low Temperature

Dial the temperature thumbwheel switch up 2 degrees. The low temperature LED should flash. Note: Remember to turn the thumbwheel switches back to their original set points once the check is completed.

Note: On the PT100SMT display, all digits and LEDs will light up when the Reset button is pushed. On the PT100 display, all digits and most of the LEDs will light up. In the System Status, only the Damper Open and Damper Closed LEDs will light. The heat, spray and egg turn LEDs will not light up unless they were already lit before the Reset button was pushed.

Fan Motor Off Switch

Turn off the fans and unplug one motor. Then, turn the fans back on. The fan failure LED should flash and the audible alarm should ring. Repeat the process, switching off the fans each time before each motor is unplugged. This checks each fan motor off switch for correct function. Turn Failure

Disconnect the turn cables at any location. The turn failure LED should flash after 5 to 7 minutes. If selected, the audible alarm also should ring.

Control Box Turn the fans off. Turn the power off - CB1, CB2 and CB3. Refer to page 56. Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off.

Power Off

Turn off the power to the incubator. All of the LEDs on the display panel should go out, causing the audible alarm to ring. Alarms

If the audible alarm bell does not ring for high tem perature, fan off or power off, check the battery, battery connections or alarm circuit.

Open the control box, and examine the PT100 boards and wiring, wiring connections and relay contacts for obvious faults such as discoloured wiring, and burned or blackened areas. Pay special attention to terminals, connections and relay points. Vacuum the interior if dust, chick down or metal shavings have accumulated. After vacuuming, ensure plug connections are snug. In older models, check that the boards are f irmly seated. Turn the power back on. Turn the fans back on.

Display Panel LEDs

Press the Reset button for less than 3 seconds to turn on LEDs. (See Note.) If a digit segment or LED does not work, replace the display panel.

PT100 Display Panel Operation Manual for Multi-Stage - Chickens

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ROUTINE MAINTENANCE FOR INCUBATOR ELECTRO-MECHANICAL CONTROLS Refer to the checklist on page 116.

EVERY THREE MONTHS Thermostats Hard water will cause lime deposits to form on the thermostats. Wash the ther mostats in white vinegar or other mild solvent. Rinse thoroughly in cold water. The clips also should be cleaned with a fine emer y cloth to remove mineral deposits. If water quality is poor, thermostats may require more frequent cleaning. Warning: The thermostat contacts are electrically live. Therefore, open the control panel and disconnect the power to the thermostats before removing. Failure to do so could result in injury.

Information Panel Incubator Thermostat Board

WEEKLY Reservoir Clean the water reservoir with detergent and a bottle brush to minimize the build-up of mineral deposits. If necessary, add distilled water to the reservoir.

Wick Replace the wick every seven (7) days or more frequently, depending upon the mineral content of the water. Mineral deposits can build up in the wick, resulting in false readings.

Check for burned wires, defective relays and burned out bulbs.

Control Box The best time to check the control box is after com plete clean-out. Wires, Connections and Bulbs

Turn the power off. Open the control box, the cover interlock switch will disconnect the power to fans. Check the wiring, wiring connections and relay contacts for obvious faults, such as discoloured wiring, or burned or blackened areas. Pay special attention to relays points, connections and terminals. Check for burnt out bulbs. Close the Control Box Cover, the fans will switch on.

To Install a Wick


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Warning: In order to test the following circuits, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Make sure all personnel are clear of the fans before switching on.

High Temperature Circuit

Motor Off Circuit

Using the insulated jumper wire, connect one clip to bottom contact of one of the thermostats. ther mostats. Attach the other clip to the top contact of the High Temperature thermostat (middle thermostat). The high temperature light on the Information Panel comes on, the audible alarm will sound, and the damper starts opening. If the heat and auxiliary heat pilot light are on they will turn off during this test. Remove jumper wire from both contacts when test is complete.

Turn off the fans and unplug one motor. Then, turn the fans back on. The Motor Off light on the information panel should illuminate and the audible alar m should ring. Repeat the process, switching off the fans each time before each motor is unplugged. This checks each fan motor off switch for correct function.

Heat Circuit Main Heat – – Attach Attach jumper wire to the bottom contact of a thermostat. Connect the other insulated alligator clip to the top contact of the Heat thermostat (5th from left) once the heat pilot light illuminates. The heat pilot light should turn off and the damper starts to open. Remove jumper wire from both contacts, the heat pilot light illuminates and the damper starts to close. Auxiliary Heat – Attach Attach jumper wire to the bottom contact of a thermostat. Connect the other insulated alligator clip to the top contact of the Auxiliary Heat thermostat (4th from left) once the auxiliary heat pilot light illuminates. The auxiliary heat pilot light should turn off. Remove jumper wire from both contacts when test is complete.

Power Off Check

Turn off the power to the incubator. All the lights for the machine being tested should go out on the Information Panel causing the audible alarm to ring. Note: If the bell does not ring to indicate high temNote: If perature, motor off and/or power off, check the battery, the battery connections or the alarm circuit. Replace pilot lights as required. Be careful during this examination of the control box since the power has not have been disconnected. Warning: If rewiring or relay replacement is required, turn off the power. Failure to do so could result in injury.

Low Temperature Circuit.

The Low Temperature Temperature circuit can be tested for proper function immediately after fresh fr esh eggs have been loaded into the machine. Using an insulated jumper wire, connect one clip to bottom contact of one of the thermostats. Attach the other clip to the top contact of the Low Temperature Temperature thermostat (2nd from left). The Low Temperature light on the Information Infor mation Panel should go out and the humidity spray will come on. Remove the jumper wire, the spray will stop and the Low TemTem perature light will come on. Humidity Circuit

To check the High Humidity Light on the Information Panel remove the wick from the humidistat. Replace the wick once the test has been completed. The Low Humidity light on the Information Panel should be checked following each set of fresh eggs.


109

ROUTINE MAINTENANCE FOR INCUBATORS

Check the water spray nozzles for correct distance from fr om the ceiling and correct positioning. Refer to page 136 for specific measurements.

Refer to the checklist on page 117. Spray Nozzle Condition

BEFORE EVERY SET Egg Tray Tray Frames F rames

Both water pressure and nozzle condition affect droplet size and number, which in turn, affects how efficiently moisture is absorbed into the air.

Inevitably, some water droplets injected into the air Before loading egg racks, check the egg tray frame stream are deposited on surfaces or objects in the flow turning mechanism. Connect the air lines to the comladen with minerals, the solids are pressed air a ir supply. If any rubbing or binding occurs, path. When water is laden locate and fix the problem. Check the turn sensors and left behind as the water evaporates. Nozzles block or partially block. The spray pattern is disrupted and excables by using a battery-operated tester. cessive dripping occurs. Drip pans, rack tops, extrusions, panels and sensors quickly become enWarning: The tray frames will turn when air lines are connected, possibly causing injury. crusted with these deposits. Not only is this unsightly unsightly,, Therefore, ensure that no one is working within but cleaning becomes difficult, protecti protective ve coatings rapthe tray frames or any other component of the idly diminish and corrosion is accelerated. Routine incubator racks when you are connecting the maintenance becomes unpleasant and machine perair lines. formance is reduced.

Space Saver Intake Duct

Low water pressure, partially blocked nozzles, or poor spray pattern can result in uneven temperature distriCheck the spacing of the intake duct. The correct spacma chine, e.g., ing is 5/8 inches (15.5 mm) and the duct should be bution, measured at the exit end of the machine, parallel with the centre post on both sides. Replace or top section temperature is highest while the bottom section is lowest. Therefore, maintain the spray nozrepair damaged parts as required. zles to specifications for optimum performance.

AFTER EVERY TRANSFER

Refer to page 42 for water pressure and water quality specifications.

Incubator Racks Grease all castor wheels and plate bearings after sanitizing the incubator racks. One or two pumps of a grease gun should suffice. Any more will result in forcing grease out through the rubber seals.

WEEKLY Spray Nozzles Clean the spray nozzles. After cleaning, check the water nozzle spray pattern. It should be a 60 degrees fan pattern and there should be no excessive dripping. If the nozzles are not producing the correct spray pattern, they may need to be replaced or the water pressure may be too low.

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Dismantle the spray nozzle for cleaning.

To Clean Spray Nozzles

Disconnect the nozzles at the Kwik coupler. Remove the nozzles from the body and dismantle. Clean the nozzle components in an ultrasonic cleaner. Alternatively, soak the parts in pure white vinegar or other mild solvent; thoroughly rinse. Do not use a wire to clean the orifice. This could result in damage and an incorrect spray pattern. Note: The spray nozzles are located in front of Note: the fans. To avoid injury, turn off the fans before removing the nozzles. Use a small, narrow stiletype stepladder to stand upon when disconnecting the nozzles.

To Check the Water Pressure

Check the water pressure at the nozzles by inserting a gauge fitted for the Kwik connect into the cou pling. The pressure should be at least 65 psi (5 bars). bars).

Water Pan Check the water pan level. Water pans should remain relatively dry. If not, excessive spraying probably probab ly has occurred. If one pan is full and the other empty,, check for blocked nozzles on the empty side. empty Otherwise, check for poor incubator room conditions. The optimum room temperature is 80.0 °F (26.6°° C), with a relative humidity of 50 to 60 (26.6 percent.

Threshold Gasket. Replace if worn.

Door Seals Check door seals for torn or missing door gaskets. Replace missing or worn gaskets. Damaged door gaskets can result in poor air a ir flow. flow.

Threshold Gaskets Check the threshold gasket for wear. If it is damaged, replace it.

Curtains Check incubator rack curtains and brackets for damage. Any split or damaged curtains should be replaced.

Rubber Gaskets Check all rubber gaskets on the rack baffle, side wall and venturi for damage. Replace any gaskets that are torn or damaged.

Gaskets on rack baffle, side wall and venturi. Check both sides.

Compressor Drain the water from the air compressor and filter/ trap regularly. Older air compressor regulators are mounted near the entrance of the incubator. The com pressed air moisture trap is not self-draining. On newer models, drain the air compressor regulator by opening the petcock at the base of the automatic drain trap; closing it when all water has been drained. All compressor tanks have a drain petcock located on the underside. Open the petcock and drain until the escaping air is clear of water or water vapour.

Drain plug

Air Compressor Regulator


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MONTHLY Heat Rods Use an ampere clamp (or amp probe) to check the amperage of each heater. The reading should be between 11 and 14 amperes. If not, replace the heater element.

Fans Check for excessive fan vibration. If you are unable to read the nameplate on the motor clearly or the motor frame assembly is rattling, the fan is vibrating too much. Before determining the cause of the excessive vibration, turn off the fans and turn off the power to the incubator. Inspect the motor mounts for loose bolts and connections, the motor for worn bearings, and the f an blade for correct pitch or distortion. See pages 138 to 142 for fan specifications. If vibration continues, re place the motor or fan blade. Note: To avoid injury, turn off the fans and turn off power before unplugging or working with fans. Before switching the fans on again, allow them to stop completely. If you do not, some of the fans may run backwards, upsetting the air flow. All fans should run in a counter-clockwise direction when viewed from behind the motor. If a fan does run backwards, simply switch it off, allowing it to stop before turning it on.

EVERY THREE MONTHS Wash and Sanitize Thoroughly clean the interior of the incubator. There is no need to leave one incubator empty for this pur pose, although some hatcheries prefer to do so. Eggs can be held in other incubators (position 6) or grouped together in a warm hallway.

Check the amperage of each heater.

Once the incubator has reached the appropriate tem perature and humidity, the egg-f illed racks can be returned in their correct order to the incubator. Proceed to check the following systems. (The best time to check these components is after eggs have been loaded into the incubator.)

Damper System Checked for proper opening and closing. The arrow on the knob on the drive box will indicate if the dampe r is closing or opening. Check for the following potential problems: If the damper opens when the main heat is on, check for reversed wiring (EM Controls only). If the incubator calls for main heat, and the damper is not moving and is open more than 1/2 in. (13 mm) the damper drive motor may need replacing. If the knob on the drive box is turning b ut the damper is not moving, replace the plastic drive block on the threaded rod in the damper drive. The drive motor should be turning at 5-1/2 to 6 revolutions per minute.

Both the intake and exhaust damper slides should move freely without binding. Also, the size of both openings The inside of the incubator can be washed and sanitized using a team of three or four people. Organized should be identical. The damper openings should be 1/2 in. (13 mm) when the damper is in the fully closed properly, it should take no longer than 45 minutes to one hour to complete. Refer to Chapter 5 - Cleaning position. Procedures on page 93. Avoid splashing water on motors and electrical connections. All motors and electrical connections must be dry before the incubator is restarted and warmed.

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Fan Motors, Switches and Blades

EVERY SIX MONTHS

Clean fan motor off switches, blades and motors during complete clean-out and sanitation. Refer to Chapter 5 - Cleaning Procedures on page 93.

Water Line Strainer

Fan Blade Spacing and Motor RPM Upon completion, check the fan spacing. See page 138 to 142 for fan spacing for current motor mount PB4723 as well as older motor mounts. Note: If fan motors are repaired or rewound, it is recommended that revolutions per minute (rpm) be checked when the motors are reinstalled in an incubator. Use motors of similar rpm (± 2.5%) in each incubator. Do not mix low rpm motor with high rpm motors and vice versa.

Clean the water line strainer, which is generally located within the incoming water line and before the first incubator. Turn off the water, loosen the retaining nut, and remove the strainer screen. Flush and rinse the screen to remove debris. Replace the screen, insert and tighten the retaining nut, and turn the water back on. The frequency of cleaning will depend upon the mineral content of the water.

Procedure for Checking RPM

Jamesway suggests the use of a strobe light to check rpm, as no physical contact with the motor is required and all motors can be checked at one time. With practice the strobe light can also be used to identify fan blade defects. Check the rpm when the motor is under load, i.e., when incubator is in normal operation and filled with eggs. Plug strobe light into power source. Stand in the entrance end of incubator. Switch on strobe light and switch off incubator lights. Adjust the strobe flash rate to a value similar to rpm marked on motor nameplate, e.g., Motor PB5146: 1625 rpm at 60 Hz, 1325 rpm at 50 Hz. Fine-tune until fan blades appear to stop. Focus on a blade that is easily identifiable (small scratch or mark) and ensure that its location does not change. If the blade in the chosen position appears to be static, record the strobe flash rate. The recorded value is the revolutions per minute of the motor or motors. The reading taken with strobe light should be within ± 2.5% of rpm specified on motor nameplate.

Water Line Strainer

V-Groove Tracks Check the level of the V-groove tracks if the space between any two incubator racks exceeds 1/4 in. (6.35 mm), top or bottom. If the space between two racks is greater at the top, then the track may be high at this point or low at the space between the preceding or following racks. Note: Close fit of all racks is essential for proper air flow. Incubator racks must never have a space between them of more than 1/4 inch (6.35 mm) top or bottom. If shifting of the floors or a loose levelling screw pushes the tracks out of level, ad just the tracks.

Note: If the fan blade does not appear to be static, i.e., the mark appears, disappears, reappears, the strobe light flash rate may be set x2, x3, x4 …. (multiple of desired rpm) too high or too low. Ad just flash rate to rpm value on the nameplate.


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To Level Tracking

To raise tracking, turn levelling screws clockwise. To lower tracking, turn levelling screws counter-clockwise. Make sure that all wheels are in contact with the track.

Racks must f it closely and evenly for proper air flow. If shifting of the floors or a loose levelling screw pushes the tracks out of level, adjust the tracks.

Switch Plates In side-door entry/exit incubators, the proper alignment of the switch plates also should be checked. Careless handling of incubator racks, such as pushing too fast, can cause the switch plates to become miss-aligned. Realign all switch plates to prevent the wheels from jamming.

Switch Plate for Side-Door Incubators

114


Maintenance Schedule for PT100 Incubator Controls All of the items mentioned below should be checked, as scheduled. Refer to page 106 and your control manual for additional notes. 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 Weekly

Every 3 Months

A) Sensor 1. Reservoir - clean and fill as required 2. Wick - replace 3. Probes - clean B) Calibration (See PT100SMT Controls Manual , page 86.) C) Display Panel - check the following LEDs 1. High Humidity 2. Low Humidity 3. High Temperature 4. Low Temperature 5. Fan Motor Off Switch 6. Turn Failure 7. Power Off 8. Alarms D) Control Box 1. Clean, vacuum if required 2. Wire condition 3. Terminal condition 4. Relay condition 5. Boards - position firmly (older models) Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. Turn the fans off. Voltage Checkpoints. If required, refer to page 88 in The PT100SMT Control and System Manual.


115

Maintenance Schedule for Electro-Mechanical Incubator Controls All of the items mentioned below should be checked, as scheduled. Refer to page 108 and your control manual for additional notes. 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 Weekly

Every 3 Months

A) Thermostat Board 1. Reservoir - clean and fill as required 2. Wick - replace 3. Thermostats - clean B) Information Panel 1. Wire condition 2. Relays and connections condition 3. Bulb condition C) Control Box 1. Clean, vacuum if necessary 2. Wire condition 3. Relays and connections condition 4. Bulb condition D) Check the following circuits 1. High Temperature 2. Heat 3. Humidity 4. Motor Off 5. Power Off Warning: 1. The thermostat contacts are electrically live. Therefore, before cleaning the thermostats, open the control panel and disconnect the power to the thermostats. Failure to do so could result in injury. 2. Before working on the Information Panel or Control Box, disconnect the fans and heater. 3. In order to check circuitry, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure. For circuit checks, refer to page 109.

116


Maintenance Schedule for Incubators All of the items mentioned below should be checked, as scheduled. Refer to pages 110–114. 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 Before After Every Weekly Every Transfer Set

Monthly

Every 3 Months

Every 6 Months

A) Egg Turning Mechanism 1. Turn operation condition 2. Air cylinder and fittings condition 3. Turn sensor and cable condition 4. Air lines condition 5. Air connections condition 6. Turning drop cords condition B) Space Saver Incubator 1. Intake duct position (5/8 inch or 15.5 mm) C) Incubator Racks 1. Wash and sanitize 2. General condition 3. Castors and bearing plate - grease D) Spray Nozzles 1. Clean, replace if required 2. Check spray pattern 3. Check position E) Water Pan 1. Check water level F) Doors 1. Doors seal properly 2. Doors latch properly 3. Door gasket condition 4. Threshold gasket condition Note: The air cylinders should be checked for leaks including damaged or worn parts. When checking racks and turning operation, look for excessive wear, binding or rubbing of any parts.


117

Maintenance Schedule for Incubators (continued) Items to be Checked

Time Schedule Before After Every Weekly Every Transfer Set

G) Rubber Gaskets 1. Baffles condition 2. Side wall condition 3. Venturi condition H) Compressor 1. Reading 2. Water build-up? 3. Tank drain I)

Heat Rods

1. Check amperage (11 to 14 amp) J) Fans 1. Fan condition (vibration?) 2. Switches, blades and motors - clean 3. Blade spacing - check 4. Motor rpm - check K) Damper 1. Opening and closing properly 2. Slides move freely 3. Damper openings equal 4. Closed position correct 5. Damper motor (5-1/2 to 6 rpm) L) General Machine 1. Wash and sanitize (See Chapter 5.) 2. Check joint, caulk as required M) Water Strainer 1. Clean N) V-Groove Tracking 1. Level as required O) Side-Door Incubators 1. Align switch plates

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Monthly

Every 3 Months

Every 6 Months

HATCHERS Routine maintenance of hatchers, while similar to that of incubators, includes additional concerns because of the twice-weekly cleaning and sanitizing programs. Frequently cleaning with a high pressure washer sub jects the hatcher to harsh conditions.

ROUTINE MAINTENANCE FOR PT100 HATCHER CONTROLS Refer to the checklist on page 129.

TWICE-WEEKLY Water Reservoir Clean the water reservoir with detergent and a bottle brush to remove chick down. Fill the water reservoir with distilled water only. This will help minimize the build-up of mineral deposits inside the reservoir.

Wick Change the wick after each hatch, and after cleaning the reservoir. Mineral deposits build up in the wicking and can cause false readings. To Install a Wick


EVERY THREE MONTHS

Make sure that the temperature probe baffle is not out of position or damaged. The baffle should be on a horizontal plane to protect the probe from coming into direct contact with the spray or stray water particles.

Calibration Check the accuracy of the temperature and readings. It is important that the electro-therm (HA1071) be positioned correctly next to the PT100 probe. Allow the shaft of the electro-therm to bend. Fit the tip of the shaft into the plastic sleeve and as close to the PT100 sensor as possible. They should not touch. For the testing procedure and calibration refer to The PT100SMT Controls and System Manual , page 85.

Display Panel When the hatcher is empty, check the display panel. Follow the procedures normally implemented following clean-up, such as hooking up the fans and heat ring, locating the tracking, and installing the thresholds. Do not load the hatcher racks. Close the doors and switch on the machine. Wait for the hatcher to warm up to about 90 to 95°F (32 to 35°C). Dial the temperature or humidity thumbwheel switches up or down, to simulate various machine conditions. High Humidity

Dial the humidity thumbwheel down 2 degrees or more below the actual humidity read-out. The high humidity LED and alarm lamp should flash. Alternatively, remove the wick from the probe.

Temperature Sensor Electro-therm Shaft

Probes Hard water will cause a build-up of calcium and lime on the probes. Wash them in white vinegar or other mild solvent, and rinse thoroughly with water. Failure to do so may result in deterioration. If water quality is poor, you may have to clean the probes more often.

1/4 in (6.4 mm) Plastic Tubing Tape holds tubing together 3/8 in. (9.5 mm) Plastic Tubing

Calibration -placement of the electro-therm (HA1071) next to the PT100 sensor


119

Low Humidity

The low humidity LED should be flashing since the actual humidity is below normal set point. If it is not, dial the humidity thumbwheel up 2 degrees or more above the actual humidity read-out. The low humidity LED should flash. High Temperature

Dial the temperature thumbwheel down one degree or more below the actual temperature re ad-out. The high temperature LED and alarm lamp should flash, the damper should start opening, the blower(s) should come on, the auxiliary damper should start to lift, the spray usually should come on, and the audible alarm should ring. Alternatively, press and hold the Test button on the display panel until a “1” appears and the audible alarm is activated. Note: Remember to move the thumbwheel dials back to their original set points once the check is completed.

Low Temperature

The low temperature LED should be flashing since the actual temperature is below set point. If not, dial the temperature thumbwheel switch up two degrees or more above the actual read-out. The low temperature LED should flash.

For PX Hatchers Air Cylinder

Check the air cylinder function by dialling the tem perature down 2 deg rees or more (see the High Temperature check.) The 1-inch (25 mm) primary auxiliary cooling cylinder will be activated first, followed by the 2-inch (5 cm) secondary auxiliary cooling cylinder.

PX Hatcher Air Cylinder Assembly

For 2-Door Hatchers Blowers

Check blowers by dialling the temperature down 2 degrees or more (see High Temperature ). The blower(s) should come on.

Power Off Alarms

Auxiliary Damper

Turn off the power to the hatcher. All LEDs on the display panel should go out and the audible alarm should ring.

Check the auxiliary damper operation (see High Tem- perature ). When the high temperature alarm rings, open the hatcher door and visually check that the auxiliary damper lifts clear of the slide.

Fan Motor Off and Door Open Alarms Turn off the fans. The alarm should ring until a door is opened. Close the door and open the other. The alarm should ring momentarily. Wait until the fans stop rotating and unplug one motor. Close the door or hold down the door switch arm to simulate a closed door. Then turn the fan back on. The motor off LED should flash and the audible alarm should ring. Repeat the process, switching off the fan before reconnecting the first motor and unplugging another. This will check each motor off current sensing device for correct functioning.

120


Control Box Turn the fans off. Turn the power off. Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 Vac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off.

Open the control box, and examine the PT100 boards and wiring, wiring connections and relay contacts for obvious faults such as discoloured wiring, and burned or blackened areas. Pay special attention to terminals, connections and relay points. Vacuum the interior if dust, chick down or metal shavings have accumulated. After vacuuming, ensure plug connections are snug. In older models, check that the boards are firmly seated. Turn the power back on. Turn the fans back on.

CB3 CB2 CB1

PT100 Control Box showing CB1, CB2 and CB3


121

ROUTINE MAINTENANCE FOR ELECTRO-MECHANICAL HATCHER CONTROLS Refer to the checklist on page 130.

AFTER EVERY HATCH Thermostat Board Clean after every hatch. Do not use a high pressure washer on thermostats. Instead, use compressed air to remove fluff from all parts of the thermostat board. To sanitize, hold the thermostat board over a basin of water with disinfectant and apply the mixture with a paint brush. Do not get the electrical connections wet. Check the rubber grommets that seal the angle thermometers. The foam gasket on the thermostat assembly should be inspected and replaced if necessary. If the gasket is installed on the centre post, check it before installing the thermostat assembly. If the thermostat board assembly is plugged in correctly, the bulb will illuminate when the hatcher is switched on. If it does not light up, replace the assembly immediately.

TWICE WEEKLY Water Reservoir Clean the water reservoir with detergent and a bottle brush to remove chick down. Fill the water reservoir with distilled water only. This will help minimize the build-up of mineral deposits inside the reservoir.

Electro-Mechanical Hatcher Thermostat Board

EVERY THREE MONTHS Thermostats Hard water will cause lime deposits to form on the thermostats. Wash the thermostats in white vinegar or other mild solvent. Rinse thoroughly in cold water. The clips also should be cleaned with a fine emer y cloth to remove mineral deposits. If water quality is poor, thermostats may require more frequent clea ning. The best time to clean the thermostats is af ter a hatch when the thermostat board is removed for cleaning. Warning: The thermostat contacts are electrically live. Therefore, open the control panel and disconnect the power to the thermostats before removing. Failure to do so could result in injury.

Wick

Control Box

Change the wick after each hatch, and after cleaning the reservoir. Mineral deposits build up in the wicking and can cause false readings.

The best time to check the control box is after washing, but before transfer. (The hatcher is empty.) Vacuum the box if dust or down has accumulated.

To Install a Wick

Hold the top of the wicking with one hand. Gently slide over the extended end of the thermostat. Seat the wicking firmly around the bulb. Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking should be 12 in. (30 cm) in length.

122


Warning: Turn off the power. Disconnect the fans and heater.

Wires, Connections and Bulbs

Motor Off Circuit

The check can be made with or without the thermostat board installed. Unlatch the control box cover and swing it down gently. If the thermostats are installed, be careful that the latch does not damage the angle thermometers. Check the wiring, wiring connections and relay contacts for obvious faults, such as discoloured wiring, or burned or blackened areas. Pay special attention to relays points, connections and terminals. Check for burnt out bulbs.

Close the doors. Connect the alligator clips to Terminal 36 or 36A on TB2 and Terminal 2 on TB1. The motor off pilot light should come on, and the alarm should ring. If one door is opened, the alarm should stop ringing. When the door is closed, the alarm should ring. Open the other door. This should cause the alarm to stop ringing. The heat pilot light should stay on.

Warning: For the following procedure, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure.

High Temperature Circuit

Using the jumper wire, connect one clip to Terminal 38 on TB2. Attach the other clip to Terminal 5 on TB1. The high temperature pilot light should come on, the damper should start opening, the auxiliary damper should lift, and the alarm should ring. The heat pilot light should stay on.

Power Off Check

Close the doors. Turn off the power to the hatcher. All of the pilot lights on the control box should go out, and the alarm should ring. Note: If the bell does not ring to indicate high temperature, motor off and/or power off, check the battery, the battery connections or the alarm circuit. Replace pilot lights as required. Be careful during this examination of the control box since the power has not have been disconnected. Warning: If rewiring or relay replacement is required, turn off the power. Failure to do so could result in injury.

Blower Circuit

Leave the clip connected to Terminal 38 on TB2 and attach the other clip to Terminal 7 on TB1. The blower light and motor (Big J) or motors (Super J) should come on. The heat pilot light should stay on. Heat Circuit

Connect the jumper wire to Terminal 38 on TB2 and Terminal 11 on TB1. The heat pilot light should go out, the damper should start opening, and the spray should come on. Humidity Circuit

Using a second jumper wire, bridge Terminals 38 on TB2 and 12 on TB1. The spray should stop, and the pilot light should go out.


123

ROUTINE MAINTENANCE FOR HATCHERS Refer to the checklist on page 131.

AFTER EVERY HATCH Wash and Sanitize Thoroughly wash and sanitize hatcher racks, dollies and the interior of the hatcher. Refer to Chapter 5 - Cleaning Procedures on page 93 for this procedure. Avoid splashing water on motors and electrical connections. All motors and electrical connections must be dry before the hatcher is restarted and warmed.

TWICE-WEEKLY Spray Nozzles Clean the spray nozzles. After cleaning, check the water nozzle spray pattern. It should be a 60 degrees fan pattern and there should be no excessive dripping. If the nozzles are not producing the correct spray pattern, they may need to be replaced or the water pressure may be too low.

Spray Nozzle Condition Both water pressure and nozzle condition affect droplet size and number, which in turn, affects how efficiently moisture is absorbed into the air. Inevitably, some water droplets injected into the air stream are deposited on surfaces or objects in the flow path. When water is laden with minerals, the solids are left behind as the water evaporates. Nozzles block or partially block. The spray pattern is disrupted and excessive dripping occurs. Drip pans, rack tops, extrusions, panels and sensors quickly become encrusted with these deposits. Not only is this unsightly, but cleaning becomes difficult, protective coatings rapidly diminish and corrosion is accelerated. Routine maintenance becomes unpleasant and machine performance is reduced.

124


Low water pressure, partially blocked nozzles, or poor spray pattern can result in uneven temperature distri bution, measured at the exit end of the machine, e.g., top section temperature is highest while the bottom section is lowest. Therefore, maintain the spray nozzles to specifications for optimum performance. Refer to page 42 for water pressure and water quality specifications. To Clean the Spray Nozzles

Remove the exhaust duct at the back of the hatcher. Disconnect the Kwik connect coupler from the spray nozzle assembly, loosen the wing nuts, and lift to remove. Unfasten the nozzles from the body and dismantle. Use an ultrasonic cleaner to clean the spray nozzle components. Alternatively, they can be soaked in pure white vinegar or other mild acid solvent. Thoroughly rinse with water. Do not use a wire to clean the orifice as it is likely to cause damage. This will result in an incorrect spray pattern. When reassembling the hatcher after clean-up, centre the spray nozzles on the fan shafts and fastened securely.

Dismantle the spray nozzle for cleaning.

To Check the Water Pressure

Check the water pressure at the nozzles by inser ting a gauge fitted for the Kwik connect into the coupling. The pressure should be at least 65 psi (4.5 bars).

Exhaust Duct Check for torn or missing gaskets before installing. Replace any gaskets if necessary.

Door Seals Check for torn or missing door gaskets. Replace any gaskets if necessary. Damaged gaskets will result in poor air flow.

Threshold Gaskets Check the threshold gaskets for tears. Torn or missing threshold seals will result in poor hatching conditions in the lower trays. Therefore, keep all threshold seals in good order. Threshold Gasket

WEEKLY All Joints After clean-up, check the silicone sealant used on all joints. If new sealant is required, warm the inside of the cabinet to remove moisture from the crevices. Using a dry clean cloth or paper towel, remove any residue with alcohol. Re-caulk with silicone sealant.

Hatcher Racks Grease all castor wheels and plate bearings after sanitizing the hatcher racks. One or two pumps of a grease gun should suffice. Any more will result in forcing grease out through the rubber seals.

After clean-up, reseal joints as required.

For 2-Door Hatchers Blower

Unplug, unlatch and remove the blower box. Clean and sanitize the area around the damper slide. Using an air hose clean the f ins of the blower fan. Replace the box and plug in the blower(s).

Use only one or two pumps when greasing the castor wheels.

Clean and sanitize the area around the damper slide. Operation Manual for Multi-Stage - Chickens

125

MONTHLY Fans Check for excessive fan vibration. If you are unable to read the nameplate on the motor clearly or the motor frame assembly is rattling, the fan is vibrating too much. Before determining the cause of the excessive vibration, turn off the fans, turn off the power to the hatcher and unplug the motor. Inspect the fan stand or motor mounts for loose bolts and connections, the motor shaft for worn bearings, and the fan blade for correct pitch or distortion. See page 140 for fan specifications. If vibration continues, replace the motor or fan blade.

Warning: To avoid injury, turn off the fans and turn off power before unplugging or working with fans. Note: Before switching the fans on again, allow them to stop completely. If you do not, some of the fans may run backwards, upsetting the air flow. All fans should run in a counter-clockwise direction when viewed from behind the motor. If a fan does run backwards, simply switch it off, allowing it to stop before turning it on.

Cabinet Finally, inspect the cabinet for signs of penetrating light. Stand inside the cabinet with the threshold installed and the doors closed. Small areas of light around door switch arms and at the ends of thresholds are considered normal. If other light is visible, such as along the top or bottom corners of the doors, adjust the door latches.

For PX Hatchers Air Cylinder Control Assembly

After clean-up, check all air cylinders and air cylinder control assembly fittings and fasteners. Adjust and tighten any that are loose. If air pressure is high, above 25 psi (1.7 bars), the extreme, rapid, back and forth movement of the piston in each cylinder can cause buddy nuts, jam nuts and socket set screws to loosen. The air pressure should be lowered to the recommended 20 psi (1.4 bars) by adjusting the regulator on the f ilter assembly. See the PX Hatcher installation and parts manual.

Heat Rings Use an ampere clamp (or amp probe) to check the amperage of each heater. The reading should be between 6 and 8 amperes. If not, replace the heater element. Check the heater for correct operation. The best time to do this is immediately after transfer, when the hatcher is calling for heat. Use an ampere clamp to check the amperage of the heater. Switch off the power, lift the cover off the control box, clamp around one of the heat ring wires (either number 10 or 50), and switch the power back on. The reading should be between 6 and 8 amperes. I f it is not, replace the heat ring. Remember that with electro-mechanical controls only, if the damper slide is open more than 1/ 8 in. (3.175 mm), the heat ring will not draw any current. With PT100 controls, the heat rings will operate regardless of damper opening.

126


Use an ampere clamp to check the amperage of the heater.

EVERY THREE MONTHS Fan Motors and Blades Clean fan motor during complete clean-out and sanitation. See pages 94 to 96. Turn off the fan motors, Clean the blades and motors with a damp sanitized cloth or brush. Be careful not to bend the blades when cleaning. Do not use a high pressure washer on the motors. Check the fan spacing upon completion. Turn the hatcher back on.

Fan Blade Spacing and Motor RPM Upon completion, check the fan spacing. See page 140 for fan spacing for current motor mounts. Note: If fan motors are repaired or rewound, it is recommended that revolutions per minute (rpm) be checked when the motors are reinstalled. Use motors of similar rpm (± 2.5%) in each hatcher. Do not mix low rpm motor with high rpm motors and vice versa.

Procedure for Checking RPM

Jamesway suggests the use of a strobe light to check rpm, as no physical contact with the motor is required and all motors can be checked at one time. With practice the strobe light can also be used to identify fan blade defects.

Note: If the fan blade does not appear to be static, i.e., the mark appears, disappears, reappears, the strobe light flash rate may be set x2, x3, x4 …. (multiple of desired rpm) too high or too low. Ad just flash rate to rpm value on the nameplate.

Damper System The arrow on the knob of the drive box will indicate whether the damper is closing when the machine calls for heat. The damper should be opening when the heat pilot light is off. After clean-up and before egg transfer, while the hatcher is warming, check for the following potential problems: If the knob on the drive box is turning b ut the damper is not moving, replace the plastic drive block on the threaded rod in the damper drive. The drive motor always should turn at 5-1/2 to 6 revolutions per minute. The intake damper slide should move freely, without binding. Also, the opening should be set at 1/8 in. (3.2 mm) in the fully closed position. If the damper is not moving but open more than 1/8 in. (3.2 mm), the sigma relay (EM Controls only) or damper motor should be replaced.

Check the rpm when the motor is under load, i.e., when hatcher is in normal operation and filled with eggs. Plug strobe light into power source. Stand in the entrance end of the hatcher. Switch on strobe light and switch off hatcher lights. Adjust the strobe flash rate to a value similar to rpm marked on motor nameplate, e.g., Motor PB5146: 1625 rpm at 60 Hz, 1325 rpm at 50 Hz. Fine-tune until fan blades appear to stop. Focus on a blade that is easily identifiable (small scratch or mark) and ensure that its location does not change. If the blade in the chosen position appears to be static, record the strobe flash rate. The recorded value is the revolutions per minute of the motor or motors. The reading taken with strobe light should be within ± 2.5% of rpm specified on motor nameplate.


127

For 2-Door Hatchers

Check for the following potential problem: If the damper is opening when the heat light is on, the wiring may be reversed (EM Controls only). Auxiliary Damper – Lift the auxiliary damper, check the gasket around the opening, then release. The lid should be under pressure from the spring in the motor and compress the gasket slightly. If not, remove the damper lid from the crank arm. Adjust the arm so it is more or less parallel with the angle of the motor mount bracket. Reattach the lid and test again. Scratch marks on the roof of the blower box also could mean incorrect assembly. See the installation and parts manual for more details. Replace the gasket, if necessary. Blower – Remove the blower box and thoroughly clean the inside of the blower. Remove dirt from hard to reach areas using compressed air. Clean dirt from the blower blades using a paint brush dipped in disinfectant. After thoroughly cleaning the blower and box, check the gasket around the base. Replace it if necessary. Reinstall the blower box, oil the bearings, plug in and chec k.

Water Line Strainer Clean the water line strainer, which is generally located within the incoming water line and before the first hatcher. Turn off the water, loosen the retaining nut, and remove the strainer screen. Flush and rinse the screen to remove debris. Replace the screen, insert and tighten the retaining nut, and turn the water back on. The frequency of cleaning will depend upon the mineral content of the water.

The frequency of cleaning the water line strainer will depend upon the mineral content of the water.

128


Maintenance Schedule for PT100 Hatcher Controls All of the items mentioned below should be checked, as scheduled. Refer to page 119 and your control manual for additional notes. 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 Twice Weekly

Every 3 Months

A) Sensor 1. Reservoir - clean and fill as required 2. Wick - replace 3. Probes - clean B) Calibration (See PT100SMT Controls Manual , page 86.) C) Display Panel - check the following LEDs 1. High Humidity 2. Low Humidity 3. High Temperature 4. Low Temperature D) Alarms 1. Power Off Alarm 2. Fan Motor Off and Door Open Alarms E) PX Hatcher 1. Air Cylinder condition F) 2-Door Hatchers 1. Blowers condition 2. Auxiliary Damper condition G) Control Box 1. Clean, vacuum as required 2. Wire condition 3. Terminal condition 4. Relay condition 5. Boards - position firmly (older models) Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. Turn the fans off. Voltage Checkpoints. If required, refer to page 88 in The PT100SMT Controls and System Manual . Operation Manual for Multi-Stage - Chickens

129

Maintenance Schedule for Electro-Mechanical Hatcher Controls All of the items mentioned below should be checked, as scheduled. Refer to pages 122 and your control manual for additional notes. 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 After Every Hatch

Twice Weekly

Every 3 Months

A) Thermostat Board 1. Wash and sanitize 2. Grommet condition 3. Gasket condition 4. Operating properly 5. Reservoir - clean and fill as required 6. Wick - replace 7. Thermostats - clean B) Control Box and Information Panel 1. Wire condition 2. Relays and connections condition 3. Bulb condition C) Check the following circuits 1. High Temperature 2. Blower 3. Heat 4. Humidity 5. Motor Off 6. Power Off Warning: 1. The thermostat contacts are electrically live. Therefore, before cleaning the thermostats, open the control panel and disconnect the power to the thermostats. Failure to do so could result in injury. 2. Before working on the Control Box and Information Panel, disconnect the fans and heater. 3. In order to check circuitry, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure. For circuit checks, refer to page 123.

130


Maintenance Schedule for Hatchers All of the items mentioned below should be checked, as scheduled. Refer to pages 124 to 128. 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


Twice Weekly

Weekly

Monthly

Every 3 Months

A) Hatcher Racks and Dollies 1. Wash and sanitize 2. General condition 3. Castors and bearing plate - grease (racks only) B) General Machine 1. Wash and sanitize (See Chapter 5.) 2. Check joints, caulk as required 3. Check for light penetration C) Spray Nozzles 1. Clean, replace if required 2. Check spray pattern 3. Check position 4. Check pressure - 65 psi (4.5 bars) D) Exhaust Duct 1. Gasket condition E) Doors 1. Doors seal properly 2. Doors latch properly 3. Door gasket condition 4. Threshold gasket condition F) Damper 1. Opening and closing properly 2. Slides move freely 3. Damper openings equal (PX Hatcher only) 4. Closed position correct 5. Damper motor (5.5 to 6 rpm) G) PX Hatcher 1. Air cylinder


131

Maintenance Schedule for Hatchers (continued) Items to be Checked


H) 2-Door Hatcher 1. Blower clean and sanitize 2. Blower thorough cleaning and sanitizing 3. Check auxiliary damper I)

Heat Rings

1. Check amperage (6 to 8 amp) J) Fans 1. Fan condition (vibration?) 2. Switches, blades and motors - clean 3. Blade spacing - check 4. Motor rpm - check K) Water Strainer 1. Clean

132


Twice Weekly

Weekly

Monthly

Every 3 Months

ROUTINE MAINTENANCE FOR VENTILATION EQUIPMENT

MONTHLY

A routine maintenance program is an integral part in keeping incubator and hatcher circulation problems to a minimum. A suggested maintenance schedule for ventilation equipment includes:

Grease and inspect bearings. Check damper actuation. Inspect vents.

AS REQUIRED

Furnaces

Cooling Units Grease and inspect bearings. Check damper actuation. If the unit is a combination cooling and heating unit, inspect vents.

Humidifiers Service the humidifiers according to geographical and climatic conditions.

Evaporative Coolers

Furnaces

Exhaust Fans

Clean or replace filters.

Grease and inspect bearings. Inspect the pulley alignment. Clean the blades.

Grease and inspect bearings.

Cooling Units Clean or replace the filters.

EVERY SIX MONTHS

WEEKLY

Furnaces

Furnaces

Clean and lubricate the motor. Tighten mounting hardware. Inspect and tighten electrical connections. Clean the blower.

Check the belt tension and condition.

Cooling Units Check the belt tension and condition.

Evaporative Coolers During the cooling season, check and adjust, as necessary, the following: float and water level, water distribution, belt tension and condition, pulley alignment, and pad condition and placement.

Exhaust Fans Check the belt tension and condition.

Cooling Units Clean and lubricate the motor. Clean the blower and cooling coils. Tighten mounting hardware and electrical connections. Replace air filters and check refrigerant charge.

Evaporative Coolers Inspect cowlings. Check and tighten electrical connections. Tighten mounting hardware and clean the blower(s).

Exhaust Fans Check damper actuation. Inspect and tighten electrical connections. Tighten mounting hardware.


133

Maintenance Schedule for Ventilation All of the items mentioned below should be checked, as scheduled. Refer to the preceding page. 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 As Required

A) Humidifiers 1. Service for climatic conditions B) Furnaces 1. Clean filters, replace as required 2. Check belt tension and condition 3. Grease and inspect bearings 4. Check damper actuation 5. Inspect vents 6. Clean and lubricate motor 7. Tighten mounting hardware 8. Inspect and tighten electrical connections 9. Clean blower C) Cooling Units 1. Clean filters, replace as required 2. Check belt condition and tension 3. Grease and inspect bearings 3. Check damper actuation 4. Inspect vents, if combination heating/cooling unit D) Evaporative Coolers (during cooling season) 1. Float and water level 2. Water distribution 3. Belt tension and condition 4. Pulley alignment 5. Pad condition and placement 6. Grease and inspect bearings 7. Inspect cowlings 8. Tighten mounting hardware 9. Inspect and tighten electrical connections 10. Clean blowers

134


Weekly

Monthly

Every 6 Months

Maintenance Schedule for Ventilation (continued) Items to be Checked

Time Schedule As Required

Weekly

Monthly

Every 6 Months

E) Exhaust Fans 1. Belt tension and condition 2. Grease and inspect bearings 3. Inspect pulley alignment 4. Clean blades 5. Check damper actuation 6. Inspect and tighten electrical connections 7. Tighten mounting hardware


135

SPECIFICATIONS FOR VENTILATION COMPONENTS INCUBATOR DAMPER POSITIONS Note: When the damper is in fully closed position, there is a spatial opening of 1/2 inch (13 mm).

1/2 in. (13 mm) fully closed

Fully closed damper position for PT100 controls


Fully closed damper position for EM controls

POSITIONING OF SPRAY NOZZLES Note: To prevent dripping, keep the nozzle tip slightly higher than the elbow centre.

Correct measurements for locating angle of spray nozzle assembly

SPACE SAVER INTAKE DUCT For correct spacing of the Space Saver intake duct, refer to page 101.

136


HATCHER DAMPER POSITIONS PX Hatcher Note: When the damper is in fully closed position, there is a spatial opening of 1/8 inch (3 mm).


Fully closed damper position for PT100 controls

2-Door Hatcher Note: When the damper is in fully closed position, there is a spatial opening of 1/8 inch (3 mm).


Fully closed damper position


137

GENERAL CONSIDERATIONS FOR FAN BLADE SPACING 1. When adjusting the fan blade spacing, use the specifications for you particular blade and motor mount. These specifications can be found on the following pages. 2. Irrespective of the blade or the motor mount, all fans should be almost centred in the venturi, i.e., half of the fan blade depth should be located slightly under half of the venturi depth. See illustration. 3. All motor mounts in a machine should be the same. Do not mix and match motor mounts. Note: When the blades are correctly spaced, the solid red line and the dotted red line should meet on the same vertical plane.

138


Locking Flange Nut Venturi

Motor Mount

Fan Blade

Motor

FAN BLADE SPACING FOR 50 HZ AREA - OLDER MOTOR MOUNT

Standard installation No spacer required.

Spacer MB10513 Motor 0.125 in. (3 mm) between fan blades and motor mount ring

A.

B. 1.75 in. (44.45 mm)

Spacer shown Venturi

Locking Flange Nut

Motor Mount Correct spacing between fan blades and older motor mount

Clockwise

PB4351 — 32˚, 4 blade Big J - 50 cycle areas Use with spacer. See B.

PB4133 — 30˚, 5 blade Big J - 50 cycle areas No spacer required. See A.

Blade rotation for 50 Hz fans


139

FAN BLADE SPACING FOR 60 HZ AREA - OLDER MOTOR MOUNT

Standard installation No spacer required.

Spacer MB10513 Motor 0.125 in. (3 mm) between fan blades and motor mount ring

A.

B. 1.75 in. (44.45 mm)

Spacer shown Venturi

Locking Flange Nut

Motor Mount Correct spacing between fan blades and older motor mount

Clockwise

PB4351 - 32˚. 4 blade Super J — 60 cycle areas Use with spacer. See B.

PB4350 - 26˚. 4 blade Big J — 60 cycle areas No spacer required. See A.

Blade rotation for 60 Hz fans

140


FAN BLADE SPACING FOR 50 HZ AREA - NEW MOTOR MOUNT Locking Flange Nut Venturi Fan Blade

Motor Mount PB4723 0.375 in. (9.53 mm)

Between fan blades and motor mount for fan blades PB4351 (32˚ CW). Big J

Motor

0.750 in. Between fan blades and motor mount (19.05 mm) for fan blades PB4133 (30˚ CW). Super J

2.437 in. (61.90 mm) Correct spacing between fan blades and new motor mount

FAN BLADE SPACING FOR 60 HZ AREA - NEW MOTOR MOUNT Locking Flange Nut Venturi Fan Blade

Motor Mount PB4723 0.375 in. (9.53 mm)

Between fan blades and motor mount for fan blades PB4351 (32˚ CW). Super J

Motor

0.750 in. Between fan blades and motor mount (19.05 mm) for fan blades PB4350 (26˚ CW). Big J

2.437 in. (61.90 mm)

Correct spacing between fan blades and new motor mount


141

FAN BLADE SPACING FOR HATCHERS

1/8 in. (3 mm) PX Hatcher Correct spacing between fan and motor mount

142


60 cycle fans 1/2 in. (13 mm) 50 cycle fans 1/4 to 3/8 in. (6 to 10 mm) 2-Door Hatcher Correct spacing between fan and motor mount

7. Optimizing Performance • additional monitoring for incubators • time of transfer • monitoring the hatch • controlling other variables • general rules for adjusting set times • analysing overall performance • troubleshooting performance


143

144


The Jamesway multi-stage incubators are designed to be low maintenance, but do require proper upkeep for optimum performance and efficiency. Basic good performance begins with using the specifications outlined in Chapter 3 and the procedures outlined in Chapters 4, 5 and 6 , as well as any additional procedures found in your control system manual. Regardless of age, size or location, your hatcher y is only as good as its operational, monitoring and maintenance programs. Do not underestimate their importance. Adapt programs tailored to your specific needs. The new procedures outlined in this chapter can be added to your existing programs. They will further enhance performance and efficiency. It is suggested that these procedures be implemented after the basic principles of running a hatchery are firmly in place.

ENTRANCE END TEMPERATURE A useful method to determine machine performance is to monitor the entrance end temperatures twentyfour (24) hours after transfer. The entrance end temperature twenty four (24) hours after transfer in the Super J and Big J incubators should be 100.3°F (37.94°C) and 100.5°F (38.06°C), respectively. Entrance end temperatures which vary more than one or two tenths of a degree from the norm indicate a problem and need correcting. Improper temperatures contribute to an accelerated, slow or uneven hatch. Note: The monitoring time, 24 hours after transfer, is specific. The internal conditions of the incubator are now stable. The eggs used for this measurement must be in an endothermic state, i.e. requiring heat. Therefore, entrance end eggs are used as they always require heat.

Note: A monitoring schedule for Entrance End Temperature, Exit End Temperature, Internal Dif- ferential Pressure, and Damper Performance (both PT100 and EM) is on page 157. Include this schedule in your existing hatchery monitoring program.

Position 2

Position 1

Monitoring entrance end temperature. Use Electro-therm HA1071. Operation Manual for Multi-Stage - Chickens

145

Entrance End Temperature Twenty-Four (24) Hours After Transfer Clip Super J

100.3°F

37.94°C

Big J

100.5°F

38.06°C

Side to side temperatures not in agreement indicate an unsuitable environmental condition. Contributing factors such as incorrect air distribution, air leakage, incorrect humidification, egg size imbalance or other miscellaneous problems require immediate attention. Unsatisfactory performance may also result if side to side temperatures are in agreement but too high or too low, i.e., the incubator is overheating or too c ool. See Troubleshooting Performance on page 155. Note: Once any adjustments have been made and satisfactory machine conditions have been achieved, it may be necessary to adjust set times. Refer to General Rules for Adjusting Set Times on page 154.

Electro-therm Egg Horizontal Brace

Egg Flat

Diagonal Brace

Tray Frame

Side view showing placement of Electro-therm HA1071. The probe should be placed on the “ egg side ” of the braces. The tip of the probe should be at the junction of the horizontal and diagonal braces.

PROCEDURE TO MEASURE ENTRANCE END TEMPERATURE Clamp the probe of the electro-therm (HA1071), on the “egg side” of the braces, at the cross brace of the incubator rack beneath the fans. Centre the tip of the probe at the junction of horizontal brace and the cross braces.

Position 2

Position 1

For the first reading, allow 10 to 15 minutes for the probe of the electro-therm to stabilize. For subsequent readings, the electro-therm will stabilize in 3 to 5 minutes. Read and record the temperature. Repeat the procedure on the other side of the incubator. Note: Use a properly calibrated electro-therm. The entrance end temperature must be taken in the incubator twenty-four (24) hours after each transfer.

146


Precise placement of the electro-therm is important.

EXIT END TEMPERATURE Monitoring temperatures at the exit end (eggs in exothermic stage, i.e. giving off heat) requires a slightly different technique from that used at the entrance end of the machine. Although measurements taken at the opposite end indicate the temperature of the air exiting the egg mass, readings taken in the 5 th or 6th position are the internal temperature of infertile eggs. The internal temperature of an infertile egg should be very close to set point, i.e., 98.8 °F (37.11°C) for the Super J incubator, 99.0°F (37.22°C) for the Big J incubator. Internal Temperature of Infertile Eggs Super J

very close to 98.8°F

37.11°C

Big J

very close to 99.0°F

37.22°C

Super J & SST very close to 98.6°F

37.0°C

Take and record internal egg temperatures 2 to 4 hours before removing the eggs for transfer. For approximately twelve to eighteen hours following transfer, the internal temperature of an infertile egg in the fifth (5 th) position will normally be two or three tenths of a degree Fahrenheit (0.1°C to 0.17°C) lower than set point.

Large discrepancies in top to bottom and/or side to side temperatures can lead to problems. Some of the common factors contributing to this unevenness in overall temperature are improper humidification and incorrect airflow and/or poor environmental conditions. See Troubleshooting Performance on page 155.

PROCEDURE TO MEASURE EXIT END TEMPERATURE Use a properly calibrated electro-therm with a nonconductive sheath such as HA1071. Probe the inside of designated infertile eggs at the top, middle and bottom tray levels of each incubator rack, both left and right as illustrated above. A variation of one or two tenths of a degree Fahrenheit (0.06°C to 0.17°C) is not uncommon, with the middle giving the highest reading and the top and bottom at set point. Note: Once any adjustments have been made and satisfactory machine conditions have been achieved, it may be necessary to adjust set times. Refer to General Rules for Adjusting Set Times on page 154.

Electro- therm inserted into an infertile egg in the middle position

Location of the infertile eggs and placement of the electro-therm probe


147

INTERNAL INCUBATOR PRESSURE Measure incubator internal differential pressure every third or fourth month to monitor the condition of the rubber gaskets, curtain seal and incubator air distribution. Investigate any inconsistencies.

Move the end of the tube to a similar location on the left side. Record the left side pressure. Compare both pressure readings. Internal Machine Pressure Super J (6th position level)

PROCEDURE TO MEASURE INTERNAL INCUBATOR PRESSURE

0.50–0.55 inches of water

The pressure should be measured with a magnehelic gauge and extension tube attached to the high pressure port. Locate the gauge in the entrance end of the incubator. Run the tube through the rubber gasket surrounding the wheels, under the racks, and locate the end between the fifth (5th) and sixth (6 th) rack position on the right side of the incubator.

124–137 Pa Big J (all racks turned) 0.40–0.45 inches of water 100–112 Pa Super J and SST (5th and 6th position level) 0.60–0.62 inches of water 149–154 Pa

Record the right side pressure.

High pressure hose attaches here.

X INCHES OF WATER

l

Low pressure hose attaches here.

.3

.2

.1 0

.1

.2

l lllllllll l l l l l l l l l .3 l l l l l l

l l l l l l l l l l l l l l l .5 l l l l .4

.4

l l .5 l l l l

MAGNEHELIC

X

MAX.PRESSURE 15 PSIG

Position 2 CAUTION

HA1031

The extension hose from the high pressure port should be located underneath the racks, between the 5th and 6th positions.

Note: The magnehelic gauge must be held in the vertical position in order to give a correct reading. Hold the gauge against the wall to ensure this position.

148


Position 1

The internal machine pressure should be in the range described in the following chart.

INCUBATOR DAMPER POSITION AT SET

Immediately after the eggs are set, the dampers close to their minimum opening of 0.5 in. ( 12.7 mm). This is Pressure imbalances can indicate any of the following: poor ventilation, impaired air flow, negative room or the intake and exhaust “closed position.” The “closed intake plenum pressure, damaged fan blades, wrong position” is maintained as long as the incubator temfan blades, improperly adjusted fan blades, door(s) per ature does not exceed its set point. Once the temperature exceeds set point, approximately 1.0 to sealing improperly, motors running backwards, gas1.5 hours after eggs have been loaded, the damper will kets at fan end in unsatisfactory condition or curtains overlapping incorrectly. See Troubleshooting Perform- start to open, and continue to do so gradually, until reaching the optimum operating range, usually within ance on page 155. 4 to 6 hours. Note: If the SST egg flat is used in the Super J incubator, static pressure readings will be higher INCUBATOR DAMPER POSITION AT –between 0.60 and 0.62 inches of water (149 to th th 154 Pa). Both the 5 and 6 position racks must TRANSFER be levelled. In the Big J incubator all racks must Twelve to twenty-four hours after the eggs have been be connected to the turning system at all times. set, eggs located in the 6 th position will be transferred No levelling of racks is required. into the hatcher. Following transfer, i.e., 6 th position Once any adjustments have been made and satracks removed, the damper will close to somewhere isfactory machine conditions have been achieved, between 0.75 and 1.0 in. (19.1 and 25.4 mm) for PT100 it may be necessary to adjust set times. Refer to Controls and 0.75 in. (11.9 mm) for Electro-M echaniGeneral Rules for Adjusting Set Times on page cal Controls for approximately 30 minutes before 154. returning to the normal operating range. The dampers will proceed to function within the standard operating range for the next three or four days, until the next DAMPER PERFORMANCE eggs are set. The optimum incubator room temperature for the Jamesway multi-stage incubator is 80 °F (26.67°C) and ELECTRO-MECHANICAL INCUBATORS the optimum relative humidity is 55 percent. A slight positive room pressure of 0.005 to 0.015 inches of water Damper performance may be adversely affected by thermostat and humidistat calibration or old thermo(1.2 to 3.7 Pa), compared to external ambient condistats, as well as poor clip condition, causing the heat tions, is recommended. Jamesway has found these rods and spray to cycle incorrectly. See table below for conditions to be ideal, and under normal circumstances the incubator intake and exhaust damper should open proper sequence. to the optimum setting, 1.50 in. (38.1 mm) with an The electro-mechanical machines must cycle properly. operating range of 1.25 to 1.75 in. (31.8 to 44.5 mm) The correct cycling sequence is: main heat on, then for PT100 Controls and 1.25 in. (31.8 mm) with an auxiliary heat on; auxiliary heat off, then main heat operating range of 1.0 to 1.50 in. (25.4 to 38.1 mm) off. for Electro-Mechanical Controls. Exhaust Damper Opening Optimum

Range

PT100 Controls

1.50 in.

1.25–1.75 in.

38.1 mm

31.8–44.5 mm

1.25 in.

1.0–1.50 in.

31.8 mm

25.4–38.1 mm

E/M Controls

Heat and spray should not be on at the same time. Spray is utilized in the Jamesway machine primarily for cooling, and if it is on with heat, it means the machine is trying to heat and cool at the same time. If spray is on when heat comes on, it should go off almost immediately. Check thermostats. All thermostats, humidistats and clips must be kept clean if the machine is to perform Operation Manual for Multi-Stage - Chickens

149

properly. A proper wick is also needed for proper cycling. Any thermostat or humidistat 5 to 7 years old probably needs replacing due to improper calibration, which causes the machine not to cycle or to cycle too slowly. Even new thermostats must be matched to achieve proper cycling. Using wrong, dirty or improperly calibrated thermostats and/or humidistats will result in altered set points, which in turn will cause the machines not to cycle properly.

Note: In EM controlled machines, you should see a one Fahrenheit degree (0.6°C) swing in temperature and no more than a four tenth Fahrenheit (0.2°C) swing in the wet bulb reading. With the correct set point of 98.8°F (37.11°C) and 86°F (30°C) the expected swing would be 98.3°F to 99.3°F (36.83°C to 37.39°C) dry bulb and 85.8°F to 86.2°F (29.89°C to 30.11°C) wet bulb.

Improper cycling will cause the machine to overheat or over cool, The resulting wide swings in temperature and /or humidity will cause problems with hatch, chick quality and performance. Use only properly calibrated and cleaned thermostats or humidistats in clean clips, with properly positioned and functioning spray nozzles, and operate the machine in correct environmental conditions. Activity

Heat Function

Spray Function

1. Heating–temperature less than set point

Aux. Heat–off

Spray–off

Main Heat–on

(Wet bulb above set point)

Damper–closing 2. Cooling–temperature greater than set point

Aux. Heat–off

Spray–on

Main Heat – off

(Wet bulb below set point)

Damper–opening 3. Heating–temperature less than set point

Aux. Heat – off

Spray–may be on or off

Main Heat–on Damper–closing 4. Heating–temperature less than 0.2 below

Aux. Heat–off

Spray–off

Main Heat–on


Damper–closing 5. Repeat cycle starting with No.1 above.

Aux. Heat–on

Spray–off

Main Heat–on


Damper–closing

150


TIME OF TRANSFER Jamesway recommends the transfer of eggs from the incubator into the hatcher be done at 444 hours of incubation for Monday and Tuesday transfers and at 432 hours of incubation for Friday and Saturday transfers, i.e., Monday & Tuesday transfer – 444 hours, eggs in incubator 6th position for 12 hours, Thursday and Friday transfer – 432 hours, eggs in incubator 6 th position 24 hours. Most of the heat produced in the Jamesway incubator is from embryonic development in eggs located in the Day of Transfer

fifth (5th) and sixth (6th) rack position. If eggs are transferred too early, i.e., the sixth (6 th) position removed, the machine has to compensate for the heat lost, causing the heat rod to come on and the damper to close more than normal. If the eggs are transferred after eighteen and a half days, i.e., the sixth (6 th) position racks are left in the machine longer than 444 hours, overheating will occur. The embryos in all positions will be affected and problems, including an increase in early dead, an uneven draggy hatch and poor chick quality, may be observed.

Time of Transfer

1. Same Day as Hatch e.g. Normally early in week Monday (Set Thursday)

444 hours of incubation, 12 hours 6 th position

Tuesday (Set Friday)

444 hours of incubation, 12 hours 6 th position e.g., Set 6:00 a.m. Transfer 6 p.m.

2. Day after Hatch e.g. Normally late in week Friday (Set Monday)

432 hours of incubation, 24 hours 6 th position

Saturday (Set Tuesday)

432 hours of incubation, 24 hours 6 th position e.g., Set 6:00 a.m. Transfer 6:00 a.m.

SUN

MON

TUE

WED

THU

FRI

WEEK 0

1

2

WEEK 1

3

4

WEEK 2

5

WEEK 3

7

1

2

8

2

3

WEEK 4

9

3

4

10

4

5

WEEK 5

11

5

WEEK 6

13

7

8

14

8

9

WEEK 7

15

9

10

16

10

11

WEEK 8

17

11

WEEK 9

19

13

1

SAT

Legend Eggs to incubator Transfer to hatcher Pull chicks from hatcher Set on Monday Set on Thursday

7

13 14

20

14

15

Schedule for incubating, transferring and hatching of eggs


151

MONITORING THE HATCH Twelve hours prior to pull time, check on the progress of the hatch. Sample count three trays – top, middle and bottom – on each side of the hatcher. Ideally 50 to 60 percent of the chicks should be out of the shell and 10 percent of them still wet, or recently hatched. See Hatching the Eggs on page 86 and Troubleshooting Performance on page 155. Ideal Progress of Hatch

Time

50–60% out of shell

12 hours prior to pull

10% still wet/just hatched 12 hours prior to pull

If your observations differ from those above, check hatcher temperature, humidity, calibration, equipment specifications and ventilation. Dehydration is likely if more than 60 percent of birds are out twelve hours before pull. An uneven draggy hatch is possible if less than 50 percent of the chicks have hatched twelve hours prior to pull time. Set time adjustments may be necessary once all other operational criteria have been checked and proved correct. See Monitoring Schedule for Incubators and Hatchers on pages 101 and 102, and Chapter 3, Tem- perature and Humidity Specifications on page 47.

CONTROLLING OTHER VARIABLES TO IMPROVE PERFORMANCE GROUPING OF EGGS—FLOCK AGE AND EGG SIZE The supply of eggs to the hatchery, which should be reasonably constant throughout the year, originates from a mix of young, prime and old flocks. The ratio of young, prime and old flocks required to maintain this constant supply is about 20:60:20, giving a mean flock age of between 41 and 44 weeks. To achieve optimum results from your equipment, the mean age of the flocks producing the eggs in the incu bator should be 41 to 44 weeks and the ratio of eggs in the incubator from young, prime and old flocks should also be as close as possible to 20:60:20. The incubator

152


set point for your machines is the best temperature at which to incubate the average fertile egg based on flock age. Avoid grouping eggs according to size and age of flock, a practice not recommended by Jamesway. Recommended Grouping of Eggs Ratio of Young/Prime/Old

20/60/20

Young Flock 20%

Age 26–33 weeks

Prime Flock 60%

Age 34–52 weeks

Old Flock 20%

Age 53+ weeks

Mean

Age 41–44 weeks

PROBLEMS CAUSED BY INCORRECTLY GROUPING EGGS Continually setting complete groups of small, medium or large eggs, or eggs from young, prime or old flocks, is likely to produce inconsistent results. For example, an incubator which is usually set with sma ll eggs will likely have increased airflow and a lower pressure differential. The reverse is true if large eggs are always set in a machine. Under these circumstances it may be necessary to adjust dry and wet bulb temperatures to compensate for a lower or higher embryonic heat production. Other problems may also arise. Air, like water, takes the path of least resistance, and if one side of the setter is loaded with small eggs and the other with large, more air will flow through the side holding the smaller eggs. This will result in a side to side airflow, temperature and pressure imbalance, and is likely to cause a reduction in hatch and chick quality from both large and small eggs.

OPTIMUM GROUPING OF EGGS Following the recommendations given above will ensure that airflow, temperature gradients through the egg mass, pressure differentials across ends (entrance and exit) and side to side balance will be consistent from one machine to the next. It is easier and simpler to operate and maintain all machines in a similar manner than it is to frequently adjust parameters for individual incubators. In general, any deviation from recommended parameters will result in the need to adjust incubator temperature set

points and other operational procedures, with the ever pr ese nt li ke li ho od fo r er ror s an d de cli ne in performance.

time between gathering and placement in the cooler, the temperature and humidity of the cooler and the egg grading location.

Note: Since it may not always be possible to attain the flock age ratio or recommended egg settings, some temperature adjustments and operational changes may be required. Should this be the case, please contact Jamesway for further information and assistance on optimizing your equipment.

To prevent pre-incubation and sweating of eggs, trans port eggs only in a controlled environment egg truck, and handle and store eggs properly at the hatchery. Preincubation should be eliminated at the source to achieve desired results.

Refer to General Rules for Adjusting Set Times on page 154.

PRE-INCUBATION AND PRE-WARMING OF EGGS Since most hatcheries do not provide proper facilities in which to pre-warm eggs before placing them in the incubators, Jamesway does not recommend pre-warming of eggs prior to set. Set eggs directly from the egg storage area. Placing eggs in the corridor in front of incubators several hours before setting does not allow all eggs to warm up equally. Eggs in the centre of the incubator racks will take longer to reach room temperature than eggs near the outside. Incorrect pre-warming of eggs can have a harmful effect on results, the most common being an uneven hatch. Condensation on the eggshell surface may also occur if the room into which the eggs are being placed is improperly conditioned. Proper pre-warming of eggs requires some method of forcing air through the egg mass in order for all eggs to warm at equal rates. Since most hatcheries do not provide such facilities, Jamesway recommends direct removal of the eggs from the cool room to the incubator, where adequate air movement is available. If condensation on the eggshells does occur, the presence of moisture on the shell surface is brief and less likely to have a detrimental impact on embryonic growth. Pre-incubation in the fresh eggs can amplify any observed problem with uneven or accelerated hatch. The breeder department needs to be involved in helping to eliminate this serious concern. Some areas to check when determining causes of pre-incubation include the number of time eggs are gathered from the nests, the

Note: Mottled and weak germal discs in the fresh eggs, which can also be noted in the fresh egg breakout, indicate some breeder flock stress.

PARTIAL AND SKIPPED SET Jamesway’s multi-stage incubators rely on embryo heat to establish an optimum energy balance inside the machine. Any disruption of this balance results in lost heat and a need for compensation. In general, a partial setting or skipping a set altogether is not recommended, although occasionally it may be unavoidable.

SKIPPED SET If it is necessary to skip a set, the empty incubator racks should be placed into the incubator in position one, beneath the fans, in the usual manner, i.e., the empty rack is treated as if it were full and loaded into the incubator accordingly. To help compensate for the loss of embryonic heat, the following set should be loaded about two hours earlier than normal.

PARTIAL SET Partial sets should be treated in a similar manner to a skipped set. Place eggs against eggs, and the empty column or spaces directly beneath the fans, when loading partially set racks. Depending on the number of eggs in the racks, load the next eggs an hour or two earlier than normal. This will compensate for some of the embryonic heat lost when the partial set of eggs reaches the exothermic stage. Note: Refer to Loading a Partial Set on page 54 and General Rules for Adjusting Set Times on page 154.


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GENERAL RULES FOR ADJUSTING SET TIMES Once any adjustments have been made and satisfactory machine conditions have been achieved, it may be necessary to adjust set times. In general these rules apply: 1. At machine start up or when one or more sets are skipped, set points are based on the days of incubation of the oldest eggs in the incubator. (Refer to Chapter 3 - Temperature and Humidity Specifications .) 2. Whenever the oldest eggs in the incubator have less than fourteen (14) days of incubation, adjustments in the set point are needed, due to the loss of embryonic heat produced by eggs in the 5 th and 6th position. 3. If a single set is skipped it is beneficial to set the next eggs two (2) hours earlier than normal, to help compensate for the loss of embryonic heat.

Note: Time of set adjustments is based on the setting time of the eggs that were transferred earlier that day or the day before and are currently in the hatcher. Using the examples given a reading is taken Saturday, 24 hours after a Friday morning transfer. Considering that the eggs in the hatcher had been loaded into the incubator on a Monday at 6 o’clock in the morning, nineteen (19) days earlier, the set times are as follows: Temperature 100.5°F (38.06°C), set time Monday at 6:30 to 7:00 a.m. (later) Temperature 100.7°F (38.17°C), set time Monday at 7:00 to 8:00 a.m. (later) Temperature 100.1°F (37.78°C), set time Monday at 5:00 to 5:30 a.m. (earlier) Temperature 99.9°F (37.72°C), set time Monday at 4:00 to 5:00 a.m. (earlier).

ANALYSING OVERALL PERFORMANCE

4. Set eggs from young breeder flocks (26 through 33 weeks of age) two (2) hours earlier. 5. Set eggs from old flocks with low fertility (53 weeks and older) two (2) hours earlier. 6. For each one tenth (0.1°F or 0.6°C) variation from 100.3°F (37.94°C) for the Super J or 100.5°F (38.06°C) for the Big J a thirty (30) minute adjustment is needed. For example, in a Super J incubator with a desired entrance end temperature of 100.3°F (37.94°C): • If actual temperature is 100.5 °F (38.06°C), set eggs 1/2 to 1 hour later. • If actual temperature is 100.7 °F (38.17°C), set eggs 1 to 2 hours later. • If actual temperature is 100.1 °F (37.78°C), set eggs 1/2 to 1 hour earlier. • If actual temperature is 99.9°F (37.72°C), set eggs 1 to 2 hours earlier.

VARIATION OF AIR CELL SIZE When candling the eggs in your incubators to take the internal infertile egg temperature, you may notice some variation in the size of the air cells. This indicates im proper moisture loss in the eggs, which causes problems with chick quality, performance and hatchability. As conditions are corrected (as discussed and outlined throughout this chapter), you should see this concern eliminated. Note: When doing an egg breakout and observing the hatch in the hatcher trays, you will also notice chicks pipped both high and low, which supports your findings during the candling that there is a variation in air cell size.

HATCHER RESIDUE BREAKOUT

Analysis of the hatch residue is one of the most useful tools for monitoring hatchery efficiency, but unfortu7. Eggs held in storage 0 to 7 days, no adjustment. nately each hatch day this information is thrown away 8. Eggs held in storage 7 to 10 days set one (1) hour before it can be compiled. Although sorting through earlier. the hatch residue is a messy job and takes some time, 9. Eggs held in storage for 10 days or longer set two the information obtained will help you recognize and (2) hours earlier.

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monitor problems that affect the efficient operation of your hatchery. A hatch residue breakout can identify breeder problems, as well as identify hatchery-related problems. The implementation of a monthly hatch residue breakout on every flock being hatched, regardless of hatchability or performance, is recommended. Com pile and monitor the information to help make your operation more efficient and productive. See Analys- ing Hatch Residue on pages 162 to 166 for further details.

Possible Solutions: Balance both sides of incubator. Use similar age flock. Check fans, gaskets, curtains Check ventilation Check spray nozzles

2. UNEVEN TEMPERATURE, TOP TO BOTTOM FRESH EGG BREAKOUT A sample of fresh eggs from the egg room from flocks in production can be a source of valuable information. These eggs, when broken out, can reveal areas of concern such as fertility, pre-incubation and mottling. If you are experiencing a high early death loss of em bryos, this sampling can help pinpoint some probable causes. Armed with this information, you can go to the source of the problem and take the necessary corrective action.

Possible Causes: Improper humidification Poor airflow Incorrect ventilation Possible Solutions: Check spray nozzles Check fans, gaskets, curtains

TROUBLESHOOTING PERFORMANCE

Check ventilation

3. DAMPERS NOT IN RANGE Several factors can affect the efficiency of incubator performance. The following suggests possible observations, causes and remedies.

1. UNEVEN TEMPERATURE, SIDE TO SIDE Possible Causes: Improper setting Egg size not similar Flock age not similar Age of eggs Poor airflow Incorrect ventilation Improper humidification

Optimum Range: 1.25 to 1.75 in. (3.18 to 4.45 cm) for PT100 Controls and 1.0 to 1.5 in. (2.54 to 3.81 cm) for E/M Controls Possible Causes: Incubator too cool Incubator too hot Poor airflow Poor external conditions Improper humidification Possible Solutions: (See Damper Performance for details.) Check fans, gaskets, curtains Check ventilation Check spray nozzles


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4. HIGH EARLY EMBRYO MORTALITY Possible Causes: Damper out of range >1.75 in. (4.45 cm) for PT100 Controls or >1.5 in. (3.81 cm) for E/M Controls

6. DIFFERENTIAL PRESSURE OUT OF RANGE Ranges: Super J, 0.50 to 0.55 in. w. g. (124 to 137 Pa)

Poor external conditions

Big J, 0.40 to 0.45 in. w. g. (100 to 112 Pa)

Incubator too hot

SST Flat, 0.60 to 0.62 in. w. g. (149 to 154 Pa)

Insufficient humidification

Possible Causes:

Poor air flow

Poor ventilation

Transferring too late

Damaged gaskets

Possible Solutions: (See Damper Performance on page 149 for details.) Check ventilation Check spray nozzles Correct transfer time

Curtain overlap Improper setting Motors running backwards Possible Solutions: (See Internal Incubator Pressure for details.)

5. HIGH LATE EMBRYO MORTALITY

Check gaskets, curtains

Possible Causes:

Check Grouping of Eggs on page 152.

Damper out of range <1.25 in. (3.18 cm) for PT100 Controls or <1.0 in. (2.54 cm) for E/M Controls Poor external conditions Incubator too cool Excessive humidification Transferring too early Possible Solutions: (See Damper Performance on page 149 for details.) Check ventilation Check spray nozzles Check heat rods Correct transfer time

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Check motors

Monitoring Schedule for Incubators and Hatchers Check all of the items below as scheduled. Refer to pages 145 to 150 for additional notes Assess each item. Unsatisfactory assessments include: values or performance not within tolerance, imbalances, or any variance from the norm. Investigate any discrepancy. Resolve the problem to avoid loss. Items to be Checked

Time

Entrance End Temperature Air Temperature

24 hours post-transfer

Super J

100.3°F (37.9°C)


Big J

100.5°F (38.1°C)


Exit End Temperature Internal Egg

2–4 hours pre-transfer

Super J

98.8°F (37.1°C)


Big J

99.0°F (37.2°C)


SST Flat 98.6°F (37.0°C)


Internal Differential Pressure 5th /6th Position (Six racks per side)

every 3 months

Super J

0.50–0.55 in. w.g. (124–137 Pa) (6 th position level)

Big J

0.40–0.45 in. w.g. (100–112 Pa) (All positions turned)

SST Flat 0.60–0.62 in. w.g. (149–154 Pa) Super J only, 5 th & 6 th position level) Damper Performance—PT100 Controls Sequence for Ideal Conditions 0.5 in. (1.27 cm)—closed position

Eggs set

Damper starts opening

1.0–1.5 hours after set

Range

1.25–1.75 in. (3.18–4.45 cm)

4-6 hours after set

0.75–1.0 in. (1.91–2.54 cm)

After transfer

Range

1.25–1.75 in. (3.18–4.45 cm)

0.5 hours after transfer

Range

1.25–1.75 in. (3.18–4.45 cm)

for next 3–4 days

Damper

Damper Performance—E/M Controls Sequence for Ideal Conditions 0.5 in. (1.27 cm)—closed position

Eggs set

Damper starts opening

1.0–1.5 hours after set

Range

1.0–1.5 in. (2.54–3.81 cm)

Damper 0.75 in. (1.91 cm)

4–6 hours after set After transfer

Range

1.0–1.5 in. (2.54–3.81 cm)

0.5 hours after transfer

Range

1.0–1.5 in. (2.54–3.81 cm)

for next 3–4 days


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8. Chick Development and Troubleshooting Hatchability •

chicken embryology

• analysing chick residue


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CHICKEN EMBRYOLOGY, THE TIMING OF MAJOR EMBRYONIC DEVELOPMENTS 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 Normal size of air cell at various stages of incubation

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

35 hours, Beginning of formation of ear pits 36 hours, First sign of amnion 46 hours, Formation of throat

Day 3 Beginning of formation of nose, wings, legs, allantois Amnion completely surrounds embryo

Day 4

22 hours, Beginning of formation of head

Beginning of formation of tongue

23 hours, Appearance of blood islands

Embryo completely separates from yolk sac and turned on left side

24 hours, Beginning of formation of eyes

Allantois breaks through amnion

Day 2 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

Day 5 Preventriculus and gizzard formed Formation of reproductive organs - sex division

Day 6 Beginning of formation of beak and eggtooth Main division of legs and wings Voluntary movement begins Operation Manual for Multi-Stage - Chickens

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Day 7 Indication of digits in legs and wings Abdomen more prominent due to development of viscera

Day 18 Growth of embryo nearly complete

Day 19 Yolk sac draws into body cavity through umbilicus

Day 8 Beginning of formation of feathers

Day 9

Embryo occupies most of space with in egg except air cell

Day 20

Embryo begins to look bird-like

Yolk sac completely drawn into body cavity

Mouth opening appears

Embryo becomes chick, breaks amnion, starts breathing in air cell

Day 10

Allantois ceases to function and starts to dry up

Beak start to harden Skin pores visible to naked aye Digits completely separated

Day 12

Day 21 Chick hatches

ANALYSING HATCH RESIDUE

Toes fully for med First few visible feathers

Day 13 Appearance of scales and claws Body fairly well covered with feathers

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).

Day 14 Embryo turns its heat towards blunt end of egg

1. CHICKS HATCH LATE Possible causes:

Day 15 Small intestines taken into body

Variable room temperature Large eggs

Day 16 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

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Old eggs Incorrect thermometer Temperature too 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

Temperature too high, 20 to 21 days Humidity too low, 20 to 21 days

Possible causes: Inadequate breeder ration

6. MALPOSITIONS

Temperature too high, 1 to 10 days

Possible causes:

Humidity too high, 19th day

Inadequate breeder ration Egg set small end up

3. FULLY DEVELOPED EMBRYO WITH BEAK IN AIR CELL Possible causes: Inadequate breeder ration

Odd-shaped eggs set Inadequate turning

Incubator air circulation poor

7. STICKY CHICKS (ALBUMEN STICKING TO CHICKS)

Temperature too high, 20 to 21 days

Possible causes:

Humidity too high, 20 to 21 days

Eggs transferred too late

Shell quality


4. CHICKS PIPPING EARLY

Down collectors not adequate

Possible causes: Temperature too high, 1 to 19 days Humidity too low, 1 to 19 days 5. Chick Dead After Pipping Shell Possible causes:

8. STICKY CHICKS (ALBUMEN STICKING TO DOWN) Possible causes: Old eggs

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 CO2 content of air too high, 20 to 21 days Incorrect temperature, 1 to 19 days

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 Operation Manual for Multi-Stage - Chickens

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10. EGGS EXPLODING

Nutrition

Possible causes:

Humidity

Bacterial contamination of eggs

Fumigation

Dirty eggs

Insufficient turning of 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

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

12. BLOOD RING (EMBRYONIC DEATH 2 TO 4 DAYS)

14. AIR CELL TOO SMALL

Possible causes:

Possible causes:

Heredity

Inadequate breeder ration

Diseased breeding flock

Large eggs

Old eggs


Rough handling of hatching eggs Incubating temperature too high Incubating temperature too low

Possible causes:

Holding temperature

Small eggs

Contamination

Humidity too low, 1 to 19 days

Shell quality Young flock

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15. AIR CELL TOO LARGE


16. CHICKS HATCH EARLY

20. SOFT CHICKS

Possible causes:

Possible causes:

Small eggs

Unsanitary incubator conditions

Leghorn eggs versus meat-type eggs

Temperature too low, 1 to 19 days

Incorrect thermometer



21. CHICKS DEHYDRATED Possible causes:

17. CHICKS TOO SMALL

Eggs set too early

Possible causes:

Humidity too low, 20 to 21 days

Eggs produced in hot weather Small eggs Thin, porous eggshells Humidity too low, 1 to 19 days

18. CHICKS TOO LARGE Possible causes: Large eggs Humidity too high, 1 to 19 days

Chicks left in hatcher too long after hatching completed

22. MUSHY CHICKS Possible cause: Unsanitary incubator conditions

23. UNHEALED NAVEL, DRY Possible causes: Inadequate breeder ration

19. TRAYS NOT UNIFORM IN HATCH OR CHICK QUALITY

Temperature too low, 20 to 21 days

Possible causes:


Eggs from different breeds

Wide temperature variation in incubator

Humidity not lowered after hatching completed

Eggs of different sizes Eggs of different ages when set Disease or stress in some breeder flocks Inadequate incubation air circulation & heat distribution

24. UNHEALED NAVEL, WET AND WITH ODOUR Possible cause: Omphalitis Unsanitary hatchery and incubators


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25. CHICKS CANNOT STAND Possible causes: 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

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

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9. Appendices • the importance of egg and chick transportation • give day old chicks the best start • hatchery sanitation concepts, logistics and assessment • practical hatchery sanitation guidelines • what to do with hatchery waste • breakout analyses guide for hatcheries • glossary


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APPENDIX I - THE IMPORTANCE OF EGG AND CHICK TRANSPORTATION by Ron Meijerhof , Centre for Applied Poultry Re- search, “ H et Spelderholt ” , Beerbergen, The Netherlands The necessary task of transporting hatching eggs and chicks to and from the hatchery is a very deli- cate 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 dayold 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 clea n 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 16 to 18 °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 trans ported 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.


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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 trans po rta tion, mo re de ma nds on the tr an sp or tati on 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 tra ns portation of over 48 hours without any signif icant mortality increase because of energy obtained from the yolk sac. In the f irst 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 tem perature in the house, within the chick boxes, between the birds, it is adequate for transportation. Overheating can have especially negative effects on the chicks.

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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 trans portation 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 concer n 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 im portant 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

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 ver y strict ways of stacking the boxes on pallets. Another important as pect of air transportation is timing, because hatchery managers do not want their chicks to wait at the air port 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.


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APPENDIX II - GIVE DAY-OLD CHICKS THE BEST START by Dr.V Raghavan , Sin HengChan Berhad, Malaysia

Optimisation of the hatcheryprocessis vital in producing quality day-old chicks. To maintain the quality the chicks need a good start in life ranging fromreceptionatthefarm,stagein brooding,stress control, feeding and management. Aiming for the bestresultsinbettereconomicreturnandlower production costs.

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 theintestinal cleo Ceco-Colic J unction is removed and transferred to tetrathionate brilliant green for culture of Salmonella species.

The first few days of a chick’s life are very crucial, Arrival of the Chicks and they need full attention and maximum care from You have got a date for receiving the chicks fromyour the farmer. If not, problems will develop at later stages. hatchery. So get ready to receive them. See that the Giving the chicks the best start in life will help it grow house is properly disinfected and also all the equipinto abest broiler or an eff icient layer or breeder. Any ment like brooders, feeders, waterers. Make sure that slackness or laziness may prove costly as poultry is a the curtains are in position and the litter material is timely and expensive operation. Any delay in adopting clean and dry. any of the operations will increase the severity of the When the chicks arrive the brooding begins. The term problem. ‘brooding’ originates from the German word ‘Brod’ Chick quality is the subject of frequent concern to the which means to heat. Brooding refers to the rearing of poultry industry as field performance is often linked day-old chicks to an age of 6-8 weeks protecting them to substandard chick quality. There is no national stand- from all inclement weather, predators and other probard for routine assessment of chick quality, and actual It all starts with good parent stock managecauses of problems are often undermined. A chick of ment 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 driedmembranes should protrudefrom the naval area.

•

Firm body to touch.

•

Absenceof any sign of stress- pantingrespiratory 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.

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.


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lems. 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 tem perature. 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.

brooder, it should be around 90°F or 32°C. Due to trans port 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 a ge when temperature remains at 65 – 70°F or 18 – 21°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.

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 Over the past 25 years an enormous amount of knowltype brooding and battery brooding. The brooding tem perature assists chicks in absorption of the yolk and edge has been gained about control of diseases in protects them from chilling. It also regulates the sys- poultry, and it is essential that emphasis is put first and foremost to disease prevention in chicks rather than tem of the chicks to digest the feed. treatment. Once a disease has broken out on a farm Brooder houses should be airy and protect the chicks unit it may be difficult to stop. It is not always easy to from wind and cold. It should be expected to be ready recognise the onset of a disease, diagnose the cause or by 5-7 days before arrival of the chicks. It should be take corrective action. Treatment may be very expenthoroughly disinfected and the required equipment sive and mass medication methods inevitably treat should be installed after thorough disinfection. A thin healthy as well as diseased flock, adding to the finanlayer (2.5 to 5 cm) of clean, soft, and dry bedding macial burden. terial is required to cover the floor. It should absorb When disease does occur it is vital to begin remedial moisture from the droppings of the chicks. action as soon as possible. Carefully observing the daily routine can provide an early indication of trouble. Keep Mortality during Brooding checking on chick appearance, behaviour and general During brooding not all chicks will survive. There are well being, feed and water consumption and mortality several reasons why mortality occurs. It can be due to pattern. exhaustion (high temperature, poor ventilation, high intensity of light), stress of transportation, impaction Control of Wet Droppings (litter eating), pasty vents (chick quality, looseness of Wet droppings are a serious problem, especially in gut), or yolk sac infection (check with hatchery). broiler chicks during the first 10 days of their life. It After arrival of the chicks take the chick boxes directly predisposes the chicks to infec tion by the litter moisto the brooder house. Open the boxes and put the chicks ture being too high, presence of ammonia, etc. Farmers under the brooder. Check the initial temperature of the often have to change litter. Factors affecting wet drop-

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pings 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), m odify 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 trans port 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.


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APPENDIX III - HATCHERY SANITATION: CONCEPTS, LOGISTICS AND ASSESSMENT

place tremendous pressures on quality at all levels of incubation (setters, hatchers, chick pull). In essence, hatchery sanitation programmes, like all other areas of By M.K. Eckman, Ph.D. Professor and Avian Patholo- live production, are expected to produce a quality prodgist, ACES Department of Poultry Science, Auburn uct (chick) within the economic constraints of the University, Alabama, USA integrated operation. The following material will not Variation in sanitation programmes, product selec- detail chemical selection and/or specific procedures, tion procedures and implementation is common but rather stress concepts, basic biological principles among modern day broiler hatcheries. However, and operational guidelines for developing long-term, certain basic concepts, cardinal rules and facility sound programmes in hatchery sanitation. 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 ex pected performance (Table 1). Table 1 - Sanitation Chemicals: Significant Factors 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

ph – use dilution Water hardness Chemical compatibility Temperature Application method Organic matter Surface and porosity Microbiological load Product flow (hatchery) Activity of area Chemical concentration Contact time 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

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 Table 2 - Basic QAC Programme* 1. Egg Handling and Breakout – Twice Monthly a. 7 to 14 – days and residue b. 450–750 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, 1.085. c. Establish standard by flock age. *Detailed Programme – Eckman, M.K. 1990.


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surface or piece of equipment, but rather involves a blend of product application, management and operational procedures on a continual basis. 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.

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

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 f ine 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 r emain sterile. Limiting microbial exposure in combination with shell quality is the key for effective hatching egg sanitation.

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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.

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 thehatchery. Therefore, traffic flow through hatcher rooms should be minimized when at all possible during the hatching process. Following clean-up and disinfection, hatchers should beallowed 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, productchoicewill beablendof preferencesbythehatchery 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 andpast experience. Productselection, if done properly, should involve acareful 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 theuser level.

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 microbial load. Water quality checks by local or state municipalities should be routinely conducted and guidelines established. Airborne contaminants Incoming air via ventilation is another source of microbial contamination. This is particularly applicable to spore forming fungal species (i.e. Aspergillus). Climatic extremeswill affect ventilation rates and dilution factors uniqueto each hatchery. Extremely low ambient temperatures may result in limited in-coming fresh air and thus, increased microbial loads. In contrast, extremely high ambient temperatures often coincide with poor egg-shell quality due to heat stress in the breeders. Eitherextrememayimpactthemicrobial load of the hatchery. Overall most hatcheries are typically under constant pressure in terms of in-coming microbial loads. Therefore sanitation programmes are a continual process that limits both theentry and microbial bloom in all key areas of operation. Applying sanitation programmes Methods of application of sanitation chemicals are probably as signif icant as their choice of chemicals. Methods rangefrom direct surfaceapplication to misting, standard and thermal fogging, course spraying and fumigation for surface and space disinfection. Broad generalizationsregardingsafety inapplicationareusually 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 useof pesticides, in most instances, should beby or under the direction of certified pesticide applicators.

The assessment of the effectiveness of sanitation proChemical applications in thechick processing areaare grammes involves measuring operational procedures usually less stringent as clean-up and disinfection are and chemical efficacy in both the breeder and hatchconducted on an all-in, all-out basis when activities ery phases. Standard procedures for assessing shell are completed and product (i.e. chick) is not present. quality, egg cleanliness, shell breakage and microbioOperation Manual for Multi-Stage - Chickens

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logical 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 signif icant: 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 all phases of live production, quality programmes in terms of sanitation will continueto pay dividends in the hatching and delivery of the modernday 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 placementof parentbreedersandcontinuethroughthe hatchery phase and broiler grow-out.


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APPENDIX IV - PRACTICAL HATCHERY SANITATION GUIDELINES TO ASSURE QUALITY By Donna Hill , DVM, MAM, Dilplomate ACPV, Maryland, USA. An effective hatchery sanitation program is the cor- nerstone 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.

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.

•

source of contamination to the hatchery and all other hatches. Bacteria that are able to penetrate the egg shell, multi ply 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 manage r 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 agr eed 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 diff icult 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 Correlate hatchery baselines with bottom line f ield handling equipment is critical to any hatchery sanita performance measures to determine the true results tion program. These areas are often the source of a of your sanitation program. bacterial and mould bloom when they are not properly cleaned before utilization with seasonal changes.

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

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/ disinfecting 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 Operation Manual for Multi-Stage - Chickens

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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.

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 • Compatibility between the cleaners and sanitisers to prevent the development of resistant midisinfectants which are used. crobes. They demonstrated that microorganisms The hardest part of any sanitation program is to con- become resistant over time when exposed to the same disinfectant continually. When different compounds sistently remove all organic matter from the surfaces (acidic and alkaline) which were chemically compatto allow exposure of microorganisms to the disinfectible were rotated, less resistance developed. This ant and sanitiser. Organic matter, such as fluff, blood, research also showed that this strategy may be more shells, meconium, and dirt render disinfectants effective in combating biofilms. 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.

Standard operating procedures for vaccine mixing, administration, and equipment sanitation must be instituted to prevent contamination of the chick via vaccine administration.

The Effectiveness of a Sanitiser and Disinfectant 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 for mulated to be used with a foamer. The effectiveness of a

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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.

•

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 f ield 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 mor tality or performance problem.

Hatchery Monitoring Program The sanitation index includes a microbiological sam pling of fifty critical control points in the hatchery (Figure 1). The sampling includes twenty-five air sam ples, ten vaccine samples (1cc), and fifteen contact samples. Air samples are done with TSA plates ex 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

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.

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 pr udent to monitor water sources independently of your normal hatchery sanitation program. Since finding pseudomonas in a water source is a significant f inding in a hatchery, the objective of this program is to identify it before it becomes a problem and the hatcher y is forced to resume using for maldehyde. At least 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 . Operation Manual for Multi-Stage - Chickens

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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 neede d.

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 hatcher y or egg sanitation needs to be improved. If dehydration is the primary cause of mortality, then set/pull times and hatcher y ventilation need to be investigated, not sanitation. Culturing the yolk sacs of field mor tality 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: None Light Moderate Heavy

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Bacteria 0 colonies 1–10 colonies 11–49 colonies >50 colonies


Mould 0 colonies 1–2 colonies 3–5 colonies >5 colonies

Weight Factor 1 2 3 4

Hatchery Audit

Hatchery

Day

# Plates

Bacterial Growth

Date

%

Time

Weight Factor

Heavy

x4=

Medium

x3=

Light

x2=

None

x1=

Total

Colony Ranking 0 = None 1-10 = light 11- 49 = Moderate >50 = Heavy

Total

# Plates

Mould Growth

%

Weight Factor

Heavy

x4=

Medium

x3=

Light

x2=

None

x1= Total

Total

Colony Ranking 1-2 = light 3-5 = Moderate >5 = Heavy

Score Bacteria Score

=

x.50=

Mould Score

=

x.50= Total Score

Example Worksheet for Hatchery Sanitation Audit


185

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APPENDIX V - 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 f ield. 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 Multi-Stage - Chickens

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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.

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APPENDIX VI - 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.

analysis will not gain valuable information on other important sources of reproductive failure such as em bryonic 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 er ror. The other two methods of breakout re quire 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. Refe r 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. 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

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 Multi-Stage - Chickens

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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

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 97.69 perc ent and that early embryonic mortality was good at 2.47 percent.

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 moniHowever, egg collection and selection on the breeder tor the week-to-week status of their breeders throughout farm appeared to be a little sloppy because farm cracks, the life of the flocks. Candling can be done as early as upside down and cull egg percentages were all greater five days of incubation, but errors in candling often than 0.50 percent. occur at this time. Because of the rapid growth rate of the embryos during the second week of incubation, very Hatch Day Breakout few, if any, candling errors are made on the ninth or tenth day of incubation. There are two methods of The hatch day breakout analysis involves sampling unhatched eggs from breeder flocks, and classifying candling that may be used. The fastest method involves the use of a table or mass candler. An entire tray of them into the various causes of reproductive failure. hatching eggs may be placed on the mass candler and The procedures for this valuable management tool are examined with one observation . Clear eggs consist of described below. infertiles and eggs with early dead embryos and emit The hatch day breakout analysis should be performed more light than eggs with viable embryos. Clear eggs at least once every two weeks on samples of eggs from are removed from the tray to be broken out. Candling all breeder flocks, regardless of hatchability performwith a spot candler is a little slower, but it is more acance or flock age. Even good hatching flocks should curate for several reasons. By examining each egg be monitored to get a true picture of hatchery and individually with a spot candler, less errors are com-

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reproductive 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.

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 f iller 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.

Table 1 - 7-12 Day Candling and Breakdown Analysis Form Date: 10/14/96

Company: Big Bird

Hatchery Location: Athens

Breeder Flock Flock #: 24

Breed:

Test: No Test

Hatch Date: 12/27/95

Male

Female

X

Y

Age (wks): 38

Tray #

eggs / tray

infertile

early dead

farm racks

upside down

cull eggs

1

162

3

5

1

2

1

5

162

5

5

10

162

4

3

2

2

2

1

15

162

3

3

1

Totals:

648

15

16

4

4

5

2.31

2.47

0.62

0.62

0.77

Persents:

Fertility = 100 - % infertile = 97.69%

The best procedure is to break and peel the large end of the eggs since embryonic development will most often be located 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.

1

Embryo Mortality Determination There are some cases when the em bryo 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.

Other Observations

The classifications of embryonic death may be as detailed as the hatchery manager wishes. It must be kept in mind when starting a breakout program that the quality control perOperation Manual for Multi-Stage - Chickens

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Table 2 - Data Collection – Hatch Day Breakout General Flock number Flock age Male breed Female breed Sample size, sample index Setter number Management type (test) Hatchability

Reproductive Failures Infertiles Embryo mortality Pipped, unhatched Cull eggs Farm and transfer cracks Contaminated eggs Cull chicks Upside down

son 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. •

sify the egg, the presence or absence of early embryonic development must be established. Most eggs ca n 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 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 left 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 eggtooth. 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.

“Generally speaking, an infertile yolk will be a brighter yellow than a fertile yolk.”

18. Head under right wing.

“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.”

20. Yolk sac completely drawn into body; beak pips into air cell.

•

Although these statements are correct, there may be instances when they are not fail safe. To accurately clas-

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19. Amniotic fluid disappears (embryo swallows it); yolk sac half withdrawn.

21. Shell pipping; normal hatching.

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 m alodorous 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 Male

Female

% Egg

Hatchery

Production 73.8

Location: Athens

Breeder Flock

Actual

Hatch date:

#Set: 28,600

# eggs / trayup

infer tile

dead embr yos 1-7

168

20

168

Flock #: 42 Test: No Test

Breed: X

Y

Hatch %: 80.98

dead embryos 8-14

Age (wks): 38

Setter #: 16

dead embr yos 15-21

pipped unhatched

8

4

1

13

9

2

5

168

11

5

1

6

168

16

6

1

3

1

2

Totals: 676

50

28

2

14

7

5

2

Percents:

7.44

4.17

2.08

2.08

1.04

0.74

0.30

cull chicks

cracks farm

cracks transpor t

1

2

1

1

1

cont

cull eggs

2

1

1

1

1

small end

1

2

2

1

1

2

5

5

2

0.30

0.74

0.74

0.30

Other Observations Fertility: 92.56

Estimated Hatch: 81.85

Sample Index: 0.87

% Hatch of Fertiles: 87.49

Spread: 11.58

Shell Quality: OK

Malformations: None


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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 80.98 percent. First, the fertility of 92.56 percent should be about 4 percent higher for this age flock. Also, the percent hatch of fertiles was too low at 87.49 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 tha t the problems of low hatchability of Flock #42 stem from both breeder flock and hatchery. The low sample index of 0.87 reveals 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.

Table 5 - Examples for Calculating Reproductive Efficiency Values Formula: % Fertility = 100 – (# infertiles ÷ sample size) x 100 Example: 100 – (50 ÷ 672) x 100 = 92.56% Formula: % Hatchability = (# Hatched ÷ # Set) x 100 Example: (23,160 ÷ 28,600) x 100 = 80.98% Formula: % Hatch of Fertiles = (Hatchability ÷ Fertility) x 100 Example: (80.98 ÷ 92.56) x 100 = 87.49

Figure 1: Influence of flock age on reproductive performance

Formula: Spread = Fertility - Hatchability Example: 92.56 – 80.98 = 11.58 Formula: % Estimated Hatchability = 100 - % Reproductive Failures Example: 100 – (7.44 + 4.17 + 0.30 + 2.08 + 1.04 + 0.74 + 0.30 + 0.30 + 0.74 + 0.74 + 0.30) = 81.85% Formula: Sample Index = % Estimated Hatchability % Hatchability Example: 81.85 – 80.98 = 0.87

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Figure 2: Influence of flock age on embryo mortality

GLOSSARY Air Space: in eggs, is critical for the hatching chick. The air space is located at the broad end of the eggs, between shell membranes and provides the chick with air prior to chipping of the shell. It also is a measure of quality in table eggs. Albumen: The chief protein constituent of plant and animal tissues. The white of an egg, which is secreted around the yolk in the oviduct, is almost pure albumen. When an egg is broken out it can be seen as two layers, inner and outer albumen. This is an important measure of quality. Both the inner and outer albumen should be free from inclusions. In fresh eggs, from healthy stock, they should “stand up” well, only spreading out over a small area. “Watery whites” are indicators of staleness and/or respiratory diseases. The albumen represents about 60 percent by weight of an egg. Blood Ring: This usually refers to the candled appearance of an egg in which the embryo has died at a young age. Breed: A population of a species that have distinct characteristics that differentiate them from other populations in that species. Individuals within that population that reproduce with another individual of the population will produce offspring that are recognizable as members of that population. Breeds can further be divided into varieties based on differences within the breed. (See Species .) Breeder Flock: A flock of chickens used to produce fertile eggs intended for hatching. Broiler: This term normally applies to young chickens, but is also used to describe other forms of livestock that are reared intensively for meat. Due to their efficient conversion of about 2:1, chickens can undercut other high-quality meats. Most are killed between 35 to 42 days and weights, expected by major breeders, range from 3.3 to 6.8 lb. (1.5 to 3.1 kg) for males and 2.6 to 5.3 lb. (1.2 to 2.4 kg) for females. Separate-sex growing enables more precise weights to be achieved and allows more efficient use of feed. This term is also applied to a chicken that is 35 days old or older. Fryer is old terminology.

Candling: is the process of examining eggs with a bright light for the purpose of detecting flaws. Candling will show cracks in the shell, some internal faults, like blood spots, and meat spots. In the case of incubated eggs, detected infertile clears and dead-in-shell can be removed after 8 to 10 days or during the transfer from incubator to hatcher. Large candling booths are darkened and the eggs are rotated automatically over a group of electric lights. All eggs should be candled to remove cracks, before being sold to consumers and to remove infertile eggs during incubation. Chick: The young of birds, particularly chickens and gamebirds. Cracks: indicate cracked eggs and is the main cause of downgrading. Cage floor design and slope, calcium intake, age and breed of bird, packaging and handling are all critical factors in deter mining the percentage of cracks. Day Old: An abbreviation to describe day-old chicks. Chicks normally leave the hatchery on the day they are hatched. Before leaving, they are culled, sexed and vaccinated as appropriate. The main brooding requirements of all day-olds are clean, draught-free quarters, temperatures of 90 to 100 °F (32 to 38°C) under the brooder, easy access to clean water and balanced feed in the form of crumbs. Chicks, which are sent out not separated by sex, are termed “as hatched ”. De-Beaking: is a rather less extreme measure than its name suggests. It is the trimming of the end of the upper and lower beak by a red-hot blade which cuts and cauterizes in one movement. Dry Bulb Temperature: The temperature measured with a standard thermometer or electronic sensor. Egg: The reproductive element of birds. Millions of chicken eggs are produced each year in the United States for human consumption. (See Hatching Eggs .)

An averaged-sized chicken egg weighs about 62 g of which the shell accounts for about 12 percent by mass. Its contents consist of 12.1 percent protein, 10.5 percent fat, 65.6 percent water and 11.8 percent minerals, vitamins and carbohydrates. The weight of the white (albumen) is about twice


195

the weight of the yolk. Vitamins contained, A, B, D, E and K, are mainly in the yolk. Egg protein is of the highest quality and is the standard against which all other proteins are judged. (See Air Space and Albumen) Embryo: Development of the embryo in the egg star ts at 80.6°F (27°C) for chickens. Therefore, hatching eggs should normally be kept cool before incubation. Development to hatching normally takes 21 days for chickens. (See Incubation). Fertility: Normal range of the percentage of fertile eggs produced is from 70 to nearly 100 percent. The percentage rises through broilers, brown layers and white layers. Main factors affecting fertility are heredity, health, age, nutrition and ratio of males to females. In heavy breeds, breeding and thus fertility is achieved by artificial insemination. Fumigation: Formaldehyde is the gas given off during fumigation of housing, equipment or eggs. It is active against a wide range of pathogens and is produced by heating paraformaldehyde crystals or adding formalin to potassium permanganate. Green: describes chicks which have recently hatched and are still wet or at least plump. Hairline Crack: Fine cracks in the egg shell. In fresh eggs, they can only be detected by candling. As they get older, they become more apparent. Hatching Eggs describes fertile eggs that will be set by a hen or hatched in an incubator. A chicken egg must be incubated for 21 days. Hatch of Fertiles: The percentage of fertile eggs which hatch (hopefully above 90 percent). Hatch, Percent Hatch, Hatching Percent, or Hatch of Total: The percentage of all eggs set which hatch, whether they were fertile or not. A typical hatch might be 80 to 90 percent. Hatcher: A machine used to maintain proper conditions for embryos during the final few (usually three) days before hatching. Hatchery: A facility in which eggs are hatched. Modern hatcheries are usually equipped with large incubators (setters) and hatchers for incubation and hatching. As well as sexing and boxing the saleable chicks, many hatcheries now vaccinate as required.

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Hen: after 12 months of lay a pullet becomes a hen. This is the current definition for censuses and has superseded "after the f irst moult", as the length of the first laying period varies widely. Humidity: This is the amount of moisture in the air. During incubation humidity is an important factor and should be adjusted to obtain optimum moisture loss from the egg. HVAC System: Heating, Ventilation and Air Conditioning System. Hybrid: also known as a crossbred. A hybrid is the result of purposeful crossing of two species to pr od uc e of fs pr in g wi th a un iq ue se t of characteristics. Hybrids often exhibit hybrid vigour and thus are superior to either of their pare nts. But the effect of crossing pure lines is variable, and bre ede rs have and do experi ment with many different crosses to find the best combination. Today, most commercial stock is hybrid. Mating two hybrid birds will not produce offspring with the same characteristics of the parents. (See Breed ). Incubation Time: The time between setting of eggs and pulling of chicks. Incubation: The process of warming and maintaining eggs, under conditions favourable for embryonic development or hatching. Small still-air incubators are operated at the higher temperature of 101 °F (38.4°C) whereas 98.6°F (37°C) is the norm for chicken eggs in cabinet incubators. In cabinet incubators, eggs are trayed broad end up and turned automatically to 45 degrees each side of the vertical. Incubator and hatcher are usually separate and air flow is controlled. In still-air machines, eggs are usually placed on their sides and rolled an odd number of times daily through 180 degrees. (See Embryo .) Incubator: A machine designed for warming and maintaining eggs under conditions favourable for embryonic development. See incubation above. Also known as setter. Keyes Trays: These trays are made of moulded pulp or plastic, most are for 30 eggs. Used mainly for transporting eggs from the farm to storage area.

Layer: A bird kept for egg production. Most are hybrids. Common layer breeds such as Leghorn chickens have been developed to lay many eggs and generally do not set a nest well. They perform best in laying cages and their average production improves every year through genetic selection and better management techniques. (See Meat Breeds .) Malpositions: An embryo in any position except head under right wing positioned in the large end of the shell. Examples of malpositions are head under left wing or head between legs. Meat Breeds: Breeds of chickens developed for their quick growth and heavy muscles. These breeds are developed for eating. Pip: An egg in which the chick has broken the shell in an attempt to hatch. Pipping: Breaking of shell by the chick to allow it to escape. Pre-Incubation: Premature development of the embryo before storage. Pre-Warming: Warming of eggs after storage but before setting in incubators. Pull: Removal of chicks from hatchers when the hatch is complete. Relative Humidity (RH): The amount of moisture in the air at a given temperature compared to the maximum amount of moisture the air, at the same temperature, can hold. It is expressed as a percentage. Set: Group of eggs placed in an incubator at one time. Setter: Incubator used for first 18 to 19 days of incubation. (See Incubator.) Setting: Placing of a group of eggs in the incubator. Sexing: Males and females can be sexed at a day-old by vent sexing, feather development or down colour. The first can be applied to all day-olds; slow/fast feathering is a sex-linked characteristic bred into some broiler stocks; and most brown eggers have sex-linked feather colour. An increasing number of meat birds are reared sex separate to improve feed eff iciency and for control over f inal weights.

Sex-link: A genetic trait that creates a difference, (usually in colour) between males and females. Most often this is used to refer to traits that make chicks of different genders visibly distinct for ease of sexing. The term may apply to the gene or characteristic, or is often applied to hybrid crosses that display this characteristic such as the Golden Sex-link. Soft-Shelled Eggs: occur mainly when pullets are coming into lay rapidly before the egg-shelling mechanism has settled down. But if they occur in association with thinner and weaker shells in older birds, then calcium intake may be too low or a respiratory disease present. Species: A distinction for a specific type of animals. For example, chickens are a species. There may be many breeds of each species. Typically, species cannot interbreed successfully, for example a chicken and a goose cannot produce offspring together. If species can cross, the offspring are typically sterile like a mule (horse x donkey). Spread: The difference between, fertility and hatch. A 10 to 12 percent spread is typical for chicken eggs. Sweating: Condensation of water vapour on surface of eggs which are cooler than the “dew point” of ambient air. Transfer: Movement of eggs from incubators (setters) to hatchers. This process may also involve candling. True Fertility: The percentage of hatching eggs which are fertile. This can only be determined by incubation, candling and breakout of the clears to determine which eggs were fertile or by breaking out potentially fertile eggs to examine the germinal disc (e.g. a sample might be examined to estimate fertility of a flock). Washing Eggs: Machines range from batch/bucket types to continuous flow, spray-wash designs handling thousands an hour. Wet Bulb Temperature: The temperature measured by a standard thermometer equipped with a wet sock over the bulb. For accurate measurements air


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