Documente Academic
Documente Profesional
Documente Cultură
MANOPSC
Revision D1
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 Company Inc.
Table of Contents
Chapter 1 - Introduction
Multi-Stage Incubation ............................................................................................................................... 15
Air Flow ................................................................................................................................................. 16
The Laminar Air Flow Pattern .......................................................................................................... 16
Air Flow within an Incubator ............................................................................................................. 16
Air Flow within a Hatcher ................................................................................................................. 17
Specifications for 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
Cabinet, Entrance ................................................................................................................................. 20
PT100 Controls ..................................................................................................................................... 21
Display Panel ................................................................................................................................... 21
Machine Controller ........................................................................................................................... 21
Temperature and Humidity Sensor .................................................................................................. 22
Multi-Stage Incubator with PT100 Controls ........................................................................................... 22
2-Door Hatcher with PT100 Controls .................................................................................................... 23
PX Hatcher with PT100 Controls .......................................................................................................... 23
Electro-Mechanical Controls ................................................................................................................. 24
Incubator Information Panel ............................................................................................................. 24
Incubator Control Box ...................................................................................................................... 24
Incubator Thermostat Board ............................................................................................................ 24
Hatcher Control Box and Information Panel ..................................................................................... 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 ...................................................................................................................................... 30
SST Egg Transport System .............................................................................................................. 30
The Automatic Incubator Rack Loader ............................................................................................. 30
Incubator Racks ............................................................................................................................... 31
Hatcher Racks ................................................................................................................................. 31
Rack Specifications ......................................................................................................................... 31
Hatcher Dollies 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, PB3040 .............................................................................................. 35
Digital Thermometer, HA1070 ............................................................................................................... 35
Velometer Air flow Meter, HA1061 ........................................................................................................ 35
Incubator Rack Tester, HA1145 ............................................................................................................ 35
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
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 embryos 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.
A distinctive feature of the Jamesway 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.
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 incubator fans, and the natural heat which radiates from
the eggs with the most embryological 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 embryos 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
Exhaust
Intake
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
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
COMPONENT IDENTIFICATION
CABINET, BASIC
Controls on the roof
eliminates interior wires
and conduits which collect
dirt and bacteria.
CABINET, ENTRANCE
Intake Duct
Tracking
Threshold
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.
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.
Guards in place
Operation Manual for Multi-Stage - Chickens 21
Probe
Wick (PB4077)
Plug
Distilled Water
Reservoir
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
Rack Stop
PT100
Display Panel
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
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
Humidistat with
Wick (P1507)
Main Heat
Thermostat
Plug
Distilled
Water
Reservoir
High Temp.Thermostat
Distilled
Water
Reservoir
Thermostat Board
located on right side
Thermostat Board
Reservoir
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).
PT100 Controls
EM Controls
Venturi
Fans
Air Intake
Entrance End
Damper Slide
Spray Nozzles
Water Pan
Exhaust
Damper Drive Box
Intake Duct
Heat Elements
Exit End
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
Junction Box
Assembly
connects to
Umbilical Cable.
Damper Slide
Latch (1 of 6)
Fan Dolly
Kickstand
2-Door Hatcher
Motors
Blower Box
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
Entrance
Door
Trough in plenum floor slopes towards drain and external exhaust.
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
Optional valve to
each machine for
maintenance
Valve
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
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.
Type of Dolly
Baskets
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.
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.
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.
Control Box
Thermostat
Junction Box
Mercury thermostats
are used as the
temperature sensing
devices.
Recommended
thermostats:
for incubators 101F
for hatchers 100F.
DIGITAL THERMOMETER
HA1070
2. Multi-Stage
Requirements
ventilation requirements
water requirements
electrical requirements
air requirements
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 feasible 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 facilitates 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.
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
6468F
1820C
Relative Humidity, % RH
7580%
7580%
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.
Incubator Room
Minimum Temperature, dry bulb
General Conditions
73F
23C
85F
29C
80F
27C
Relative Humidity, % RH
50-60%
50-60%
640 m3/h
1.03.0 Pa*
* cfm (cubic feet per minute), in. w. g. (inches water gauge), Pa (Pascals)
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.
Hatcher Room
Minimum Temperature, dry bulb
General Conditions
73F
23C
85F
29C
80F
27C
Relative Humidity, % RH
5060%
5060%
375 cfm
640 m3/h
1.03.0 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
General Conditions
7080F
2127C
Relative Humidity, % RH
4050%
4050%
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
General Conditions
7080F
2127C
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 hatchery 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
General Conditions
7080F
2127C
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 clean 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.
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,
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 incubators 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.
3. Temperature and
Humidity
Specifications
for systems using PT100 controls
for systems using electromechanical controls
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.
Humidity
Days 110
99.9F (37.72C)
88.0F (31.11C)
Days 10 and 11
99.6F (37.56C)
86.0F (30.00C)
Days 12 and 13
99.3F (37.39C)
86.0F (30.00C)
Day 14
Normal Run
Humidity
Days 110
99.9F (37.72C)
88.0F (31.11C)
Days 10 and 11
99.6F (37.56C)
86.0F (30.00C)
Days 12 and 13
99.2F (37.33C)
86.0F (30.00C)
Day 14
Normal Run
Humidity
Days 110
99.9F (37.72C)
88.0F (31.11C)
Days 10 and 11
99.6F (37.56C)
86.0F (30.00C)
Days 12 and 13
99.2F (37.33C)
86.0F (30.00C)
Day 14
Normal Run
Humidity
Big J at Transfer
98.5F (36.94C)
86.0F (30.00C)
Super J at Transfer
98.5F (36.94C)
86.0F (30.00C)
High Temp.
Aux. Heat
Main Heat
Start-up
8486-88F
97.0F
100.5F
99.75F
100.0F
Day 114
29-30-31C
36.11C
38.06C
37.64C
37.78C
PB1809
PB1812
PB1437
PB1435
PB1436
Normal Run
8486-88F
97.0F
100.0F
98.8F
99.0 F
Day 1518
2930-31C
36.11C
37.78C
37.11C
37.22C
PB1809
PB1812
PB1436
PB1433
PB1434
High Temp.
Aux. Heat
Main Heat
Start-up
84-86-88F
97.0F
100.5F
99.75F
100.0F
Day 114
29-30-31C
36.11C
38.06C
37.64C
37.78C
PB1809
PB1812
PB1437
PB1435
PB1436
Normal Run
848688F
97.0F
100.0F
98.6F
98.8F
Day 1518
293031C
36.11C
37.78C
37.0C
37.11C
PB1809
PB1812
PB1436
PB3759
PB1433
High Temp.
Aux.Heat
Main Heat
Start-up
Normal Run
848688F
97.0F
100.5F
99.75F
100.0F
293031C
36.11C
38.06C
37.64C
36.67C
PB1809
PB1812
PB1437
PB1435
PB1436
848688F
97.0F
100.0F
98.4F
98.6F
293031C
36.11C
36.67C
36.89C
37.0C
PB1809
PB1812
PB1436
PB3760
PB3759
Temp. Read.
Humidity
Hum. Read.
Big J
99.5F
99.0F
98.8F
98100F
86.0F
8488F
Day 1821
37.5C
37.22C
37.11C
36.6737.78C
30C
2931C
PB1925
PB1434
PB1433
PB1923
PB1926
PB1924
Super J
99.5F
98.8F
98.6F
98100F
86.0F
8488F
Day 1821
37.5C
37.11C
37C
36.6737.78C
30C
2931C
PB1925
PB1433
PB3759
PB1923
PB1926
PB1924
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
Poultry hatcheries should produce the greatest possible 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.
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.
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 manufacturers instructions for
proper operation.
LOADING A FULL SET
Place two racks side by side.
Start with the first tray at the top left tier of the incubator rack.
Load eggs working downward until the first tier is full.
Continue loading eggs, starting 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 mirror 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 Operation Manual for Multi-Stage - Chickens
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.
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.
PREPARING TO START
THE INCUBATOR
After every new installation of a Jamesway incubator
or hatcher, a Jamesway technician will start each incubator 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 machines left. Your right is the machines
right. (If you are not sure which doors are at the entrance, remember that the fans are located at the
entrance end.)
PRE START
INCUBATORS WITH PT100 OR
PT100SMT CONTROLS
CB3
CB2
CB1
CB1, CB2 and CB3 are located behind the panel door on
the front of the control box.
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.
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.
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.
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 incubator 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.
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 fits 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.
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 display panel or the information panel of the
electro-mechanical controls.
Connect the male plug into the female plug of each
adjoining rack.
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.
No rubber gaskets?
Make sure the curtain overlaps the centre aisle door.
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.
The time clock should activate a manual egg turn sequence for up to four (4) incubators.
RN KN
RN KNO
Turn the dial clockwise one (1) hour on the time clock.
1
3
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
Incubator Number
3
4
5
6
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.
Incubator Number
3
4
5
6
Alarm System
Control Box Pilot Lights
Main Heat
Auxiliary Heat
Humidity
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
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
When pushing the racks, grip the side frame close to the
ends. Watch where you are going!
Use two people to load the rack. Push on the side frame.
The back of the rack faces the outside wall.
Entrance End
Exit End
Set 1
Set 1
Entrance End
Exit End
Set 2
Set 1
Set 2
Set 1
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
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
SUN
MON
Legend
Eggs to incubator
Transfer to hatcher
Pull chicks from hatcher
Set on Monday
Set on Thursday
TUE
WED
THU
FRI
WEEK 0
WEEK 1
WEEK 2
WEEK 3
WEEK 4
10
WEEK 5
11
12
WEEK 6
13
14
WEEK 7
15
10
16
10
11
WEEK 8
17
11
12
18
12
13
WEEK 9
19
13
14
20
14
15
SAT
CB3
CB2
CB1
CB1, CB2 and CB3 are located behind the panel on the
front of the control box.
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.
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.
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
Make sure the rack rear wheels are over the bump in the
U-channel rack stop (left) or the stop bolt in the V-groove
rack stop (right).
BIG J INCUBATORS
Note: Start and complete the procedure, on this
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
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.
TRANSFER PATTERNS
There are three components to the transfer pattern:
1. Placement of eggs within a given column.
2. Placement of columns in a rack or on a dolly.
3. Placement of the rack or dolly within the hatcher.
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.
Left-hand
Side
Exit
Door
Position 4
Position 5 Position 6
Exit
Door
Right-hand
Side
PX Hatcher
Left-hand
Side
Exit
Door
Position 4
Position 5 Position 6
Right-hand
Side
Exit
Door
2-Door Hatcher
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.
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 left-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.
Open the left-hand hatcher door and turn off the fans.
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 incubator 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
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 manufacturers instructions.
During the three days eggs are in the hatcher, record the
temperature and humidity twice per day.
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.
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.
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 17th 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.
5. Cleaning
Procedures
general guidelines
complete clean-out and
sanitation of incubators
specific cleaning practices
for hatchers
Diseases and infections always have been a major concern of the poultry industry, especially in the hatchery.
Fortunately, microbial contamination can be prevented
and controlled through a highly 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.
Remove as much organic matter and debrisincluding down, egg shells, droppings and tissue residueas
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 microbial organisms.
Apply disinfectants.
FOR PERSONNEL
Follow your hatcherys bio-security procedures. This
will include appropriate laundering and disinfecting
of work clothes.
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.
Thoroughly clean the water reservoir. 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.
6. Routine Monitoring
and Maintenance
PT100 and EM controls
incubators and hatchers
ventilation
checklists
specifications for ventilation and
fan blade spacing
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).
MONITORING INCUBATORS
It is important to 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 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 prepare and follow a checklist suited to your hatchery.
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 prepare 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 monitoring
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.
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
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
Twice
Daily
Daily
Time Schedule
Twice Daily
and
Twice Nightly
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
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.
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.
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
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.
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 temperature, fan off or power off, check the battery, battery
connections or alarm circuit.
ROUTINE MAINTENANCE
FOR INCUBATOR
ELECTRO-MECHANICAL CONTROLS
Refer to the checklist on page 116.
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.
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.
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 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.
Heat Circuit
Main HeatAttach 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 HeatAttach 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.
ROUTINE MAINTENANCE
FOR INCUBATORS
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.
Check the spacing of the intake duct. The correct spacing is 5/8 inches (15.5 mm) and the duct should be
parallel with the centre post on both sides. Replace or
repair damaged parts as required.
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.
Door Seals
Check door seals for torn or missing door gaskets.
Replace missing or worn gaskets. Damaged door
gaskets can result in poor air 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.
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 compressed 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
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 fan
blade for correct pitch or distortion. See pages 138 to
142 for fan specifications. If vibration continues, replace 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.
Once the incubator has reached the appropriate temperature and humidity, the egg-filled 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 damper
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 but 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
should be identical. The damper openings should be
1/2 in. (13 mm) when the damper is in the fully closed
position.
Clean fan motor off switches, blades and motors during complete clean-out and sanitation. Refer to Chapter
5 - Cleaning Procedures on page 93.
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.
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, adjust the tracks.
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 fit 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.
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.
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.
Time Schedule
Before After Every Weekly
Every Transfer
Set
Monthly
Every 3
Months
Every 6
Months
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
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 subjects the hatcher to harsh conditions.
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.
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 read-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 temperature down 2 degrees 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.
Auxiliary Damper
Check the auxiliary damper operation (see High Temperature ). When the high temperature alarm rings, open
the hatcher door and visually check that the auxiliary
damper lifts clear of the slide.
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.
CB3
CB2
CB1
Wick
Control Box
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 Operation Manual for Multi-Stage - Chickens
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.
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.
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.
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.
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.
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 filter
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. If 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.
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 but 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.
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
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.
Time Schedule
After
Every
Hatch
Twice
Weekly
Weekly
Monthly
Every 3
Months
Time Schedule
After
Every
Hatch
H) 2-Door Hatcher
1. Blower clean and sanitize
2. Blower thorough cleaning and sanitizing
3. Check auxiliary damper
I)
Heat Rings
Twice
Weekly
Weekly
Monthly
Every 3
Months
ROUTINE MAINTENANCE
FOR VENTILATION EQUIPMENT
MONTHLY
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
Grease and inspect bearings. Inspect the pulley alignment. Clean the blades.
Cooling Units
Clean or replace the filters.
WEEKLY
Furnaces
Furnaces
Clean and lubricate the motor. Tighten mounting hardware. Inspect and tighten electrical connections. Clean
the blower.
Cooling Units
Clean and lubricate the motor. Clean the blower and
cooling coils. Tighten mounting hardware and electrical connections. Replace air f ilters 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.
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
Weekly
Monthly
Every 6
Months
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
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
1/2 in.
(13 mm)
fully closed
1/8 in.
(3 mm)
fully closed
2-Door Hatcher
Note: When the damper is in fully closed position, there is a spatial opening of 1/8 inch (3 mm).
1/8 in.
(3 mm)
fully closed
Motor Mount
Fan Blade
Motor
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
Motor Mount
Clockwise
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
Motor Mount
Clockwise
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)
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)
PX Hatcher
Correct spacing between fan and motor mount
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
Position 2
Position 1
100.3F
37.94C
Big J
100.5F
38.06C
Electro-therm
Egg
Horizontal
Brace
Egg Flat
Diagonal
Brace
Tray Frame
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
37.11C
Big J
37.22C
37.0C
Electro- therm
inserted into an
infertile egg in
the middle
position
PROCEDURE TO MEASURE
INTERNAL INCUBATOR PRESSURE
124137 Pa
Big J (all racks turned)
0.400.45 inches of water
100112 Pa
Super J and SST (5th and 6th position level)
0.600.62 inches of water
149154 Pa
High pressure
hose attaches
here.
X
INCHES OF WATER
0 .1
.2 .1
.2
.3
lllllllllllllllllllll .3
.4 llllllllll
llllll .4
llll .5
.5 llllll
l
ll l
MAGNEHELIC
Low pressure
hose attaches
here.
Position 2
CAUTION
HA1031
Position 1
DAMPER PERFORMANCE
The optimum incubator room temperature for the
Jamesway multi-stage incubator is 80F (26.67C) and
the optimum relative humidity is 55 percent. A slight
positive room pressure of 0.005 to 0.015 inches of water
(1.2 to 3.7 Pa), compared to external ambient conditions, is recommended. Jamesway has found these
conditions to be ideal, and under normal circumstances
the incubator intake and exhaust damper should open
to the optimum setting, 1.50 in. (38.1 mm) with an
operating range of 1.25 to 1.75 in. (31.8 to 44.5 mm)
for PT100 Controls and 1.25 in. (31.8 mm) with an
operating range of 1.0 to 1.50 in. (25.4 to 38.1 mm)
for Electro-Mechanical Controls.
Exhaust Damper Opening
Optimum
Range
PT100 Controls
1.50 in.
1.251.75 in.
38.1 mm
31.844.5 mm
1.25 in.
1.01.50 in.
31.8 mm
25.438.1 mm
E/M Controls
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.
Heat Function
Spray Function
Aux. Heatoff
Sprayoff
Main Heaton
Damperclosing
2. Coolingtemperature greater than set point
Aux. Heatoff
Sprayon
Damperopening
3. Heatingtemperature less than set point
Spraymay be on or off
Main Heaton
Damperclosing
4. Heatingtemperature less than 0.2 below
Aux. Heatoff
Sprayoff
Main Heaton
Damperclosing
5. Repeat cycle starting with No.1 above.
Aux. Heaton
Sprayoff
Main Heaton
Damperclosing
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 transfer444 hours, eggs in
incubator 6th position for 12 hours, Thursday and Friday transfer432 hours, eggs in incubator 6th 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 (6th) 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 (6th) 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
SUN
MON
TUE
WED
THU
FRI
WEEK 0
WEEK 1
WEEK 2
WEEK 3
WEEK 4
10
WEEK 5
11
12
WEEK 6
13
14
WEEK 7
15
10
16
10
11
WEEK 8
17
11
12
18
12
13
WEEK 9
19
13
14
20
14
15
SAT
Legend
Eggs to incubator
Transfer to hatcher
Pull chicks from hatcher
Set on Monday
Set on Thursday
Time
20/60/20
Mean
points and other operational procedures, with the everpresent likelihood for errors and decline in
performance.
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, transport 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.
ANALYSING OVERALL
PERFORMANCE
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
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
Insufficient humidification
Possible Causes:
Poor ventilation
Damaged gaskets
Curtain overlap
Improper setting
Motors running backwards
Possible Solutions: (See Internal Incubator Pressure
for details.)
Possible Causes:
Check motors
Time
24 hours post-transfer
Super J
100.3F (37.9C)
24 hours post-transfer
Big J
100.5F (38.1C)
24 hours post-transfer
24 hours pre-transfer
Super J
98.8F (37.1C)
24 hours pre-transfer
Big J
99.0F (37.2C)
24 hours pre-transfer
24 hours pre-transfer
every 3 months
th
Super J
Big J
SST Flat 0.600.62 in. w.g. (149154 Pa) Super J only, 5th & 6th position level)
Damper PerformancePT100 Controls
Sequence for Ideal Conditions
0.5 in. (1.27 cm)closed position
Eggs set
Range
Damper
After transfer
Range
Range
Eggs set
Range
Range
Range
8. Chick Development
and Troubleshooting
Hatchability
chicken embryology
analysing chick residue
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
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 161
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
Day 10
Day 21
Chick hatches
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
Day 15
Small intestines taken into body
Day 16
Old eggs
Possible causes:
Inadequate breeder ration
6. MALPOSITIONS
Possible causes:
Possible causes:
Shell quality
Possible causes:
Temperature too high, 1 to 19 days
Humidity too low, 1 to 19 days
5. Chick Dead After Pipping Shell
Possible causes:
Nutrition
Possible causes:
Humidity
Fumigation
Dirty eggs
Possible causes:
Possible causes:
Heredity
Large eggs
Old eggs
Holding temperature
Small eggs
Contamination
Shell quality
Young flock
164 Operation Manual for Multi-Stage - Chickens
Possible causes:
Possible causes:
Small eggs
Incorrect thermometer
Possible causes:
Possible causes:
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
by Ron Meijerhof, Centre for Applied Poultry Research, Het Spelderholt, Beerbergen, The
Netherlands
The necessary task of transporting hatching eggs
and chicks to and from the hatchery is a very delicate process. Therefore it is wise to be familiar with
the elements which determine optimal transportation conditions.
In modern poultry production, transportation is an
important issue. It is often associated with conveying
broilers to the processing plant, and is viewed as critical. However, the transportation process of both
hatching eggs from breeder farms to hatchery and 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 clean as possible
and floor eggs should be avoided.
Temperature Control
After collection, eggs are stored for several days at the
farm and then transported to the hatchery. When eggs
are collected twice a week from the breeder farm, storage temperatures of 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 transported and placed at another temperature for several
hours.
Avoid Temperature Shocks
Climactic control is also important during the winter
because major temperature shocks should be avoided.
It is a common occurrence for transportation vehicles
to be temperature controlled, but, during egg loading
and unloading, especially at breeder farms, mistakes
are made. Eggs adapt to temperature changes very
quickly, especially when there is much air movement.
Therefore, when eggs are loaded in wintertime, especially when the wind is blowing, the containers should
not be placed outside for long periods of time. When
weather conditions are bad, it is suggested to cover up
the containers with plastic shelters, removing them
when transportation is completed so eggs can adapt to
the new temperature. However, use of these covers is
not advisable in very sunny weather because direct sun
radiation on the cover will create a dramatic temperature rise directly under the cover.
Relative Humidity
Hatching eggs are normally stored under high relative
humidity to prevent moisture loss. Under normal conditions, it is not necessary to have high relative humidity
during transportation because, with a short transport
time, moisture loss is limited. In this situation, a high
relative humidity might even be negative because it
increases the risk of contamination by sweating when
the egg room is colder than the transportation vehicle.
Even when eggs are transported over longer distances
or by air freight, increasing the humidity is normally
unnecessary.
Motion
Theoretically, vibration of the egg due to transport has
a negative effect on hatchability. In earlier experiments,
a relationship between transportation movements and
some embryonic abnormalities were reported. However, in modern transportation vehicles, this influence
will be small or non-existent if the driver is skilled and
loading and unloading is done with care. Also, the
number of cracks will be very limited when eggs are
packed and transported correctly.
Transportation of Day-Old Chicks
After pulling the hatch, the chicks are processed, packed
in cardboard or plastic boxes of 50 or 100 each, and
transported to the grower. Often, this type of transportation is done in trucks over limited distances. It is
obvious that with increasing distances and time of transportation, more demands on the transportation
conditions should be made. Although many countries
limit chick transportation time to hours, transportation
times of 24 hours or more do occurwhen the parent
stock is transported, for example.
Under optimal conditions, chicks can withstand transportation of over 48 hours without any significant
mortality increase because of energy obtained from the
yolk sac. In the first days, the yolk sacs provide chicks
with all necessary nutrients. Research has shown that
holding chicks for 24 hours without feed and water
can even improve performance, probably because the
birds have more time to utilise the nutrients from the
yolk sac. Holding the chicks for 48 hours or longer
resulted in a slightly decreased performance, although
mortality was still not significantly altered.
The two key factors that will have a negative influence
on chick quality during transportation are overheating
and dehydration. This indicates that ventilation and
climactic conditions such as temperature and humidity should be carefully considered.
Control Temperature and Humidity
The optimal transportation temperature is between 24
and 26 C. Although this is much lower than the temperature in the house, within the chick boxes, between
the birds, it is adequate for transportation. Overheating can have especially negative effects on the chicks.
As mentioned earlier, it is important to avoid dehydration and, at first glance, increasing humidity in the truck
appears to be a practical method of preventing it. In
reality, this method is ineffective because humidity in
the chick boxes is rather high, due to moisture production of the chicks and limited ventilation, and increasing
outside humidity does not improve the situation.
Increasing humidity when transporting in cardboard
boxes can have an especially negative effect because
the boxes get weak and cold and stacks may collapse.
So, in practise, humidity is often uncontrolled in transportation trucks. However, dehydration can occur if the
ventilation rate is too high. To avoid dehydration, preventing overheating is the first step. When chicks are
transported over extended periods of time, an injection of moisture is often given during chick processing.
Giving Enough Ventilation
Probably the biggest problem during transportation is
providing the chicks with enough ventilation. Boxes
containing 50 or 100 chicks produce a lot of heat and
use a lot of oxygen. Placing the stacks of boxes far
enough apart will encourage sufficient air flow, leaving only the concern of desired temperature. However,
economics forces us to increase the number of chicks
per truck and, therefore, place the stacks more tightly.
This will result in a more restricted ventilation between
and in the stacks and an increased demand for total
amount of ventilation. In this situation it is very important to pay enough attention to providing the chicks
with adequate ventilation. This begins with choosing
boxes that allow enough air flow, but also by ascertaining that the pre-stamped holes of the carton boxes
are punched out while packing. Nonoptimal transportation conditions do not always result in an increased
number of dead chicks, but will hurt the birds 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
Straight toes.
brooder, it should be around 90F or 32C. Due to transport chicks will be under stress, so only provide them
with clean drinking water with electrolytes or glucose.
Burn empty chick boxes. According to season and age
of the chicks brooding temperature must be maintained.
The temperature should be around 95F or 33C during the first week, then it should be reduced by 5F or
2.7C every week up to 7 weeks of age when temperature remains at 6570F or 1821C. Record the
temperature daily by hanging a thermometer at chick
level.
Hygiene and Health
The single most important factor in keeping chicks
healthy is maintaining good hygiene - it is your insurance policy. Healthy breeders and hygienic hatchery
management contribute greatly to disease free chicks.
If good hygiene standards are maintained on the farm
the chicks can achieve uninterrupted growth and production aided by appropriate vaccination and
medication. Hygiene does not mean just a choice of
the right disinfectant. It is a total concept dedicated to
maintaining the highest and cleanest standards.
Over the past 25 years an enormous amount of knowledge has been gained about control of diseases in
poultry, and it is essential that emphasis is put first and
foremost to disease prevention in chicks rather than
treatment. Once a disease has broken out on a farm
unit it may be difficult to stop. It is not always easy to
recognise the onset of a disease, diagnose the cause or
take corrective action. Treatment may be very expensive and mass medication methods inevitably treat
healthy as well as diseased flock, adding to the financial burden.
When disease does occur it is vital to begin remedial
action as soon as possible. Carefully observing the daily
routine can provide an early indication of trouble. Keep
checking on chick appearance, behaviour and general
well being, feed and water consumption and mortality
pattern.
Control of Wet Droppings
Wet droppings are a serious problem, especially in
broiler chicks during the first 10 days of their life. It
predisposes the chicks to infection by the litter moisture being too high, presence of ammonia, etc. Farmers
often have to change litter. Factors affecting wet drop-
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), modify salt levels in the
feed, use nipple drinkers, and check water quality. The
use of various items like zeolite, bentonite can be considered through the feed, to reduce litter moisture.
Having had a quality chick the next point is to control
the various forms of stress. Stress factors like boxing,
packing, beak trimming, vaccination, transport could
be minimised by liaising with the hatchery manager to
hold the chicks for a longer time in the hatchery in
order to allow them to settle down instead of sending
them abruptly to the farm. Care must be taken to transport the chick during the evening or during the cooler
parts of the day.
Water before Feed
Do not introduce any feed for the first four hours after
arrival of the chicks, just give clean water with electrolytes or specific liquid nutrients. Let the chicks settle
down and overcome stress. Introduce either a starter
mash or crumble. Each chick should get a minimum
of 5 cm linear space of feeding up to 2-3 weeks. The
proper feeding of the chicks contributes to a uniform
growth. The feed must be properly balanced to contain
all the nutrient requirements for growth and production, and should be free of toxins.
Pasty vents are due to poor quality chicks or looseness
in the gut. Do not pick away the pasted faecal material
- it may cause injury and encourage cannibalism. Clean
the areas gently with a moist cloth or cotton. Swab and
dip in mild antiseptic solutions like potassium permanganate. If the chicks are too small and too pasty, cull
them.
By M.K. Eckman, Ph.D. Professor and Avian Pathologist, ACES Department of Poultry Science, Auburn
University, Alabama, USA
Variation in sanitation programmes, product selection procedures and implementation is common
among modern day broiler hatcheries. However,
certain basic concepts, cardinal rules and facility
designs characterise the better programmes.
It is not uncommon for the hatchery labour force to
expend 70 percent of their time on various types of
sanitation activities. In contrast, the cost of sanitation
chemicals, regardless of form (i.e. sanitizers, disinfectants, detergents, etc.), is estimated to constitute only 5
percent of the total sanitation programme. Therefore,
a major consideration should be placed on purchasing
the best products available as they are a minor portion
of the total programme expenditure. Moreover, the use
of sanitation chemicals is but one phase in a comprehensive programme. Equipment, application, surface
type, product flow (chicken, eggs) traffic patterns,
ventilation, rolling stock (vehicles) and microbiological monitoring impact the selection of sanitation
chemicals with regard to their label claims and expected performance (Table 1).
Table 1 - Sanitation Chemicals:
Significant Factors
1.
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
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 fine coat of dust on
the eggs. Prior to grading, storage, transport or sanitizing, such eggs must be blown free of dust and debris
with a pressurized air source. Plastic covers on egg
buggies are optional, however, they limit microbial
exposure during storage and transport. Washing, course
spraying and foaming are reasonably common practices and are most effective when done immediately
upon collection of eggs. A variety of chemicals are
available and label directions are best obtained from
the suppliers. However, many producers continue to
rely on quality management for a clean egg-pack and
do not sanitize hatching eggs with chemical application. Proper handling of hatching eggs limits
breakage and subsequent penetration with either bacterial or fungal species. Also, the rapid changes in
ambient temperatures during storage, transport and
hatching must be avoided to prevent sweating or
condensation on shell surfaces. The negative impact
of condensation on hatching eggs is magnified when
shell quality is marginal or below standard. Obviously,
once eggs are laid they do not remain sterile. Limiting
microbial exposure in combination with shell quality
is the key for effective hatching egg sanitation.
Information pertinent to product selection will originate as label claims, safety data sheets, technical
bulletins and past experience. Product selection, if done
properly, should involve a careful review of label claims
an information provided in writing by the supplier. Information on product application, disposal and user
friendliness should be readily available through the
basic supplier or distributor and will be a reflection of
product stewardship at the user level.
Chemical applications in the chick processing area are
usually less stringent as clean-up and disinfection are
conducted on an all-in, all-out basis when activities
are completed and product (i.e. chick) is not present.
Rolling stock (egg trucks, chick buses) must be considered an extension of the hatchery and should be
cleaned and disinfected at a level similar to the egg
room or incubators. Another area that is often overlooked with regard to sanitation is the water supply.
Although water hardness (i.e. mineral deposits) may
affect equipment, the primary factor is 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 extremes will affect ventilation rates and dilution
factors unique to 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. Either extreme may impact the microbial 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 the entry and microbial bloom in all key areas of operation.
Applying sanitation programmes
Methods of application of sanitation chemicals are
probably as significant as their choice of chemicals.
Methods range from direct surface application to misting, standard and thermal fogging, course spraying and
fumigation for surface and space disinfection. Broad
generalizations regarding safety in application are usually inadequate and may vary among products. It is
strongly recommended that safety procedures should
be strictly adhered to for each product on the basis of
label instructions and safety data sheets. All sanitation
programmes should be in writing and revised as necessary. Additional use of pesticides, in most instances,
should be by or under the direction of certified pesticide applicators.
The assessment of the effectiveness of sanitation programmes involves measuring operational procedures
and chemical efficacy in both the breeder and hatchery phases. Standard procedures for assessing shell
quality, egg cleanliness, shell breakage and microbioOperation Manual for Multi-Stage - Chickens 179
The hardest part of any sanitation program is to consistently remove all organic matter from the surfaces
to allow exposure of microorganisms to the disinfectant and sanitiser. Organic matter, such as fluff, blood,
shells, meconium, and dirt render disinfectants
inactive.
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 doesnt
add excess humidity to the machine. With the decreased
shell conductance in todays high yielding breeds, anything that adds extra humidity during hatch or disrupts
air flow negatively impacts chick quality. A better solution is to fog the room and allow the machines to
pull the disinfectant in as normal airflow.
There is some work demonstrating the need for a sanitation program to incorporate a system of rotational
sanitisers to prevent the development of resistant microbes. They demonstrated that microorganisms
become resistant over time when exposed to the same
disinfectant continually. When different compounds
(acidic and alkaline) which were chemically compatible were rotated, less resistance developed. This
research also showed that this strategy may be more
effective in combating biofilms.
Not be complicated.
Be objective.
Quick.
A good monitoring program can be expanded to answer these questions, it is usually just an expansion in
sample numbers over time that is needed.
Bacteria
0 colonies
110 colonies
1149 colonies
>50 colonies
Mould
0 colonies
12 colonies
35 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
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 187
Breakout Procedure:
Breeder Flock
Flock #: 24
Breed:
Test: No Test
Male
Female
Age (wks): 38
Tray #
eggs/tray
infertile
early
dead
farm
racks
upside
down
cull eggs
162
162
10
162
15
162
Totals:
648
15
16
2.31
2.47
0.62
0.62
0.77
Persents:
Embryo Mortality
Determination
There are some cases when the embryo or the blastodisc will not appear
on the top of the yolk. When this occurs, rotate the egg and pour off some
albumen so that the germinal disc
(fertile or infertile) will appear at the
top. If the embryonic development
is still not found, the yolk may then
be poured into an empty pan and examined.
Other Observations
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 can
be classified as soon as the tops of the shells are peeled
back. Others require closer inspection. Be careful not
to let blood spots, meat spots, or yolk mottling result
in classifying an infertile egg as fertile.
Table 3 - Signs of Embryonic Development
Day
Signs
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
Female
% Egg
Hatchery
Production 73.8
Location: Athens
Breeder Flock
Actual
Hatch date:
#Set: 28,600
#
eggs/trayup
infer tile
dead
embryos
1-7
168
20
168
Breed: X
Hatch %: 80.98
dead
embryos
8-14
Age (wks): 38
Setter #: 16
dead
embryos
15-21
pipped
unhatched
13
168
11
168
16
Totals:
676
50
28
14
Percents:
7.44
4.17
2.08
2.08
1.04
0.74
0.30
cull
chicks
cracks
farm
cracks
transpor t
cont
cull
eggs
small
end
0.30
0.74
0.74
0.30
Other Observations
Fertility: 92.56
Spread: 11.58
Shell Quality: OK
Malformations: None
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.
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.