Innovation in incubation technology Rudy Verhelst Hatchery innovation Asia Ceva seminar Bali, Indonesia 3-4/06/2014
Overview Incubation: a growing enviroment Evolution in incubator design Innovation in technology What is needed for incubation? Traditional incubation Embryo-Response Incubation Managing the hatchery: Eagle Eye Conclusion Page 2
Incubation: a growing environment Challenges Incubator design Hatchery design & automation Technology Managing Page 35
Evolution in incubator design Multistage range S168 S336 S504 S576 S1152 1973 1977 1981 1984 1989 16,800 33,600 50,400 57,600 115,200 Page 37
Evolution in incubator design Single-stage range S576 AirStreamer 12S AirStreamer 24S BioStreamer 24S BioStreamer 24S HD 1984 2000 2004 2010 2014 57,600 57,600 115,200 115,200 129,024 Page 38
Evolution in incubator design BioStreamer HD Page 39
Evolution in incubator design BioStreamer HD 84 egg tray Reinforced trolley 84 egg tray stackable Reinforced turning Extra cooling Page 40
What is needed for incubation? Ventilation Cooling Heating CO 2 H O 2 Page 42
What is needed for incubation? Setter Hatcher Page 47
Traditional incubation multi-stage single-stage d3 d9 d16 d3 d9 d9 d9 d9 % hatchability chick quality bio-security Page 49
Traditional incubation Hatchery manager: how much temperature, ventilation and humidity needed? single-stage d9 d9 d9 d9 Based on experience, trial-and-error Page 50
Traditional incubation Typical hatchery manager never changes T, V, H for different flocks always uses same incubation program Good hatchery manager optimises T, V, H for different flocks 30 weeks 50 weeks Page 51
Traditional incubation Problem: hatchery size Good hatchery manager optimises T, V, H for different flocks complex time consuming need for automation! Page 53
Embryo-Response Incubation Automate the optimisation of Feedback from embryo incubator Incubator can listen to the embryo Let the embryo decide how much it wants! Page 55
Embryo-Response Incubation Temperature should be correct T too high too low t % hatchability hatch timing What is the correct temperature? Page 57
Embryo-Response Incubation What is the correct temperature? T embryo = 100.0 F (Visschedijk, Aviagen) T embryo = T eggshell (French, Tazawa & Nakagawa) T eggshell = 100.0 F (from d0 d18) T eggshell = T air? No! Page 58
Embryo-Response Incubation T eggshell T air need to measure T eggshell Page 61
Embryo-Response Incubation How to measure T eggshell? Manually: very time consuming e.g. 40 incubators measure T eggshell twice per day 12 eggs per machine 10 minutes per machine 40 x 10 x 2 = 800 min = 13 hours per day! Need for automation Page 62
Embryo-Response Incubation Automated measurement T eggshell OvoScan TM measures every 10 seconds 12 eggs average no human error no need to open doors bio-security temperature Page 65
Embryo-Response Incubation Automated measurement T eggshell OvoScan TM If T eggshell too high machine starts to cool If T eggshell too low machine starts to heat Page 66
Embryo-Response Incubation CO 2 and O 2 level Traditionally: based on experience Improvement: CO 2 measurement Optimise incubator ventilation Higher CO 2 levels during embryo development (d0-d9) improved cardiovascular system (Willemsen et al) Requires hermetically sealed machine Page 68
Embryo-Response Incubation Weight loss of eggs should be correct Traditionally: based on experience How does weight loss work? Page 70
Embryo-Response Incubation How does weight loss work? 100% RH 80% RH 100% RH 35% RH Less weight loss More weight loss Page 71
Embryo-Response Incubation How does weight loss work? How much weight loss is needed? Too low: air cell too small, embryo risks drawning Too high: embryo dries out Weight loss at d18: 11-12% (Aviagen) need to measure weight loss Page 72
Embryo-Response Incubation Dynamic Weight Loss System Measures weight 150 eggs every hour Predicts weight loss at d18 ventilation OK ventilation Page 78
# hatched chicks Embryo-Response Incubation Main goal hatcher: synchronised hatch Why? incubation time Early hatchers: have to stay >24h in hatcher dry out no feed or water access Page 80
Embryo-Response Incubation Main goal hatcher: synchronised hatch # hatched chicks incubation time Better chick uniformity Page 82
Embryo-Response Incubation Main goal hatcher: synchronised hatch How? Synchro-Hatch Detects moment that embryos are in internal pipping Signal for hatcher modify Page 83
Embryo-Response Incubation Main goal hatcher: synchronised hatch Synchro-Hatch Field results: 30% smaller hatch window +0.77% hatchability more uniform chicks improved post hatch performance # chicks hatched [%] 35 30 25 20 15 10 With Synchro-Hatch Control group 5 0-519 00 19 12 20 00 20 12 21 00 incubation time [days hours] Page 84
Embryo-Response Incubation Humidity in hatcher Hatch peak detection humidity ventilation Page 86
Embryo-Response Incubation Setter Hatcher Page 87
Managing the hatchery: Eagle Eye TM Page 89
Managing the hatchery: Eagle Eye TM Page 90
Conclusion Incubation: a growing enviroment Challenges Incubator design Hatchery design & automation Technology Managing Page 92
Conclusion Evolution in incubator design Challenges Incubator design Hatchery design & automation Technology Managing Page 93
Challenges Incubator design Hatchery design & automation Technology Managing Conclusion Innovation in technology Embryo-Response Incubation TM Page 94
Conclusion Managing the hatchery: Eagle Eye TM Challenges Incubator design Hatchery design & automation Technology Managing Page 95
Questions Page 96