Over the previous 15 years the hatchery has undergone continuous expansion and development, from the initial capacity of 20 million day-old chicks annually – to the hatchery of today with a capacity more than 100 million day-old chicks annually. The average capacity of 2 million chicks weekly - approximately 500 000 pcs. on a typical production day.
The design and operation of the hatchery have permanently been based on a hygienic one-way production flow through the entire building. Currently, after the latest expansion and the newest automation fully implemented, the hatchery is among the largest and most modern equipped plants in Europe.
Egg receiving, egg storage and preparation for incubation:
Eggs delivered from breeder farms are collected to the company’s own vehicles – thus we ensure transport hygiene and a proper climate around the eggs from a farm to the hatchery. Upon arrival eggs are unloaded into the egg handling area through the delivery area with full climate control – due to the highest protection of eggs.
Within such area the eggs are inspected and assessed for the quality - according to company’s own protocols. Thereafter a part of the eggs are transferred from farm trays to incubation trays. Automation of these processes secure an efficient and safe handling of eggs with correct positioning of particular egg.
After the arrival to the hatchery – and prior to incubation all eggs are disinfected in chambers, which secure an effective and steady disinfection level of each individual egg. The standard time of storing eggs (before starting the incubation process) amounts to 1 – 2 days.
An unique system for maintaining and controlling eggs’ storage conditions has been used to guarantee the highest level of hygiene. By replacing commonly used ceiling-mounted cooling units onto a ventilation based on mechanical air filtration and ozone-based sanitation, a risk of possible cross- contamination has been eliminated.
Incubation and hatching - the process:
Single-stage incubation is adapted within the entire hatchery that ensures precise adjusting climate conditions to the incubated egg with accurate needs at each stage of the process. Step-based programs allow the best conditions for comfortable growing embryos within the fertilized eggs at the different stages of its developments with regards to a temperature, humidity as well as ventilation across the units. This process takes place for the first 18 – 19 days of the complete incubation period of about 21.5 days.
Subsequently, after the major part of incubation period, eggs are transferred into the hatcher apparatuses. This takes place by a fully automated transfer process, where eggs are being controlled in terms of fertilization and quality; being handled in an efficient and careful way at a rate of 80.000 – 90.000 eggs / hour.
Chick hatching and selection / handling:
After successful hatching, in the dedicated areas chicks are transported to the dispatch and handling area, where they are unloaded using gentle and efficient automation systems – at speed of 70.000 – 75.000 pcs. / hour. This automation allows the staff to devote full focus directly at the grading and selection of chicks prior to counting and packing into transport boxes.
Prior to dispatch and loading chicks are vaccinated in accordance to individual clients’ demands, all is managed by the company’s own veterinarian who is supported by the vaccines manufactures and suppliers and process control on daily basis.
Hygiene process control:
The hatchery is equipped with four (4) fully automatic washing and disinfection lines. These serve to cleaning the farm egg trays, setter trays and trolleys, hatcher baskets and trolleys as well as the transport boxes for day-old chicks.
Critical control points connected with washing processes are secure through installing additional lines of soaking as well as disinfection modules, which increase quality of cleaning processes.
Applied equipment involves the most recently developed and innovative technical solutions.