For correct hatchery functioning there was a need of proper rooms planing in order to facilitate the work organization and sanitary condition maintenance. There are strictly outlined tracks in the plant, on which hatching eggs and chicks are carried. Hatching eggs from parent breeders are transported in cars on trolleys and transferred to egg storage and then the shortest way to the egg sorting room. Before starting hatch an accurate disinfection of equipment and rooms is done.
Trolleys with eggs prepared for hatch are moved to disinfection chamber and then to hatching egg storehouse, which is equipped with airconditioning and humidifiers. Optimal time from laying an egg to the beinning of hatching process is between 3 to 7 days.
To get better hatching results and also not to make heat shock, the eggs are preheated before setting.
The most important technical element of every hatchery is always the system of setters, hatchers and ventialtion. In Hama Plus hatchery the newest technology of poultry incubation by Pas Reform Hatchery Technologies was employed. The setters capacity is 115 200 eggs each, in one production cycle lasting 18 days.
Each setter and hatcher is connected to central computer SmartCenter, functioning as hatchery production management system. The goal of SmartCenter is to reach and keep the conditions in incubator in a completely automated way. SmartCenter controls and monitors assigned parameters (temperature, humidity, turning position angle, air flow, CO2).
An innovative ventilation system was installed in the hatchery. The efficiency of such solution is much higher in comparison to conventional approach to ventilation.
The hatchers are next element of production chain. The difference concerns less capacity of hatcher (19 200 eggs) and the type of hatching trays. Hatching eggs need about 3 days in hatcher to hatching the chicks. Control program needs 4 basic information:
- ventilation valve regulation.
Supervision over production cycle is being done by reading the data from central computer. It enables to compare assigned values to real ones, which are inserted to computer by system of sensors placed in setters and transmitting the measurements to central computer every 10 minutes.
Thanks to this, a quick reaction can be made, in case of any improperities. Each setter and hatcher is equipped with own alarm system, which turns on in emergency. Control program has also graphic functions, which let compare input and output parameters. In case of necessity, incubators can be run manually.
Incubation of chicken embryo lasts 21 days, in this period embryo is the most exposed to adverse external stimulus. In order to avoid the risk of infection single stage (all in/all out) incubation is practiced. To obtain full spectrum of incubation process and information about size of planned hatch and also to eliminate infertilized eggs, the lighting of hatching eggs is conducted.
This operation is being done during the transfer, which starts in 18th day and consists on moving eggs from setter trays to hatch baskets. This process is fully automated thanks to utilization of specialist machine, which transfers eggs from setter trays to hatch baskets by nozzles and system of sensors. Baskets with eggs are placed into hatchers in which the hatch of chicks is being held.
The hatches in the hatchery take place four times a week. Pulling out the chicks lasts usually 4 to 5 hours. Chickens are put directly on the transmission belt from which they are forwarded in the direction of automatic counter being able to count over 60 000 chicks per hour. Chicks are packed into transport boxes. Finally, these boxes are piled up and loaded on transport trolleys.
WIn order to assure maximum sanitary conditions, the vacuum system of production waste was installed in the hatchery.
The plant has its own, modern veterinary surgery. On clients request, chicks can be vaccinated against contagious diseases; IB, ND, Mareka, Gumboro, Reo, TRT/SHS. Vaccination is done by trained personel. DanHatch uses vaccines only from reputed producers, including clients requests.