TechFocus_EGGS 0325 - Using Smart Eggs to Detect Hatchabili…

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Using Smart Eggs to Detect Hatchability Problems By Mark Foote, Hatchery Specialist, Cobb Europe When troubleshooting hatchability issues, customers frequently assume incubation profiles are the main issue. However, the true issue is often the ‘raw material’ or ‘hatching egg’.

Hair-line or micro cracks on the eggshell are often missed and can significantly impact hatchability. We recommend routine quality assurance checks on all incoming eggs to the hatchery. This is a critical control point to ensure the quality of day-old chicks. Allowing substandard eggs into the hatchery increases the risk of contamination, and can negatively impact chick quality. Ideally, only clean eggs that are free of cracks and the correct shape and weight should be incubated (Image 1).

Image 2 : Crack not easily visible after lay.

significantly easier the following day after the cuticle has dried or using a light (torch) (Images 2, 3 and 4 ).

Hair-line cracks are fine and typically run lengthwise along the eggshell. Hairline cracks on freshly- laid eggs can be detected through gently squeezing or by tapping one egg against another to hear a dull thud. As breeder flocks age, egg weight increases and shell quality declines, increasing

Image 1: Hatching egg selection guide.

The integration of automated equipment such as automatic nest systems, cross-conveyors, and egg packing machines on laying farms has significantly reduced labor requirements. However, this automation has also complicated the egg inspection and grading process. Rolling and movement of eggs on and between belts increases the risk of ‘pressure cracks’ or hair-line cracks . After being laid, the outside layer of the shell (cuticle) is still drying making cracks difficult to see. Detecting cracks is

Image 3 : Crack under light

Smart eggs can connect to an app on a phone or computer. Most smart eggs are easy to use and come with instructions to set up and use them in production facilities. Data collected by the egg can be downloaded to view g-force values and determine whether corrective actions are required to reduce impacts. In practice when good eggs are incubated with eggs that have micro- or small hair-line cracks, significant losses occur in hatchability and chick quality (Table 1). Case Study – A producer raised concern that their breeder flock had come into egg production with hatchability levels that were on standard. Yet, a few weeks later, the producer reported that hatchability remained flat with no increase and was now below standard. The hatchery reported that the fertility was on standard but egg breakouts had indicated many early losses during incubation. Quality checks on the eggs in the egg storage room using a torch found about 10 % of the eggs were cracked, mainly hair-line cracks. The laying farm was asked to check for damage during egg collection and handling on site and reported about 2 % of eggs with cracks and no obvious issues. Field technicians visited the farm to observe the practices and conducted checks in the egg storage room. They found the same incidence (10 % cracked eggs) seen in the hatchery. The discrepancy occurred because the farm staff was conducting checks visually, not using a torch. Further investigation revealed the egg belt was being run at excessive speeds and the packing machine was not aligned correctly. Hatchability rose to 84 % after the egg collection belts were slowed. Smart eggs confirmed that the in-feed and transfer head areas of the egg packers were sites of significant g-force. Maintenance and suppliers worked together to make adjustments that ultimately increased hatchability to 91 %.

Image 4 : Crack on cuticle day after lay

- Cracks that facilitate bacteria translocation into the egg causing bangers or exploders. - Damage to the chalaza and internal membranes. - Eggshell damage and / or cracks allowing excessive moisture loss and subsequent yolk and albumen drying out Today there are several products on the market that can mimic an egg’s journey from the nest to the hatchery. These smart eggs are equipped with sensors to measure g-force allowing management to identify high risk areas that may cause cracked eggs. Research indicates that reducing the impacts on eggs from 30 g to 20 g decreases crack rates from over 7.7 % to less than 1 % (Van Mourik et. al 2017). the risks of cracks. The incidence of cracked eggs varies by flock age, generally ranging from 1 % to 3 % of total eggs laid. The number and degree of impacts an egg experiences while moving along automated equipment varies. Some high pressure points, such as drops between belts, can impose a considerable amount of g-force on the egg leading to cracks. High g-force impacts on eggs can cause:

Table 1. Results of an internal trial comparing the incubation outcome of uncracked and cracked eggs

Embryonic death

Exploders (%)

Late (15 to 21 days) (%)

Middle (8 to 14 days) (%)

Infertile eggs

Early (0 to 7 days) (%)

**Cull chicks (%)

*2nd – grade chicks (%)

Total hatch (%) 89.6

Good eggs

0.9

0.7 4.0

2.9

0.2

3.1

0.2

Eggs with hairline cracks

66.4

5.1

4.4 3.8

12.5

0.3

13.7

3.3

Difference

23.2

4.2

3.7 0.2

9.6

0.1

10.6

3.1

*defined as chicks with small quality defects

**chicks with major defects, injuries or deformities

Data from a single unpublished internal trial, for reference only.

3/10

7.1/9

100 90 80 70 60 50 40 30 20 10 0

Score: 5/10

Score: 9/10

Score: 4/10

Score: 8/10

Score: 3/10

Score: 7/10

Score: 2/10

Score: 6/10

Score: 1/10

Score: 4/10

Figure 1: Egg packer transfer head

Figure 2: Conveyor from nest to main conveyor

References: Van Mourik, S., Alders, B. P. G. J., Helderman, F., Van De Ven, L. J. F., & Koerkamp, P. G. (2017). Predicting hairline fractures in eggs of mature hens. Poultry science, 96(6), 1956-1962.

The example graphs above highlight the smart egg readings in g-forces from samples taken from the nest conveyor to the main conveyor (Figure 2), and the transfer head on the egg packer (Figure 1). With this smart egg, it reports a score out of 10, with the lower numbers detrimental and the higher numbers acceptable. In this case, clearly the egg packer in figure 1, was a major root cause for the damage. High risk areas to monitor for potential cracked eggs: • Automatic nest belts – movement on belts, eggs colliding together, vibration and jarring. • Cross-conveyors feeding the main conveyor belt, monitoring speeds and drops. • Egg baskets - manual collection and too many eggs in baskets. • Egg packing machine - staff pushing eggs towards the infeed, transfer head. • Traying area (if used) – do not put setter trays directly on worktops. Use another tray underneath (stacking them) or a raised platform to prevent eggs impacting and cracking on the worktop when placed in the setter tray. • Floors and surfaces – eggs may be jarred when moving in trolleys across uneven floors or surfaces. • Transportation – poor roads, driver awareness, loading and securing eggs.

About this author From 1982 to 1997 Mark worked at Sun Valley Poultry Ltd (Cargill Meats Europe) as a Hatchery Supervisor and progressed to the position of Hatcheries Manager for both chicken and turkey hatcheries for over 10 years, producing 1 million chicks per week. During this period he also spent time developing his knowledge in the broiler breeding department. In 1997 Mark moved to Grampian Country Food Group (Vion UK). He held the position of National Hatcheries Manager, responsible for nine hatcheries producing 4.25 million chicks per week. Mark joined Cobb Europe in 2004 as Technical Manager for UK and Ireland. From 2008 to 2013, he was given extra responsibilities as Account & Technical Manager for Africa, supporting distributors and their customers. In 2013, Mark became a Hatchery Specialist covering the EMEA region.

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