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.
Technical Focus - Optimising Egg Collection and Hatchability, Copyright © 2025 Cobb-Vantress, LLC. All Rights Reserved.
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