The Hatchery of the Future

Cutting edge technologies like on-farm hatching, in-ovo sexing, and in-ovo vaccination are transforming the interface between the hatchery and the farm.

By moving all post-hatch handling steps pre-hatch, these technologies can eliminate live animal handling at the hatchery all together, resulting in a supply chain that’s both more efficient and humane.

Consider the pros and cons of day-old chicks vs. fertilized eggs from the perspective of a process engineer. Chicks are uncontrollable. They move autonomously, need to be fed and watered to survive, and are irregularly shaped. They are sensitive to pathogens in the environment and need to be handled gently to avoid injury or death. They are moved on conveyor belts, sometimes in baskets, where their movement is unrestrained and chaotic. In areas where automation is infeasible, chicks are handled by skilled laborers who are notoriously difficult to hire, train, and retain.

Fertilized eggs, on the other hand, are a much more sensible unit of engineering. They are controllable, immobile, storable, and have a regular shape. There is well-developed automation equipment that can handle huge amounts of eggs in a gentle and orderly way. Eggs can sit snugly and motionless in trays and can be moved with vacuum suction cups for precise handling.

It should therefore come as no surprise that a number of new technologies are re-engineering processing steps that are traditionally done with day-old chicks so that they can be done with fertilized eggs instead. Sexing, transportation, vaccination, and even early feeding could all eventually be moved to pre-hatch solutions which are both more efficient, and also better for animal welfare. Each new technology by itself has a host of benefits, but the portfolio of technologies taken together have overlapping synergies that will mutually drive their adoption. 

Pre-Hatch Technologies

On-Farm Hatching

On-farm hatching is a practice where hatching eggs are transported from the hatchery directly to the farm on day 18 of incubation, when they would traditionally be moved from the setter to the hatcher. Chicks then hatch on or near the ground in their rearing facility, bypassing the stressful processing and transportation that are a traditionally part of the hatching process.

On-farm hatching technology companies provide equipment and infrastructure to make this practice as simple and cheap as possible for farmers. The practice is currently gaining popularity in the European broiler industry, with multiple companies actively pushing different solutions onto the market.  

The production benefits of on-farm hatching for broilers are numerous. Without post-hatch processing and transport, chicks have immediate access to food and water, which allows them to start eating and gaining weight right away. This also allows for better intestinal development which, combined with the lack of exposure to pathogens during hatching and transportation, significantly decreases the need for antibiotics. One recent study found that flocks hatched on-farm experienced 44 percent less antibiotic use than conventionally hatched chickens and a 5.6 times greater probability of being antibiotic-free. Another study found that total mortality was around half a percent lower in on-farm hatched chicks. 

In order for on-farm hatching to be successful, processing steps like vaccination, sexing, or beak treatment, need to either be done on the farm or in ovo. Fortunately, in-ovo solutions are becoming more widely available.

In-Ovo Sexing

In-ovo sexing is a new technology where the sex of a chicken egg can be determined while it’s still developing. This provides egg producers an alternative to the culling of day-old male chicks. Eggs are removed from the setter incubator mid-way through incubation and run through a sexing circuit where male eggs are removed and turned into a beneficial byproduct like protein powder. Female eggs are then returned to the incubator to complete their incubation. 

The technology has advanced rapidly over the last few years, and is now widely available in the European layer market. It is expected in the US in 2025. 

The technology generally costs more right now, although costs are rapidly falling. Long term, in-ovo sexing is fundamentally an automation technology, meaning that the natural incentives of economics and engineering will inevitably push costs down until it is at cost parity with or cheaper than paying manual sexers.

In-ovo sexing will also allow for egg producers to use the other pre-hatch technologies, which otherwise are only available to broiler producers. For example, on-farm hatching for layers is infeasible given that males would be intermixed with the flock. However, once egg producers can hatch only females, they may benefit tremendously from on-farm hatching. Similarly, in-ovo vaccination or feeding is wasteful for layers since half of the vaccines or food goes to waste. In-ovo sexing solves this problem, halving the potential cost of in-ovo vaccination or feeding.

In-Ovo Vaccination

In-ovo vaccination is the most well-established pre-hatch  technology, having been common practice for broilers for many years. This technology involves administering vaccines to embryos inside the egg, typically around day 18 of incubation as eggs are being moved from the setter to the hatching incubator. The vaccine for Marek’s disease is the most commonly administered in-ovo vaccine.

For vaccines that can be administered in-ovo, doing so has a host of benefits. More capable automation equipment means that in-ovo vaccinated eggs have a more consistent and uniform delivery across each embryo. Additionally, administering the vaccine pre-hatch gives the chick’s immune system the maximum amount of time to fortify itself against the disease, making vaccination significantly more effective. In-ovo vaccination also allows hatcheries to save on the costs of hiring and training skilled laborers to perform manual post-hatch vaccination. 

Historically, in-ovo vaccination has been uncommon for layers because all of the vaccines administered to males go to waste. However, in-ovo sexing may make this an option for egg producers as well as broiler producers.

In-Ovo Feeding

In-ovo feeding is a new technology where food is injected directly into the egg before hatching. This technique, also administered around day 18, aims to provide a nutritional boost to the embryos, giving them a head start on development. Many different types of nutrients have been studied, including vitamins, amino acids, carbohydrates, probiotics, and prebiotics.

In the academic literature, in-ovo feeding has been shown to improve the chick's early life growth, reduce mortality, increase hatchability, and improve overall productivity. Early access to nutrients can also assist gastrointestinal development, leading to better health outcomes.

Despite these benefits, in-ovo feeding is the most nascent of the technologies, having seen limited adoption outside of academia. It remains to be seen whether it will see adoption in industry. However, for layers, adoption would likely be contingent on in-ovo sexing, so as not to waste the food administered to the male embryos.

The Hatchery of the Future

Currently, in-ovo sexing is only used for layers, and on-farm hatching and in-ovo vaccination are primarily used for broilers. However, as in-ovo sexing becomes more widespread, on-farm hatching and in-ovo vaccination may become more common for layers as well.

Although the academic literature on the effects of on-farm hatching on layers is still young, preliminary results suggest that the reduction in early-life stress will have a host of additional benefits for both animal welfare and production efficiency. One study found that less stressed chickens lay more eggs per week and each egg tended to be around 2 grams larger. Early life stress has also been correlated to injurious pecking, one of the biggest welfare challenges for egg producers, and the underlying reason for beak treatment at the hatchery. 

In the longer term, we may also see in-ovo sexing for broilers. Separate sex rearing of broilers helps farmers meet strict requirements around the target weight of the birds by increasing the uniformity in slaughter weights within each single-sex flock. There are already initiatives underway to automate sexing for day-old broiler chicks, given the challenges associated with hiring skilled laborers in today’s economic climate. However, since an individual broiler is less economically valuable than an individual layer, in-ovo sexing would need to be substantially cheaper for broilers than for layers. 

Fortunately, in-ovo sexing may also be technically simpler for broilers than for layers, potentially allowing it to attain the required cost point. One of the technical hurdles for in-ovo sexing of layers is that it needs to be done as early as possible in the embryo’s development to guarantee that the embryo will not experience pain when destroyed. However, the younger the embryo is, the more likely it is that sex-differentiating features are underdeveloped or impossible to detect. 

However, since broilers are not culled, but rather reared separately by sex, there is little incentive to push in-ovo sexing to work as early as possible. In-ovo sexing of broilers could happen as late as day 18 when eggs are almost ready to hatch because the sex-differentiating features of the embryos will be fully developed. Performing sexing when the eggs are already being moved between incubators (or being in-ovo vaccinated) minimizes the number of times eggs are removed from incubation. While such initiatives haven’t reached the market yet, it’s possible this will be an application of the technology as costs fall. 

Similar to how in-ovo sexing will enable other beneficial practices for layers, it could do the same thing for broilers. For example, on-farm hatching combined with separate-sex rearing is only possible with in-ovo sexing. Additionally, in-ovo sexing could unlock sex-specific in-ovo vaccination regimes. Males and females have slightly different immune systems, meaning that sex-specific vaccination regimes may help keep chickens even healthier. The potential benefits of sex-specific in-ovo vaccination were previously impractical to consider, but a combination of in-ovo sexing and vaccination could make this imminently practicable.

With this portfolio of pre-hatch technologies, the hatcheries of the future for both broilers and layers could conduct all handling and processing before the chick becomes aware of what’s happening. Indeed, the poultry industry will have a strong incentive to move in this direction over time given the natural advantages of fertilized eggs for automation and process engineering, as well as the overlapping synergies between the technologies. The chicks born in the Hatchery of the Future will therefore start life in a substantially safer and less stressful way, and the industry will benefit from the significant advancements in both welfare and productivity.

If you’re interested in accelerating the transition to the hatchery of the future, don’t hesitate to reach out!