Hatchery Layout Design Multi Stage and Single Stage

Hatchery Layout Design Multi Stage and Single Stage Hatcheries

Design Objectives • Create Efficient Process Flow – Minimize egg handling and transportation – Increase employee productivity – Provide biosecurity • Maximize Functionality – Allow space for easy and efficient handling of eggs and chicks – Provide sufficient storage for equipment – Allow room for automation (optional)

Process Flow and Functionality Incubator Room Incubator Racks Hatcher Dollies Incubator Room Eggs Chicks Hatcher Room Pull/ Wash Egg Room Clean Room Chick Room

Design Objectives • Minimize Costs – – Reduce capital cost Reduce egg and chick loss Reduce employee fatigue and absenteeism Reduce lost production during expansion • Plan for Possible Future Expansion – Design for expansion on 3 sides of building – Place machines to allow for additional machines – Plan processing rooms so that production is not disrupted while addition is under construction

Minimize Costs Phase 1 Egg Room Incubator Room Phase 2 Incubator Room Clean Room Hatcher Room Pull/Wash Chick Room Hatcher Room

Future Expansion Phase 3 Phase 4 Egg Receiving Egg Room Incubator Room Hatcher Room Future Room Clean Room Incubator Room Pull/Wash Hatcher Room Maint. /Water Elect. Future Room Chick Room Storage Office

Hatchery Layout Information 1. Multi Stage or Single Stage machines? 2. How many chicks per week? 3. Number of hatches per week? 4. Type of bird (chicken, turkey, duck)? 5. T-Shaped or Rectangular Layout?

T-Shaped Hatchery Future Incubator Room Future Egg Room Future Hatcher Room Embrex Hatcher Room Clean Wash Pull Chick Storage Office Future

Rectangular Hatchery Break Room Hatcher Room Incubator Room Mech. Water Elect. Office Storage Egg Receiving Clean Room Pull/Wash Room Chick Room

Additional Information • Type of Production (Broiler, Layer, Breeder) • Egg Flat (Standard - 42 egg flat) • Incubator Rack (Standard - 15 -tier rack) • Optional rooms (Fumigation, Vaccine) • Automation (Sexing/Vaccinating Carousels)

Elect. Incubator Room Clean Room Pull/ Wash Chick Room Incubator Room Maint. Incubator Room Offices Egg Room Storage Incubator Room Hatcher Room Mech. / Water Hatcher Room Incubator Room Hatcher Room Large Rectangular Hatchery Box Room

Requesting a Layout How does a person obtain a hatchery layout from Jamesway Incubator’s Sales Engineering Department?

Complete the QRF Don’t be left behind! Fill out the QRF!

Multi Stage Machines Chicken Space Saver (12 Racks) 2 RACKS INTO 1 - Chicken Incubator Turkey/Duck Space Saver (8 Racks) X 2 per Week 1 - Px Hatcher 2 RACKS INTO 1 - Turkey/Duck Incubator Hatch Commander (6 Racks) Px C/W X 1 per Week 1 - C/W Hatcher 2 RACKS INTO 1 - Hatch Commander Incubator Px 1 - Px Hatcher X 1 per Week

Multi Stage - Chicken • Space Saver Incubators and Px Hatchers – Incubator capacity - 90, 720 eggs (Super J) – Hatcher capacity -15, 120 eggs (Super J) • 42 egg flat (Super J capacity) • 36 egg flat (Big J capacity) Incubator to Hatcher ratio 1: 1

Multi Stage - Chicken Customer wants to produce 150, 000 chickens per week. Weekly chick output: 150, 000 chicks Weekly egg capacity: 150, 000 chicks /. 83 hatch rate = 180, 722 eggs Total egg capacity: 180, 722 eggs x 3 weeks = 542, 168 eggs Total incubators: 542, 168 eggs / 90, 720 incubator capacity = 5. 9 incubators Design hatchery for: 6 incubators and 6 hatchers 2 Hatches per week – 1 hatcher room - 6 hatchers in one room – 75, 000 chicks per hatch day 4 Hatches per week – 2 hatcher rooms - 3 hatchers in each room – 38, 000 chicks per hatch day

Egg Room Future Incubator Room Rack Storage Multi Stage Chicken Hatchery Transfer Future Incubator Rooms Clean Room Hatcher Room Pull/ Wash Future Hatcher Rooms Chick Room Storage Break Elect. Water Maint. Future Box Room

Multi Stage - Turkey or Duck • Space Saver Incubators and Commonwall (C/W) Hatchers – Incubator capacity - 37, 440 eggs (Super J) – Hatcher capacity - 9, 360 eggs (Super J) • 30 egg flat (Super J capacity) • 25 egg flat (Big J capacity) Incubator to Hatcher ratio 2: 1

Multi Stage - Turkey or Duck Customer wants annual capacity of 8 million turkey eggs. Annual capacity: 8 million eggs Weekly egg capacity: 8 million eggs / 52 weeks = 153, 846 eggs Total egg capacity: 153, 846 eggs x 4 weeks = 615, 384 eggs Total incubators: 615, 384 eggs / 37, 440 incubator capacity = 16. 5 incubators Design hatchery for: 16 incubators and 8 hatchers 2 Hatches per week – 1 hatcher room - 8 hatchers in one room – 60, 000 poults per hatch day 4 Hatches per week – 2 hatcher rooms - 4 hatchers in each room – 30, 000 poults per hatch day

Multi Stage Duck Hatchery Hatcher Room Incubator Room Break Transfer Shop Incubator Room Water Storage Elect. Office Egg Room Clean Room Pull/ Wash Duckling Room

Single Stage Machines P 60 INTO 1 - P 60 Incubator (Large) P 40 1 - P 20 Incubator (Small) P 30 2 - P 30 Hatchers (Medium) INTO 1 - P 40 Incubator (Medium) P 20 P 30 P 20 2 - P 20 Hatchers (Small) INTO P 20 1 - P 20 Hatcher (Small)

Single Stage - Chicken • P 60 Platinum Incubators and P 30 Platinum Hatchers – Incubator capacity - 60, 480 eggs – Hatcher capacity - 30, 240 eggs • 42 egg flat • 15 tier rack Incubator to Hatcher ratio 3: 1 PLUS Even number of hatchers in each room

Single Stage - Chicken Customer wants to produce 400, 000 chickens per week. Weekly chick output: 400, 000 chicks Weekly egg capacity: 400, 000 chicks /. 83 hatch rate = 481, 928 eggs Total egg capacity: 481, 928 eggs x 3 weeks = 1, 445, 783 eggs Total incubators: 1, 445, 783 eggs / 60, 480 incubator capacity = 23. 9 incubators Design hatchery for: 24 incubators and 8 hatchers 2 Hatches per week – 1 hatcher room - 8 hatchers in one room – 200, 000 chicks per hatch day 4 Hatches per week – 2 hatcher rooms - 4 hatchers in each room – 100, 000 chicks per hatch day

Single Stage Chicken Hatchery Hatcher Room Incubator Room Mech. Elect. Water Shop Egg Room Clean Room Pull/ Wash Chick Processing Chick Box Return

Single Stage P 120 1 - P 120 Incubator (Extra Large) P 120 INTO OR INTO P 30 4 - P 30 Hatchers (Medium) 3 - P 40 Hatchers (Large) P 40

Single Stage - P 120 • P 120 Platinum Incubators and P 30 Platinum Hatchers – Incubator capacity - 120, 960 eggs – Hatcher capacity - 30, 240 eggs Incubator to Hatcher ratio 3: 2 PLUS Even number of hatchers in each room • P 120 Platinum Incubators and P 40 Platinum Hatchers – Incubator capacity - 120, 960 eggs – Hatcher capacity - 30, 240 eggs Incubator to Hatcher ratio 2: 1 PLUS Even number of hatchers in each room

Hatcher Room Incubator Room Single Stage P 120 Hatchery Mech. Water Shop Office Break Room Egg Room Clean Room Pull/ Wash Elect. Chick Processing

Single Stage - Turkey or Duck • Medium Incubators and Small Hatchers – Incubator capacity - 24, 960 eggs – Hatcher capacity - 12, 480 eggs • 30 egg flat • 13 tier rack Incubator to Hatcher ratio 4: 1 PLUS Even number of hatchers in each room

Single Stage - Turkey or Duck Customer wants to produce 2 million turkeys per year. Annual poult output: 2 million poults Annual egg capacity: 2 million poults /. 83 hatch rate = 2, 409, 638 eggs Weekly egg capacity: 2, 409, 638 eggs / 52 weeks = 46, 339 eggs Total egg capacity: 46, 339 eggs x 4 weeks = 185, 356 eggs Total incubators: 185, 356 eggs / 24, 960 incubator capacity = 7. 4 incubators Design hatchery for: 8 incubators and 2 hatchers 2 Hatches per week – 1 hatcher room - 2 hatchers in one room – 21, 000 poults per hatch day

Single Stage Turkey Hatcher Room Water Incubator Room Mech. Elect. Break Room Egg Room Clean Room Pull/ Wash Room Chick Room Vac. Office

Evolution of a Hatchery Layout - I Hatcher Room Incubator Room Mech. Water Elect. Break Room Shop Office Vac. Egg Room Clean Room Pull/ Wash Room Chick Room

Evolution of a Hatchery Layout - II Mech. Incubator Room Future Incubator Room Hatcher Room Transfer Room Pull/ Wash Room Egg Room Hatcher Room Box Wash Chick Room Box Return Elect. Break Water Office

Evolution of a Hatchery Layout - III Elect. Incubator Room Hatcher Room Incubator Room Transfer Room Incubator Room Mech. Break Shop Water Office Pull/ Wash Egg Room Clean Room Box Wash Chick Room Box Return

Future Incubator Room Hatcher Room Incubator Room Transfer Room Evolution of a Hatchery Layout - IV Incubator Room Wash Pull Egg Room Chick Room Clean Room Egg Receiving Dock Box Wash Box Return Chick Delivery Dock

Layout Approval When Specific Layout is Approved by Customer Proceed with HVAC Quote