Recently, I was confronted with a distressing email from a concerned customer reporting a significant problem in their hatchery. They described a distressing situation where numerous embryos were dying prematurely, leaving trays filled with clears during the incubation process. This was indeed an alarming deviation from their usual successful operations. But what was the cause of this catastrophe?
Upon receiving this troubling report, my initial step was to access the hatchery’s management system remotely. Reviewing the climate data, everything seemed relatively normal except for consistently low CO2 levels. However, delving deeper into the pre-heat phase, a significant anomaly surfaced. A pre-heat session was followed by a brief period of heating to the incubation set point, after which the temperature was inexplicably reduced to 65°F. This irregularity raised questions about a possible premature loading of the setter, although it seemed improbable that such a mistake could result in such a high rate of early mortality.
To gain further insight, I arranged an online meeting with the hatchery manager. During our discussion, a crucial detail emerged. The hatchery had received advice from a consultant, endorsed by the manager’s superior, to fumigate eggs with formalin. Although this practice was not standard at the hatchery, they reluctantly followed the suggestion. Furthermore, the consultant recommended weekly boiling of liquid formalin in the air handling unit to sanitize the setter’s air distribution system. Unfortunately, during the incubation cycle in question, despite the dampers being closed, formalin vapor infiltrated the setter, causing significant harm to the developing embryos.
Formalin exposure during the early stages of incubation is known to be particularly detrimental to embryo development, a fact well-documented in scientific literature. Fortunately, the hatchery manager refrained from repeating the formalin treatment after observing a drop in hatch rates preceding the reported issue. His email inquiry, though disguised as a test, was a crucial step in validating his suspicions.
In conclusion, the root cause of the early embryo mortality was traced back to the inadvertent exposure to formalin, driven by misguided advice from a consultant. This incident underscores the importance of meticulous adherence to established protocols and the critical role of informed decision-making in hatchery management. With a vigilant approach and a commitment to best practices, the hatchery swiftly recovered, restoring normalcy to its operations.
This incident serves as a valuable lesson for hatcheries worldwide, highlighting the need for continuous vigilance and skepticism towards unconventional practices. By prioritizing the well-being of embryos and maintaining rigorous standards, hatcheries can mitigate the risk of similar incidents and ensure the consistent production of healthy chicks.
