Multi Stage and Single Stage Hatcheries - PowerPoint Presentation

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Uploaded On 2022-07-15

Multi Stage and Single Stage Hatcheries - PPT Presentation

Hatchery Layout Design 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 ID: 928880

incubator room egg hatcher room incubator hatcher egg eggs capacity hatchers stage hatchery chick wash incubators pull clean future

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Slide1

Multi Stage andSingle Stage Hatcheries

Hatchery Layout Design

Slide2

Design ObjectivesCreate 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)

Slide3

Process Flow and Functionality

Eggs

Chicks

Hatcher Dollies

Incubator Racks

Egg Room

Clean Room

Pull/ Wash

Chick Room

Hatcher Room

Incubator Room

Slide4

Design ObjectivesMinimize 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 buildingPlace machines to allow for additional machinesPlan processing rooms so that production is not disrupted while addition is under construction

Slide5

Minimize Costs

Egg Room

Clean Room

Pull/Wash

Chick Room

Incubator Room

Hatcher Room

Incubator Room

Hatcher Room

Phase 1

Phase 2

Slide6

Future Expansion

Clean Room

Pull/Wash

Chick Room

Egg Receiving

Egg Room

Incubator Room

Hatcher Room

Future Room

Hatcher Room

Incubator Room

Hatcher Room

Future Room

Phase 3

Phase 4

Storage

Office

Maint./Water

Elect.

Slide7

Hatchery Layout Information

1. Multi Stage or Single Stage machines?

How many chicks per week?

3. Number of

hatches

per week?4. Type of bird (chicken, turkey, duck)?5. T-Shaped or Rectangular Layout?

Slide8

T-Shaped Hatchery

Egg Room

Embrex

Clean

Wash

Pull

Chick

Future Incubator Room

Future Hatcher Room

Incubator Room

Hatcher Room

Future

Storage

Office

Slide9

Rectangular Hatchery

Egg Storage

Clean Room

Egg Receiving

Pull/Wash Room

Chick Room

Storage

Elect.

Water

Mech.

Break Room

Office

Incubator Room

Hatcher Room

Slide10

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)

Slide11

Large Rectangular Hatchery

Egg Room

Mech./ Water

Storage

Clean Room

Pull/ Wash

Chick Room

Offices

Box Room

Maint

Elect.

Incubator Room

Hatcher Room

Incubator Room

Hatcher Room

Slide12

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

Slide13

Complete the QRF

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

Slide14

Multi Stage Machines

1 - Chicken Incubator 1 -

Hatcher

1 - Turkey/Duck Incubator 1 - C/W Hatcher

1 - Hatch Commander Incubator 1 -

Hatcher

Chicken Space Saver(12 Racks)

2 RACKS INTO

Turkey/Duck

Space Saver

(8 Racks)

Hatch

Commander(6 Racks)

C/W

2 RACKS INTO

X 2

per WeekX 1per Week

X 1per Week

Slide15

Multi Stage - Chicken

Space Saver Incubators and

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

Slide16

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 week1 hatcher room - 6 hatchers in one room75,000 chicks per hatch day4 Hatches per week

2 hatcher rooms - 3 hatchers in each room38,000 chicks per hatch day

Slide17

Multi Stage Chicken Hatchery

Hatcher Room

Incubator Room

Future Incubator Rooms

Future Hatcher Rooms

Future

Egg Room

Transfer

Clean Room

Rack Storage

Pull/ Wash

Chick Room

Storage

Box Room

Elect.

Break

Water

Maint.

Slide18

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

Slide19

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 incubatorsDesign hatchery for: 16

incubators and 8 hatchers2 Hatches per week1 hatcher room - 8 hatchers in one room60,000

poults per hatch day4 Hatches per week2 hatcher rooms - 4 hatchers in each room30,000 poults per hatch day

Slide20

Multi Stage Duck Hatchery

Incubator Room

Egg Room

Clean Room

Pull/

Wash

Duckling Room

Hatcher Room

Transfer

Break

Shop

Elect.

Office

Storage

Water

Slide21

Single Stage Machines

1 - P60 Incubator (Large) 2 - P30 Hatchers (Medium)

- P40 Incubator (Medium) 2 - P20 Hatchers (Small)

- P20 Incubator (Small) 1 - P20 Hatcher (Small)

P40

P20

P60

P30

P20

INTOINTO

INTO

Slide22

Single Stage - Chicken

P60 Platinum Incubators and P30 Platinum Hatchers

Incubator capacity - 60,480 eggs

Hatcher capacity - 30,240 eggs

42 egg flat

15 tier rack

Incubator to Hatcher ratio 3:1

PLUSEven number of hatchers in each room

Slide23

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 week1 hatcher room - 8 hatchers in one room200,000 chicks per hatch day4 Hatches per week

2 hatcher rooms - 4 hatchers in each room100,000 chicks per hatch day

Slide24

Single Stage Chicken Hatchery

Egg Room

Pull/ Wash

Chick Processing

Incubator Room

Hatcher Room

Chick Box Return

Mech.

Shop

Elect.

Water

Clean Room

Slide25

Single Stage P120

1 - P120 Incubator

(Extra Large)

4 - P30 Hatchers (Medium) 3 - P40 Hatchers (Large)

INTO

P120

P40

INTO

P30

P30P30P30OR

Slide26

Single Stage - P120P120 Platinum Incubators and

P30 Platinum Hatchers

Incubator capacity - 120,960 eggs

Hatcher capacity - 30,240 eggs

P120 Platinum Incubators and

P40 Platinum Hatchers

Incubator capacity - 120,960 eggsHatcher capacity - 30,240 eggs

Incubator to Hatcher ratio 3:2 PLUSEven number of hatchers in each room

Incubator to Hatcher ratio

2:1 PLUSEven number of hatchers in each room

Slide27

Single Stage P120 Hatchery

Egg Room

Pull/ Wash

Chick Processing

Incubator Room

Hatcher Room

Mech.

Shop

Elect.

Water

Clean Room

Office

Break Room

Slide28

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

PLUSEven number of hatchers in each room

Slide29

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 hatchers2 Hatches per week

1 hatcher room - 2 hatchers in one room21,000 poults per hatch day

Slide30

Single Stage Turkey Hatchery

Incubator Room

Hatcher Room

Chick Room

Pull/ Wash Room

Clean Room

Egg Room

Water

Elect.

Mech.

Office

Break Room

Vac.

Slide31

Evolution of a Hatchery Layout - I

Egg Room

Clean Room

Pull/ Wash Room

Chick Room

Incubator Room

Hatcher Room

Vac.

Office

Water

Elect.

Mech.

Shop

Break Room

Slide32

Evolution of a Hatchery Layout - II

Egg Room

Box Wash

Box Return

Pull/ Wash Room

Chick Room

Future Incubator Room

Incubator Room

Hatcher Room

Transfer Room

Mech.

Water

Break

Office

Elect.

Slide33

Evolution of a Hatchery Layout - III

Egg Room

Incubator Room

Clean Room

Incubator Room

Hatcher Room

Transfer Room

Pull/ Wash

Box Return

Chick Room

Box Wash

Office

Break

Elect.

Mech.

Shop

Water

Slide34

Evolution of a Hatchery Layout - IV

Egg Receiving Dock

Egg Room

Future Incubator Room

Clean Room

Box Wash

Box Return

Pull

Chick Room

Wash

Chick Delivery Dock

Incubator Room

Transfer Room

Hatcher Room

Slide35

Layout Approval

When Specific Layout is Approved by Customer

Proceed with HVAC Quote

Multi Stage and Single Stage Hatcheries - PowerPoint Presentation

Multi Stage and Single Stage Hatcheries - PPT Presentation

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