Optimizing hatchery operations with Preventive Maintenance

To stay ahead of problems and avoid costly downtime, hatcheries need a well-structured and technically sound Preventive Maintenance program. This isn’t just about fixing things before they break; it’s about implementing a way of working around reliability and focussing on continuous improvement.

When equipment fails unexpectedly, it can cause a chain reaction of issues:

• Setters or hatchers that lose temperature control can harm embryo development
• HVAC or chillers that stop working can throw off humidity and temperature, affecting incubation consistency
• Generators that fail during a power outage can bring the entire hatchery to a halt
• Automation or alarm systems that go down can delay critical responses to environmental changes
• Delivery trucks that break down can delay chick shipments, affecting customer satisfaction and animal welfare

These problems often happen during nights, weekends, or holidays, when fewer staff and spare parts are available. The result? Frustrated workers, emergency repair costs, and lower performance on key traits like hatchability, day-old chick quality, and energy use.

A strong maintenance program uses a mix of strategies, depending on the type of equipment and how critical it is:

• Scheduled Maintenance (Time-Based): Tasks done at regular intervals—daily, weekly, or based on operating hours.
• Example: Lubricate fan bearings every 7 days; replace air filters monthly.
• Condition-Based Maintenance: Tasks triggered by real-time data like vibration, noise, or temperature.
• Example: Replace motor bearings when vibration levels exceed ISO 10816 standards
• Manufacturer-Guided Maintenance: Following the original equipment manufacturers’ recommendations for part replacements and service intervals.
• Example: Replace the V-belts after 2,000 hours, as advised in the equipment manual

Using all three approaches together helps balance cost, risk, and reliability!

A clear maintenance schedule helps ensure nothing gets missed:

• Every Day: Visual checks, alarm tests, temperature and humidity calibration
• Every Week: Lubrication, belt tension checks, flushing water lines
• Each Incubation Cycle: Calibrate setters and hatchers, check egg turning systems
• Every 3–6 Months: Test generator loads, descale chillers, update PLC firmware

These tasks should be adjusted based on equipment age, usage, and past performance data.

Every piece of equipment should have its own checklist. This helps:

• Make sure no task is skipped
• Keep procedures consistent across technicians
• Track who did what and when, using signatures or digital logbooks

Digital maintenance systems can take this further, helping you spot trends, optimize schedules, and make better decisions over time.

Preventive maintenance isn’t just about avoiding mechanic breakdowns or failures, to be honest it’s a smart investment in performance, reliability, and long-term savings. A well-run preventive maintenance program helps hatcheries:

• To keep operations running smoothly
• To extend the life of expensive equipment
• To deliver consistent chick quality
• To improve energy efficiency
• To reduce emergency costs and stress

By combining scheduled, condition-based, and by the manufacturer recommended tasks with good documentation and data analysis, hatcheries can stay ahead of problems and focus on what matters most: producing healthy, first-quality day-old chicks.