Broiler hatchery · 40M day-old chicks / year
Broiler hatchery — Uzbekistan
Illustrative scenario: single-stage broiler hatchery for a Central Asian integrator. Sourcing covered setters, hatchers, egg-handling automation, chick processing and HVAC.
Load requirements
Design loads used to size housing, utilities and equipment.
Egg intake
800,000 eggs/week
Peak electrical load
420 kW
Cooling load
580 kW (chilled water + DX backup)
Steam / humidification
180 kg/h at 3 bar
Fresh air (hatcher hall)
22,000 m³/h with HEPA on chick side
Water demand
18 m³/day (process + wash)
System design choices
Why each subsystem was specified the way it was.
| Area | Choice | Rationale |
|---|---|---|
| Incubation | Single-stage setters, 115,200 egg capacity ea. | Single-stage temperature/CO₂ profiles improve hatch of fertile vs multi-stage in this climate. |
| Hatchers | 6 units, 19-day transfer, 3-week cycle | Matches setter output; supports 800k egg/week intake with 1-day buffer. |
| HVAC | Zoned egg/setter/hatcher/chick halls, pressure cascade | Positive pressure on chick side prevents cross-contamination from hatcher exhaust. |
| Chick handling | Automated counter + vaccinator + box filler | Reduces manual contact, improves count accuracy to ±0.3% per box. |
| Backup power | 800 kVA prime + N+1 UPS on incubators | Even a 5-min interruption during setter runs risks a batch — UPS bridges to genset start. |
Results
Representative KPIs achieved on projects of this scope.
Hatch of fertile
91.2%
Chick grade-A
98.1%
7-day mortality (customer)
0.9%
Contamination rejects
0.11%
Energy per chick
0.19 kWh
Representative outcomes
- Typical scope: 12 setters + 6 hatchers, single-stage
- Typical outcome: hatch of fertile ~91.2%
- Typical outcome: chick grade-A ~98.1%
Note: This case study is an anonymized reference scenario. Specific client identities, contract values and commercial terms are withheld under NDA. Figures reflect typical outcomes for projects of this scope and are not a guarantee for your project.