Building and Operating a Mini-hatchery (Sand method) - Training Manual

Building and operating a mini-hatchery:
Sand method

International Fund for Palli Karma-Sahayak Foundation
Agricultural Development (PKSF)
Via Paolo di Dono, 44 Bhaban Plot: E-4/B, Agargaon
00142 Rome, Italy Administrative Area Sher-e-Bangla Nagar
Tel: +39 06 54591 Dhaka 1207
Fax: +39 06 5043463 Bangladesh
E-mail: ifad@ifad.org
www.ifad.org Palli Karma-Sahayak Foundation
www.ruralpovertyportal.org

The opinions expressed in this publication are those of the authors and do not necessarily represent
those of the International Fund for Agricultural Development (IFAD). The designations employed and
the presentation of material in this publication do not imply the expression of any opinion whatsoever
on the part of IFAD concerning the legal status of any country, territory, city or area or of its authorities,
or concerning the delimitation of its frontiers or boundaries. The designations “developed” and For more information, to comment or to share your experience
“developing” countries are intended for statistical convenience and do not necessarily express a and knowledge of simple mini-hatcheries, please contact:
judgement about the stage reached by a particular country or area in the development process. Antonio Rota
Senior Technical Adviser, Livestock and Farming Systems
Policy and Technical Advisory Division
Cover:
IFAD
©IFAD/G.M.B. Akash
E-mail: a.rota@ifad.org
Photos in the text are from the video Mini-hatchery by Sayeed Kazol. or
ISBN 978-92-9072-274-8 S.M. Rajiur Rahman
© 2011 by the International Fund for Agricultural Development (IFAD) Training Officer, MFTS Project
PKSF, Bangladesh
September 2011 E-mail: smrajiurrahman@yahoo.com

Table of contents

About this manual 2
Acknowledgements 2
Introduction 3
Equipment and facilities needed for a sand-based mini-hatchery 5
Operating the mini-hatchery 7

Annex I: A business plan of sand-type mini-hatchery 15
Annex II: Candling eggs 17

Additional reading 19

About this manual
Backyard poultry production is an important source of income and nutrition for the rural
poor in the developing world. The foundation of this system is a regular supply of chicks and
ducklings. This manual describes:
• How to make a sand-type mini-hatchery;
• How to collect and select fertile eggs;
• How to place the eggs in the incubator;
• The day-to-day operation of the hatchery; and
• How to handle chicks or ducklings as they hatch.

The manual is aimed at both extension agents and backyard poultry rearers.

Acknowledgements
This manual was prepared by S.M. Rajiur Rahman, Training Officer, Microfinance and
Technical Support Project, Palli Karma-Sahayak Foundation, Bangladesh.
The author is grateful to the Policy and Technical Advisory Division (PTA) of the
International Fund for Agricultural Development (IFAD) for financial support and other
services without which this manual could not have been prepared. The author is grateful to
Antonio Rota, IFAD Senior Technical Adviser, Livestock and Farming Systems, PTA for his
cooperation and important suggestions in developing the manual.
The author gratefully acknowledges the following for their assistance in preparing the
manual and producing the video:
• Nigel Brett, IFAD Country Programme Manager
• Fazlul Kader, Deputy Managing Director (Operation), Palli Karma-Sahayak Foundation,
Bangladesh
• Sarah Jesmin, Project Coordinator, Microfinance and Technical Support Project,
Bangladesh
• Kazi Abdul Fattah, Livestock Coordinator, Microfinance and Technical Support Project,
Bangladesh
• Beneficiaries of the IFAD-supported Microfinance and Technical Support Project who
have established mini-hatcheries in the Districts of Kishoreganj of Bangladesh

Special thanks go to the following technical peer reviewers:
• Shabbir Ahmed Chowdhury, Director, Microfinance, Bangladesh Rural Advancement
Committee International, Bangladesh
• Mohammad A. Saleque, Senior Adviser, Agriculture and Livestock, Bangladesh Rural
Advancement Committee International, Bangladesh
• Olaf Thieme, Livestock Development Officer, Animal Production and Health Division,
Food and Agriculture Organization of the United Nations, Rome
• Emmanuel B. Sonaiya, Department of Animal Science, Obafemi Awolowo University,
Ile-Ife, Nigeria

The author wishes to thank Paul Neate for editing the manual.

2

Introduction
Mini-hatcheries, or incubators, have been used to hatch chicken and duck eggs in Egypt and
China for some 3,000 years. Mini-hatcheries have been in use in Bangladesh since the 1970s.
In 1992, BRAC – a Bangladesh-based non-governmental organization – started a programme
to promote the use of an incubator based on heated rice husk. However, the system was not
widely adopted, largely because of poor management of fertile eggs in the supply chain.
With financial support from the International Fund for Agricultural Development (IFAD),
the Palli Karma-Sahayak Foundation (PKSF) expanded the conventional incubation process,
producing a more efficient and functional system, building on an adapted, comprehensive
training programme that covered all aspects of the rural poultry production chain. In
particular, a four-week practical training programme for rural women was developed and
carried out by a livestock agent at the village level.
Mini-hatcheries can be constructed from cheap materials available locally, such as
rice husk, quilts and sand, to retain heat. The incubators can be easily made using readily
available skills and tools.
Sand-based mini-hatcheries give the highest hatching percentages for both chicken and
duck eggs (80-85 per cent and 70-72 per cent respectively, compared with 70-75 per cent and
65-68 per cent for rice husk incubators and 75-80 per cent and 60-62 per cent for rice husk
and quilt incubators. As a result, sand-based incubators are gaining popularity. The advantages
and disadvantages of the different types of incubators are shown in the Table below.
This manual aims to provide people with the skills and knowledge needed both to
construct sand-based incubators and to operate them efficiently.

3

Advantages and disadvantages of different types of small-scale incubators
for hatching chicken and duck eggs
Parameter Electric incubator Sand method Rice husk method Rice husk and
quilt method
Electricity Required Not required Not required Not required
Equipment Sophisticated Local/traditional Local/traditional Local/traditional
modern equipment materials materials materials
Installation in Cannot be installed Can be installed Can be installed in remote Can be installed in remote
remote areas in areas without in remote areas areas where electricity is areas where electricity is
electricity where electricity not available not available
is not available
Installation cost Highest Lowest Higher than sand method Higher than sand and
but much lower than rice husk methods but
electric incubator much lower than
electric incubator
Maintenance Highest Lowest Higher than Higher than sand and rice
cost sand method husk methods but lower
than electric incubator
Temperature Automatic Easier than rice More difficult than sand Easier than rice husk
regulation husk and quilt and rice husk and quilt method
method method
Humidity Automatic Manual Manual Manual
regulation
Hatching 80-85% 80-85% 70-75% 75-80%
percentage
(chicken eggs)
Fuel cost Highest Lowest Higher than sand method Higher than sand and rice
husk method
Users Only wealthy All, including All, including landless and All, including landless and
people can afford landless and resource-poor households resource-poor households
this system resource-poor in marginal areas in marginal areas
households in
marginal areas

4

Equipment and facilities needed
for a sand-based mini-hatchery
To operate a sand-based mini-hatchery you need:
• An incubator, including:
• Kerosene lamps to heat the incubator
• Thermometers to monitor temperature in the incubator
• A water bowl to maintain humidity inside the incubator
• Fertile eggs
• Egg trays
• Chick boxes
• A candling box (see Annex II)
• Antiseptic solution for washing the eggs and disinfecting the incubator
• Somewhere to keep the incubator

Building a sand-based incubator
The incubator consists of a wooden cabinet lined with insulating material and equipped with
trays to hold the sand (heat retention) and eggs. There should be a hatch in the top of the
cabinet to allow hot air to be released to regulate the temperature inside the incubator.
The size of the cabinet depends on the number of eggs to be incubated. An incubator of
135 cm tall, 230 cm wide and 105 cm deep can accommodate three hatching trays and
incubate 1,200 to 1,500 eggs at a time.
The cabinet should be made of wood. The walls, roof and doors should be lined with a
layer of cotton wool (in rolls), 8-12 cm thick. The trays may be made of wood or metal.
The trays rest on a rack made of wood or metal. The sand tray should be set 50 cm above
the floor of the cabinet. The first hatching tray should be 15-20 cm above the sand tray,
with each additional hatching tray set 15-20 cm above the previous tray (see diagram below).
There should be a gap of 8 cm between the edges of the trays and the walls and doors of the
cabinet to allow air to circulate.

Width: 230 cm

Hatch
Hatch Depth: 105 cm

8-12 cm thick
layer of cotton Egg tray Width of trays:
56-61 cm
Egg tray
15-20 cm
between trays Height:
Egg tray 135 cm
.................................................................
..................................................................
1.5-3.0 cm ..................................................................
..................................................................
Sand tray
sand layer ................................................................. 8 cm between
tray and wall
Kerosene of the box
50 cm lamps

Diagram of the sand-based incubator and its internal arrangement

5

A sand-based incubator with three hatching trays.

The sand tray should be lined with black cloth to retain the sand and filled with a layer of
sand, between 1.5-3 cm thick. The hatching trays should be lined with a layer of jute sacking
and a black cloth.

Hatchery room
Ideally, the incubator should be kept in a room set aside for the hatchery. The room should be
built using low-cost local materials (such as bamboo, stra.w, hardboard, polythene, etc.). It
should have a door and windows that can be closed to help control the temperature in the
room and hence in the incubator.

Hatching trays lined with jute sacking and black cloth.

6

Operating the mini-hatchery
Hatchery sanitation
Good sanitation must be maintained to prevent disease in the hatchery.
A good sanitation programme consists of 90 per cent good management and 10 per cent
disinfection and fumigation.
• Wash and disinfect the floor of the hatchery room every day.
• Remove broken, infertile and spoiled eggs as soon as you see them.
• When chicks and ducklings start to hatch, remove eggshells and weak
or dead chicks immediately.
• After all the eggs have hatched, remove the trays and cloth liners and wash
and disinfect them thoroughly.

The incubation process
Chicken eggs hatch after 21 days, while duck eggs hatch after 28 days.

DAY 1

Collect fertile eggs from breeding flocks where roosters and hens
and drakes and ducks are kept together, with a ratio of at least one rooster or a Eggs can be stored for up to
7 days at 59° F to 64.4° F
drake for every 10 hens or ducks. Select well-shaped, standard-sized eggs.
(15° C to 18° C) and
75-80 per cent relative
Clean the eggs and wash them with a mild antiseptic solution in hot water. humidity before being
Locally available household antiseptics such as Dettol® and Savlon® can be placed in the incubator.
used for this. a Purchase eggs from
nearby breeding flocks to
Place the clean eggs in egg trays, put them in a sunny place and minimize the distance the
warm them to 100° F (37.5° C). Alternatively, warm them carefully eggs must be transported.
Take care to avoid
over a kerosene stove.
damaging the eggs in
transit and protect them
from large changes
in temperature.

Warming eggs in the sun.

7

Place two or three lit kerosene lamps in the incubator and allow the
temperature in the incubator to rise to 98° F to 100° F (36.5° C to 37.5° C).
This should take 2 to 3 hours. The lit kerosene lamps must be clean and the
operator should be careful to regulate the flame to avoid producing smoke,
which would poison the embryos in the eggs.

Once the incubator has reached the desired temperature, carefully arrange the
warm eggs on the hatching trays. The eggs should be set at a 45° angle, with
the narrower end pointing down.

Arrange the eggs on the
hatching trays, with the
narrower end pointing down.

Place a bowl of water on the floor of the incubator to maintain humidity at
a Maintain the humidity 70-80 per cent.
in the incubation box at
70-80 per cent. Ideally,
you should measure the
Place a laboratory thermometer on each hatching tray and check the
humidity using a temperature every time you turn the eggs (6 to 8 hours). If the temperature
hygrometer. If the air falls below 98° F (36.5° C), increase the size of the flame of the kerosene
in the incubation box lamps. If it rises above 100° F (37.5° C), open the hatch in the top of the
is dry, the eggs will take incubator to release some hot air and reduce the flames in the lamps or
longer to hatch.
remove one or more of the lamps.

Ideally, monitor the humidity
in the incubation box using
a hygrometer.

8

DAYS 2 TO 18 (CHICKEN EGGS) AND
DAYS 2 TO 24 (DUCK EGGS)

Turn the eggs every 6 to 8 hours.

Carefully turn the eggs
every 6 to 8 hours.

Continue turning the eggs until Day 18 for chicken eggs and until Day 24
for duck eggs.

Check the temperature inside the incubator every time you turn the eggs to
ensure that it is consistently between 98° F and 100° F (36.5° C to 37.5° C).

If the temperature falls below 98° F (36.5° C), increase the size of the flame of
the kerosene lamps. If it rises too high, open the hatch in the top of the
incubator to release some hot air and reduce the flames in the lamps or
remove one or more of the lamps.

Remove and throw away any broken eggs.

Add water to the water bowl in the incubator whenever it runs low. This is
important to maintain the humidity in the incubator.

9

CANDLING THE EGGS:
DAYS 7 AND 14 (CHICKEN EGGS),
AND DAYS 7 AND 21 (DUCK EGGS)

Candle the eggs on Day 7 and Day 14 to identify infertile and spoiled eggs.
a Candling: Place a candle or
electric light bulb inside a
Remove all the infertile and spoiled eggs from the incubation chamber.
box with an egg-sized hole
in the side. Place each egg After 7 days infertile eggs are still safe to eat, but spoiled eggs should be
in turn into the hole and discarded. After 14 days, spoiled eggs need to be discarded.
observe the pattern of light
shining through the shell. Some 75-90 per cent of eggs from a good breeding flock should be fertile.
(See Annex II.)
- Fertile egg:
You will see a faint
pattern of blood vessels.
- Infertile egg:
These are transparent,
with no sign of
blood vessels.
- Spoiled egg:
These are opaque.
Candling an egg to check
whether it is fertile.

Check the temperature
inside the incubator every
time you turn the eggs
(6 to 8 hours). It should
be kept at 98° F to 100° F
(36.5° C to 37.5° C).

10

DAY 19 (CHICKEN EGGS)

Stop turning the eggs.

Cracks are seen on the chicken eggshells.

Once a day, gently moisten the eggs using a wet cotton cloth to soften the shell
and help the chicks emerge.

Initial hatching phase.


Chicks will start to come out from the eggs.


Most of the chicks will have hatched.

If a chick is having difficulty getting out of the egg, wash your hands and then
gently break the shell, taking care not to tear the chick’s umbilical cord.

Remove chick gently from
the egg taking care not to
tear the umbilical cord.

11

Chicks are dry within 30 to 45 minutes after emerging from their shells.
Once dry, they rapidly overheat in the incubator. Remove chicks as soon as
they are dry and place them in a holding basket equipped with a heat lamp
to keep them warm.

Day-old chicks are
now ready for the
brooding phase.

Day-old chicks from the hatchery are now ready for the next production phase:
brooding.

Remove eggshells, dead chicks and spoiled eggs from the hatching trays.
Dispose of them hygienically, for example by burying them in the soil.

Once all the chicks have hatched, remove the cloth linings from the hatching
trays and clean and disinfect the incubator thoroughly so that it is ready for
the next batch of eggs.

Once all the chicks have
hatched, clean the
incubator thoroughly.

12

DAY 24 (DUCK EGGS)

Stop turning the eggs.

DAY 26 (DUCK EGGS)

Cracks are seen on the duck eggshells.

Gently moisten the eggs using the wet cotton cloth to soften the shell and help
the ducklings to emerge.

DAY 27 (DUCK EGGS)

Ducklings start to hatch from the eggs.

DAY 28 (DUCK EGGS)

Most of the ducklings will have hatched from the eggs.

Hatched ducklings.

If a duckling is having difficulty getting out of the egg, wash your hands
and gently break the shell, taking care not to tear the umbilical cord
of the duckling.

Remove duckling gently
from the egg taking care not
to tear the umbilical cord.

13

Ducklings dry within 30 to 45 minutes after emerging from their shells. Once
dry, they rapidly overheat in the incubator. Remove the ducklings as soon as
they are dry and place them in a holding basket equipped with a heat lamp
to keep them warm.

Day-old ducklings from the hatchery are now ready for the next production
phase: brooding.

Remove eggshells, dead ducklings and spoiled eggs from the hatching trays.
Dispose of them hygienically, for example by burying them in the soil.

Eggshells, dead ducklings
and spoiled eggs should
be buried.

Once all the ducklings have hatched, remove the cloth linings from the
hatching trays and clean the incubator thoroughly so that it is ready for the
next batch of eggs.

Remove cloth lining from
the hatching trays before
cleaning the incubator.

14

Annex I

A business plan of sand-type mini-hatchery
Incubator establishment costs
Fixed costs
Description Measurement/quantity Approximate cost United States
(BDT) dollars*
Incubator Height 135 cm x width 230 cm 8 000/-
x depth 105 cm
Open weave tray 2 80/-
Kerosene lamp, bulb 3 500/-
Thermometer 3 50/-
Black cloth 5m 300/-
Cotton 10 kg 1 500/-
Jute sacks 4 (estimate) 120/-
Candler 1 150/-
Water pot 1 100/-
Marker 1 30/-
Egg tray 20 500/-
Chick box 5 750/-
Total 12 080/- 170

* 1 US$ = 71 Bangladesh taka (BDT).

Operational costs for incubating 600 eggs
Description Measurement/quantity Approximate cost United States
(BDT) dollars*

Chicken eggs
Fertile eggs 600 eggs x 8.50 BDT per egg 5 100/-
Kerosene, Lump sum 600/-
disinfectant, antiseptic
solution, etc.
Total 5 700/- 80

Duck eggs
Fertile eggs 600 eggs x 7.50 BDT per egg 4 500/-
Kerosene, Lump sum 800/-
disinfectant, antiseptic
solution, etc.
Total 5 300/- 75

* 1 US$ = 71 BDT.

15

Income per batch of 600 eggs
Chick production
Chicks hatched 510 (hatchability of 85 per cent)
Chick sales 510 x 21 BDT per chick = 10 710 BDT (US$151)*
Sale of edible eggs 70 infertile (edible) eggs x 5.5 BDT per egg = 385 BDT (US$5)
after first candling
Total sales 11 095 BDT (US$156)
Net income 11 095 BDT – 5 700 BDT = 5 395 BDT (US$76)

* 1 US$ = 71 BDT.

Duckling production
Ducklings hatched 432 (hatchability of 72 per cent)
Duckling sales 432 x 18 BDT per duckling = 7 776 BDT (US$110)*
Sale of edible eggs 70 infertile (edible) eggs x 5.5 BDT per egg = 385 BDT (US$5)
after first candling
Total sales 8 161 BDT (US$115)
Net income 8 161 BDT – 5 300 BDT= 2 861 BDT (US$40)

* 1 US$ = 71 BDT.

Note: Depreciation of 150 BDT to 160 BDT (US$2) may be deducted from each batch income. This is based on
total fixed cost for the incubator of 12,080 BDT, with an operational life of 10 years and utilization for 8 months
per year, i.e. depreciation spread over 80 months.

16

Annex II

Candling eggs
Candling is the process of shining light through an egg to determine whether the egg is fertile,
infertile or spoiled.
The manual recommends candling on Day 7 and Day 14 for chicken eggs, and Day 7 and
21 for duck eggs. The principle is simple: In a dark room a source of light is placed against the
eggshell, and the light passes through illuminating its contents. If the egg is fertile a tiny
network of blood vessels emerging from a dark red spot (similar to a spider) will be seen (see
photo below). If the egg is infertile the yolk will appear as a floating shadow with no sign of
blood vessels. And if the egg is spoiled it will appear opaque.
A candler can be easily made by using a 25 to 60 Watt light bulb (if electricity is available)
or a candle placed in a container (small box or empty tin can), with a hole (3-4 cm) to let the
light pass through (Figure 1). A battery torch can also be used with a box or tin can placed on
top and the egg positioned over a hole to allow the light to shine through (Figure 2).

Remember:
• Always handle the eggs with care and do not keep them out of the incubator for more
than 10 to 15 minutes.
• Infertile chicken eggs at Day 7 can be consumed, while infertile chicken eggs at Day 14
must be disposed of hygienically.

Figure 1. Figure 2.
Candler using a light bulb A torch candler

Egg

Light Box or tin can

Torch

17

Building and Operating a Mini-hatchery (Sand method) - Training Manual

Additional reading
Card, L. E., and M.C. Nesheim. 1972. Poultry production (11th ed., reprinted). Philadelphia, USA:
Lea & Febiger.
Khan, M.A. 1983. Dim Prashfutaner Katha. [A book on the principles of duck hatchery operation].
Friends in Village Development of Bangladesh, Khadim Nagar, Sylhet, Bangladesh.
Khan, M.S.R., and K.S. Farid. 2011. Study on the technical and financial aspects of mini- hatcheries
(for chicken and duck) and poultry model breeders including diseases associated with the production in
the two systems. Research report submitted to the Microfinance and Technical Support Project,
Palli Karma-Sahayak Foundation (PKSF). Dhaka, Bangladesh: PKSF.
Nahar, J., K.A. Fattah, S.M. Rajiur Rahman, Y. Ali, A. Sarwar, E. Mallorie, and F. Dolberg. 2006.
The rice husk hatchery in the microfinance and technical support project in Bangladesh.
INFPD Newsletter 16(2):27–29.
Rajiur Rahman, S.M. 2008. Family poultry development through micro-credit and technical
support. World’s Poultry Science Journal 64(2).
Rota, A., N. Brett, J. Nahar, S.M. Rajiur Rahman, Y. Ali, A. Sarwar, and K.A. Fattah. 2006.
The experience with mini-hatcheries technology in Bangladesh. Available at:
http://www.enrap.org/events/ifad-events/ifad-fao-study-tour-on-microfinance-for-marginal-
and-small-farmers-reaching-the-target-group-2/Paper - Mini-hatcheries poultry.doc
Sumy, M.M.C., and M.M Islam. 2010. Study on the viability and profitability of improved backyard
poultry enterprises in the poultry model chain in Bangladesh. Research report submitted to the
Microfinance and Technical Support Project, Palli Karma-Sahayak Foundation (PKSF).
Dhaka, Bangladesh: PKSF.

19

Building and Operating a Mini-hatchery (Sand method) - Training Manual

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