In the world of high-volume manufacturing, a 15% process inefficiency is more than a rounding error: It’s a systemic failure. If a car manufacturer discovered that 15 out of every 100 chassis moving through the assembly line were structurally hollow, but continued to paint, polish, and wire them before finally discarding them at the shipping dock, the shareholders would demand an immediate overhaul.
Yet, for decades, the poultry industry has had to operate under this exact set of conditions.
The biological reality is that roughly 8% to 20% of eggs (yes, there is a lot of variability, e.g. between different breeds) entering any given hatchery are infertile. Until recently, these "clears" were an invisible tax on production. Because the industry lacked a non-invasive way to reveal what is hidden inside before incubation, the only option was to treat every egg as a high-value asset. We set them, turned them, and monitored them for weeks, only to discover the waste during candling.
This is a massive data gap. With the emergence of advanced imaging and AI, specifically through the partnership between Orbem and the Vencomatic Group, we are seeing a shift from "guessing" to "knowing."
Here is why identifying clear eggs before incubation is becoming the new global standard for operational excellence.
The Myth of "Free" Incubation
There is a common misconception that since the machines are running anyway, an extra 10% of eggs doesn't "cost" much. In reality, the cost of an empty egg is compounded across three distinct areas: space, energy, and labor.
Hatchery profitability is inherently tied to throughput per square meter. When 15% of our setter capacity is occupied by infertile eggs, we are effectively paying for a facility that is 15% smaller than its potential.
For many operations, the solution to increasing demand is to build more or buy more. However, by removing clear eggs before incubation, many hatcheries find they already possess the capacity they need. It’s not about building more; it’s about utilizing the hidden capacity currently occupied by waste. Filling every tray with 100% viable eggs allows for a massive increase in output without having to invest heavily in physical expansion.
From Waste to Commodity
Perhaps the most compelling argument for fertilization status detection before incubation is the transition from a linear waste model to a circular one.
Once an egg has been incubated for days, it is legally and biologically "waste" - according to Annex I, Point 5.1 of Regulation (EC) No 853/2004 [ref]. It often carries a disposal cost, requiring specialized handling and transport to landfills or rendering plants.
However, an infertile egg detected before it enters the biosecure hatchery environment or incubator is a different product entirely. Because it has never been heated, it remains a high-quality, shelf-stable industrial commodity. These eggs can be diverted into secondary markets - such as industry eggs and breaker eggs.
- Old Model: Pay a disposal fee to get rid of waste.
- New Model: Receive a commodity price for a secondary product.
This shift alone can fundamentally alter the ROI of a hatchery operation.
Moving from Best Guesses to Guaranteed Results
Even with solid historical data, the variance in actual fertility can make hitting precise chick numbers a challenge.
By using MRI technology to check eggs before they ever hit the setter, we stop managing by probability and start managing with certainty.
- Total Predictability: We aren't guessing how many chicks there will be in three weeks. We know exactly how many viable embryos are entering the incubator.
- Building Partner Trust: When you can meet delivery volumes with certainty, you become the most reliable link in the supply chain.
Seeing the Invisible
For years, the industry relied on candling, but candling is a reactive tool. It tells us what happened after we’ve already invested days of energy and labor.
The move toward precise, efficient production requires a proactive approach. Using non-invasive AI-powered MRI, such as the Genus Scale, allows hatcheries to gather data at the earliest possible point. By combining MRI and AI, Orbem can process thousands of eggs per hour, identifying fertility with near-perfect accuracy without ever touching the shell.
This isn't just about automation; it’s about intelligence. It’s about having the data to make decisions before day 0 that used to be made on day 18.
A New Standard for a Modern Industry
The poultry industry has always been a leader in conversion efficiency, but clear eggs have remained a stubborn blind spot. As margins tighten and the pressure for sustainable, transparent production grows, past approaches are no longer sufficient.
The goal for the modern hatchery is clear: stop treating inefficiency as an unavoidable cost of doing business. It’s time to stop incubating clear eggs.
About the Author
Barbara Jilek, Senior Press & Content Marketing Manager
Barbara secures media coverage, builds relationships with journalists, and loves telling Orbem’s story.
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