Advanced imaging technology originally developed for medical diagnostics is now being adapted for broiler, layer and turkey hatcheries, offering producers the ability to detect egg quality issues and optimize production in ways previously impossible.
The technology represents part of a broader shift toward "smart hatcheries" that use artificial intelligence and vision systems to provide real-time insights into production performance.
“Automation is supporting KPIs, helping hatcheries achieve, maintain or improve them," Jennifer Volz, Head of Global Business Development at Orbem USA Inc. said during the 2026 International Production and Processing Expo.
The industry is entering a new phase where operators want to understand exactly where they're losing even fractions of a percentage point in hatchability, she noted.
According to a presentation at the 2025 Poultry Tech Summit, the imaging technology combines magnetic resonance imaging (MRI) with artificial intelligence to scan eggs in less than a second, enabling commercial hatcheries to sort male and female eggs for layer operations, detect fertilization status before incubation or identify phenotypes that can optimize breeding programs and farming practices.
Detecting hidden problems
One of the most significant applications involves identifying hairline cracks and internal egg defects that are difficult or impossible to spot with the naked eye. These issues are often underestimated in the layer industry, Volz said, adding that: "If you ask someone, they might say they have only 2%, but if you really check, you might see 7 or 8%."
The technology can also verify air chamber positioning before incubation begins – a critical factor for hatchery operations using in-ovo vaccination. When eggs are improperly positioned, 80% fail to hatch and 30% of those that do hatch produce poor-quality chicks. For a hatchery processing 1 million eggs weekly with just 3% upside-down eggs, this translates to annual losses exceeding 1 million chicks.
Contamination control
Advanced detection systems can identify dirty eggs, damaged shells, and early embryo mortality before these problems spread through the hatchery. By removing contaminated eggs at the transfer stage, producers reduce cross-contamination risks in hatchers and prevent dirty eggs from breaking onto healthy chicks during processing.
Operations upgrading from traditional candling to heartbeat detection technology see significant gains: approximately 0.2% improvement with young flocks and 2-3% with older flocks, averaging 0.5-1% more sellable chicks overall, Volz reported.
Beyond the egg room
The smart hatchery concept extends throughout the production process. Automated feather sexing using vision technology eliminates the need for manual labor in a task that's particularly difficult to staff in high-wage markets like the United States. Vision-based chick counting systems operate at belt speeds six times lower than traditional counters, addressing animal welfare concerns while maintaining accuracy.
Data integration
Integrated software platforms complete the technological package by tracking products from egg receipt through chick dispatch. These systems collect detailed performance data – including contamination rates by farm, embryo mortality by stage and even performance variations between different setter locations.
"With those data, you can better monitor your production and see the performance of your flock with much more detail," Volz said.
Future developments will expand monitoring to include machine performance metrics, tracking equipment starts, stops, errors and maintenance issues to further optimize operations.
