Patent Description:
A large proportion of modern chickens that are grown to be sources of their meat to be consumed, especially the ones grown in the US, are grown to relatively large sizes (heavier than <NUM>,<NUM> (<NUM> pounds)). The large size is believed to be desirable as it provides breast meat in relatively large quantities per chicken. Chickens grown for their meat are called "broilers". Chickens grown to larger sizes (heavier than <NUM>,<NUM> (<NUM> pounds)) for their meat are sometimes referred to as "big birds".

However, chickens of these large sizes, especially heavier than <NUM>,<NUM> (<NUM> pounds), are often found to have a condition called "Woody Breast" or "Wooden Breast" (referred to herein as Woody Breast or WB). In this condition the breast muscles (which provide the breast meat) have a very hard texture and lower nutritional value. These characteristics substantially reduce the value of the breast meat. It has been estimated that on average <NUM>-<NUM>% of big birds (<NUM>,<NUM> (<NUM> pounds) or more in weight at the time of slaughter) suffer from Woody Breast, resulting in undesirable overall losses to the chicken growers. Woody Breast is exhibited in the live chicken, before any processing or cooking of the chicken for its meat, and is not prevented or reduced by any processing or cooking of the breast meat. There is no known solution for treating or avoiding Woody Breast condition, other than reducing the size to which the chickens are grown, which itself would reduce their overall value.

The hatchability of the egg is an important characteristic, in that it relates to the ability of a live, healthy chick to emerge from the egg in which it had been developing as an embryo. The hatch weight (that is, the weight of the chick at the time that it hatches) is important in that it relates to the ability of the chick to survive and grow to adult size. The increased weight gain (tendency to gain weight) as the chicken grows is significant because it indicates the total meat that will be harvested and can be sold. Mortality is important in that it indicates a higher likelihood that the chicken will reach adult size and will be in good health when it reaches its adult size.

<CIT> and <CIT> disclose methods and devices for incubating poultry eggs to hatching in an environment enriched with CO2.

The present invention identifies specific treatment regimens applying carbon dioxide (CO<NUM>) concentrations and regimens (or "recipes") to unhatched fertilized embryonic poultry eggs while they are being incubated, that in the case of chicken eggs have been found to be successful in reducing Woody Breast in chickens hatched from the treated eggs, and in promoting the other characteristics mentioned herein (namely increased hatchability of the egg; increased hatch weight of the chicken; increased viability and decreased mortality of the chicken; and increased weight gain of the growing chicken). These effects have been found with the regimens described herein of established CO<NUM> concentrations in the incubator for established periods of time. These regimens are all practically and safely implementable in commercial hatcheries, without causing any other harmful side effects such as reduced hatchability, increased mortality, or other disease conditions, to the hatched chickens.

The present invention can be characterized as a method of incubating a fertilized unhatched chicken or other poultry egg to hatching, comprising incubating the egg for an incubation period of <NUM> to <NUM> consecutive days in a gaseous atmosphere which is in contact with the egg, and during that time, injecting carbon dioxide from a source outside the egg into the gaseous atmosphere as necessary so that for at least one period of time (or, alternatively, at least six periods of time) of at least <NUM> hours (or, alternatively, of at least <NUM> hours) the carbon dioxide concentration in the gaseous atmosphere which is in contact with the egg is <NUM>,<NUM> ppm to <NUM>,<NUM> ppm.

The inventors have identified several regimens, including the following:
Regimen <NUM>: The fertilized unhatched chicken or other poultry egg is exposed for at least one day, preferably at least <NUM> days, and more preferably at least <NUM> days of the first <NUM> days of the incubation period to a gaseous atmosphere which is in contact with the egg and which contains carbon dioxide at an incubation concentration that is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>, and during the <NUM>-day period feeding carbon dioxide into the atmosphere as necessary to maintain the CO<NUM> concentration in which the egg is incubated at said incubation concentration, and then for <NUM> consecutive days immediately following the <NUM>-day period incubating the egg in an atmosphere into which no additional CO<NUM> is fed from any source outside the egg or into which CO<NUM> is fed from a source outside the egg as necessary to maintain the CO<NUM> concentration of the atmosphere in contact with the egg at a concentration that is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>.

In a preferred embodiment of this Regimen <NUM>, the set value throughout the first <NUM> days is constant for all <NUM> days.

Regimen <NUM>: In a second preferred regimen, the fertilized unhatched chicken or other poultry egg is exposed to a gaseous atmosphere which is in contact with the egg for consecutive incremental periods in each of which incremental periods the carbon dioxide concentration in the gaseous atmosphere is maintained at a value that is within <NUM>%, and preferably within <NUM>%, of a set value that is constant throughout the incremental period and is between the CO<NUM> concentration of the ambient atmosphere (which is considered to be on the order of <NUM> ppm to as high as <NUM> ppm CO<NUM>) and <NUM>,<NUM> ppm CO<NUM> by feeding carbon dioxide into the gaseous atmosphere from a source outside the egg as necessary to maintain the CO<NUM> concentration in the gaseous atmosphere within <NUM>%, and preferably within <NUM>%, of said set value, wherein the set values and the CO<NUM> concentrations in the gaseous atmosphere increase from each of said incremental periods to the next incremental period, such that in the last incremental period the CO<NUM> concentration in the gaseous atmosphere is within <NUM>%, and preferably within <NUM>%, of a value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>, and then for <NUM> consecutive days immediately following the first <NUM> days of the incubation period incubating the egg in an atmosphere into which no additional CO<NUM> is fed from any source outside the egg or into which CO<NUM> is fed from a source outside the egg as necessary to maintain the CO<NUM> concentration of the atmosphere in contact with the egg at a concentration that is within <NUM>%, and preferably within <NUM>%, of a constant set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>.

In a preferred embodiment of Regimen <NUM>, each set value increases from one incremental period to the next incremental period linearly, that is, by equal increments.

Regimen <NUM>: A third preferred regimen comprises, throughout the incubation period, alternatingly.

In preferred aspects of this regimen, each exposure period is <NUM> to <NUM> hours in duration and each intervening period is <NUM> to <NUM> hours in duration; and there are <NUM> to <NUM> exposure periods and <NUM> to <NUM> intervening periods.

Regimen <NUM>: A fourth preferred regimen comprises, throughout the incubation period, alternatingly.

In preferred aspects of this fourth regimen, each exposure period is <NUM> to <NUM> hours in duration and each intervening period is <NUM> to <NUM> hours in duration.

As used throughout this description and the claims herein, "ppm" means parts per million on a weight basis.

As used throughout this description and the claims herein, the term "ambient atmosphere" means the atmosphere in the region inside and immediately outside the incubator.

As used throughout this description and the claims herein, the term "as necessary" means that carbon dioxide is added if the CO<NUM> concentration of the atmosphere into which the CO<NUM> is to be added is below a desired range or level, and that no CO<NUM> is added if the CO<NUM> concentration in the atmosphere is at a level that is within the desired range or is at a desired level.

As used throughout this description and the claims herein, "carbon dioxide from a source outside the egg" excludes carbon dioxide that has entered the incubator from the natural atmosphere outside the incubator and excludes carbon dioxide that has passed out of the egg through the shell of the egg from inside the egg.

As used throughout this description and the claims herein, "relative humidity" of air or gas refers to the amount of water vapor currently present in the air or gas as percentage of maximum amount of water vapor that the air or gas can hold (without causing precipitation) at the given air or gas temperature. When maximum water vapor capacity of the air or gas, at the given temperature, is reached or exceeded, i.e. when relative humidity reaches <NUM>%, water vapor will precipitate out as liquid water. Many different devices are easily available and used by those skilled in the art to measure relative humidity in the air or gas.

As used throughout this description and the claims herein, the term "incubation" refers to the period when fertilized eggs are placed in a controlled atmosphere environment which is warm enough to promote embryo growth and development. Typically, in commercial hatcheries, the first <NUM> days of incubation take place in a room or equipment that is referred to as either the setter or the incubator and the process is usually referred to as setting. Then the developed eggs are transferred to a separate room or equipment called the hatcher and the process is usually referred to as hatching. As used throughout this description and the claims herein, the term "incubation" refers to the combination of the setting and hatching phases.

In most commercial chicken hatcheries, the setting period is usually <NUM> days and the hatching period is usually <NUM> days. In some cases, these periods can be different. The present invention also applies if the setting and hatching periods are different than what is described throughout this description and the claims herein. For example, if the total period is <NUM> days rather than <NUM> days, the present invention would still apply. In this case, either by feeding carbon dioxide into the gaseous atmosphere from a source outside the egg for <NUM> days or even extending the period proportionally to <NUM> days.

The present invention can also apply for incubation of poultry species other than chicken. As used herein, "poultry" means chicken, turkey, duck, and goose. For example, the present invention would also apply to turkey egg incubation. Typically, turkey egg incubation periods are longer than chicken egg incubation periods. As in the previous paragraph the CO<NUM> regimens described in this invention can be kept the same or the time periods can be extended proportionally.

The present invention provides methods, recipes and equipment for the incubation under controlled CO<NUM> concentrations of unhatched fertilized embryonic eggs of chickens to increase the respiratory and vascular system development and respiratory and vascular function of the chickens before and after hatching, with all other incubation conditions and controls being comparable. In commercial incubating methods and equipment that do not practice the present invention, the CO<NUM> concentration evolves in an uncontrolled and varying fashion naturally or by happenstance due to limiting otherwise conditioned air circulation in the incubator. The present invention discovered the criticality of controlling the CO<NUM> concentration and specific regimens of concentration and timing in the incubator atmosphere to hatch and grow healthy chickens exhibiting reduced, or no, incidence of Woody Breast, and exhibiting the other characteristics mentioned herein (increased hatchability; increased hatch weight; increased viability and decreased mortality; and increased weight gain).

The aspects of the present invention that involve incubation in atmospheres that contain carbon dioxide are advantageously carried out with any fertilized chicken eggs and especially with fertilized eggs that are expected, upon hatching, to produce chickens that are capable with appropriate care and feeding to grow into chickens exhibiting weight of at least <NUM>,<NUM> (<NUM> pounds), preferably at least <NUM> (<NUM>,<NUM> pounds), and even at least <NUM>,<NUM> or <NUM>,<NUM> (<NUM> or <NUM> pounds), by <NUM> to <NUM> days after hatching. Such eggs are preferably obtained from chickens that are genetically favored to produce eggs which will hatch to produce chickens of such sizes.

The aspects of this invention that involve incubation under specific conditions in atmospheres that contain carbon dioxide, can be carried out in an incubator that is largely of conventional design and features, and that is provided with the capability of feeding carbon dioxide into the incubator, and with the capability of measuring the concentration of carbon dioxide in the atmosphere within the incubator and of initiating and discontinuing the feeding of carbon dioxide into the incubator in response to measured values of the concentration of carbon dioxide within the incubator.

For example, referring to <FIG>, an incubator useful in the practice of this invention comprises a structure <NUM> that houses an enclosed space <NUM> that is defined by walls <NUM> and by a floor (not shown) and a ceiling (not shown) which are sealed to the walls, and that contains at least one entry <NUM> through which persons and trolleys or racks with eggs can pass into and out of space <NUM> to place eggs in the incubator and to remove eggs or hatched chicks out of the incubator. The vertical distance from floor to ceiling is typically on the order of six feet or more in larger structures typically used by commercial scale producers, which enable persons to stand inside the incubator, but smaller structures can be used too. Typically, the walls are insulated, and usually the floor and ceiling are also insulated, to help hold heat within space <NUM> in aid of the incubation of eggs within the incubator.

Gas line <NUM> ending at outlet <NUM> inside space <NUM> conveys gaseous carbon dioxide or a gas composition that contains carbon dioxide through controllable valve <NUM> from gas source <NUM> which can be a storage tank, cylinder, vessel or container, or a delivery truck, which contains carbon dioxide at a delivery concentration that is typically at least <NUM> vol. One or more probe(s) <NUM> measures the carbon dioxide concentration inside space <NUM>. Monitor <NUM> controls the opening and closing of valve <NUM> in line <NUM> in response to the values measured by probe <NUM>, by comparing the measured concentration values to preprogrammed values in monitor <NUM> of the concentration of CO<NUM> that is to be maintained in space <NUM>. When the measured value of the carbon dioxide concentration is below a predetermined desired value stored in the monitor <NUM>, the monitor opens valve <NUM> so that carbon dioxide is fed into space <NUM> until the measured value of the CO<NUM> concentration in the gaseous atmosphere in space <NUM> has increased to the desired value. Carbon dioxide can be fed by any of numerous ways, including (but not limited to) feeding a gaseous stream of <NUM>% carbon dioxide, or feeding a gaseous stream that is a combination (mixture) of carbon dioxide together with one or more other gaseous substances, or feeding liquid or solid carbon dioxide, or adding a substance that can generate or release carbon dioxide into the gaseous atmosphere. When the measured carbon dioxide concentration in space <NUM> reaches the desired value, as detected by probe <NUM> and monitor <NUM>, monitor <NUM> closes valve <NUM>. Exhaust port <NUM> represents any suitable opening, openable and closable on demand, through which atmosphere can be vented out of space <NUM>. The incubator should preferably also include equipment that provides the ability to measure the amounts of fresh or conditioned air (from outside the incubator) flowing into the incubator, and/or the flow rate at which the atmosphere within the incubator leaves the incubator. This measurement can then be used to determine the flow rate of CO<NUM> feeding required to maintain a certain concentration of CO<NUM>.

To lower the CO<NUM> concentration in the atmosphere to which the egg is exposed in the incubator, one can feed air, or oxygen and/or nitrogen, into the atmosphere while removing atmosphere from the interior of the incubator, whereby the amount of CO<NUM> in the atmosphere relative to other gaseous components present is lowered.

The incubator is also equipped with air or gas temperature control (which can be either or both of a heater, and/or cooler such as an air conditioner unit <NUM> and with a source <NUM> of water vapor such as a steam line or an evaporator, all of which are known and conventionally available, and each of which are equipped with suitable controls to activate and deactivate the supply of heat, cooling and of humidity, respectively, so as to controllably maintain the atmosphere in space <NUM> at desired values of temperature and relative humidity. The incubator typically comprises a number of racks on which the eggs to be incubated are placed.

Most commercial incubators contain an internal fan <NUM> that distributes or mixes the air inside the incubator, ensuring uniform temperature and humidity conditions. Location of carbon dioxide gas outlet <NUM> within the incubator is important relative to the location of the fan to ensure uniform distribution of the fed CO<NUM> gas. Outlet <NUM> of the carbon dioxide gas line can be composed of either a single point or injection nozzle or alternatively it can be composed of multiple nozzles or points of injection. It is important to locate the outlet <NUM> close to the fan <NUM>. A preferred configuration is a ring of nozzles that inject CO<NUM> gas very close to the internal fan inside the incubator, either right upstream or downstream of the fan <NUM>. Preferably the outlet <NUM> ring of nozzles has a diameter matching the diameter of the fan blades and located <NUM> to <NUM> inches, either upstream or downstream, from the fan.

The position of probe <NUM> is also important to ensure uniform and accurate distribution of the fed CO<NUM> gas. Preferably the probe <NUM> is located at least the distance of half the incubator width away from outlet <NUM>. Also the probe <NUM> should be located at the center of one of the egg racks, most preferably only <NUM> to <NUM> inches away from the surface of the eggs at the center of the rack. All of this ensures that the probe <NUM> is measuring the right CO<NUM> environment within the incubator and is not producing false readings. A multitude of CO<NUM> probes can be used for large incubation chambers, or for chambers with inadequate gas mixing. Average reading or some other means of utilizing spatially distributed CO<NUM> readings can be used to control CO<NUM> addition in these cases.

In operation, the gaseous atmosphere in the incubator should also include at least <NUM> vol. % oxygen, more preferably more than <NUM>% and most preferably more than <NUM> vol. % oxygen concentration.

These components, and the amounts of each component, can be provided in the incubator by known techniques of adding and measuring the desired components of the overall gaseous atmosphere.

The temperature of the gaseous atmosphere in which the eggs are incubated should be in the range of <NUM><NUM>F to <NUM>°F. The relative humidity level in the gaseous atmosphere should be <NUM>% to <NUM>% relative humidity.

Eggs being incubated need a warm (typically <NUM><NUM>F) temperature and controlled humidity for optimum growth. However, the eggs themselves generate heat and expel moisture and generate carbon dioxide during the incubation process. The amounts of heat, moisture and carbon dioxide put out by the fertilized eggs (or developing embryos) vary throughout the incubation process and can also be different from one genetic strain to another. Thus, the ability to control the amount of fresh air that is allowed to enter the incubator (accompanied by the same amount of air from within the incubator that exits it) varies depending on the strain of the birds, number of eggs inside the incubator and time during the incubation process.

Some previous studies restricted the fresh air exchanges into the incubator (non-ventilation) to increase the amount of carbon dioxide inside the incubator to approximately <NUM>,<NUM> ppm. This is an available method to increase the carbon dioxide levels inside the incubator. This method can be practiced by completely turning off the fresh air exchanges or modulating the fresh air exchanges based on incubator carbon dioxide concentration. However, this non-ventilation method, does not allow the operator to simultaneously control the carbon dioxide levels while also independently controlling the temperature and humidity, which can lead to negative effects on the hatchability of the eggs, mortality of the resulting chicken, disease incidences, low weight gain, higher food consumption etc. In most commercial incubators, more importance is given to controlling temperature and humidity levels inside the incubator. This results in a variable and uncontrolled carbon dioxide level during the incubation process.

The present invention provides a methodology for controlling the carbon dioxide levels inside the incubator without restricting or changing the amount of fresh air exchanges that is done in conventional incubators. This is achieved by feeding carbon dioxide into the incubator from an external carbon dioxide source in a controlled fashion based on measurements of carbon dioxide levels inside the incubator. Thus, as a result, carbon dioxide levels can be controlled independent of the temperature and humidity. This results in the most optimum temperature, humidity and carbon dioxide environment for egg incubation.

The incubation of chicken eggs in typical commercial practice does not employ the controlled CO<NUM> atmospheres according to the present invention, and thus does not add any CO<NUM> from an external source. As a result, the concentration of CO<NUM> in the incubator atmosphere varies widely during the multi-day course of the incubation; CO<NUM> concentration levels can and do change during the incubation between values as widely separated as <NUM> to <NUM>,<NUM> ppm. The CO<NUM> concentration changes throughout the <NUM> to <NUM> days of incubation and hatching, and there is no pattern to the change. Some CO<NUM> is generated by the egg/embryo itself as part of its respiratory process and enters the incubator atmosphere through the eggshell. Overall, in such commercial incubator operations, the concentration of CO<NUM> in the incubator atmosphere is influenced only by the exchanges of conditioned air to control temperature, oxygen and humidity levels, and not by the deliberate feeding of CO<NUM> to maintain a desired CO<NUM> level during incubation. The embryos subjected to these conditions of varying CO<NUM> concentration levels typically exhibit significant levels of Woody Breast.

To carry out the incubation method according to the present invention, one or more fertilized unhatched eggs are placed into the incubator, typically onto a rack in space <NUM> (seen in <FIG>). The desired temperature and humidity levels are established in space <NUM> by conditioning the air entering the incubator, by carrying out air exchange as needed between the atmospheres inside and outside the incubator, and by heating, cooling, humidifying, and dehumidifying the atmosphere in the incubator using conventional equipment situated within or in fluid communication with the incubator for performing each of said functions. Then, carbon dioxide concentration according to any of the regimens described herein, is established in the gaseous atmosphere in space <NUM> to which the egg(s) being incubated are exposed.

Beginning at a point in time from fertilization up to four weeks following fertilization, the fertilized unhatched egg is placed in the incubator and is kept in the incubator in contact with a gaseous atmosphere in the incubator that contains carbon dioxide at an incubation concentration that is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM> for a period of at least <NUM> days of the next <NUM> consecutive days, preferably all <NUM> days. Preferably, the incubation concentration of carbon dioxide is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>. More preferably, the incubation concentration is maintained at within <NUM>%, and preferably within <NUM>%, of <NUM>,<NUM> ppm CO<NUM>. The set value can be varied during the <NUM>-day period, but the set value is preferably constant throughout the <NUM>-day period. During the <NUM>-day period, carbon dioxide is fed into the atmosphere in the incubator as necessary to maintain the CO<NUM> concentration in which the egg is incubated at the desired incubation concentration.

<FIG> illustrates one embodiment of this regimen, in which the concentration of CO<NUM> is maintained at a constant value of <NUM>,<NUM> ppm for the full extent of <NUM> days of incubation of the egg.

At the end of the <NUM>-day period, the egg can be removed to a hatching room, or it can be kept in the incubator, for a total of up <NUM> additional days. During that period of up to <NUM> additional days, one may choose between (a) not feeding any additional CO<NUM> from any source outside the egg into the atmosphere to which the egg is exposed (thereby permitting the atmosphere to contain CO<NUM> naturally present in air and any CO<NUM> that is generated by the embryos and passes through the shell into the incubator atmosphere); and (b) feeding CO<NUM> as necessary from any source outside the egg so that the atmosphere to which the egg is exposed contains carbon dioxide at a concentration of up to within <NUM>%, and preferably within <NUM>%, of a set value that is between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM> (preferably, between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>, more preferably <NUM>,<NUM> ppm).

Beginning at a point in time from fertilization up to four weeks following fertilization, the fertilized unhatched egg is placed in the incubator in contact with a gaseous atmosphere in the incubator that contains carbon dioxide at an incubation concentration which follows the following pattern:
For up to <NUM> consecutive periods (termed "incremental periods" herein) of <NUM> to <NUM> hours each, the carbon dioxide concentration in the gaseous atmosphere is maintained at a value that is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>. In each successive incremental period, the set value increases, so that the actual carbon dioxide concentration in the incubator is higher than what it was in the immediately preceding incremental period. Preferably, the set value increases from one incremental period to the next by equal increments.

Carbon dioxide is fed into space <NUM> as necessary to increase the carbon dioxide concentration in the incubator to the next desired higher value. The carbon dioxide concentration is established and maintained at the desired value by feeding carbon dioxide into the gaseous atmosphere from a source outside the egg (such as through outlet <NUM>) as necessary to maintain the CO<NUM> concentration in the gaseous atmosphere within <NUM>%, and preferably within <NUM>%, of said set value. Preferably, in the last incremental period, the carbon dioxide concentration in the atmosphere is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm and <NUM>,<NUM> ppm CO<NUM> and more preferably within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm and <NUM>,<NUM> ppm or even more preferably within <NUM>% and preferably within <NUM>% of <NUM>,<NUM> ppm CO<NUM>. Thus, the set values in the <NUM>-hour periods near the beginning of this regimen should not be near <NUM>,<NUM> ppm CO<NUM> or even <NUM>,<NUM> ppm CO<NUM> or even <NUM>,<NUM> ppm or even <NUM>,<NUM> ppm CO<NUM>.

<FIG> illustrates an embodiment of this regimen. The distance between each pair of consecutive numbers on the x-axis (such as <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>, and so on) represents the passage of one <NUM>-hour period. In the embodiment illustrated in <FIG>, the CO<NUM> concentration is maintained at a constant level during each <NUM>-hour period, and from one <NUM>-hour period to the very next <NUM>-hour period the CO<NUM> concentration in the incubator is increased to a higher level which is then held constant throughout that next <NUM>-hour period. In this embodiment, the CO<NUM> concentration in the incubator is about <NUM> ppm during the first <NUM>-hour period, and is <NUM>,<NUM> ppm during the eighteenth <NUM>-hour period. <FIG> illustrates an embodiment in which the CO<NUM> concentration in the incubator is increased by the same increment from each <NUM>-hour period to the next, though increasing the CO<NUM> concentration in the incubator by equal increments is not necessary in the practice of this invention.

At the end of the up to <NUM> periods of up to <NUM> hours, the egg can be removed to a hatching room, or it can be kept in the incubator, for a total of up <NUM> additional days. During that period of up to <NUM> additional days, one may choose between (a) not feeding any additional CO<NUM> from any source outside the egg into the atmosphere to which the egg is exposed (thereby permitting the atmosphere to contain CO<NUM> naturally present in air and any CO<NUM> that is generated by the embryos and passes through the shell into the incubator atmosphere); and (b) feeding CO<NUM> as necessary from any source outside the egg so that the atmosphere to which the egg is exposed contains carbon dioxide at a concentration of up to within <NUM>%, and preferably within <NUM>%, of a set value that is between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM> (preferably, between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>, more preferably up to <NUM>,<NUM> ppm).

Beginning at a point in time from fertilization up to four weeks following fertilization, the fertilized unhatched egg is placed in the incubator in contact with a gaseous atmosphere in the incubator that contains carbon dioxide at an incubation concentration which follows the following pattern:
The carbon dioxide concentration in the gaseous atmosphere is alternated between values for what is termed the exposure periods, and values for what is termed the intervening periods. In the exposure periods, the carbon dioxide concentration is maintained at a value that is within <NUM>%, and preferably within <NUM>%, of a set value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm (preferably <NUM>,<NUM> ppm or even up to <NUM>,<NUM> ppm) of CO<NUM> by feeding carbon dioxide into the gaseous atmosphere from a source outside the egg as necessary to maintain the CO<NUM> concentration in the gaseous atmosphere within <NUM>%, and preferably within <NUM>%, of said set value. The set value is the same in all of the first <NUM>-hour periods of each <NUM>-hour period.

Alternatingly between exposure periods, in the intervening periods, no carbon dioxide is fed into the gaseous atmosphere of the incubator from outside the egg. The carbon dioxide concentration in the gaseous atmosphere in space <NUM> may decrease during this intervening period, or it may increase (or have its decrease offset) by carbon dioxide that passes into the space <NUM> from within the egg, through the intact but naturally microporous shell. However, for the intervening periods, the CO<NUM> concentration in the incubator can be reduced to a desired low level, as low as ambient, by opening vents that permit the atmosphere within the incubator to pass out of the incubator (optionally activating fans or blowers to facilitate movement of the atmosphere out of the incubator) and feeding ambient air at sufficient levels to establish only the lower desired CO<NUM> concentration level inside the incubator.

<FIG> illustrates an embodiment of this regimen. In this embodiment, consecutive <NUM>-hour periods are represented by the space from <NUM> to <NUM> and then by the spaces between consecutive even numbers (that is, <NUM> to <NUM>, <NUM> to <NUM>, and so on, through <NUM>-<NUM>). Within each <NUM>-hour period that is depicted in this way, the first <NUM>-hour period is the interval extending from the lower even number, to the next odd number to the right, and the second <NUM>-hour period is the interval extending from that odd number to the next even number to the right. For example, in the <NUM>-hour period that is depicted as extending from <NUM> to <NUM>, the first <NUM>-hour period extends from <NUM> to <NUM> and the second <NUM>-hour period extends from <NUM> to <NUM>.

In the embodiment illustrated in <FIG>, sufficient CO<NUM> will have been fed into the incubator atmosphere so that the CO<NUM> concentration in the incubator is <NUM>,<NUM> ppm in the <NUM>-hour period from <NUM> to <NUM> (this being an exposure period), and CO<NUM> will have been vented out of the incubator so that the CO<NUM> concentration in the incubator atmosphere is as low as ambient in the <NUM>-hour period from <NUM> to <NUM> (this being an intervening period). Then, sufficient CO<NUM> is injected into the incubator atmosphere so that the CO<NUM> concentration in the incubator is <NUM>,<NUM> ppm in the <NUM>-hour exposure period from <NUM> to <NUM>, following which addition of CO<NUM> into the incubator is discontinued and the CO<NUM> concentration in the incubator is again lowered to as low as ambient in the <NUM>-hour intervening period from <NUM> to <NUM>. This pattern is repeated alternatingly for the duration of the regimen. The establishment of CO<NUM> concentrations in the incubator alternating between <NUM>,<NUM> ppm and as low as ambient in consecutive <NUM>-hour periods is continued in the same manner through the eighteenth <NUM>-hour period. Depending on the number of eggs incubated at the same time in the incubator, the CO<NUM> levels on the alternate days when no external or additional CO2 is fed, may increase above the normal ambient value, since the eggs themselves generate CO<NUM>.

At the end of the ninth, tenth or eleventh <NUM>-hour period, the egg can be removed to a hatching room, or it can be kept in the incubator, for a total of up <NUM> days from when the egg was first placed into the incubator. During that period following the end of the ninth <NUM>-hour period, one may choose to add no carbon dioxide into the incubator from any source outside the egg, or one may choose to feed carbon dioxide from any source outside the egg to maintain a concentration in the incubator atmosphere of up to <NUM>,<NUM> ppm CO<NUM> and preferably up to <NUM>,<NUM> ppm or even <NUM>,<NUM> ppm CO<NUM>.

Beginning at a point in time from fertilization up to four weeks following fertilization, the fertilized unhatched egg is placed in the incubator in contact with a gaseous atmosphere in the incubator that contains carbon dioxide at an incubation concentration which follows the following pattern:
The carbon dioxide concentration in the gaseous atmosphere is alternated between values for what is termed the exposure periods, and values for what is termed the intervening periods. In the exposure periods, the carbon dioxide concentration is maintained at a value that is within <NUM>%, and preferably within <NUM>%, of a set value between the CO<NUM> concentration in the ambient atmosphere and <NUM>,<NUM> ppm of CO<NUM> by feeding carbon dioxide into the gaseous atmosphere from a source outside the egg as necessary to maintain the CO<NUM> concentration in the gaseous atmosphere within <NUM>%, and preferably within <NUM>%, of said set value. The CO<NUM> concentration and the set value in each exposure period is higher than the set value and CO<NUM> concentration in the preceding exposure periods, such that in the last incremental period the CO<NUM> concentration in the gaseous atmosphere is within <NUM>%, and preferably within <NUM>%, of a value between <NUM>,<NUM> ppm CO<NUM> and <NUM>,<NUM> ppm CO<NUM>.

Alternatingly between exposure periods, in the intervening periods, no carbon dioxide is fed into the gaseous atmosphere of the incubator from outside the egg. The carbon dioxide concentration in the gaseous atmosphere in space <NUM> may decrease during this intervening period, or it may increase (or have its decrease offset) by carbon dioxide that passes into the space <NUM> from within the egg, through the intact but naturally microporous shell. However, for the intervening periods, the CO<NUM> concentration in the incubator can be reduced to a desired low level such as the CO<NUM> concentration in the ambient atmosphere by opening vents that permit the atmosphere within the incubator to pass out of the incubator (optionally activating fans or blowers to facilitate movement of the atmosphere out of the incubator) and feeding air at sufficient levels to establish only the lower desired CO<NUM> concentration level inside the incubator.

<FIG> illustrates an embodiment of this regimen <NUM>. In this embodiment, consecutive <NUM>-hour periods are represented by the space from <NUM> to <NUM> and then by the spaces between consecutive even numbers (that is, <NUM> to <NUM>, <NUM> to <NUM>, and so on, through <NUM>-<NUM>). Within each <NUM>-hour period that is depicted in this way, the intervening period is the interval extending from zero or from the lower even number, to the next odd number to the right, and the exposure period is the interval extending from that odd number to the next even number to the right. For example, in the <NUM>-hour period that is depicted as extending from <NUM> to <NUM>, the intervening period extends from <NUM> to <NUM> and the exposure period extends from <NUM> to <NUM>.

In the embodiment illustrated in <FIG>, CO<NUM> will have been vented out of the incubator so that the CO<NUM> concentration in the incubator atmosphere is around <NUM> ppm in the <NUM>-hour period from <NUM> to <NUM> (this being an intervening period). Then sufficient CO<NUM> will have been fed into the incubator atmosphere so that the CO<NUM> concentration in the incubator is <NUM>,<NUM> ppm in the <NUM>-hour period from <NUM> to <NUM> (this being an exposure period). After CO<NUM> is vented from the incubator to establish the intervening period from <NUM> to <NUM>, sufficient CO<NUM> is fed into the incubator atmosphere so that the CO<NUM> concentration in the incubator is <NUM>,<NUM> ppm in the <NUM>-hour exposure period from <NUM> to <NUM>, following which addition of CO<NUM> into the incubator is discontinued and the CO<NUM> concentration in the incubator is again lowered to around <NUM> ppm in the <NUM>-hour intervening period from <NUM> to <NUM>. This pattern is repeated alternatingly for the duration of the regimen. The establishment of CO<NUM> concentrations in the incubator alternating between <NUM>,<NUM> ppm and around <NUM> ppm in consecutive <NUM>-hour periods is continued in the same manner through the eighteenth <NUM>-hour period. Depending on the number of eggs incubated at the same time in the incubator, the CO<NUM> levels on the alternate days when no external or additional CO2 is added, may increase above the normal atmospheric value of around <NUM> ppm, since the eggs themselves generate CO<NUM>.

At the end of the ninth, tenth or eleventh <NUM>-hour period, the egg can be removed to a hatching room, or it can be kept in the incubator, for a total of up <NUM> days from when the egg was first placed into the incubator. During that period following the end of the ninth <NUM>-hour period, one may choose to add no carbon dioxide into the incubator from any source outside the egg, or one may choose to feed carbon dioxide from any source outside the egg to maintain a concentration in the incubator atmosphere between <NUM>,<NUM> ppm to <NUM>,<NUM> ppm CO<NUM> and preferably between <NUM>,<NUM> ppm to <NUM>,<NUM> ppm or more preferably at <NUM>,<NUM> ppm CO<NUM>.

Establishing a lower CO<NUM> concentration in any of the respective intervening periods can be achieved in the same manner as described above with respect to Regimen <NUM>.

In each of the foregoing regimens <NUM> through <NUM>, where carbon dioxide concentrations are expressed as within <NUM>%, and preferably within <NUM>%, of a given value, it is more preferred that the concentrations are within <NUM>% (instead of within <NUM>% or <NUM>%) of the given value.

At the end of any regimen of exposing the egg to carbon dioxide-containing atmospheres as described above, a chick is thereafter hatched from the thus treated and incubated egg. The chick is then fed water and food and is grown into a fully-grown chicken, under conventional practices by which chicks are fed and enabled to grow into fully-grown chickens.

As shown in the Example below, the aforementioned regimens of exposure of the egg to an atmosphere containing prescribed concentrations of carbon dioxide, for prescribed periods of time, have been found to promote growth of chickens to full size, even to sizes in excess of <NUM>,<NUM> (<NUM> pounds) or in excess of <NUM> (<NUM>,<NUM> pounds), with reduced or no incidence of Woody Breast in the chicken.

The aforementioned benefits in addition to reduction of incidence of Woody Breast, namely increased hatchability of the egg; increased hatch weight of the chicken; increased viability and decreased mortality of the chicken; increased weight gain of the growing chicken;, have also been found with the regimens described herein of established CO<NUM> concentrations in the incubator for established periods of time.

Procedures that incorporate any of these regimens have additional advantages. They are practically implementable in commercial hatcheries while still allowing hatchery personnel to enter the incubators for short periods, as they normally do to perform regular tasks, without endangering the personnel on account of excessive or prolonged exposure to an atmosphere containing unsafe levels of carbon dioxide. In addition, these regimens do not cause other harmful side-effects to the chicken through its life cycle. Thus, these regimens do not cause reduction in rate of growth, final weight, % hatchability, % livability, or susceptibility to other disorders or diseases.

The above regimens of incubation in the presence of increased and controlled concentrations of CO<NUM> have been found to show reduction in incidence or severity of Woody Breast in chickens.

<NUM> fertilized eggs from a commonly used commercial chicken strain, Ross <NUM>, that were less than <NUM> week old since being laid, and laid in the same laying facility by layers (chickens) of the same age, were split equally into three batches of <NUM> each. One batch, referred to as control batch, was incubated for <NUM> days in an atmosphere in which no additional CO<NUM> was injected into this atmosphere from any source outside the egg. For this batch, the CO<NUM> concentration inside the incubator varied between the CO<NUM> concentration of the ambient atmosphere (i.e. about <NUM> ppm) and as high as <NUM>,<NUM> ppm (resulting from CO<NUM> generation by the eggs themselves). The second batch, referred to as <NUM>,<NUM> ppm test CO<NUM> batch or <NUM>% CO<NUM> test batch, was incubated for <NUM> days wherein the CO<NUM> concentration in the incubator from the start of the first day through the end of the eighteenth day was maintained at <NUM>,<NUM> ppm (i.e. <NUM>% CO<NUM>) by occasional injections of CO<NUM> as necessary. The third batch, referred to as <NUM>,<NUM> ppm test CO<NUM> batch or <NUM>% CO<NUM> test batch, was incubated for <NUM> days according to Regimen <NUM> described herein, wherein the CO<NUM> concentration in the incubator from the start of the first day through the end of the eighteenth day was maintained at <NUM>,<NUM> ppm (i.e. <NUM>% CO<NUM>) by occasional injections of CO<NUM> as necessary. All three batches were incubated at approximately <NUM><NUM>F and between <NUM>% and <NUM>% relative humidity. At the end of the eighteenth day of incubation, all three batches of eggs were transferred to hatcher equipment, where the eggs hatched over the next <NUM> days. No external CO<NUM> was injected into the hatcher from any source outside the eggs for this period of <NUM> days. Thus, the only difference between the conditions under which the three batches were incubated was that in the control batch no additional CO<NUM> was injected, whereas for the other two batches additional, external CO<NUM> was injected to subject the eggs to CO<NUM> concentrations of <NUM>,<NUM> ppm and <NUM>,<NUM> ppm respectively. During the incubation period the oxygen concentration in the control incubator was always above <NUM>%, whereas in the <NUM>,<NUM> ppm and <NUM>,<NUM> ppm CO<NUM> controlled incubators, the oxygen level was typically above <NUM>%.

Once the chicks hatched, approximately <NUM> of the male chicks from each batch were taken to grow cages and they began to be fed water and feed. From this point onwards, there was no difference in the treatment of the birds. <NUM> days after hatching the chickens from each batch were weighed and then stunned. Then the birds were measured for Woody Breast scores by manual palpitation by a trained panel of experts under single-blinded conditions. Each breast was given a score of either <NUM>, <NUM>, <NUM> or <NUM>. Score <NUM> means no WB was detected. Score <NUM> meant very high levels of WB detected and scores <NUM> and <NUM> meant intermediate levels of WB were detected. Results: <FIG>, <FIG> compare various parameters for chicken that were hatched from eggs that were incubated in CO<NUM> conditions where no external CO<NUM> was injected into the incubator (referred to as 'control' birds) vs. chicken that were hatched from eggs that were subjected to constant CO<NUM> concentrations of <NUM>,<NUM> ppm in the incubator for <NUM> days (referred to as '<NUM>,<NUM> ppm CO<NUM>' or '<NUM>% CO<NUM>' birds) vs. chicken that were hatched from eggs that were subjected to constant CO<NUM> concentrations of <NUM>,<NUM> ppm in the incubator for <NUM> days (referred to as '<NUM>,000ppm CO<NUM>' or '<NUM>% CO<NUM>' birds). <FIG> shows Woody Breast scores for chickens in the three batches. As can be seen, the CO<NUM> treatment according to Regimen <NUM> at <NUM>,<NUM> ppm (<NUM>% CO<NUM>) significantly reduced the incidence of WB in the chickens compared to the control birds. The % of birds scoring <NUM> reduced from <NUM>% to <NUM>%. However, for the <NUM>% CO<NUM> test batch, the WB scores were higher, indicating an increase in WB incidence. There was an increase in score <NUM> scores from <NUM>% in control to <NUM>% in the <NUM>% CO<NUM> batch, which is significant. These results show that simply increasing the concentration of CO<NUM> in the incubator is not sufficient. Specific recipes are needed to improve the woody breast scores of the birds. <FIG> compares the percent of fertile eggs that hatched at the end of <NUM> days of incubation. <NUM>% of the control birds hatched at the end of the <NUM> days, whereas <NUM>% of the <NUM>% CO<NUM> test birds hatched, whereas <NUM>% of the test <NUM>% CO<NUM> eggs hatched. This is important since an increase in hatchability significantly improves the profitability of the operation. <FIG> compares the average weight of the chicken just after they hatched. The average weight of the birds increased by approximately <NUM>% due to the <NUM>% CO<NUM> treatment in the incubator. <FIG> compares the final weight of the birds at <NUM> days. The average weight of the <NUM>% CO<NUM> birds was approximately <NUM>% higher than the control birds. <FIG> compares the percentage of hatched birds that survived through to the end of the <NUM> days. Approximately <NUM>% more of the <NUM>% CO<NUM> birds survived compared to the control birds.

<NUM> fertilized eggs from a commonly used commercial chicken strain, Ross <NUM>, that were less than <NUM> week old since being laid, and laid in the same laying facility by layers (chickens) of the same age, were split equally into batches of <NUM> each. One batch, referred to as control batch, was incubated for <NUM> days in an atmosphere in which no additional CO<NUM> was injected into this atmosphere from any source outside the egg. For this batch, the CO<NUM> concentration inside the incubator varied between ambient atmospheric (i.e. about <NUM> ppm) and as high as <NUM>,<NUM> ppm (resulting from CO<NUM> generation by the egg). The other batch, referred to as test CO<NUM> ramp batch or <NUM>% CO<NUM> ramp test batch, was incubated for <NUM> days according to Regimen <NUM> described herein, wherein the CO<NUM> concentration in the incubator for the first <NUM> hours was maintained at normal atmospheric conditions (i.e. approximately <NUM> ppm) by not injecting any additional external CO<NUM> and then every <NUM> hours the CO<NUM> concentration was increased for <NUM> hours by an equal amount such that on the <NUM>th day the CO<NUM> concentration was <NUM>,<NUM> ppm (i.e. <NUM>% CO<NUM>) by occasional injections of CO<NUM> as necessary. Both batches were incubated at approximately <NUM><NUM>F and between <NUM>% and <NUM>% relative humidity. At the end of the eighteenth day of incubation, both batches of eggs were transferred to hatcher equipment, where the eggs hatched over the next <NUM> days. No CO<NUM> was injected into the hatcher from any source outside the eggs for this period of <NUM> days for either batch. Thus, the only difference between the conditions under which the two batches were incubated was that one batch was subjected to the Regimen <NUM> reaching a concentration of <NUM>,<NUM> ppm CO<NUM> concentration on the <NUM>th day. During the incubation period the oxygen concentration in the control incubator was always above <NUM>%, whereas in the <NUM>% CO<NUM> ramp up incubators, the oxygen level was typically above <NUM>%.

Once the chicks hatched, approximately <NUM> of the male chicks from each batch were taken to grow cages and they began to be fed water and feed. From this point onwards, there was no difference in the treatment of the birds. <NUM> days after hatching the chickens from each batch were weighed and then stunned. Then the birds were measured for Woody Breast scores by manual palpitation by a trained panel of experts under single-blinded conditions. Each breast was given a score of either <NUM>, <NUM>, <NUM> or <NUM>. Score <NUM> means no WB was detected. Score <NUM> meant very high levels of WB detected and scores <NUM> and <NUM> meant intermediate levels of WB were detected. Results: <FIG>, <FIG> compare various parameters for chicken that were hatched from eggs that were incubated in CO<NUM> conditions where no external CO<NUM> was injected into the incubator (referred to as 'control' birds) vs. chicken that were hatched from eggs that were subjected to ramp up CO<NUM> concentrations reaching <NUM>,<NUM> ppm in the incubator on day <NUM> (referred to as '<NUM>,000ppm CO<NUM> ramp up' or '<NUM>% CO<NUM> ramp up' birds). <FIG> shows Woody Breast scores for chickens which as eggs being incubated had been subjected to ramp up CO<NUM> concentrations reaching <NUM>,<NUM> ppm CO<NUM> in the incubator, or atmospheric CO<NUM> concentration with no injection of additional CO<NUM> into the incubator from any source outside of the egg. As can be seen, the CO<NUM> treatment according to Regimen <NUM> significantly reduced the incidence of WB in the chickens. The % of birds scoring <NUM> reduced from <NUM>% to <NUM>%. <FIG> compares the percent of fertile eggs that hatched at the end of <NUM> days of incubation. <NUM>% of the control birds hatched at the end of the <NUM> days, whereas <NUM>% of the test <NUM>% CO<NUM> ramp up eggs hatched. This is important since an increase in hatchability significantly improves the profitability of the operation. <FIG> compares the average weight of the chicken just after they hatched. The average weight of the birds at hatch was approximately <NUM>% lower for the <NUM>% CO<NUM> ramp up treatment in the incubator compared to the control batch. However as seen in <FIG>, the <NUM>% CO<NUM> ramp up birds quickly put on weight during the next <NUM> days, ending up slightly heavier than the control birds. <FIG> shows the there was no statistical difference in the percentage of birds that survived, although the average livability was slightly higher in the control birds.

<NUM> fertilized eggs from a commonly used commercial chicken strain, Ross <NUM>, that were less than <NUM> week old since being laid, and laid in the same laying facility by layers (chickens) of the same age, were split equally into batches of <NUM> each. One batch, referred to as control batch, was incubated for <NUM> days in an atmosphere in which no additional CO<NUM> was injected into this atmosphere from any source outside the egg. For this batch, the CO<NUM> concentration inside the incubator varied between normal atmospheric (i.e. about <NUM> ppm) and as high as <NUM>,<NUM> ppm (resulting from CO<NUM> generation by the egg). The other batch, referred to as <NUM>,<NUM> ppm test CO<NUM> on-off batch or <NUM>% CO<NUM> on-off test batch, was incubated for <NUM> days according to Regime <NUM> described herein, wherein the CO<NUM> concentration in the incubator for the first <NUM> hours was maintained constant at <NUM>,<NUM> ppm, followed by the next <NUM> hours where no external CO<NUM> was injected into the incubator (and the only CO<NUM> in the incubator came from the normal atmosphere and the CO<NUM> generation from the eggs). These two <NUM> hour periods were then continuously repeated till the end of day <NUM>. During the CO<NUM> off periods, the CO<NUM> concentration in the incubator was between <NUM> ppm and <NUM>,<NUM> ppm. Both batches were incubated at approximately <NUM><NUM>F and between <NUM>% and <NUM>% relative humidity. At the end of the eighteenth day of incubation, both batches of eggs were transferred to hatcher equipment, where the eggs hatched over the next <NUM> days. No CO<NUM> was injected into the hatcher from any source outside the eggs for this period of <NUM> days. Thus, the only difference between the conditions under which the two batches were incubated was that one batch was subjected to the Regimen <NUM> reaching a concentration of <NUM>,<NUM> ppm CO<NUM> concentration on the <NUM>th day. During the incubation period the oxygen concentration in the control incubator was always above <NUM>%, whereas in the <NUM>% CO<NUM> on-off incubators, the oxygen level was typically above <NUM>%.

Claim 1:
A method of incubating a fertilized unhatched poultry egg to hatching, comprising incubating the egg for an incubation period of <NUM> to <NUM> consecutive days in a gaseous atmosphere which is in contact with the egg, and during that time, feeding carbon dioxide from a source outside the egg into the gaseous atmosphere as necessary so that for at least one period of time of at least <NUM> hours the carbon dioxide concentration in the gaseous atmosphere which is in contact with the egg is <NUM>,<NUM> ppm to <NUM>,<NUM> ppm.