An incubator is the artificial “mother hen” for every fertile egg inside it. If even one key part malfunctions—like the heating element, fan, or sensor—the embryo development can stop instantly. Farmers around the world lose thousands of chicks each year due to preventable incubator failures.
- In developed countries like the US and Europe, farmers use fully automated incubators, which require sensor calibration and part replacements every 12–18 months.
- In developing regions like India, Pakistan, and Nigeria, power failures and high humidity make battery backups, water tray maintenance, and rust prevention crucial.
- In tropical countries like Brazil and Malaysia, high moisture accelerates corrosion of metal parts—especially fans and heaters.
Understanding which incubator parts fail most often, why they fail, and how to replace them ensures healthy hatchlings and high success rates.
🔥 1. Heating Element – The Core of Temperature Control
The heating element is what keeps eggs warm at the precise temperature required for embryo development. Over time, it can burn out or lose efficiency.
Signs of Failure
- Temperature fluctuations even after calibration
- Heating takes too long to reach set temperature
- Burnt smell or visible damage to the heating coil
Why It Matters
Embryos are extremely sensitive to temperature drops or spikes. Even a few degrees difference can lead to weak chicks, deformities, or embryo death.
Country Insights
- US/Europe: Farmers prefer ceramic heating elements due to longer lifespan.
- Brazil/Malaysia: High humidity accelerates corrosion—farmers often use rust-proof elements.
- India/Pakistan/Nigeria: Power surges can burn elements—voltage stabilizers are widely used.
Replacement Tips
- Always choose a manufacturer-recommended heating element.
- Test the incubator with dummy eggs before restarting incubation.
- Keep dust away to prevent overheating and short circuits.
💧 2. Humidity Sensor & Water Tray
Humidity is critical during lockdown stage (last 3 days). A faulty sensor or evaporator tray can cause chicks to stick to shells, leading to death before hatching.
Signs of Failure
- Incorrect humidity readings
- Excess water condensation or overly dry environment
- Poor hatch rates despite correct temperature
Why It Matters
Humidity ensures proper egg membrane flexibility. If too low, chicks can’t break free; if too high, embryos can drown.
Country Insights
- Europe/US: Automated humidifiers are common, but sensors still require annual replacement.
- India/Nigeria: Open water trays need regular cleaning to prevent algae and bacteria growth.
- Brazil/Malaysia: Due to high ambient humidity, farmers use dehumidifiers in hatch rooms.
Replacement Tips
- Replace humidity sensors every 12–18 months if used frequently.
- Clean water trays regularly to prevent mold and bacterial buildup.
🔄 3. Egg Turner Motor
Automatic turning prevents chicks from sticking to the shell. Over time, the motor wears out, leaving eggs unturned.
Signs of Failure
- Egg trays not moving at set intervals
- Grinding noises from the motor
- Uneven turning of eggs
Why It Matters
Turning keeps the embryo centered and yolk sac properly absorbed. Without turning, hatch rates drop dramatically.
Country Insights
- US/Europe: Automatic turners are standard; motors usually last 2–3 years.
- India/Pakistan: Manual turning is still common due to cost—motorized systems fail faster in dusty farms.
- Brazil/Nigeria: Poor-quality motors often fail mid-cycle—farmers prefer imported or branded parts.
Replacement Tips
- Test the motor before setting eggs.
- Avoid overloading the turner with more eggs than recommended.
🌡️ 4. Thermostat & Temperature Sensor
Even a slight sensor error can cause overheating or underheating. These are small parts but among the most common reasons for hatching failures.
Signs of Failure
- Incubator shows correct temperature, but an external thermometer shows variation
- Temperature fluctuates too frequently
Why It Matters
Embryos need stable 37.5°C (99.5°F). Just 1°C deviation can reduce hatch success by 30–50%.
Country Insights
- US/Europe: Digital thermostats with automatic calibration alerts are common.
- India/Nigeria: Cheaper incubators often have poor thermostats—farmers replace them with digital models for accuracy.
Replacement Tips
- Calibrate sensors monthly.
- Replace cheap thermostats with digital high-accuracy models.
💨 5. Incubator Fan
The fan circulates warm air evenly. A slow or faulty fan creates hot and cold spots inside the incubator.
Signs of Failure
- Uneven temperature readings in different corners
- Strange noise or vibration from the fan
Why It Matters
Still air can suffocate embryos or cause some to develop slower than others.
Country Insights
- Brazil/Malaysia: Humidity causes metal fans to rust faster—farmers switch to plastic blade fans.
- India/Pakistan: Dust build-up is a major reason for motor jams.
Replacement Tips
- Clean the fan blades frequently to prevent dust buildup.
- Replace bearings or the entire fan if noise increases.
🪟 6. Viewing Window Seal
If the seal around the viewing window cracks, warm air escapes, causing temperature drops.
Signs of Failure
- Condensation forming inside the glass
- Heat loss despite the incubator working properly
Why It Matters
Even tiny heat losses affect hatch timing and chick survival.
Country Insights
- US/Europe: Incubators with double-glass viewing windows are preferred for insulation.
- India/Nigeria: Seals degrade faster due to high heat exposure and manual cleaning chemicals.
Replacement Tips
- Replace seals every 1–2 years.
- Use heat-resistant silicone to create airtight sealing.
🔋 7. Backup Power System (Optional)
Power outages during incubation can kill embryos within hours. A backup battery or UPS is essential for remote areas.
Country Insights
- US/Europe: Many hatcheries have automatic UPS backup systems.
- India/Pakistan/Nigeria: Frequent power cuts make solar UPS systems popular.
- Brazil/Malaysia: Backup generators are used in large poultry farms.
Signs of Failure
- Short backup time
- System not switching automatically during outages
Why It Matters
Embryos cannot survive extended cooling periods, especially after Day 10.
Replacement Tips
- Replace batteries every 2–3 years.
- Test backup monthly.
🕹️ 8. Control Panel or PCB Board
The control board manages all sensors and functions. If it fails, the incubator becomes useless.
Signs of Failure
- Screen freezing or error codes
- No response to button inputs
Replacement Tips
- Replace PCB only with the exact model for your incubator.
- Have a manual backup thermometer and hygrometer to monitor eggs until repair is done.
Country Insights
- US/Europe: Farmers replace PCB boards when upgrading incubator models.
- India/Brazil/Nigeria: PCB failures are common in locally-made incubators due to power fluctuations.
🧽 Maintenance Practices to Reduce Part Failures
✅ Clean incubator after every hatch – Remove shells, disinfect trays, and dry completely.
✅ Check sensors monthly – Cross-check with a reliable thermometer and hygrometer.
✅ Lubricate moving parts – Avoids motor burnout.
✅ Replace worn-out parts early – Prevents losing entire batches of eggs.
🌍 Country-Specific Tips for Farmers
- USA & Canada: Many farmers invest in automated incubators with digital alerts; replacing sensors annually is common.
- India & Pakistan: Frequent power cuts mean battery backup or solar solutions are essential to prevent embryo death.
- Brazil & Nigeria: High humidity environments cause faster corrosion of metal parts—clean water trays and fans more frequently.
- Europe & Australia: Farmers focus on energy-efficient incubators; replacing heating elements with modern ceramic types is trending.
📌 Final Thoughts
Your incubator is a lifeline for successful hatching. Most failures come from overlooking small parts like sensors, motors, or fans. By maintaining a regular replacement schedule and keeping backups ready, you can achieve higher hatch rates and healthier chicks.
❓ FAQs
Q1: How often should I replace incubator sensors?
A: Every 12–18 months, especially if used frequently.
Q2: What causes egg turner failure?
A: Overloading trays or dust build-up on the motor gears.
Q3: Can I repair a heating element?
A: It’s safer to replace it entirely than attempt repairs.
Q4: What is the most expensive part to replace?
A: The control board (PCB) is usually the costliest.
Q5: How can I prevent frequent part failures?
✅ Regular cleaning
✅ Monthly calibration
✅ Avoid power surges by using a stabilizer
Q6: What part fails most often?
A: The heating element and humidity sensor are the most common failures.
Q7: How to prevent power-related failures?
A: Use voltage stabilizers, UPS systems, or solar backups.
Q8: Should I buy original parts or generic ones?
A: Always buy manufacturer-recommended parts for safety.
Q9: What is the best way to test an incubator?
A: Run it for 24–48 hours with dummy eggs before starting incubation.