Driving Better Performance at Capetta Hatchery in Italy

Case Study: Transforming Hatchery Operations with WingScan

Capetta Hatchery, Neive, Italy

Background

Capetta Hatchery in Neive, Italy, is owned and managed by Sergio Capetta and produces around 480,000 chicks each week, equating to approximately 24 million chicks annually. The business had been relying on traditional manual chick sexing, a process that was becoming increasingly difficult to sustain due to labor shortages and inconsistent results.

Challenge

Manual sexing presented serious operational challenges. Skilled labor was becoming harder to find, especially for a role that requires precision and is often performed at unusual hours. As Sergio Capetta explained, “the job of the sexer is a very particular job… staff can no longer be found who are suited to do the job well.”

The process was also labor intensive and inefficient. Around ten workers were needed on the line, often working shifts lasting up to twelve hours. Even with this level of staffing, productivity remained limited and accuracy could vary as workers became fatigued.

Manual handling raised additional concerns about chick welfare. Chicks were handled multiple times during the process, increasing stress and the risk of trauma.

Faced with these pressures, Sergio Capetta saw change as essential.

Solution

Capetta Hatchery implemented WingScan, an automated chick sexing system designed to increase throughput, improve accuracy, and reduce reliance on manual labor while enhancing animal welfare.

On the installation, Sergio Capetta said: “For my business, there is no future without this machine… in a few years you won’t find anyone doing manual sexing anymore.”

Implementation

The introduction of WingScan had a huge impact. Instead of ten workers carrying out manual sexing, the operation now runs efficiently with four to five people. One person loads crates onto the conveyor while three operators place chicks onto the line, allowing the machine to run continuously.

Hatchery Manager Domenico Torre described the new setup: “With 4 or 5 people, we can process a large number of chicks… the machine keeps running continuously at a steady pace.”

The system proved easy to adopt. Operators were able to quickly understand how to use it, thanks to its intuitive interface. As WingScan operator Erik Sarotto noted, “Interacting with the machine is very easy because it’s very intuitive… you immediately know where to act.”

Results

Productivity and Labor Efficiency

The most immediate impact was a significant increase in throughput. Output rose from approximately 15,000 to 16,000 chicks per hour to as many as 35,000 to 40,000 chicks per hour.

At the same time, labor requirements dropped. “Before, on the line, there were around 10 people… now on the line we have one person,” said Torre, referring specifically to the role of manual sexing.

Working hours were reduced by half. “Before the working day lasted 12 hours, now it is six hours, with the same numbers of chicks,” said Sergio Capetta.

Accuracy and Consistency

WingScan delivered a major improvement in sexing accuracy. Error rates fell to around 1%. “The sexing now, in my opinion, is perfect… there is a 1% error, no more,” Capetta explained.

This improvement has also been confirmed on farms. Paolo Marenco shared that “there are no longer imbalances between males and females.”

Animal Welfare Improvements

Reducing manual handling has had a clear positive impact on chick welfare. Previously, chicks were handled multiple times throughout the process. With WingScan, that has been reduced to a single transfer step.

Marenco highlighted the difference: “Chicks experience much less trauma than before… now there is only one step, so the chicks are handled much less.”

Operators and customers have observed improvements in chick quality and lower mortality rates. Sarotto added, “they’re handled much less… there’s been a complete improvement in every area.”

Operational Reliability and Ease of Use

Operators consistently report that the system is simple and reliable. The interface provides clear, real-time feedback on performance and alerts users to issues before they escalate.

Sarotto explained, “The machine alerts you to an error before it stops… intervention is quite immediate.” Most issues are minor and resolved in seconds, often with simple cleaning.

The system also captures detailed production data, allowing operators to monitor sex ratios, unclassified chicks, and machine performance throughout the day.

Marenco summarized the experience: “Everything is completely accessible in a very, very simple way… anyone can use it.”

Service and Support

Support from the WingScan team has been proactive and dependable. The installation included training that enabled the team to manage maintenance independently.

Marenco noted, “They taught us how to handle maintenance… and they are always present and available for support.” In some cases, issues were identified remotely before production began and resolved quickly.

Capetta reinforced this view: “They respond, sometimes they anticipate us.”

Outcome

The adoption of WingScan has fundamentally improved operations at Capetta Hatchery. The business now operates with higher productivity, greater accuracy, reduced labor dependence, and improved animal welfare outcomes.

As Sergio Capetta put it, “Everyone has found an improvement, everyone,” reflecting both internal gains and positive feedback from customers.

Conclusion

By transitioning to automated sexing with WingScan, Capetta Hatchery has addressed critical labor challenges while achieving measurable gains in efficiency, quality, and welfare. The move has positioned the business for long-term sustainability in an industry where manual sexing is becoming increasingly difficult to maintain.