Smart agro-technological system for rural poultry incubation: Automation, monitoring and energy efficiency

This study addresses the limitations of conventional poultry incubators—namely thermal instability, high energy consumption and premature component wear. The objective was to design and implement a semi-industrial PID-controlled incubator to optimize energy efficiency at the Matteito Poultry Farm, located in Santa Rosa de Ocopa, a rural high-jungle district of the Junín region, Peru. An experimental methodology was applied with validation under both controlled and field conditions, comparing the proposed system with an existing commercial controller. Nine incubation cycles were analyzed: two real cycles and seven statistically estimated cycles based on previous records. The developed solution integrated PID temperature control, internal and external IoT-based monitoring, and a multilayer thermal-insulation structure. Results showed a significant reduction in mean energy consumption to 14.6 kWh per cycle, compared with 32.32 kWh for the traditional system—representing a 54.83 % saving. In addition, the system maintained stable temperatures (37.31–37.73 °C), whereas the conventional unit exhibited deviations beyond the allowable thermal margin (36.95–38.44 °C). The thermal coefficient of performance (COP) reached 0.85, surpassing the 0.70 of the conventional setup, and hatchability increased to 90.49 % versus 85.46 %, with lower embryonic mortality. These findings validate the proposed system as a robust, efficient and adaptable solution for small-scale poultry production. • First poultry incubator with PID control and IoT monitoring validated under laboratory and field conditions in the Peruvian high jungle. • Relay-oscillation-tuned PID temperature control, combined with four-layer thermal insulation, reduced energy consumption by 54.8 % (14.6 vs. 32.3 kWh per cycle). • The thermal COP reached 0.85, and temperature remained stable between 37.31 and 37.73 °C within the allowable incubation range. • Hatchability increased to 90.49 %, and embryonic mortality decreased to 9.51 %, compared with 85.46 % and 14.54 % in the conventional system. • Total cost 10–15 % lower than commercial equivalents, offering an affordable and scalable solution for small rural farms.