The effect of hen size and diet nutrient density during early lay on egg production (EP) at 24 and 69 wk of age (WOA) and late lay egg quality and hen health was evaluated. Based on bodyweight (BW) at 18 WOA ISA Brown hens were assigned as heavier (HW; n = 120) or lighter weight (LW; n =120). Sixty birds from each BW group were fed an early-lay diet of higher nutrient density (HND), or lower nutrient density (LND) between 18 and 24 WOA. From 25 WOA all hens received the same early-lay diet and then from 40 WOA the mid-lay diet. Hen average daily feed intake (ADFI), hen-day EP, egg weight (EW), egg mass (EM), and feed conversion ratio (FCR) were assessed at 24 and 69 WOA. Between 66 and 70 WOA eggshell and internal egg quality was evaluated and at 70 WOA BW, liver and bone health were assessed. At 24 WOA BW was highest in HW birds and birds receiving the HND diet (P < 0.01). Concurrently ADFI, and FCR were higher and hen-day EP was lower in HW compared to LW birds (P < 0.05). The HND diet resulted in lower ADFI and FCR at 24 WOA, but higher EW and EM compared to the LND diet (P < 0.01). At 69 WOA HW birds had higher ADFI, EW (P < 0.02) and heavier 70 WOA BW compared to LW hens. The lower FCR of the LW birds at 69 WOA was approaching significance (P = 0.054). Hen weight and diet density did not affect 69 WOA egg production. Between 18 and 69 WOA cumulative FI and EM were higher in HW hens (P < 0.01) than LW hens, as was cumulative FCR (P = 0.053). Hen weight and diet density did not alter 66–70 WOA internal egg quality, but the HND diet generated thicker eggshells and higher eggshell breaking strength (P < 0.05). Seventy WOA liver health, keel curvature and femur breaking strength did not differ. Overall LW hens had lower FCR than HW hens and the early-lay HND diet facilitated improved eggshell integrity during late lay compared to the LND diet.
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