You could get a second incubator, and use it as a "hatcher."I am wondering if instead of removing infertile eggs I could replace them with fresh ones and by that increase number of eggs that will develop. I would have to do it as early as possible.
With two incubators, it can work well to set eggs on a weekly schedule.
Every week, you candle the eggs that have been incubating for one week and the ones that have been in for two weeks. Discard any infertiles, and any that died during their second week.
Then set new eggs until the incubator is full again.
A few days later, move the 2.5 week eggs into the second incubator.
Lock them down with the appropriate humidity for hatching.
After the chicks hatch, move them to the brooder and clean the hatcher (the incubator they hatched in.)
By then, it should be just about the right day to move in the next set of eggs (the ones that were set a week later.)
I have also combined chicks that hatched a week and even two weeks apart, and I have read of other people who do it as well.I regularly run hatches in separate incubators and combine in the brooder with up to a 2 week delay.
As long as the brooder is large enough, and the newly hatched ones are fairly steady on their legs, it usually isn't a big deal to put different ages together.