Background: Proper animal welfare and economic benefits are essential for the broiler industry. Aim: This study assessed the productivity and profitability of open and closed broiler production systems in Egypt, with a particular focus on the histopathological effects of heat stress on broiler health. Methods: Data were collected from 18 broiler cycles, involving 186,300 broiler chicks (9 cycles for each system for about 6 months). The independent t-test was used to analyze data and assess outcomes. Results: According to the findings of the broiler performance study, the study was analyzed using an independent t-test to test the average body weight and performance index that significantly increased in the closed system (2.31 kg and 377.1, t ≤ 0.05, respectively) compared to the open system (2.07 kg and 224.48, t ≤ 0.05, respectively) with better feed conversion ratio and lower mortality rate in the closed system (1.65% and 5.46%, t ≤ 0.05, respectively) than in the open one (1.93% and 15.96%, t ≤ 0.05, respectively). Additionally, the profitability index for open and closed broiler houses in Egypt, as reported in our study, was 0.04 and 0.14, t ≤ 0.05, respectively. This indicates that for every 100 EGP earned as revenue, 4 EGP are returned to the farmer as net income in the open system, whereas 14 EGP are returned in the closed system. Moreover, heat-stressed birds in an open system induced several pathological alterations in different organs, such as blood vessel congestion, degeneration, and vacuolation of breast muscle and parenchymatous organs (liver and kidney). Conclusion: Productive and economic performance favors fully automated climate-controlled broiler housing; thus, a closed system is recommended for broiler farm owners. These improvements are crucial because they can directly contribute to increased profitability and sustainability in poultry farming, especially in regions experiencing extreme heat stress.