Meat + Poultry - September 2008 - 55

West Liberty Foods' plant in Tremonton, Utah was recently expanded as part of a $40 million project. (Photo courtesy of West Liberty Foods)

is increasing its production and has
improved product safety in the plant.
The entire facility now totals more than
500,000 square feet, and the new process areas include a quick-chill system,
an expanded cooling system, and a
new boiler room. The added production capabilities are in place to increase
efficiency, streamline production time,
and ultimately reduce costs. Sustainability priorities are part of the expansion, including safety measures to reduce pathogen growth by controlling
product movement, air flow, and employee interaction between raw and
processed areas. The new quick-chill
system and separating kill-and-cut areas are steps to reduce potential product contamination. The plant serves as
Indiana Packers' primary processing
facilities and corporate headquarters.
The plant can slaughter 16,500 hogs in
a two-shift operation every day. It is the
latest in several expansion and renovation projects.
A new $40 million addition has just
been added to West Liberty Foods' new
1.6 million pounds-per-week co-packing
facility that opened in Tremonton, Utah
last September. The co-packing plant is
more than 205,000 square feet in size,
including 67,000 square feet for slicing,
a 67,000 individually quick-frozen section, and a cold-storage facility owned
and operated by Millard Refrigerated
Services. The facility opened with 300
employees, but with the expansion,
now totals 420 workers. The new addition, an IQF "add-on," increases space
by 24,000 square feet. The brand-new
plant expansion includes five slice lines
and an individually quick-frozen (IQF)
line. The plant that opened last fall cost

$70 million, and is the first in the industry to manufacture 10-foot logs of luncheon meat for slicing. Products sliced
in the plant include turkey, ham, roast
beef, chicken and cheese, as well as doing IQF and fully-cooked, value-added
products, including chopped/formed,
patties, nuggets and meatballs, battered/breaded products, and char-grilled

ity will use various non-food grade animal fats produced or procured by Tyson
Foods, such as beef tallow, pork lard,
chicken fat and greases.
A relocation project announced in July
is West-Conshohocken, Pa.-based Keystone Foods move from a 75,000 squarefoot location in Gadsden, Ala. to a new
184,000 square-foot location in the same
city. The plant will double its operations,
with 200 new jobs being added to the
current 520-member workforce. Keystone
is leasing part of the new property to
Southern Cold Storage to build a storage
and distribution facility that will serve the
new plant. That will add another 40 jobs,
according to Keystone plant manager
Victor Turner. Gadsden Mayor Sherman
Guyton says the projects together represent a $127 million investment in the
city The Gadsden plant processes mostly chicken and a small amount of beef
for the restaurant industry. Some of the
company's main customers include McDonald's, Taco Bell and Pizza Hut.
Also in July, a 130,000 square-foot
meat processing plant was built in Seminole, Okla. for the Mexican company
Sigma Alimentos. Mexico's largest refrigerated foods company built a plant in
the U.S. to grow its customer base here.
The Oklahoma plant will produce Mexican-style hams, cold cuts and hot dogs.
To prevent cross-contamination in the
plant, the facility features separate raw
and ready-to-eat areas.

"During this past year,
80 percent to 90
percent of the
clients I spoke to felt
SUSTAINABLE
initiatives needed to
be a part of their new
construction and existing
building initiatives."
whole chicken breasts, chicken tenders
and other poultry products.
Tyson Foods Inc. and Syntroleum
Corp. teamed up in two months ago to
form Dynamic Fuels LLC, with the idea
of producing renewable synthetic fuels,
by converting low-grade inedible fats and
greases into renewable synthetic diesel
fuel at a new plant to be built in Geismar,
La. Replacing traditional petroleum fuel
substantially reduces total greenhouse
gas emissions. The project budget totals
$138 million, and the plant should produce about 75 million gallons of renewable synthetic fuel every year. And unlike the ethanol and bio-diesel industries,
which use food ingredients like corn and
soybeans to produce fuel, this new facilwww.MEATPOULTRY.com

Bernard Shire is M&P's Washington correspondent
based in Lancaster, Pa. With a background in editing and writing for daily news publications, he also
works as a food safety consultant and writer for
Shire & Associates.
We would like to hear from you - to comment on
this story or to request reprints, contact us by
e-mail at: meatpoultry@sosland.com.
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September 2008

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MEAT&POULTRY

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Meat + Poultry - September 2008

Table of Contents for the Digital Edition of Meat + Poultry - September 2008

Contents
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