Meat+Poultry - August 2019 - 74
C O M PA N Y P R O F I L E
packing and weighing/pricing/labeling areas
of production.
"In looking forward to the possibility of
a line-speed increase, we added automated
equipment designed to manage the speed
and also to eliminate product handling and
repetitive motion tasks," Mott says. "Even
though we have a lot of automated equipment,
some tasks still require human labor and the
human touch to pack food in a way that is
pleasing to our customers."
Gerber has an approximate 50/50 ratio of
retail to foodservice customers for over 100
SKUs in each category.
NOT JUST SPEED
The Gerber Poultry plant
runs two shifts, five
days a week to process
500,000 birds per week.
74
"Gas stunning potentially would improve
our team members' working environment
with better lighting, an extreme reduction in
feathers and airborne dust particles, as well
as a more relaxed task compared to hanging
a live bird," says Glenn Mott, vice president of
compliance. "Industry data suggests improved
quality of product with fewer blood spots in
breast meat and improved wing quality with
gas stunning versus electrical stunning."
While stunning, slaughter and evisceration
are all run on automated lines, it still requires
over two dozen workers to check, manage
and adjust the automated equipment, Mott
says. From the first step in receiving live birds
Gerber's procedures are designed to maintain
food safe process control.
The slaughtered birds are then eviscerated
to remove internal organs with a goal of
preventing cross contamination. The carcasses
are inspected during and after this process to
assure that Gerber will produce food safe and
exceptional quality chicken products.
Before the carcasses leave evisceration,
they are inspected by the in-plant USDA
inspector and conveyed to a 22,000-gallon
water chiller. The water is treated with an
organic antimicrobial to eliminate Salmonella
and Campylobacter. After the 100-minute
chilling process, carcasses move on to cutting,
deboning and grinding.
The deboning and cut-up lines are the most
hands-on, employee-heavy areas of the plant.
There's an average of 25 employees working
in each of the sizing, cut-up, deboning, tray
MEAT+ POULTRY | 08.19 | www.meatpoultry.com
The plant runs two shifts - one from 7 a.m. to
4:30 p.m. and the second from 4:30 p.m. to 1
a.m. - with the slaughter shift running from 6
a.m. to 6 p.m. The operation now processes
500,000 birds per week. For nearly two years
Gerber processed chicken six days a week
- requiring overtime hours from many of its
almost 450 employees. But thanks to some
recent changes, the plant has been able to
reduce production to just five days a week.
Despite being a small poultry player,
Gerber's joined a number of companies
recently requesting line speed waivers
from FSIS to increase production from 140
birds per minute (bpm) to 175 bpm on its
evisceration lines. After FSIS announced
it would consider waiver requests in 2018,
advocacy groups opposed the move, claiming
faster line speeds would result in more
worker injuries and jeopardize food safety.
In department meetings Gerber Poultry kept
employees updated on changes a waiver
would bring. Potential two-day weekends
were looked forward to with anticipation.
Company management also understood
that most of the opposition to waivers was
politically and activist oriented and had
previously established a detailed foundation
of data to support an application for a waiver,
if the opportunity presented itself.
The first step in the process was proving
the operation met all the necessary criteria -
operating under the New Poultry Inspection
System (NPIS) for at least one year; being in
Salmonella performance standard category
1 or 2 for young chicken carcasses; having
a history of regulated compliance with no
http://www.meatpoultry.com
Meat+Poultry - August 2019
Table of Contents for the Digital Edition of Meat+Poultry - August 2019
Meat+Poultry - August 2019
CONTENTS
COMMENTARY - Women to watch
BUSINESS NOTES - TYSON FOODS, TAJÍN TEAM UP FOR SEASONED PRODUCTS
BRISTOL FARMS, BEFORE THE BUTCHER PARTNER UP
GAP CERTIFIES APPLEGATE HOT DOG VARIETIES
BEYOND MEAT MOVES INTO MEAL KITS WITH BLUE APRON
JBS S.A. UNVEILS ETHICS, COMPLIANCE INITIATIVES
COUNTRY ARCHER ADDS NEW MEAT SNACK FLAVORS
NEWS PERSPECTIVE - Committing to improvement
WASHINGTON - Producer pressures
DELI REPORT - Deli diversity
COMPANY PROFILE - Saluting deli excellence
PACKAGING SOLUTIONS - PART AND PARCEL
INGREDIENT ISSUES - Snacking SAFELY
TOOLS OF THE TRADE - The SLICE is RIGHT
PLANT TOUR - Self-contained processing
POULTRY PROCESSING TECH - The art of air chilling
Chilling CHOICES
COMPANY PROFILE - POULTRY PRIDE: QUALITY WORTH CROWING ABOUT
FOOD SAFETY - Sanitation FIRST
SMALL BUSINESS MATTERS - CARVING OUT A NICHE
NICHE MARKETING - Building a bridge
FROM THE CORRAL - Trade fade
CALENDAR
NAMES IN THE NEWS
SHOWCASE
CLASSIFIEDS
ADVERTISERS
THE INSIDER
Ground beef trends + technology
PRODUCT PROFILE - Top of the line
INGREDIENT ISSUES - Flavors of far-flung places
FOODSERVICE ROUNDUP - Begging for burgers
CULINARY PERSPECTIVE - Innovation’s shakin’ up Shake Shack
PACKAGING SOLUTIONS - Communicating with consumers
Meat+Poultry - August 2019 - Meat+Poultry - August 2019
Meat+Poultry - August 2019 - Meat+Poultry - August 2019
Meat+Poultry - August 2019 - 2
Meat+Poultry - August 2019 - 3
Meat+Poultry - August 2019 - CONTENTS
Meat+Poultry - August 2019 - 5
Meat+Poultry - August 2019 - 6
Meat+Poultry - August 2019 - 7
Meat+Poultry - August 2019 - COMMENTARY - Women to watch
Meat+Poultry - August 2019 - 9
Meat+Poultry - August 2019 - GAP CERTIFIES APPLEGATE HOT DOG VARIETIES
Meat+Poultry - August 2019 - 11
Meat+Poultry - August 2019 - COUNTRY ARCHER ADDS NEW MEAT SNACK FLAVORS
Meat+Poultry - August 2019 - 13
Meat+Poultry - August 2019 - NEWS PERSPECTIVE - Committing to improvement
Meat+Poultry - August 2019 - 15
Meat+Poultry - August 2019 - 16
Meat+Poultry - August 2019 - 17
Meat+Poultry - August 2019 - WASHINGTON - Producer pressures
Meat+Poultry - August 2019 - 19
Meat+Poultry - August 2019 - DELI REPORT - Deli diversity
Meat+Poultry - August 2019 - 21
Meat+Poultry - August 2019 - COMPANY PROFILE - Saluting deli excellence
Meat+Poultry - August 2019 - 23
Meat+Poultry - August 2019 - 24
Meat+Poultry - August 2019 - 25
Meat+Poultry - August 2019 - PACKAGING SOLUTIONS - PART AND PARCEL
Meat+Poultry - August 2019 - 27
Meat+Poultry - August 2019 - 28
Meat+Poultry - August 2019 - 29
Meat+Poultry - August 2019 - 30
Meat+Poultry - August 2019 - 31
Meat+Poultry - August 2019 - INGREDIENT ISSUES - Snacking SAFELY
Meat+Poultry - August 2019 - 33
Meat+Poultry - August 2019 - 34
Meat+Poultry - August 2019 - 35
Meat+Poultry - August 2019 - 36
Meat+Poultry - August 2019 - 37
Meat+Poultry - August 2019 - 38
Meat+Poultry - August 2019 - 39
Meat+Poultry - August 2019 - TOOLS OF THE TRADE - The SLICE is RIGHT
Meat+Poultry - August 2019 - 41
Meat+Poultry - August 2019 - 42
Meat+Poultry - August 2019 - 43
Meat+Poultry - August 2019 - 44
Meat+Poultry - August 2019 - 45
Meat+Poultry - August 2019 - 46
Meat+Poultry - August 2019 - 47
Meat+Poultry - August 2019 - 48
Meat+Poultry - August 2019 - 49
Meat+Poultry - August 2019 - PLANT TOUR - Self-contained processing
Meat+Poultry - August 2019 - 51
Meat+Poultry - August 2019 - 52
Meat+Poultry - August 2019 - 53
Meat+Poultry - August 2019 - 54
Meat+Poultry - August 2019 - 55
Meat+Poultry - August 2019 - 56
Meat+Poultry - August 2019 - 57
Meat+Poultry - August 2019 - POULTRY PROCESSING TECH - The art of air chilling
Meat+Poultry - August 2019 - 59
Meat+Poultry - August 2019 - 60
Meat+Poultry - August 2019 - 61
Meat+Poultry - August 2019 - 62
Meat+Poultry - August 2019 - 63
Meat+Poultry - August 2019 - Chilling CHOICES
Meat+Poultry - August 2019 - 65
Meat+Poultry - August 2019 - 66
Meat+Poultry - August 2019 - 67
Meat+Poultry - August 2019 - 68
Meat+Poultry - August 2019 - 69
Meat+Poultry - August 2019 - COMPANY PROFILE - POULTRY PRIDE: QUALITY WORTH CROWING ABOUT
Meat+Poultry - August 2019 - 71
Meat+Poultry - August 2019 - 72
Meat+Poultry - August 2019 - 73
Meat+Poultry - August 2019 - 74
Meat+Poultry - August 2019 - 75
Meat+Poultry - August 2019 - 76
Meat+Poultry - August 2019 - 77
Meat+Poultry - August 2019 - FOOD SAFETY - Sanitation FIRST
Meat+Poultry - August 2019 - 79
Meat+Poultry - August 2019 - 80
Meat+Poultry - August 2019 - 81
Meat+Poultry - August 2019 - SMALL BUSINESS MATTERS - CARVING OUT A NICHE
Meat+Poultry - August 2019 - 83
Meat+Poultry - August 2019 - 84
Meat+Poultry - August 2019 - 85
Meat+Poultry - August 2019 - 86
Meat+Poultry - August 2019 - 87
Meat+Poultry - August 2019 - NICHE MARKETING - Building a bridge
Meat+Poultry - August 2019 - 89
Meat+Poultry - August 2019 - 90
Meat+Poultry - August 2019 - V 1
Meat+Poultry - August 2019 - V 2
Meat+Poultry - August 2019 - 91
Meat+Poultry - August 2019 - 92
Meat+Poultry - August 2019 - 93
Meat+Poultry - August 2019 - FROM THE CORRAL - Trade fade
Meat+Poultry - August 2019 - 95
Meat+Poultry - August 2019 - CALENDAR
Meat+Poultry - August 2019 - 97
Meat+Poultry - August 2019 - NAMES IN THE NEWS
Meat+Poultry - August 2019 - 99
Meat+Poultry - August 2019 - SHOWCASE
Meat+Poultry - August 2019 - 101
Meat+Poultry - August 2019 - CLASSIFIEDS
Meat+Poultry - August 2019 - 103
Meat+Poultry - August 2019 - 104
Meat+Poultry - August 2019 - ADVERTISERS
Meat+Poultry - August 2019 - THE INSIDER
Meat+Poultry - August 2019 - 107
Meat+Poultry - August 2019 - 108
Meat+Poultry - August 2019 - Ground beef trends + technology
Meat+Poultry - August 2019 - GB - 2
Meat+Poultry - August 2019 - GB - 3
Meat+Poultry - August 2019 - PRODUCT PROFILE - Top of the line
Meat+Poultry - August 2019 - GB - 5
Meat+Poultry - August 2019 - GB - 6
Meat+Poultry - August 2019 - GB - 7
Meat+Poultry - August 2019 - GB - 8
Meat+Poultry - August 2019 - GB - 9
Meat+Poultry - August 2019 - INGREDIENT ISSUES - Flavors of far-flung places
Meat+Poultry - August 2019 - GB - 11
Meat+Poultry - August 2019 - GB - 12
Meat+Poultry - August 2019 - GB - 13
Meat+Poultry - August 2019 - FOODSERVICE ROUNDUP - Begging for burgers
Meat+Poultry - August 2019 - GB - 15
Meat+Poultry - August 2019 - GB - 16
Meat+Poultry - August 2019 - GB - 17
Meat+Poultry - August 2019 - GB - 18
Meat+Poultry - August 2019 - GB - 19
Meat+Poultry - August 2019 - CULINARY PERSPECTIVE - Innovation’s shakin’ up Shake Shack
Meat+Poultry - August 2019 - GB - 21
Meat+Poultry - August 2019 - GB - 22
Meat+Poultry - August 2019 - GB - 23
Meat+Poultry - August 2019 - PACKAGING SOLUTIONS - Communicating with consumers
Meat+Poultry - August 2019 - GB - 25
Meat+Poultry - August 2019 - GB - 26
Meat+Poultry - August 2019 - GB - 27
Meat+Poultry - August 2019 - GB - 28
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