Poultry processors are faced with a flock of challenges, from the spread of diseases to heightened water demands

With a high risk for contamination, and the spread of disease such as salmonella, sophisticated food safety is paramount for poultry processing plants. Separating slaughter, evisceration, cutup and packaging from further processing, cooking and packaging operations is crucial to preventing cross-contamination. And air borne contaminates from kill floors and rendering areas shouldn’t mix with the air particles that surround the product processing and packaging areas. The use of pressurized mechanical and refrigeration systems to minimize the potential mixing of air and condensation is also extremely important to maintaining the sanitation of poultry processing operations.

In addition to food safety, poultry slaughter plants have massive water demands. Further processing facilities require numerous wash-down cycles per day, while RTE facilities utilize clean-in-place (CIP) systems.

Stellar can address all of these issues and also has expertise in:

  • Cooling sheds 
  • Bird unloading 
  • Water chilling 
  • Air chilling 
  • Stunning systems

Food Engineering Fab Food Plant 2016

Each year Food Engineering honors a plant as its “Fab Food Plant” and gives readers an inside look “at innovative processors who focus on lean manufacturing, sustainability and food safety.” Bell & Evans’ 160,000-square-foot chicken packaging, storage and frozen processing facility embodies all of these criteria, especially food safety.

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Bells Evans
Keystone Foods

Award Winning Poultry Processing Plant

Our work in the poultry industry is highly regarded, seen specifically in the Keystone Foods poultry processing plant. The Keystone Foods facility earned the 2010 ABC Excellence in Construction award, the 2010 ABC Excellence in Construction Safety and was named the 2010 Food Engineering Plant of the Year.

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We selected Stellar to be our design-build partner in this innovative poultry processing facility because of their reputation in the food industry with significant experience in food safety. We wanted to challenge Stellar to live up to its tagline, “Taking Solutions Further,” and we could not have been more satisfied with their innovative design, execution and the professionalism of their employees. Any challenges that arose during the project were met with innovative solutions. The backbone of this project’s success was Stellar’s and Keystone Foods’ commitment to open dialogue and collaboration. Stellar certainly lived up to their tagline.

Ed Delate
VP of Global Engineering & Corporate Social Responsibility
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Food Facility Efficiency: Assessments 101

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Food Facility Efficiency Assessments 101