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 2022 Plant of the Year

Each year Food Engineering honors a plant as its "Plant of the Year" and gives readers an inside look at the design and construction of this award-winning greenfield organic and humane chicken harvesting facility. Bell & Evans' 411,500-square-foot chicken harvesting facility has "established a new benchmark for innovation and efficiency in a poultry plant, while elevating employee and animal welfare".

Read more about this project
Bells Evans Food Plant 2022

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
Free Ebook

Food Facility Efficiency: Assessments 101

The tools you need to improve your food or beverage plant’s efficiency.

Learn More
Food Facility Efficiency Assessments 101