Key Takeaways
- Bell & Evans opened a new 160,000-sq.-ft. facility in Fredericksburg, PA, to boost production of organic poultry with no antibiotics or GMOs.
- The new plant features state-of-the-art equipment including European packaging technology and a focus on employee comfort and aesthetics.
- Scott Sechler, owner of Bell & Evans, emphasizes maintaining quality and employee roles in production despite increased automation.
Innovative Growth in Poultry Processing
Bell & Evans, a renowned producer of organic poultry, has taken significant strides by opening a new 160,000-square-foot facility in Fredericksburg, Pennsylvania. The company has distinguished itself from industrial poultry producers by adhering to stringent quality standards—producing chickens without the use of antibiotics, growth hormones, or GMOs. This commitment to ethical farming practices has earned Bell & Evans a loyal customer base, willing to pay a premium for the quality product.
The decision to expand was fueled by expectations of tripling customer orders from upscale retailers like Whole Foods, Chipotle, and Wegmans over the next decade. This ambitious plan required the relocation of its packaging operations from the original facility, which had previously won the Plant of the Year award in 2005. The new plant not only facilitates increased production capacity but also aligns with the company’s values of quality and community integration.
Scott Sechler, the current owner, focused on creating a facility that reflects the company’s brand and philosophy. With a collaborative approach to construction, Sechler evaluated multiple design-build firms, ultimately selecting Stellar, known for its high-quality construction. The design features durable materials and European equipment, creating a visually appealing and efficient space that promotes pride among employees.
The facility stands out with modern architecture that resonates with the local community’s small-town charm. It includes an employee courtyard and high-end amenities, reinforcing the company’s commitment to its workforce. Inside, the building is outfitted with extensive safety features, ergonomic designs, and advanced sanitation protocols.
In preparing the facility, Bell & Evans took measures to ensure quality processing and packaging. Notable features include a frozen processing area with three production lines for nuggets, par-fried products, and individually quick-frozen items. The innovative use of a JBT Foodtech Model DSI portioner enables the production of high-quality, whole-muscle nuggets without mechanical slicing, preserving meat integrity.
Furthermore, the facility employs a groundbreaking air-chilling process that minimizes water retention in chicken, enhancing quality while reducing packaging issues associated with moisture. Packaging operations utilize custom-built MULTIVAC machines to provide vacuum-sealed, transparent packaging that reveals product quality.
Sechler prioritized maintaining a human touch amid increasing automation. Employees are responsible for placing chicken into trays, ensuring a handmade aesthetic, while advanced automation technologies optimize processes where feasible. This balance underscores the company’s dedication to preserving local jobs and maintaining product integrity.
The facility includes state-of-the-art refrigerated shipping and receiving docks, as well as advanced cooling systems to ensure product quality. High sanitation standards are achieved through a combination of hot water cleaning methods and strategically designed chemical systems.
The new Bell & Evans facility is a testament to a brand that values quality, community, and sustainability in poultry processing. With a focus on improving efficiency while staying true to its organic roots, Bell & Evans is poised for significant growth in the competitive market of high-quality poultry products.
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