Fully Cooked Poultry Facility
Scenario
A nationally recognized producer of fully cooked meat products had a bold vision: transform an abandoned textile warehouse in Valley, Alabama, into a high-capacity poultry processing plant.
They came to Sterling Refrigeration with clear goals—and a big dream:
The facility needed to process 28,000 lbs/hr of cooked chicken on day one, with the flexibility to expand production up to 70,000 lbs/hr. Long-term, their sights were set on 1 billion pounds per year.
Due to the scale of the project, reliable health and food quality assurance were top priorities for the client.
Challenges
The abandoned textile warehouse did not have the appropriate infrastructure in place for its new intended purpose, requiring tailor-made refrigeration solutions and extensive redesigns.
The refrigeration system had to be able to handle large volumes of food processing, with the capacity to scale as operations grow.
High air quality and hygiene standards.
Any prolonged downtime would result in significant production losses for the client.
Our Solutions
Needle Bipoint Ionization to assist
with the bacterial and viral load in
the air stream.
Hygienic Air handlers for all refrigerated spaces with
exposed product.
A 4000+ TR central ammonia
refrigeration system.
Coordination with trades teams to ensure the existing infrastructure could supportthe newly installed refrigeration system.
Redundant backup for both high-stage and low-stage machines.
Designed for future expansion.
KPI's
28,000 lbs/hr
Chicken processed
Up to 70,000 lbs/hr
Designed to expand as operations scale
4,000+ TR
Two-stage refrigeration capacity