Turnkey Project Services Enable Greater Production Capacity and Efficiency.

Gray delivered a wide range of design, construction, engineering, and equipment services for the new facility. The operation includes the only air-chill turkey processing model in the Western Hemisphere—an advancement from traditional water-chill processing. This unique model greatly reduces the risk of cross-contamination and eliminates the need to introduce chemicals such as chlorine into food-grade processes, which can be absorbed and retained inside the meat. To maintain product separation and continuous processing, the birds are air-chilled on shackle chains that move throughout the refrigerated space on multiple process lines. The system features a staggering 13 miles of shackle chain, by far the largest in the poultry industry, and can process 48,000 birds per day.

To ensure stringent sanitation standards, maximum food safety, and the highest level of automation and traceability, Gray provided a variety of process utilities, including Clean-in-Place (CIP) systems and vacuum and pump systems. The plant’s CIP ozone skid system functions across critical processes, using a liquid application to treat conveyor surfaces as well as ambient O₂ molecules to treat the water supply.

Gray further supported the project with complete piping design, along with supply and installation services for the plant’s process and vacuum line systems and chillers.