Turnkey Project Services Enable Greater Production Capacity and Efficiency.
Prestage Farms, established in 1983, is a family-owned business that creates quality pork and turkey products. The company and its affiliates process more than 1 billion pounds of turkey and pork annually, employ nearly 2,000 associates, and contract with over 450 farm families.
For this greenfield project, Prestage Farms selected Gray to design and build a 295,000 s.f. state-of-the-art turkey processing facility.
- LocationCamden, SC
- Square Footage295,000 s.f.
- Operational16 months
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.
Process & Packaging Systems Engineering
Automation & Controls
Custom equipment Ovens & cookers Process skids Batching equipment Clean-in-place systems Bioreactors Extruders Distributed products Mixers & blenders
Cooper Farms is one of the largest family-owned turkey processing companies in the country, and given our customer relationships with Clemens Food Group and Champion Petfoods, the company selected Gray. This project included an expansion as well as a renovation of multiple areas inside the existing operational facility.
Clemens Food Group is one of the leading pork processing companies in the U.S. In 2014, the company came to Gray in need of facility to support its growing operations. They chose Coldwater, Michigan as the greenfield project site – the company’s first in its 125-year history.
Clemens Food Group is one of the leading pork processing companies in the U.S. When Clemens was looking to expand with a new smoked pork manufacturing facility, the company turned to trusted partner Gray for its design-build and food processing expertise.