Meat&Poultry - June 2012 - 76

CARGILL’S WACO COMPLEX

in further-processed turkey is in readyto-cook; the balance is RTE products. “We offer a variety of cooked turkey including smoked and Cajun, which are very convenient,” O’Leary says. “It takes about 1.5 hours to cook precooked turkey at home.” “When you produce 5,000 head a day of fully cooked turkey, you get pretty good at it,” adds JR Dollins, continuous improvement manager, who is also a certified Six Sigma Black Belt and a 17-year Cargill veteran. Cargill started processing turkeys in 1967. Initially a whole-bird processor, it began deboning turkeys in 1978 and ultimately began processing big toms instead of commercial-sized hens and toms. The company expanded turkey

operations through its 1998 acquisition of Plantation Foods in Waco and the 2001 acquisition of Rocco Foods in Harrisonburg, Va. The general offices of Cargill Turkey Products moved to Wichita in 2003. In 2004, Emmpak Foods Inc., which was acquired in 2001 and based in Milwaukee, was combined with Cargill Turkey Products to form Cargill Value Added Meats. In March 2008, CVAM acquired certain assets of Willow Brook Foods, which include that company’s operations in Springfield, Mo., plus the Albert Lea, Minn., cooked-meat operation named Schweigert Foods. Willow Brook Foods processed the same proteins the Waco complex does. Cargill also acquired Willow Brook’s brands.

People and technology
Although technology plays a key role at the Waco complex, “The ‘secret sauce’ to our daily success at Waco is our 677 associates,” Dollins insists. “What makes us successful is our ability to control our process plus craftsmanship,” O’Leary adds. “We have very finite recipes we follow. We make no less than 60 different products a day. These people are good at it and take a lot of pride in what they do.” Employee input is key to success in Waco. The complex has instituted a Valuing Imagination in People (VIP) program, which has yielded some impressive results. “Good teamwork imagination will create the value for our customers,

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• Meat&Poultry • June 2012 • www.MeatPoultry.com

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Meat&Poultry - June 2012

Table of Contents for the Digital Edition of Meat&Poultry - June 2012

Meat&Poultry - June 2012
Table of Contents
Commentary - Right on pace
Business Notes - Bob Evans to close plants, streamline transportation
Business Notes - Michigan JBS workers approve union contract
Business Notes - Pilgrim’s Pride announces layoffs
Business Notes - Lee to CEO of Tyson Foods China
Business Notes - BPI announces corporate layoffs
Business Notes - Jennie-O lifts Hormel earnings
Business Notes - OIE labs confirm atypical BSE in dairy cow
Washington - State vs. federal rights
Cover Story - Hormel milestones
Corporate Profiles - Snapshots of success
Corporate Profiles - Tyson
Corporate Profiles - JBS
Corporate Profiles - Hormel Foods
Corporate Profiles - Maple Leaf Foods
Corporate Profiles - Sanderson Farms
Corporate Profiles - Smithfield Foods Inc.
Corporate Profiles - Sara Lee
Burger Processing - Making its mark
Ingredient Solutions - Flavor adventures
Food Safety - Sample-ready, or not?
Meat Processing Operations & Engineering - Talking turkey and more
Meat Processing Operations & Engineering - Relying on expertise
Meat Processing Operations & Engineering - Managing sanitation
Sanitation Tips
From the Corral - Stop surprising consumers
Names in the News
New Product Showcase
Classified Advertising
Advertisers
The Insider
Meat&Poultry - June 2012 - Meat&Poultry - June 2012
Meat&Poultry - June 2012 - 2
Meat&Poultry - June 2012 - 3
Meat&Poultry - June 2012 - Table of Contents
Meat&Poultry - June 2012 - 5
Meat&Poultry - June 2012 - 6
Meat&Poultry - June 2012 - 7
Meat&Poultry - June 2012 - Commentary - Right on pace
Meat&Poultry - June 2012 - 9
Meat&Poultry - June 2012 - Business Notes - Bob Evans to close plants, streamline transportation
Meat&Poultry - June 2012 - 11
Meat&Poultry - June 2012 - Business Notes - Pilgrim’s Pride announces layoffs
Meat&Poultry - June 2012 - 13
Meat&Poultry - June 2012 - Business Notes - BPI announces corporate layoffs
Meat&Poultry - June 2012 - 15
Meat&Poultry - June 2012 - 16
Meat&Poultry - June 2012 - Business Notes - OIE labs confirm atypical BSE in dairy cow
Meat&Poultry - June 2012 - Washington - State vs. federal rights
Meat&Poultry - June 2012 - 19
Meat&Poultry - June 2012 - Cover Story - Hormel milestones
Meat&Poultry - June 2012 - 21
Meat&Poultry - June 2012 - 22
Meat&Poultry - June 2012 - 23
Meat&Poultry - June 2012 - 24
Meat&Poultry - June 2012 - 25
Meat&Poultry - June 2012 - 26
Meat&Poultry - June 2012 - 27
Meat&Poultry - June 2012 - 28
Meat&Poultry - June 2012 - 29
Meat&Poultry - June 2012 - Corporate Profiles - Snapshots of success
Meat&Poultry - June 2012 - 31
Meat&Poultry - June 2012 - Corporate Profiles - Tyson
Meat&Poultry - June 2012 - 33
Meat&Poultry - June 2012 - 34
Meat&Poultry - June 2012 - 35
Meat&Poultry - June 2012 - Corporate Profiles - JBS
Meat&Poultry - June 2012 - 37
Meat&Poultry - June 2012 - 38
Meat&Poultry - June 2012 - 39
Meat&Poultry - June 2012 - Corporate Profiles - Hormel Foods
Meat&Poultry - June 2012 - 41
Meat&Poultry - June 2012 - Corporate Profiles - Maple Leaf Foods
Meat&Poultry - June 2012 - 43
Meat&Poultry - June 2012 - 44
Meat&Poultry - June 2012 - Corporate Profiles - Sanderson Farms
Meat&Poultry - June 2012 - 46
Meat&Poultry - June 2012 - 47
Meat&Poultry - June 2012 - Corporate Profiles - Smithfield Foods Inc.
Meat&Poultry - June 2012 - 49
Meat&Poultry - June 2012 - 50
Meat&Poultry - June 2012 - 51
Meat&Poultry - June 2012 - Burger Processing - Making its mark
Meat&Poultry - June 2012 - 53
Meat&Poultry - June 2012 - 54
Meat&Poultry - June 2012 - 55
Meat&Poultry - June 2012 - 56
Meat&Poultry - June 2012 - 57
Meat&Poultry - June 2012 - Ingredient Solutions - Flavor adventures
Meat&Poultry - June 2012 - 59
Meat&Poultry - June 2012 - 60
Meat&Poultry - June 2012 - 61
Meat&Poultry - June 2012 - 62
Meat&Poultry - June 2012 - 63
Meat&Poultry - June 2012 - Food Safety - Sample-ready, or not?
Meat&Poultry - June 2012 - 65
Meat&Poultry - June 2012 - 66
Meat&Poultry - June 2012 - 67
Meat&Poultry - June 2012 - 68
Meat&Poultry - June 2012 - 69
Meat&Poultry - June 2012 - 70
Meat&Poultry - June 2012 - Meat Processing Operations & Engineering - Talking turkey and more
Meat&Poultry - June 2012 - 72
Meat&Poultry - June 2012 - 73
Meat&Poultry - June 2012 - 74
Meat&Poultry - June 2012 - 75
Meat&Poultry - June 2012 - 76
Meat&Poultry - June 2012 - 77
Meat&Poultry - June 2012 - 78
Meat&Poultry - June 2012 - 79
Meat&Poultry - June 2012 - Meat Processing Operations & Engineering - Relying on expertise
Meat&Poultry - June 2012 - 81
Meat&Poultry - June 2012 - 82
Meat&Poultry - June 2012 - 83
Meat&Poultry - June 2012 - 84
Meat&Poultry - June 2012 - 85
Meat&Poultry - June 2012 - Meat Processing Operations & Engineering - Managing sanitation
Meat&Poultry - June 2012 - 87
Meat&Poultry - June 2012 - Sanitation Tips
Meat&Poultry - June 2012 - 89
Meat&Poultry - June 2012 - 90
Meat&Poultry - June 2012 - 91
Meat&Poultry - June 2012 - From the Corral - Stop surprising consumers
Meat&Poultry - June 2012 - 93
Meat&Poultry - June 2012 - Names in the News
Meat&Poultry - June 2012 - 95
Meat&Poultry - June 2012 - New Product Showcase
Meat&Poultry - June 2012 - 97
Meat&Poultry - June 2012 - 98
Meat&Poultry - June 2012 - 99
Meat&Poultry - June 2012 - Classified Advertising
Meat&Poultry - June 2012 - 101
Meat&Poultry - June 2012 - 102
Meat&Poultry - June 2012 - 103
Meat&Poultry - June 2012 - 104
Meat&Poultry - June 2012 - Advertisers
Meat&Poultry - June 2012 - The Insider
Meat&Poultry - June 2012 - 107
Meat&Poultry - June 2012 - 108
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