Meat&Poultry - December 2014 - 62

CARGILL'S BEEF COMPLEX

Schuyler's automated distribution center added
40,000 sq. ft. in 2010. An automated box-handling
and computerized-shipping system have replaced a
manually operated system.

Japan. Cargill reintroduced Spencer

checks with our team and spend a lot

Beef to the Japanese marketplace in

of time on behavioral-based observa-

April 2013 after Japan announced in

tions capturing both the positive work

while simultaneously integrating them

January 2013 it was allowing imports

habits while identifying the potential

into Cargill's business system.

of US beef products from cattle less

risks and correcting these behaviors."

"Our system is comprised of a pal-

than 30 months old.

E r gonom ic a s si st s a r e u se d

letized unit load combined with an

Some products bound for overseas

throughout the plant and include an

individual case-pick system," Gillig

are frozen. "A Nor-Am Cold Storage

automated hide puller and moveable

says. "From a capacity standpoint,

refrigerated/frozen warehouse is con-

platforms to help split carcasses. "We

we're running about 60,000 boxes

nected to the plant by an enclosed con-

continue to look at and develop new

[per day]; we can go higher than that,

veyor," Gillig says. "Finished product

processes to incorporate more auto-

but we don't want to be known as a box

from production travels via a convey-

mation into our systems," Gillig says.

storage center - we want to be known

or system directly to Nor-Am, which

"There are areas that with current

as a distribution center."

eliminates multiple handling. All fro-

available technology and our speeds,

Boxes of products are quickly load-

zen products go to Nor-Am; we only

it is very difficult to trade the skill of

ed and unloaded into the storage rack

ship fresh, refrigerated from our facil-

our team with automation. As it makes

area, which towers approximately five

ity. They're a good partner."

sense to build automation and improve

stories high, via robotic cranes. This

Recent capital investments at

automated system ensures delivering

Schuyler totaled $3.85 million for vari-

correct orders. "Twenty-five years ago,

ous projects. Last year, it added a #2

The company's 75,000-sq.-ft. Car-

there may have been 200-300 SKUs

tallow recovery system to its render-

gill Innovation Center in Wichita,

at this plant. "Today, we have more

ing area, which resulted in solid im-

Kan., oversees and assists Schuyler in

than 1,000 SKUs," Gillig says.

provements in its waste-water system.

new product development. It features

Approximately 80 percent of final

safety for our employees, we will and
do look for these opportunities."

research, development, culinary, lab,

product is destined for domestic mar-

pilot plant and distribution capabili-

kets and leaves the plant refrigerated.

Schuyler employees undergo annual

ties. It supports Cargill beef, turkey,

"International shipping is close to 20

training for food and worker safety.

pork and other company businesses.

percent of what we make in Schuyler

Food-safety training ties into the fa-

During the plant tour, plant man-

...we're hoping to grow that a little bit

cility's HACCP plan, GMPs and the

agers continuously lauded their em-

more," says Brabec, who managed the

team's role in ensuring safe, whole-

ployees. While on a catwalk high

most recent addition to the distribu-

some beef. "Our team reviews their

above the fabrication floor at the end

tion center. "About 90 percent of our

JTP [job task procedures] annually

of the tour, Gillig grinned and says

outgoing loads are palletized."

in addition to our monthly training,

while scanning hundreds of workers

Schuyler is the only Cargill plant

which covers topics across the facility,"

working the lines and tables below,

producing Spencer Beef products for

62

In-plant training

Gillig says. "We complete daily safety

"They make it all look so easy." ■

* Meat&Poultry * December 2014 * www.MeatPoultry.com
http://www.MeatPoultry.com
Meat&Poultry - December 2014

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