Meat+Poultry - March 2019 - 8

C O M M E N TA R Y

Beyond the bottom line
The poultry line speed debate
continues. Last year, the US Dept.
of Agriculture's Food Safety and
Inspection Service (FSIS) announced
it would consider waiver requests
from processors wanting to increase
production from 140 birds per
minute up to 175 birds per minute
on evisceration lines. Immediately,
advocacy groups squawked that faster
line speeds would result in more
worker injuries and jeopardize food
safety. Requests for faster lines were
simply about processing more birds
and making more money, according
to critics. Most processors will admit
they're in business to make money, and
the chance to make more money with
increased line speeds isn't necessarily a
bad thing. But for some processors, the
need for speed isn't about greed at all.
Kidron, Ohio-based Gerber Poultry
was one of the first companies to
jump in line and request a line speed
waiver when waiver requests became
available in early 2018. For years
the company has processed 500,000
birds a week, slaughtering one shift
a day and processing two shifts a
day, 12 hours a day, six days a week.
Gerber's employee base worked a lot
of overtime each week to keep up with
the production volume.

After meeting the necessary
criteria to be eligible for a line speed
waiver - operating under the New
Poultry Inspection System (NPIS) for
at least one year; being in Salmonella
performance standard category 1 or 2
for young chicken carcasses; having a
history of regulated compliance with
no recalls or alerts for at least 120 days;
and demonstrating the procedures to
increase line speeds will maintain or
improve food safety - Gerber Poultry
was granted its waiver. And, on Oct.
12, 2018, the company slowly started
increasing its production line speed.
"We weren't going to increase our
speeds to 175 immediately," said Vice
President of Compliance Glenn Mott.
"We increased five birds per minute each
week and we tracked our performance
along the way. If we met our standards
for that week, we would increase
another five birds the next week."
By early November, the plant
reached 160 birds per minute. With that
milestone the company eliminated its
Saturday overtime production. Gerber
reached 175 bpm within the month.
"We look at not having Saturday
production anymore as being a real
benefit to our employees. Our team
members can now have real family
time on the weekends. Everyone is
more refreshed. And our maintenance
team now has more time to work on
equipment," Mott said. "Our overall
performance as far as food safety is

exactly where it needs to be, or better,
and our employee well-being based on
accidents is where it needs to be, at
zero accidents."
While Gerber's long-term plans are to
ulimately increase production - possibly
adding a slaughter and production line
in the next year or two - the company's
initial reason for increasing line
speeds was to eliminate the Saturday
production shift in an effort to reduce
production days, hours worked and job
fatigue. It was about employee welfare,
not the bottom line.
While giving workers back their
weekends was a benefit the company
was offering employees, company
officials didn't overlook the potential
drawback of eliminating overtime pay.
Gerber adjusted salaries as needed so
the reduced work time wouldn't result
in substantially smaller paychecks.
Gerber Poultry's approach to this
production issue is an impressive
display of what it means to put your
employees first. The company could
have increased its production and
simply taken the profits that would
have come from processing more birds
in less time - but instead they passed
on those benefits to employees. In the
long run, my guess is the company will
likely see productivity increase far
more than the amount those 35 birds
per minute will bring.
K I M B E R L I E C LYM A , M A N AG I N G E D I TO R
kc l y m a @ s o s l a n d .c o m

"We weren't going to increase our speeds
to 175 immediately. We increased five
birds a minute each week and we tracked
our performance along the way."
- GLENN MOTT

8

MEAT+ POULTRY | 03.19 | www.meatpoultry.com


http://www.meatpoultry.com

Meat+Poultry - March 2019

Table of Contents for the Digital Edition of Meat+Poultry - March 2019

Meat+Poultry - March 2019
CONTENTS
COMMENTARY - Beyond the bottom line
BUSINESS NOTES - LEGENDARY LEADER OF HORMEL DIES
DIETZ & WATSON TO PHASE OUT NITRATES, NITRITES
APPLEGATE FARMS LAUNCHES THE NEW FOOD COLLECTIVE
SEABOARD PARTNERS WITH PITMASTER MELISSA COOKSTON
DRIVING SALES FOR OSCAR MAYER
NSF INTERNATIONAL UNVEILS NEW GLOBAL ANIMAL WELLNESS STANDARDS
FOSTER FARMS TO EXPAND CALIFORNIA PLANT
WASHINGTON - Leadership appointments
TOP 100 - Sizing up the competition
COVER STORY - ‘La famiglia è tutto’ (Family is everything)
POULTRY PROCESSING TECH - OPERATIONAL OPPORTUNITIES
No bones about it
FOOD SAFETY - New school TOOL
PACKAGING SOLUTIONS - Climate control for meat snacks
INGREDIENT ISSUES - EXTENDING SHELF LIFE
MEAT PERSPECTIVES - Demystifying SOFT BELLIES
SMALL BUSINESS MATTERS - A WINNING TRADITION
TRADE SHOW PREVIEW - International exhibition
PROFOOD TECH RETURNS
FROM THE CORRAL - Opening eyes
CALENDAR
NAMES IN THE NEWS
SHOWCASE
CLASSIFIEDS
ADVERTISERS
THE INSIDER
Meat+Poultry - March 2019 - Meat+Poultry - March 2019
Meat+Poultry - March 2019 - Meat+Poultry - March 2019
Meat+Poultry - March 2019 - 2
Meat+Poultry - March 2019 - 3
Meat+Poultry - March 2019 - CONTENTS
Meat+Poultry - March 2019 - 5
Meat+Poultry - March 2019 - 6
Meat+Poultry - March 2019 - 7
Meat+Poultry - March 2019 - COMMENTARY - Beyond the bottom line
Meat+Poultry - March 2019 - 9
Meat+Poultry - March 2019 - APPLEGATE FARMS LAUNCHES THE NEW FOOD COLLECTIVE
Meat+Poultry - March 2019 - 11
Meat+Poultry - March 2019 - FOSTER FARMS TO EXPAND CALIFORNIA PLANT
Meat+Poultry - March 2019 - 13
Meat+Poultry - March 2019 - WASHINGTON - Leadership appointments
Meat+Poultry - March 2019 - 15
Meat+Poultry - March 2019 - TOP 100 - Sizing up the competition
Meat+Poultry - March 2019 - 17
Meat+Poultry - March 2019 - 18
Meat+Poultry - March 2019 - 19
Meat+Poultry - March 2019 - 20
Meat+Poultry - March 2019 - 21
Meat+Poultry - March 2019 - 22
Meat+Poultry - March 2019 - 23
Meat+Poultry - March 2019 - 24
Meat+Poultry - March 2019 - 25
Meat+Poultry - March 2019 - 26
Meat+Poultry - March 2019 - 27
Meat+Poultry - March 2019 - 28
Meat+Poultry - March 2019 - 29
Meat+Poultry - March 2019 - 30
Meat+Poultry - March 2019 - 31
Meat+Poultry - March 2019 - 32
Meat+Poultry - March 2019 - 33
Meat+Poultry - March 2019 - 34
Meat+Poultry - March 2019 - 35
Meat+Poultry - March 2019 - 36
Meat+Poultry - March 2019 - 37
Meat+Poultry - March 2019 - COVER STORY - ‘La famiglia è tutto’ (Family is everything)
Meat+Poultry - March 2019 - 39
Meat+Poultry - March 2019 - 40
Meat+Poultry - March 2019 - 41
Meat+Poultry - March 2019 - 42
Meat+Poultry - March 2019 - 43
Meat+Poultry - March 2019 - 44
Meat+Poultry - March 2019 - 45
Meat+Poultry - March 2019 - POULTRY PROCESSING TECH - OPERATIONAL OPPORTUNITIES
Meat+Poultry - March 2019 - 47
Meat+Poultry - March 2019 - 48
Meat+Poultry - March 2019 - 49
Meat+Poultry - March 2019 - 50
Meat+Poultry - March 2019 - 51
Meat+Poultry - March 2019 - No bones about it
Meat+Poultry - March 2019 - 53
Meat+Poultry - March 2019 - 54
Meat+Poultry - March 2019 - 55
Meat+Poultry - March 2019 - 56
Meat+Poultry - March 2019 - 57
Meat+Poultry - March 2019 - FOOD SAFETY - New school TOOL
Meat+Poultry - March 2019 - 59
Meat+Poultry - March 2019 - 60
Meat+Poultry - March 2019 - 61
Meat+Poultry - March 2019 - 62
Meat+Poultry - March 2019 - 63
Meat+Poultry - March 2019 - PACKAGING SOLUTIONS - Climate control for meat snacks
Meat+Poultry - March 2019 - 65
Meat+Poultry - March 2019 - 66
Meat+Poultry - March 2019 - 67
Meat+Poultry - March 2019 - 68
Meat+Poultry - March 2019 - 69
Meat+Poultry - March 2019 - 70
Meat+Poultry - March 2019 - 71
Meat+Poultry - March 2019 - INGREDIENT ISSUES - EXTENDING SHELF LIFE
Meat+Poultry - March 2019 - 73
Meat+Poultry - March 2019 - 74
Meat+Poultry - March 2019 - 75
Meat+Poultry - March 2019 - 76
Meat+Poultry - March 2019 - 77
Meat+Poultry - March 2019 - MEAT PERSPECTIVES - Demystifying SOFT BELLIES
Meat+Poultry - March 2019 - 79
Meat+Poultry - March 2019 - 80
Meat+Poultry - March 2019 - 81
Meat+Poultry - March 2019 - SMALL BUSINESS MATTERS - A WINNING TRADITION
Meat+Poultry - March 2019 - 83
Meat+Poultry - March 2019 - 84
Meat+Poultry - March 2019 - 85
Meat+Poultry - March 2019 - 86
Meat+Poultry - March 2019 - 87
Meat+Poultry - March 2019 - TRADE SHOW PREVIEW - International exhibition
Meat+Poultry - March 2019 - 89
Meat+Poultry - March 2019 - PROFOOD TECH RETURNS
Meat+Poultry - March 2019 - 91
Meat+Poultry - March 2019 - FROM THE CORRAL - Opening eyes
Meat+Poultry - March 2019 - 93
Meat+Poultry - March 2019 - CALENDAR
Meat+Poultry - March 2019 - 95
Meat+Poultry - March 2019 - NAMES IN THE NEWS
Meat+Poultry - March 2019 - 97
Meat+Poultry - March 2019 - SHOWCASE
Meat+Poultry - March 2019 - 99
Meat+Poultry - March 2019 - CLASSIFIEDS
Meat+Poultry - March 2019 - 101
Meat+Poultry - March 2019 - 102
Meat+Poultry - March 2019 - 103
Meat+Poultry - March 2019 - 104
Meat+Poultry - March 2019 - ADVERTISERS
Meat+Poultry - March 2019 - THE INSIDER
Meat+Poultry - March 2019 - 107
Meat+Poultry - March 2019 - 108
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