Epstein provided Design-Build services for a new 925,000 square foot, $335M Pork Processing Plant for Seaboard Triumph Foods (STF) located on a 245-acre site in Bridgeport West Industrial Park within Sioux City, Iowa. Epstein was entrusted by STF to design, engineer and build a modern fresh pork plant focused on food safety and efficiency to meet the growing demands of domestic and international customers. STF and Epstein were able to build off the learning opportunities of Triumph’s existing plant in St. Joseph, Missouri Epstein also designed and built a decade ago and Seaboard’s existing facility in Guymon, Oklahoma from the two decades ago.
This STF pork processing facility uses robotics and innovative technologies to produce a full-line of fresh pork products for retail, international, food service, and further processing markets to help fill the increasing world-wide demand for pork.
The design of the STF facility reflects a modern food processing plant incorporating many state-of-the-art technologies. These measures are visible as soon as livestock is received, utilizing a barn designed to reduce animal stress and improve comfort in conjunction with automated carbon dioxide (CO2) stunning to deliver a comprehensive animal welfare framework. Multiple vision systems are monitored to maintain traceability throughout the process as well as improve product yield via robotic harvesting technologies at critical production steps. Sanitation principles are implemented throughout the facility, including automated equipment and conveyor wash systems capable of delivering more than 3,000 gallons per minute of wash-down flow cumulatively. Finally, robust rendering and wastewater treatment systems work to maximize profitable waste recovery while meeting or exceeding all required environmental standards for the plant.
The STF plant also features a wide variety of refrigerated spaces including a -22° Snap Chill room, multiple 26° Equilibrium Bays, 24° Fresh Product Storage space as well as a 40° dock.
In addition to the pork processing component, this STF plant includes several outbuildings including a guardhouse, rendering facility and waste water treatment facility.
This facility, which was completed on September 5, 2017, employs approximately 1,100 people and processes about 3 million market hogs annually.