Enhancing Efficiency in Turkey Processing at Prestage Foods (Camden, SC) with DeLong’s Multi-Purpose Skinner (MPS)
Category: Machinery, MPS
Case Study – Prestage Foods
About Prestage Foods
Prestage Farms is a family-owned and vertically integrated turkey and pork producer established in 1983. Committed to sustainability and innovation, Prestage Foods operates state-of-the-art processing plants that leverage advanced automation and technologies to enhance both product sanitation and shelf life. Prestage Foods’ newest facility is located in Camden, South Carolina.
Learn more about Prestage Foods: https://www.prestagefoods.com/
The Challenge
In 2021, Prestage Foods announced the launch of a new turkey processing facility in Camden, South Carolina, which required innovative machinery and new team members to meet high operational demands. Although Prestage had been processing turkeys since 2001, their leadership team sought a strategic partner to help reduce labor demands, increase efficiency, and improve yield.
One key challenge involved minimizing product loss due to over-trimming, an issue that commonly affects yield in poultry processing. Recognizing DeLong’s longstanding reputation, Prestage turned to DeLong’s Gizzard Equipment to find a solution.
The Partnership
Prestage Foods’ approach to expansion, centers around sustainable job growth and technological innovation, values that DeLong’s team strongly supports. With over 50 years of experience in the poultry processing industry, DeLong’s was well-equipped to address Prestage’s unique challenges, having encountered similar issues across multiple processing facilities over the years.
In close collaboration, DeLong’s and Prestage analyzed the plant’s specific needs, focusing on methods to streamline operations and maximize yield with minimal labor. This partnership underscored both companies’ commitment to driving innovation in poultry processing.
The Solution
To address Prestage’s objectives, DeLong’s introduced their Multi-Purpose Skinner (MPS), a versatile machine designed to streamline multiple aspects of processing. Unlike standard equipment that handles only specific types of poultry, the MPS is engineered for versatility. It can efficiently remove skin or defat a variety of cuts—drumsticks, thighs, breasts, and more—for both chicken and turkey, enhancing yield while reducing the labor required.
The MPS’s multi-functional capabilities also lower the need for spare parts, allowing processors to streamline plant operations further. This flexibility has made the MPS a valuable addition to Prestage’s processing lineup, increasing productivity and simplifying operational logistics.
Learn more about the MPS: https://delongs.com/multi-purpose-skinners/
The Results
The integration of DeLong’s MPS at Prestage Foods has been transformative. The MPS has allowed the team to process 36,000 – 40,000 birds daily, reducing labor needs from a team of 8 to 4 people to a more efficient operation. This improvement has streamlined processes, increased safety, and enhanced overall efficiency for Prestage’s team.
According to WATT PoultryUSA’s 2023 Top Turkey Company rankings, Prestage Foods ranks as the 12th largest turkey processor in the United States, processing approximately 150 million pounds of turkey in 2022. This milestone demonstrates how innovative equipment like the MPS can positively impact production at scale.
DeLong’s service and support during this process were of the highest quality.
Looking Ahead
Prestage Foods executives, Zach Prestage and Gary Thomas expressed enthusiasm for DeLong’s exceptional support and commitment to the partnership.
With the success of the MPS implementation, DeLong’s is excited to continue supporting partners like Prestage Foods as they push the boundaries of innovation in poultry processing, building on a foundation of quality and reliability for years to come.
About DeLong’s Gizzard Equipment
DeLong’s Gizzard Equipment was founded in 1967 and is the leading global manufacturer of poultry processing equipment, specializing in precision-engineered rollers and solutions for poultry and gizzard processing. Known for their industry expertise, DeLong’s products meet or exceed industry standards for all major brands of processing equipment, making them the trusted choice in gizzard and poultry production.
Learn more about DeLong’s: https://delongs.com/