December 4, 2023

Tyson Foods unveils state-of-the-art automated poultry plant in Virginia, US

Tyson Foods has unveiled one of its most automated poultry plants in Danville, Virginia, United States, primarily focusing on producing fully-cooked Tyson-brand chicken products, Fox Business reported.

The company invested US$300 million in the construction of the 325,000 square-foot facility, realising the project two years after first announcing plans for the site.

Equipped with 13 high-speed automated case packing lines and five high-speed robotic case palletising units, the Danville facility stands out as one of Tyson's most automated poultry plants. In addition to advanced automation, Tyson has introduced the "first at-scale integration of wearable armband devices to improve worker health, safety, and productivity" at the plant.

Tyson Foods Poultry Group president Wes Morris said the Danville plant incorporates the latest technology that brings real-time intelligence to the company's processes, products, and workplace experience for team members.

In late 2021, Tyson outlined a US$1.3 billion investment over three years to enhance automation across its facilities, aiming to improve production capacity and efficiency. The Danville site is expected to create nearly 400 new jobs and achieve a full production capacity of approximately 4 million pounds of fully-cooked chicken products per week.

Products from the plant will include popular items like Any'tizer Snacks and Chicken Nuggets, according to Tyson. The company's extensive network encompasses 240 facilities across its four segments: beef, pork, chicken, and prepared foods.

Tyson Foods, recognised for brands such as Ball Park, Jimmy Dean, and Hillshire Farm, reported total sales of US$52.88 billion in the 2023 fiscal year, representing a slight decrease from the US$53.28 billion in fiscal 2022. The company also incurred a net loss of US$648 million during this period.

Several years ago, retail giant Costco established a plant in Nebraska dedicated to processing birds for its rotisserie chickens and other products, producing a reported 1 million birds weekly.

-      Fox Business