At 400,000 square feet, the Lincoln Premium Poultry (LPP) plant was a major investment in Costco’s supply chain for chicken. The goal was to have more control over the quality and quantity of chicken produced for two of Costco’s best-selling products: rotisserie chicken and saddle-packed chicken breasts.
The Challenge
Finding the automation opportunity.
As you would expect, the production line for this important project was thoroughly planned and assembled, optimizing every step of the process for speed and efficiency. Even so, Lincoln Premium Poultry leadership invited the Fremont Automation team to walk through to identify potential opportunities to improve output or efficiency.
During the tour, the Fremont Automation team noticed that the saddle packs for the chicken breasts were being taped by hand. When asked, the LPP representative said they’d tried to automate the taping station several times with different companies but had no success. Instead, the process required three employees to keep up with the 16 packages per minute produced by each processing line–and the plant had 9 lines.
That’s 27 employees dedicated to one inefficient process. Fremont Automation engineers had found their target.
Key Areas of Focus
27 Employees
The taping stations were a major source of labor, which could cause delays due to short staffing or shift transitions.
High Costs
Due to the number of people required to work the taping station, it was a major source of salary and overhead expenses.
Inconsistency
Whenever there is manual labor, there is the opportunity for mistakes, accidents, or delays that would reduce output.
“When we asked them if they wanted us to automate the taping station, they said ‘We’ve tried, and it’s not possible.’ If you want us to do something, tell us it’s not possible.” – Amanda Benes, CEO, Fremont Automation
The Solution
Building a machine to do the “impossible.”
Fremont Automation’s team returned to the shop and quickly developed an initial rough concept using SolidWorks, a 3D modeling software. This early design included a basic animation to provide LPP with a clear visual of the proposed automation solution. This simple animatic helped illustrate Fremont Automation’s innovative approach. Based on this example, LPP gave Fremont Automation the go-ahead to start building.
One of the primary hurdles in automating the saddlepack process was addressing how to cut the tape itself, which could quickly gum up traditional cutting tools and create maintenance headaches. Fremont Automation’s engineers explored various options before landing on the solution: the development of a proprietary, now patented, hot-wire cutter. This innovative approach not only resolved the stickiness problem but also delivered consistent and reliable cutting performance.
As the saddlepack taper came together, Fremont Automation’s engineers conducted rigorous testing and adjustments to refine the system’s performance and reliability. Special attention was paid to operation and maintenance considerations. Details like easily accessible components and deburred edges made the equipment easy to use and maintain.
Standout Solutions
Patented Hot-Wire Cutter
This unique concept solved the issue of traditional blades and cutters getting tacky and stuck while cutting the packaging tape.
Operational Ease
The equipment had to create operational efficiency in order to lower the number of employees needed on each line.
Built-In Bypass Solution
The machine could be bypassed to maintain line output in case of routine maintenance, cleaning, or staffing shortage.
The Results
Doing the work of 18 employees.
The introduction of Fremont Automation’s saddlepack taper solution at Lincoln Premium Poultry delivered transformative results. Amanda Benes recalls what it was like:
“The operators had never seen anything like this before. It was completely different yet easy to run. And after seeing the first machine in action, LPP ordered eight more. One for each line.”
By automating the previously manual taping process, LPP was able to reallocate approximately 18 workers to other roles along the production line, optimizing labor distribution and increasing workforce flexibility. This was a major advantage during a time when hiring workers and filling workforce gaps was a constant challenge.
The automation system also significantly enhanced output efficiency. Production rates rose from 16 packages per minute to a peak capacity of 20 packages per minute, surpassing initial expectations. This boost in throughput not only improved LPP’s overall production capabilities but also reinforced Fremont’s Automation’s reputation for delivering scalable and adaptable solutions.
Reallocation of 18 Workers
Automating the labor-intensive saddlepack process allowed LPP to shift two-thirds of its tape station workforce to other line roles.
Rapid Payback Period
By cutting down on labor costs and increasing production speed, the system achieved a payback period of less than one year.
Employee Upskilling
Equipment operators took on ownership of the equipment, learning to perform maintenance and upkeep in addition to operation.