Case Study
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
Industry: Poultry Processing
Challenge: Manual taping of chicken breast saddle packs causing labor bottlenecks (27 employees across 9 lines).
Solution: Custom Saddlepack Taper by Fremont Automation.
Results: Successfully automated 16 packages/minute per line, allowing LPP to redeploy 27 employees to higher-value tasks across 9 processing lines.
At 400,000 square feet, the Lincoln Premium Poultry (LPP) plant was a major investment in Costco’s supply chain. The goal: control the quality and quantity of rotisserie chickens and saddle-packed chicken breasts. Every step was optimized for speed, but one manual bottleneck remained.
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.
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.
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.
Patented Hot-Wire Cutter
Operational Ease
Built-In Bypass Solution
The introduction of Fremont Automation’s saddlepack taper solution at Lincoln Premium Poultry delivered transformative results.
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.
Automating the labor-intensive saddlepack process allowed LPP to shift two-thirds of its tape station workforce to other line roles.
By cutting down on labor costs and increasing production speed, the system achieved a payback period of less than one year.
Equipment operators took on ownership of the equipment, learning to perform maintenance and upkeep in addition to operation.
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.”
- Amanda Benes, CEO, Fremont Automation
Yes. While many consider it impossible, Fremont Automation successfully engineered a custom Saddlepack Taper for Lincoln Premium Poultry that processes 16 packages per minute.
The best way to start automating a poultry packaging line is with an assessment of your existing process to identify labor-intensive tasks, bottlenecks, and opportunities to improve throughput.
Fremont Automation walks your line with your team to understand your process and production goals. Our engineers then recommend poultry automation that fits your existing equipment and plant layout.
From there, we design and install the system, integrate it with your line, and train your team. We plan installation around your production schedule to minimize downtime.
You don’t need to know which machine you need. Start with the problem, and we’ll help you find the right automation solution.
By automating repetitive tasks like hand-taping saddle packs, plants can reallocate employees. In this case study, Lincoln Premium Poultry reassigned 27 employees from the taping line to other critical areas.
A turnkey poultry packaging automation installation covers the entire process—from evaluating your existing line and engineering the automated system to installation, integration, startup, training, and ongoing support.
Fremont Automation starts by walking your poultry processing line to understand your equipment, workflow, space constraints, bottlenecks, and production goals. Our engineers then tailor the packaging automation system to your operation and integrate it with existing upstream and downstream equipment, regardless of OEM.
To minimize production disruption, installation can be scheduled over a weekend. Fremont Automation manages equipment installation, integration, startup, and operator training so your team can get the automated system running with minimal interruption to production. Turnkey installation also includes support after startup. The engineers who design and install the equipment remain available for troubleshooting, adjustments, maintenance support, and ongoing optimization. That gives poultry processors one partner from initial line assessment through long-term operation—helping reduce installation risk, minimize downtime, and keep packaging lines moving.
