The International Production and Processing Expo (IPPE) is a big deal in the poultry industry. Every year, it brings together people from all parts of food production—farmers, processors, engineers, and tech experts. It’s the place to see the latest tools and technologies that help make food safer and easier to produce.

This year’s event in Atlanta was full of new ideas and solutions. People talked a lot about keeping workers safe, handling labor shortages, and protecting food from diseases like Avian Flu, which are all big issues in food processing today.

Fremont Automation was right in the middle of these conversations at the booth we shared with Custom Stainless Enclosures. We talked with plant managers, engineers, and operations leaders. We shared how our automation systems can help food plants run smoother and safer. We also learned a lot from others about what’s working and what still needs attention in the industry.

In this blog, we’ll share some of the most important things we learned at IPPE. Whether you’re a plant engineer, a manager, or just curious, these takeaways will give you a peek into the future of food processing.

THE ONGOING LABOR SHORTAGE CHALLENGE IN FOOD PROCESSING

Finding and keeping team members is one of the biggest challenges in food processing today. At IPPE, nearly every conversation touched on this issue. Plants are struggling to keep production running at full speed because they don’t have enough people to fill shifts.

What’s Causing the Labor Shortage?

  • Fewer workers are entering the industry.
  • Many jobs are physically demanding, leading to injuries and burnout.
  • Competition for labor is higher than ever.
  • Turnover is high, which means constant hiring and training.

This isn’t just a short-term issue. Food processors need long-term solutions to keep up with demand.

How Automation Helps

Automation is one of the best ways to keep production moving despite labor shortages. Many companies at IPPE were looking for ways to:

  • Reduce labor-intensive elements of their production line.
  • Move team members into safer, higher-skilled roles.
  • Improve efficiency without overloading their current team.

Fremont Automation is helping plants do exactly that. Our systems take on repetitive and physically demanding tasks, allowing plants to reallocate their team members to more valuable positions. Instead of struggling to hire, fill shifts, or overcome churn, companies can use automation to work smarter with the people they already have.

What’s Next?

Workforce challenges aren’t going away, so the demand for automation is growing fast. More companies are investing in smart systems to reallocate associates, reduce injuries, and keep their plants running even when team members are scarce.

If you’re dealing with labor shortages, now is the time to explore automation. It’s not about replacing people—it’s about making the best use of your team and adapting to the realities of the workforce.

KEEPING WORKERS SAFE WHILE BOOSTING PRODUCTIVITY

Worker safety was a huge topic at IPPE this year. Food processing jobs are tough. Repetitive motions, heavy lifting, and fast-paced work can lead to injuries. When associates get hurt it affects their livelihood and families. Production slows down in your plant and turnover increases. Companies are looking for better ways to protect their teams while keeping output high.

The Push for Safer Workplaces

  • Repetitive strain injuries (RSI) are a big concern in food processing. Tasks like cutting, lifting, and packing put stress on workers’ bodies over time.
  • Many companies are focusing on ergonomics—designing workstations and equipment to reduce strain and fatigue.
  • IPPE highlighted this effort with its Safety Awards, now in its fourth year, recognizing plants that prioritize worker protection.

How Automation Improves Safety

One of the best ways to prevent injuries is to take the most dangerous tasks off workers’ hands. That’s where automation comes in.

  • Less Heavy Lifting – Machines handle repetitive and high-strain tasks, reducing injuries.
  • Fewer Repetitive Motions – Automation cuts down on movements that lead to RSI.
  • Consistent Workflows – Automated systems don’t get tired, reducing mistakes that could cause accidents.

At Fremont Automation, we design our machines with safety in mind. We make sure our systems:

  • Reduce the risk of injury by handling physically demanding tasks.
  • Are easy to clean and maintain, keeping food and team members safe.
  • Help workers transition into roles that require less physical strain.

A Safer Future with Smart Automation

As labor shortages continue, companies can’t afford to lose workers to preventable injuries. The right automation solutions keep workers safe while increasing efficiency. It’s a win-win for both the team and the bottom line. By investing in safety today, food processors can build stronger, healthier teams for the future.

THE ROI OF AUTOMATION: WHY IT PAYS OFF

Automation isn’t just about keeping up with demand—it’s about making smart financial decisions. At IPPE, return on investment (ROI) was a major concern. Plant managers and engineers know automation can help, but they need to justify the cost.

Many hesitate because:

  • Upfront investment can feel risky.
  • Downtime for installation could slow production.
  • ROI expectations are tight—most plants need to see a return within 18 months.

The good news is that the right system pays for itself quickly by increasing output, reducing labor costs, and preventing injuries.

A Real-World Example: Lincoln Premium Poultry’s Automation Success

Lincoln Premium Poultry (LPP), Costco’s main poultry supplier, faced a labor-intensive challenge in its saddlepack process, requiring multiple workers per line to manually tape packages. With nine lines running, labor costs and inefficiencies were mounting. When they approached Fremont Automation, automating this process seemed impossible. But through innovative engineering, including a proprietary hot-wire cutting system, Fremont designed and implemented a custom automation solution that not only streamlined production but also increased throughput from 16 to 20 packages per minute.

The impact was immediate. LPP was able to reallocate 18 workers to more critical roles, significantly reducing manual labor without sacrificing efficiency. The system paid for itself in under a year, proving that smart automation isn’t just about reducing costs—it’s about unlocking new levels of productivity and reliability.

Investing in the Future

For many plants, automation isn’t a “maybe” anymore—it’s a necessity. A well-designed system boosts efficiency, reduces downtime, and keeps plants competitive. If you’re weighing the cost of automation, it’s worth looking beyond the price tag. The right investment today can keep your plant running stronger for years to come.

FOOD SAFETY: PROTECTING PRODUCTS AND CONSUMER TRUST

Food safety was on everyone’s mind at IPPE this year. With concerns about Avian Flu still fresh in the industry, many conversations focused on how to keep products safe and reassure consumers.

Rising Concerns Around Food Safety

Foodborne illnesses can damage a company’s reputation and bottom line. At IPPE, processors and suppliers talked about:

  • The need for better contamination control in poultry and meat processing.
  • How to improve traceability to ensure product safety.
  • Ways to communicate food safety efforts to consumers more effectively.

The poultry industry has already stepped up with stricter safety protocols and updated recommendations to reduce the risk of Avian Flu spreading. Companies are working hard to prove that their products meet the highest standards.

How Automation Supports Food Safety

Automation plays a key role in reducing contamination risks and maintaining consistent quality. Smart systems can:

  • Minimize human contact with raw food products.
  • Ensure precise, repeatable processes that lower the chance of errors.
  • Handle sanitation better, with easy-to-clean designs that meet strict washdown requirements.

At Fremont Automation, we design equipment with food safety in mind. Our machines are built for washdown environments, with stainless steel enclosures and fewer parts to make cleaning and maintenance easier.

The Future of Food Safety in Processing

As food safety regulations continue to evolve, automation will become even more critical. Companies that invest in safer, smarter systems today will be better positioned to handle future challenges—while also earning consumer trust.

MAKING THE MOVE FROM MANUAL TO AUTOMATED PROCESSES

One of the biggest questions we heard at IPPE was: How do we transition from manual work to automation without disrupting production? It’s a valid concern. Food processing plants run on tight schedules, and any slowdown can be costly. But with the right approach, automation can boost efficiency, improve safety, and pay for itself quickly—all without throwing operations off track.

Common Concerns About Automation

Attendees at IPPE wanted to know:

  • How do we introduce automation without causing downtime?
  • Will automation slow us down before it speeds us up?
  • How do we balance safety, efficiency, and cost-effectiveness?

These are the right questions to ask. A rushed or poorly planned automation rollout can create more problems than it solves. That’s why a thoughtful, strategic approach is key.

How Fremont Automation Helps Plants Transition Smoothly

At Fremont Automation, we believe in getting it right the first time. That starts with understanding your plant’s specific challenges before recommending a solution. Here’s how we make automation work for you:

  1. We start with a deep dive into your plant’s needs. Are you trying to reduce injuries? Improve output? Adapt to labor shortages? Every plant is different, and automation should be tailored to your unique goals. We learn so much from our site visits and talking with your operators.
  2. We focus on long-term efficiency and uptime. The best automation systems don’t just work well on Day 1—they keep working with minimal maintenance and downtime. Our designs prioritize reliability and easy upkeep.
  3. We collaborate with plant engineers to tailor solutions. Your plant isn’t one-size-fits-all, and neither is automation. We work closely with your team to ensure a smooth, efficient integration that improves—not disrupts—production.

The Bottom Line

Moving from manual processes to automation doesn’t have to be overwhelming. With the right plan, the right technology, and the right team, you can improve efficiency, protect your workforce, and stay ahead of the competition—without missing a beat.

What’s Next for the Industry?

IPPE made one thing clear—automation is the future of food processing. Companies across the industry are looking for ways to tackle labor shortages, improve worker safety, and keep food quality high. Smart automation is no longer just an option; it’s becoming a necessity to stay competitive.

Now is the time to evaluate your automation strategy. If you’re facing challenges with labor, safety, or efficiency, taking a proactive approach today will set your plant up for long-term success.

At Fremont Automation, we help food processors find the right automation solutions for their unique needs. If you’re ready to explore what automation can do for your plant, let’s start the conversation. The future of food processing is here—let’s build it together.