Top integrator strategies for controlling COVID-19

COVID-19 continues to be an issue of major concern for poultry processing. Leading integrators are making massive shifts in how they do business in order to protect themselves from the virus.

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Poultry processing companies are installing temporary or permanent barriers to reduce COVID-19 transmission on processing lines. (Courtesy Wayne Farms)
Poultry processing companies are installing temporary or permanent barriers to reduce COVID-19 transmission on processing lines. (Courtesy Wayne Farms)

COVID-19 continues to be an issue of major concern for poultry processing. Leading integrators are making massive shifts in how they do business to protect themselves from the virus.

Nearly eight months after the outbreak of the novel coronavirus in the United States, the disease is still a severe public health issue particularly affecting meat packing and processing. After sporadic shutdowns and intense scrutiny early in the pandemic, the number of cases and closures stayed relatively low in the poultry industry.

However, in September, Foster Farms – the 10th largest poultry company according to WATT PoultryUSA’s rankings – idled its Livingston, California, poultry plant for eight days after a total of 392 positive cases and eight employee deaths related to complications associated with COVID-19. The closure is a reminder of the diseases’ presence, and potential impact, for the entire poultry industry.

“We can never allow for any measure of complacency,” Foster Farms said in a statement issued in August 2020. “COVID-19 is not the product of a company any more than it is the fault of a people, or a community. It is a scourge.”

Across the poultry industry, processors are using input from the U.S. Centers for Disease Control and Prevention and the U.S. Department of Labor’s Occupational Safety and Health Administration to inform their operations. The commonalities are enhanced social distancing, use of personal protective equipment (PPE) to prevent virus transmission, new education for workers on how to protect themselves at work and at home and the use of new practices and technology – such as thermal imaging and body temperature checks – to detect ill workers before they go on the job.

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Tyson Foods installed thermal imaging technology to screen employees for COVID-19 symptoms before they begin their shift. (Courtesy Tyson Foods)

These new disease prevention methods bring new expenses, however. In the third quarter of its fiscal 2020 alone, Tyson Foods Inc., as a whole, spent a reported $340 million on what it called direct incremental expenses related to COVID-19. These included costs associated with PPE, production facility sanitization and virus testing.

Tyson Foods

The largest integrated poultry company in the U.S., according to WATT PoultryUSA’s rankings, employs 120,000 working at more than 450 locations, including about 140 production facilities, in the U.S. Along with poultry, it is involved in the production of beef, pork and prepared foods.

At its production facilities, Tyson provides hand sanitizer, numerous hand washing stations and has made elevated use of PPE, such as surgical face coverings and plastic face shields, mandatory for its employees. After arriving to the site, all employees pass through a digital temperature check station – powered by machinery made by Thermoteknix Systems Ltd. – and, if necessary, a temperature check from trained medical staff. Those with a body temperature above 104 F (40 C) are sent home. All areas are regularly sanitized. Some production facilities are also using UV air filters to control airborne transmission of the disease. Those who can work from home are asked to do so.

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Along with staggering breaks and moving break rooms outside, physical barriers were installed in break rooms at Tyson Foods facilities to promote social distancing. (Courtesy Tyson Foods)

The Springdale, Arkansas, based company is also conducting a robust COVID-19 employee testing program. In its latest announcement on the disease, issued July 30, 2020, the company said it has tested nearly a third of its workforce for COVID-19 and less than 1% of the workforce had an active case of COVID-19 at the time.

From now on, Tyson plans on testing thousands of workers every week across all its facilities. The plan calls for:

  • Testing of employees with no symptoms based on what it calls an algorithm-based selection process. The actual number of employees tested will vary from week to week based on factors such as the number of positive cases involving plant workers and the surrounding community.
  • Testing of employees it finds to be symptomatic using regular health screenings upon arrival for work.
  • Testing of employees who were in close contact with others with COVID-19 symptoms or a positive COVID-19 test.

In the July announcement, Tyson said it created a new executive position – chief medical officer – and will hire about 200 nurses and administrative support personnel to augment its existing staff of more than 400 working on its health services team. The new hires will be charged with conducting on-site testing.

Pilgrim’s Pride

Pilgrim’s Pride Corp.’s parent company, JBS S.A., has – according to CEO Gilberto Tomazoni in the company’s first and second quarter of 2020 earnings reports – taken more than 1,000 actions to protect its global workforce of about 240,000. Those measures include providing temperature testing and outpatient services, supplying additional PPE, expanding cafeteria spaces and break areas, enhancing cleaning and sanitation and mandating physical distancing between employees. The company also established a $120 million fund dedicated to combating the disease.

Sanderson Farms

Sanderson Farms Inc. is the third largest poultry company in the U.S. and employs 17,000 in the country. It was one of the first companies to announce it had a positive case in March 2020. Since then, its dedicated significant resources toward disease prevention and workforce protection.

“We are continuously monitoring operations, and we continue to consult with infectious disease experts to adopt precautions and put guidelines in place throughout the company to mitigate the spread of the virus,” the company said in a release on its COVID-19 prevention measures.

It has taken the same steps as other companies – more PPE distribution, sanitation, social distancing and training on how to avoid the virus at work and at home – and its also established a COVID-19 hotline for its employees. Sanderson is also offering paid leave for any employee self-quarantining with symptoms of COVID.

Perdue Foods

Perdue is the fourth largest poultry company in the U.S. and it employs more than 19,500. Like other companies, since March it has boosted its cleaning and sanitation, enhanced social distancing or added barriers where distancing isn’t possible, added non-contact temperature checks before workers begin their shifts and began distributing personal protective equipment, according to company statements released since March 2020. Employees who are not feeling well, or think they may have been exposed to the virus, are encouraged to stay home.

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As part of its COVID-19 response, Perdue Foods distributed care packages including masks, hand sanitizer and a thermometer to take home to their family.  (Courtesy Perdue Foods)

Also, the company increased its access to its onsite Wellness Centers. The centers are staffed with healthcare provides and are available to all Perdue employees and their families free of staff. Those who cannot visit the center in person can speak with a doctor using telehealth services available through the company’s healthcare provider at no cost.

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