Smithfield Packaged Meats and Fresh Pork Processing Plant
SIOUX FALLS, SOUTH DAKOTA
Epstein is serving as design-builder for the new processing facility consolidating fresh pork processing and value-added packaged meats production, replacing their century-old downtown operation. Designed to improve product flow, production efficiency and food safety, the facility will incorporate advanced automation and modern processing systems while providing the flexibility to adapt to evolving products, technologies and customer needs. The project will support their Sioux Falls workforce, strengthen relationships with regional agricultural producers and position the company for continued long-term growth.
TYPE
Design-Build
SIZE
1,100,000 Square Feet
JBS USA Fresh Sausage Processing Plant
PERRY, IOWA
Epstein is serving as design-builder for a new 150,000 square foot sausage processing facility in Perry, Iowa. Designed to produce approximately 130 million pounds of sausage annually, the plant will integrate sow processing with deboning, blending, forming, packaging, shipping and supporting operations in a highly efficient production environment. Epstein’s multidisciplinary team is coordinating process, architectural and engineering design with procurement and construction to support food safety, operational flow, maintainability and future workforce growth. The facility is currently under construction.
TYPE Design-Build
SIZE
150,000 Square Feet
JBS USA Beef Fabrication and Ground Beef Expansion
CACTUS, TEXAS
Epstein is serving as design-builder for a major expansion of beef production facility which will add a 110,000-square-foot fabrication floor designed to improve production flow, increase capacity and support more efficient operations within one of JBS USA’s largest beef plants. With construction of the new fabrication area nearing completion, Epstein is preparing for the next phase: converting the existing fabrication space into an expanded ground beef operation. Together, the improvements will modernize critical production areas, strengthen long-term operational flexibility and support continued investment in the Cactus facility.
TYPE
Design-Build
SIZE
1,300,000 Square Feet
Wholesome Farms Protein Processing Plant
FREMONT, NEBRASKA
Epstein served as the design-builder for Wholestone Farms after completing a multiyear master plan to modernize and rebuild an existing protein processing plant. The new plant involved a boiler plant replacement, snap chill, new rendering & wastewater pretreatment building, state-of-the-art cut floor, automated packaging, cold storage, and office expansion.
TYPE
Design-Build
PROJECT SIZE
1,000,000 Square Feet
Cherkizovo Group Pork Processing Plant
TULA, RUSSIA
Preliminary Design for a 1,500 head per hour, state of the art pork processing facility. The project scope includes a full suite of robotic automation, rendering, and wastewater treatment. In addition to fresh processing, the project includes a separate further process operation that will produce bacon, ham and sausage.
Cloverdale Feasibility Study and Master Plan MANDAN, NORTH DAKOTA
Epstein provided architecture and engineering services to conduct a feasibility study and develop a master plan to explore what changes would need to me made to the plant footprint, process and material flows, process equipment, utilities, warehouse and site to be able to efficiently produce 1,000,000 lbs/week of product.
Coastal Plains Meat Co. VERMILLION PARISH, LOUISIANA
DesignBuild services for a greenfield beef plant. The new plant will process up to 200 head per day on a single shift and produces primals, sub-primal case ready and ground beef.
Ed Miniat Expansion Master Plan
SOUTH HOLLAND, ILLINOIS
Epstein provided architecture and engineering services to develop an overall master plan for an expansion to meat processing facility addressed a variety of expansion program needs including employee amenity areas, location and size, office expansion areas, and material and personnel movement relating to travel distances and maintaining raw/cooked separation.
The Innovative Investment Hub 4.0 WILCOX, ARIZONA
Design-build services for agreenfield beef plant. that will initially process 2,000 head per day on a single shift and a second shift of equal capacity will be added in the future. The plant produces primals, sub-primal case ready products and ground beef. The scope includes rendering and storage and land application of treated wastewater.
Perdido River Meats Meat Processing Facility & Retail Butcher Shop
ATMORE, ALABAMA
Epstein provided full-service design and engineering for a new USDA beef and hog processing facility. The 18,000-square-foot plant was designed to slaughter and process approximately 50 cattle and 10 hogs per week for retail sale, producing case-ready cuts sold in an on-site butcher shop that Epstein also designed. Located adjacent to a heavily trafficked Interstate 65 exit on the Poarch Creek Indian Reservation, the project included a 1,400-square-foot retail butcher shop open to the public. Epstein delivered architecture along with civil, structural, and MEP engineering services for the $25 million development. Key scope elements included steel structural framing, insulated metal panel wall systems, and a large glass-enclosed drive-thru
Seaboard Triumph Foods Pork Processing Plant
ST. JOSEPH, MISSOURI
Design-build services for a new 750,000 square foot, $270M pork processing facility. The plant was designed to process 1,400 head per hour on one shift and prior to completion a 200,000 square foot addition was added to support a second shift of production.
Smithfield MULTIPLE LOCATIONS
Epstein has has completed dozens of architeture and engineering design projects which include:
■ A “Bacon Plant of the Future” that employed the best in-class-technology to deliver premium quality and yield, while reducing total staffing and labor cost.
■ A new 1,106 head per hour fresh meat plant in Sioux City, IA
■ A new 120 head per hour sow processing plant and sausage operation in Godwin, NC
■ A new livestock barn at their Sioux Falls, SD plant
■ A new spice blending plant in Eastvale, CA
■ Three expansions (sliced bacon, dry sausage and ham) for their Patrick Cudahy operation in Wisconsin
Swift Prepared Foods Renovation SWANTON, VERMONT
Epstein served as Industrial Process Engineer, with a scope covering master planning, interior renovations, equipment installation, and expansion to allow for 10,000,000 pounds of packaged meats products (4–5 varieties) to be produced.
Tyson Fresh Meats Freezer Expansion 1
LEXINGTON, NEBRASKA
Design-build services for a freezer expansion for a cooked packaged meat processing plant. The $47M, 50,000 square foot, 70 foot clear facility accommodates an automated storage and retrieval system, as well as improved the flow, efficiency and capacity of the plant’s boxed beef storage and distribution systems.
Plan with vision. Design with intention. Build with confidence. Adapt for the future.
Trusted by organizations across sectors, geographies, and project types.
ACCO Brands*
Alberto-Culver Company*
Albertsons Companies, Inc*
Alpina US*
Amway Corp.
Aramark
Army & Air Force Exchange Service
Aryzta*
Avon
Cameron
Capital Area Food Bank*
Cargill, Incorporated*
Cedar Concepts Corp.
Cherkizovo Group*
Cloverdale Foods Company*
Daily’s Premium Meats LLC
Ed Miniat LLC*
G&W Electric Co.
Greater Chicago Food Depository*
Indiana Kitchen*
Iscar Tools Inc.
JBS USA*
JDL Development
Jewel-Osco*
John Morrell & Co*
Kansas City Sausage Co.*
Keebler Company*
Kekén*
Kikkoman Corporation*
Kroger Co.*
Magid Glove & Safety
Maple Leaf Foods*
Maytag Corporation
Medline Industries
Mid-South Food Bank*
Molex
Newly Weds Foods*
Norson*
Patrick Cudahy*
Poarch Creek Indians
Premium Iowa Pork, LLC*
Roche Holding AG
Ruiz Foods*
Saratoga Food Specialist*
Seaboard Foods LP*
Seaboard Triumph Foods*
Sensient
Smithfield
Solo
Unilever*
Vegetable
Viscofan
VWR
WaterSaver
Whirlpool
Wholestone
WinCo
Sensient Technologies
Smithfield Foods, Inc.*
Cup Co.
Foods, Inc.*
Genetics
Turkey Hill Dairy*
Unilever*
Vegetable Juices, Inc.*
Viscofan USA*
International
Grainger, Inc.
WaterSaver Faucet Co.
Whirlpool Corporation
Wholestone Farms*
WinCo Foods*
