Tyson Foods has opened a new $300 million fully cooked food production facility in Danville, Virginia. The facility will be one of the company’s most-automated plants to date, marking the deployment of innovation pilots and prototypes at scale.
The 325,000-square-foot facility represents a significant investment in the local community, opening up over 400 new jobs. It will produce approximately 4 million pounds of fully cooked poultry products weekly, including chicken nuggets and wings.
“The Commonwealth’s business climate, infrastructure, and skilled workforce facilitate a long-term partnership with Tyson Foods, and we thank the company for reinvesting in Virginia with its operation in Danville-Pittsylvania County,” said Gov. Glenn Youngkin. The facility is located in the Cane Creek Centre, a local business park owned by the city of Danville and Pittsylvania County in Southside Virginia.
“Danville represents a significant commitment to the region and we take our responsibility to enhance the communities where we live and work seriously. This plant is also a significant step toward our ongoing goal of operational excellence by investing in innovative technology and automation,” said Donnie King, president and CEO, Tyson Foods. “This facility delivers on our commitment to ensuring best-in-class service for our customers and accelerating our long-term growth.”
Industry-first technology
The Danville facility is one of the company’s most highly automated plants, featuring high-speed automated case packing lines and robotic case palletizing units. The technology helps to maximize operational efficiency and increase overall team member safety.
“The combination of our team and technology at Danville will strengthen our ability to better meet demand for retail and foodservice fully-cooked Tyson brand products,” said Wes Morris, group president, Poultry, Tyson Foods. “The Danville plant incorporates the latest technology that brings real-time intelligence to our processes, products, and workplace experience for team members.”
It also includes a product inspection process that incorporates metal detection, X-ray, and vision grading to ensure consumers receive high-quality products.
Danville will integrate wearable armband devices that Tyson says will monitor worker health, safety, and productivity.
“The award-winning solution, for every frontline team member, integrates technology featuring sensors that relay environmental data to safety managers to better identify risk exposures,” writes Tyson in a press release.