Zone 1
Ground beef production takes place in Zone 1. Because the potential for microbial loads is greatest in this zone, it requires the strictest control, processing and testing procedures. Strict raw material requirements and specifications for age and color are constantly observed. Metal detection and regular inspection of equipment are standard operating procedures. Tools are sanitized, and temperatures are kept at strictly controlled levels. Personnel are disinfected - sanitized boot to hand - before coming near the floor. Clothing requirements are strict, with coats, hairnets and beard nets required. Crews clean before and throughout every production day, and we carry out thorough, ongoing sponge, air and product tests. Shelf-life testing on all ground beef products is conducted routinely.

Zone 2
Zone 2 includes all cold-climate areas of the plant, including fabrication, sales cooler and hotbox. All beef cooling, fabrication, packaging and shipping to customers occurs in Zone 2, so temperature control is critical and rigidly maintained. We conduct microbial testing by sponge and air on carcasses, primals, trim and equipment. Uniforms are required to be disinfected with boot- and hand-sanitizers, and personnel also follow strict and sanitary clothing requirements for coats, hairnets and beard nets. Cleaning crews sanitize the facilities from floor to machinery.

Zone 3
This zone comprises plant common areas and areas that provide physical separation, including secure entryways, air curtains and physical distance between divisions. In the plant common areas, movement of personnel and equipment from zone to zone is most important, and employees follow procedures that ensure proper sanitation. Continual efforts are made to ensure optimum food safety, and whenever deemed necessary, new welfare areas are added. Additional safety measures include diligent hand washing, welfare area table sanitizing and repeated floor sanitizing throughout the day.

Zone 4
This zone includes the slaughter floor, where intervention processes and procedures are critical in the reduction of possible microbial contamination. Personnel are disinfected with boot sanitizer and are bound to an Employee Transition Policy and clothing requirements for sanitary coats, hairnets and beard nets. Our multiple intervention processes are proven and repeatable. First, multiple Hock Steam Vacuums remove particles. Second, a Hot Pre-evisceration Organic Acid Spray further cleans the entire carcass. Next, the Thermal Pasteurization Process sprays the carcass surface with heated water. We follow with a cold water carcass wash and organic acid rinse. Then, we incorporate an additional Thermal Pasteurization Process, spraying the entire carcass with heated water. And, a state-of-the-art Spray Cabinet applies Sanova®, an acidified sodium chlorite antimicrobial solution. Both of these last two harvest floor interventions have proven to reduce pathogenic bacteria to historically low levels.

Zone 5
The emphasis in Zone 5 is on animal welfare, including safe and humane handling during unloading and in cattle holding pens. General security and tool sanitation are also critical in this zone. Personnel follow an Employee Transition Policy and Uniform Segregation ID Safety Policy to ensure that we continue to lead the way in food safety.