$60 Million Commitment

Cargill Pork

Russellville, AR • 479-968-4560

Founded: Cargill Inc., 1865

Pork production: 10 million live head

Feed production: 850,000 tpy at

five locations

Number of Cargill Pork employees: 6,000

Key personnel at Hedrick:

• Jane Fallon, pork production

general manager

• Mike Sodak, mill manager

• Sarah Greeson, production supervisor

• Sara Johnson, administrator

Supplier List
Air compressor .........Ingersoll Rand
Automation system ....Repete Corp.
Bearing sensors .....4B Components
Ltd.
Bin level monitors ..BinMaster Level
Controls
Boiler ......................Cleaver Brooks
Bucket elevators ......... InterSystems
Contractor ..Younglove Construction
LLC
Distributor ..Hayes & Stolz Ind. Mfg.
Co. Inc.
Dust collection system ...... Air-Con
Corp.
Elevator buckets ..........Maxi-Lift Inc.
Engineering ................... Younglove
Construction LLC
Hammermills .............. Andritz Inc.
Magnets ...... Puritan Magnetics Inc.
Manlift .....Schumacher Elevator Co.
Mass flow meters .. Endress+Hauser
Microingredient system .................
InterSystems
Mixer .............Scott Equipment Co.
Motion sensors ....Maxi-Tronic Inc.
Pellet cooler ....Geelen Counterflow
Pellet mills .................. Andritz Inc.
Scales ..............Mettler Toledo, LLC
Rice Lake Weighing Systems
Screeners ............Rotex Global LLC
Screw conveyors .... Anderson Crane

On May 12, 2015, over 200 invited guests visited Cargill Pork’s newest feed mill outside of Hedrick, IA (641-933-4141), for a dedication ceremony at the 350,000-tpy swine feed operation.

The very next day, Grain Journal arrived for its own visit to the 163-foot-tall slipform concrete structure at the intersection of State Highways 23 and 149.

“Southeastern Iowa is an important area for us,” says Jane Fallon, a 31-year veteran with Cargill

and currently Cargill Pork general manager for production based out of West Des Moines, IA. “It has a critical mass of pork production in the region. There was a need for a modern milling facility in this area. We have access to high-quality swine feed ingredients like corn and soybean meal. Having our own feed mill here allows us to control the quality of the end product.”

The new $29 million feed mill is only part of a $60 million capital investment in the area. Cargill also completed a major expansion of its pork processing plant at Ottumwa, IA, about 12 miles to the south, doubling its daily output of bacon.

Fallon says that when the feed mill reachesfull capacity, operating ‘round the clock six days a week, it will serve hog producers under contract to Cargill within a 35-mile radius. Those hogs, in turn, will be processed at Ottumwa and at another Cargill Pork plant in Beardstown, IL.

Construction

Cargill Pork hired Younglove Construction LLC, Sioux City, IA (712-277- 3906), as its design build partner on the project. “We worked diligently together to design the structure you see today,” Fallon says. “Younglove is well known for its professionalism, craftsmanship, and mill design, and we took that into consideration in awarding the contract.”

Cargill and Younglove broke ground on the mill in September 2013 and poured the concrete foundation slab that winter in some excessively cold temperatures. Unfavorably cold and snowy weather over the course of two winters caused the project to be stretched out over 18 months. “It’s hard to avoid

bad weather in Iowa,” she comments.

Test runs began early in the spring of 2015, and the startup phase was completed in May.

Mill Description

The finished mill includes both feed ingredient and whole grain storage inside the slip.

The two whole corn silos are 30 feet in diameter x 163 tall holding 170,000 bushels total, in total a seven-day supply when the mill is operating at capacity. The hopper-bottomed silos send corn

to two 250-hp Andritz hammermills for grinding.

The mill also includes 23 ingredient bins holding an average total of 1,600 tons and 16 finished feed loadout bins, rated at 1,300 tons.

The mill is set up dual 10,000-bph InterSystems receiving legs.

Production

All milling operations are under the control of a Repete automation system.

The system batches ingredients and sends them to a Scott twin-shaft mixer, including a 24-bin InterSystems microingredient system. Average mix time currently is three minutes per batch, and liquid ingredients and fats may be added at the mixer, as well as at a postpelleting system.

All feeds produced at Hedrick are pelleted on a pair of Andritz pellet mills rated at a total of 80 tph, when both mills are running at capacity. Steam for the pelleting operation is provided by a Cleaver Brooks boiler.

Pellets then run through a Geelen counterflow cooler. The mill has no pellet crumbler, but Mill Manager Mike Sodak said nursery feeds can be manufactured.

Feed trucks are loaded through a stationary spout while parked on a 70- foot Mettler Toledo scale. The plant operates a fleet of six trucks and loads 50 to 60 truckloads per day.

Ed Zdrojewski, editor