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BPI offers the right solutions: company's unequaled expertise in processing boneless lean beef evolves to machinery development and more.

Beef Products Inc., Dakota Dunes, SD, is not only the world's leading manufacturer of boneless lean beef, through its association with Freezing Machines Inc. it also offers a new series of high-quality pumps and grinders assembled at its new machinery manufacturing wing. Dakota Cold Storage, BPI's new, completely automated refrigerated warehouse, is built adjacent to the company's South Sioux City, NE, processing plant.

Lean beef trimmings

Before discussing the machinery options and refrigerated warehouse, let's get to the meat of the matter. BPI, Boneless Lean Beef Trimmings are lean and flavorful ingredients that are essential to processing a range of lean, high-quality, and cost-effective products that millions of Americans consume every day. These products include fresh and frozen hamburger patties, taco meats, low-fat hot dogs, beef-stick snacks, and sausage, just to name a few.

In fact, BPI, Boneless Lean Beef Trimmings are found in most ground beef made in the United States. BPI's trimmings are used by major packers and processors as an integral part of their ground beef or hamburger blends. And they are also used by the majority of QSR (quick-service restaurant) chains, HRI (hotel, restaurant, and institution) suppliers, and foodservice suppliers in the country. What's more, these trimmings are also approved for use in the USDA's AMS (Agricultural Marketing Service) School Lunch Program.

BPI's product is currently used in school lunch programs at blends of up to 10 percent, however, most commercial grinds incorporating the product are at blend rates of 15 to 25 percent or more. Made to customer specs, the majority of BPI's lean beef trimmings are finished as 94-percent lean, lean beef trimmings in 60-pound boxes. Seeing that consumer and customer demand is increasing for leaner products, BPI plans to introduce a 98-percent lean product.

BPI's high-quality products are made by processes, controls, safeguards, and custom-designed equipment the company has developed. All BPI plants, located in South Sioux City, NE; Waterloo, IA; Amarillo, TX; and Finney Country, KS, as well as its refrigerated warehouse and equipment assembly facility, are computer linked and interlinked to a master-control station at corporate headquarters in Dakota Dunes, SD. Each facility communicates critical real-time information, including temperatures, times, pressures, production speeds, refrigeration and hydraulic data, and more to the master control room. These controls ensure the most consistent, high-quality beef available industry-wide, company executives relay. And this crucial monitoring never ceases--it takes place 24 hours a day, seven days a week. What's more, plant and control-room personnel maintain constant contact via two-way radios. It's all part of the company's operating philosophy that values communication and cooperation.

Food safety is of the utmost importance to the company. BPI's product naturally has a higher pH than typical ground beef thanks to its process and patented pH-enhancing technology. And BPI's quality-assurance department monitors and records microbiological results on both incoming raw materials and finished product.

Among other things, BPI's QA department draws a sample of BPI product approximately every 10 seconds from the finished product flow (equivalent to a sample from each box of finished product produced). Each sample becomes part of a composite sample representing each box on a pallet. The composite sample is then analyzed for fat, moisture, and protein. Each box is bar-coded, and this information is entered into a corporate QA computerized pallet and bar-coded box-tracking system.

Two-hour composite samples are then sent to an independent laboratory for microbial testing throughout every day. Tests include total plate count, E. coli, Coliform, Salmonella, Listeria, Staph, and E. coli O157:H7. BPI never wavers from its rigid test-and-hold commitment.

To ensure complete safety, BPI also tests extensively for the presence of central nervous tissue (CNT). A daily composite is sent to an independent, outside laboratory, and samples are tested for presence of CNS. Product is not released for shipment without a completed microbial profile, including a negative E. coli O157:H7 result and confirmation of no evidence of CNA tissue.

In underscoring its commitment to maximizing product safety, the company invites customers to participate in its BPI, Test and Hold Guarantee for E. coli O157:H7 and Salmonella for their finished products. (See feature on page 10 of the July 2003 issue of The NATIONAL PROVISIONER for more details.)

Pumps and grinders

Freezing Machines Inc. (FMI), an affiliated company, offers its new FMI-BPI Series of pumps and grinders.

"We needed high-volume grinders and pumps that were dependable, sanitary, and built to last--so we developed our own," answers Eldon Roth, BPI founder and president, when asked why his company is involved in machinery building.

BPI pump and grinder features include:

* Innovative design

* Superior performance

* Designed for sanitation--features CIP (clean in place) technology

* Fully automated and operator friendly

* All stainless construction for maximum hygiene

* Built and developed by a meat processor for meat processors

* Optional controls and monitoring through BPI's master control center

BPI is no stranger to machinery design. It has been successful during its 24-year history in large part by designing its own equipment for its own unique processes. In fact, today BPI designs or modifies most of the machinery and systems used in its four plants.

Dakota Cold Storage

BPI's new, fully automated Dakota Cold Storage facility will help the company to keep up with increasing product demand. Highlights include:

* Packaged product arrives from the adjacent South Sioux City processing plant via conveyor in an overhead, enclosed bridge

* Each box entering the facility is untouched by human hands until its reaches the processor.

* An automated palletizer stacks boxes in a variety of configurations.

* The freezer holds up to 28 million pounds. Fifteen levels of cold-storage racks soar 115 feet in height and are loaded by automatic crane.

* Temperatures are: Palletizing area, 27[degrees] F; holding freezer, 0[degrees] F to -5[degrees] F; and truck loading, 40[degrees] E

* Delivery trucks back into one of five loading doors--backing in far enough inside of the facility to prevent product exposure to the outside environment.

For more information on BPI's products and services, phone (605) 217-8000, e-mail, or visit
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Title Annotation:Beef Products Inc; Freezing Machines Inc
Publication:Food Processing
Geographic Code:1USA
Date:Jun 1, 2005
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