The 411,500 sq. ft. Bell & Evans Organic Chicken Harvesting Facility in Fredericksburg, PA., incorporates all the newest innovations in the poultry industry to create a cutting-edge, one-of-a-kind facility.
After visiting many European poultry farms, Bell & Evans’ Owner decided to incorporate what he saw into his own facility. Stellar designed the plant in five phases which enabled construction to begin while decisions were still in progress for later phases of the project. The facility features automation and robotics technology, employee welfare spaces and sustainable elements.
Despite navigating the challenges presented by the onset of the COVID-19 pandemic and resulting supply chain repercussions, Stellar was able to bring the complex ideas and high-end desires of Bell & Evans to life in a dynamic and collaborative way. Even though there were many complicated systems and components that required careful design, consideration and coordination to properly implement, Stellar’s team successfully accomplished the challenge with weeks to spare.
Embracing Design-Build Efficiencies
Using design-build allowed Stellar site personnel to begin construction while the architects and engineers were still in the process of designing the remainder of the facility. Because of this, the team was able to complete the project weeks in advance and stay ahead of possible conflicts and challenges. For this project, Steller integrated automation and robotics technology, sustainable elements, high-end materials and unique employee welfare spaces.
From water conservation to a heat recovery system, sustainable elements were laced throughout the facility. To conserve and recycle water, the facility redirects 40% of its potable water usage to reconditioned systems throughout the plant. Between the plant’s water reconditioning systems and Bell & Evans signature 100% Air Chill Processing method, these two processes save 400,000 gallons of water per day. Stellar’s installation of a sustainable ammonia refrigeration system, along with using their rendering plant’s waste heat to produce 55% of the facility’s hot water needs, will allow it to reduce the plant’s carbon emissions by more than half.
Bell & Evans received the first green loan in U.S. poultry from Rabobank for this new harvesting facility. The facility will allow the company to double production capacity over the next few years.
Design-Build Team
| Client/Owner: | Bell & Evans |
| Design-Build Firm: | Stellar Group, Inc. |
| Architect: | Stellar Group, Inc. |
| Engineer: | Stellar Group, Inc. |
| Project Cost: | $187 Million |
| Construction Duration: | 22 Months |
