Howdy, Neil Dudley here! I wanted to take a minute to give every customer of Pederson’s our plant tour experience! Unfortunately, it is likely not the most feasible dream (at least not at this minute, and I feel like writing)… so, for now, here is our step-by-step, virtual plant tour experience!
I figure since we are famous for bacon, that seems like the best place to start. About a year ago, Cineflex came to our plant and created a great little video for the TV Show, Food Factory. These guys did a great job capturing the heart of our people and the process behind the bacon! Take a look at the video and then read more about each step of the process below!
We never inject our meat with anything. Instead, we use these tumblers to mix the seasonings into the meat. This part of the process plays a huge role in making the product taste so good. In my opinion, this is where the magic happens!
Straight from the tumblers, bellies are hung on metal hangers called combs, and then are hung on racks. From there, they are wheeled in to smokers, where they are left to smoke for six hours. Most run of the mill, cured bacon is injected with curing solutions and liquid smoke to give it it’s flavor. Here at Pederson’s, bacon is only tumbled and smoked, and yet emerges with the best flavor.
Here I am inside one of our two, 4 truck (2000 lb.) smoke houses. We also have another 8 truck house and one single truck house. That all adds up to approximately 8500 lbs. of smoke house capacity!
There are an average of 16 packages of bacon per box, which equals about one pork belly. But, before the cases of bacon get sent out to a customer, they are passed through a metal detector. Passing the product through a metal detector before it ships out is a standard required by several customers, and we are happy to oblige.
The next step is to take those racks of seasoned, tumbled, smoked & chilled bellies, and wheel ’em on in to the packaging room. There, one of our press operators puts each belly, one by one, in to a machine that presses them to a specific shape, which will help with slicing, and packaging.
There’s an order pick ticket printed for our shipping team so they know what items to pull to put on a pallet that will then get loaded into this refrigerated tractor trailer bound for our 3PL service provider.