Cargill Innovates Beef Processing with Cutting-Edge AI Technology in Fort Morgan
Fort Morgan, Colorado — In an industry long reliant on painstaking manual labor, meat giant Cargill is revolutionizing beef processing by introducing advanced artificial intelligence (AI) technology to enhance efficiency and worker safety. At its Fort Morgan plant, which processes approximately 4,000 cattle daily, Cargill has invested $24 million as part of a larger $90 million technology upgrade plan aimed at refining production and increasing yields.
Addressing Challenges in Beef Processing
Despite widespread automation across various industries, the task of industrial cattle slaughter remains a physically demanding and labor-intensive process. According to Jarrod Gillig, senior vice president of Cargill’s North American beef business, the proficiency of beef carving not only affects employee well-being but also the company’s financial performance. Cargill seeks to ease the workload for their employees while simultaneously improving yield through the use of innovative solutions.
Introducing CarVe: The AI-Powered Carving Assistant
Central to this modernization effort is CarVe, a computer visioning system developed under Cargill’s Factory of the Future initiative. This technology employs overhead cameras to monitor production lines, providing real-time feedback on individual worker performance to frontline managers. From assessing the pace of work to evaluating knife sharpness and even analyzing workers’ emotional states influenced by on- and off-the-job factors, CarVe offers detailed insights designed to optimize operations.
Currently piloted in limited production lines at the Fort Morgan plant and one other facility in Canada, CarVe has garnered positive reactions from management and employees alike. The AI-driven system helps managers focus personalized coaching where it is most needed, rather than generalizing feedback across entire teams. The "gamification" aspect—such as digital leaderboards—motivates employees by spotlighting excellent performance and encouraging healthy competition.
Combatting Supply Constraints with Technology
The necessity for such advancements is underscored by the ongoing challenges in the U.S. cattle supply. As explained by Kenton Oschner, executive director of the Colorado Beef Council, drought conditions since around 2020 forced many producers to sell cattle rather than rebuild herds, leading to record-low cattle numbers. Simultaneously, American demand for beef remains at an all-time high, creating supply chain pressures and elevated cattle prices.
These market dynamics have forced beef processing plants nationwide to innovate. While some facilities, such as Tyson’s Lexington plant and JBS’s Los Angeles facility, are closing, Cargill is doubling down on technological upgrades to maximize meat yield from the available livestock. Even small improvements matter; Cargill notes that a 1% yield increase could translate to hundreds of millions of pounds of additional beef going into the food system annually.
Enhancing Worker Safety and Morale
In addition to boosting yields, CarVe aims to improve worker safety by identifying hazardous practices that could lead to injuries from knives or repetitive motions involving heavy muscle work. Brad Down, Cargill’s case-ready protein operations manager, emphasized that the technology could decrease workplace injuries that traditionally result in hospital visits. Cargill’s management has proactively engaged with union leadership to communicate the purpose and scope of CarVe, addressing concerns that the system might resemble "Big Brother" surveillance.
The Future of Beef Production at Cargill
The Fort Morgan plant’s adoption of CarVe forms part of over 100 Factory of the Future projects implemented across 35 Cargill protein-processing facilities in North America. Alongside CarVe, initiatives include smart saws, automated package handling, foreign object detection, and early warning systems for equipment and safety issues.
Cargill’s General Manager of North American beef, Johanna Hernandez, leads visitors around the Fort Morgan facility, showcasing how technology and skilled labor can work hand in hand. Through the integration of AI and human expertise, Cargill hopes to sustain its leadership in an increasingly competitive and resource-constrained industry.
As the cattle supply tightens and consumer demand intensifies, the Fort Morgan plant’s high-tech approach exemplifies how innovation can help the beef industry meet modern challenges, ensuring more efficient production, healthier workplaces, and more meat on America’s tables.
Written by Tracy Ross for The Colorado Sun, December 22, 2025.
