Cargill Boosts Beef Processing Efficiency with $24 Million Tech Investment at Fort Morgan Plant
Fort Morgan, Colorado – December 22, 2025 — As the U.S. cattle supply faces historic lows, meat processing giant Cargill is turning to advanced technology to enhance its beef production capabilities. The company recently unveiled a $24 million investment in cutting-edge equipment at its Fort Morgan beef processing plant, aiming to improve yield, employee safety, and efficiency amid ongoing industry challenges.
Tackling Tough Work with Smarter Tech
Industrial cattle slaughter remains a largely manual and physically demanding task. Processing around 4,000 head of cattle daily at Fort Morgan, Cargill’s employees engage in intricate carving and cutting operations that require significant skill and endurance. Jarrod Gillig, Senior Vice President of Cargill’s North American beef business, emphasizes that both “the proficiency of carving and worker well-being” play crucial roles in the company’s profitability and sustainability.
To address these challenges, Cargill’s “Factory of the Future” initiative has introduced a revolutionary artificial intelligence system called CarVe. This computer vision technology uses overhead cameras to observe production lines in real time, delivering instant feedback on employee performance directly to frontline managers. The system, currently piloted on select lines at two of Cargill’s eight beef processing plants across the United States and Canada, has received enthusiastic reviews from plant managers and workers alike.
Maximizing Meat Yield Amid Tight Supplies
With U.S. cattle numbers at record lows due to prolonged drought and economic pressures on producers, efficiency in processing every animal has never been more critical. Kenton Oschner, Executive Director of the Colorado Beef Council, explains that many producers have sold off herds rather than rebuilding due to high cattle prices and dry conditions, leading to fewer animals reaching packing plants.
In this environment, even a modest yield improvement of 1% — the increase Cargill hopes to realize with CarVe — can translate into hundreds of millions of additional pounds of beef annually. According to company estimates, full deployment of CarVe across their primary beef facilities could generate enough extra meat for more than one million additional meals from the cattle they process.
Inside the Fort Morgan Process
At Fort Morgan, cattle are carefully ushered into a single-file chute designed by renowned animal science expert Temple Grandin. Following humane slaughter practices mandated by the USDA, including stunning and bleeding, the carcasses move through a detailed process of skinning and cutting driven by hundreds of skilled workers. These workers break down each animal into familiar steaks, roasts, and ground beef products.
The complexity and labor intensity of these operations highlight the importance of technological enhancements that can help workers maintain precision and reduce fatigue.
How CarVe Works: Gamification Meets Efficiency
Beyond improving meat yield, CarVe focuses on the human element of processing. By monitoring knife sharpness, cutting pace, and even “emotional behavior,” the system’s AI-supported insights allow managers to provide targeted, real-time coaching rather than broad generalities. Ron Logan, Cargill’s Slaughter Manager, calls the “gamification” aspect a “game changer” that boosts morale and motivates employees through digital performance scoreboards.
This personalized feedback approach not only supports consistent high-quality workmanship but also prioritizes employee health and safety. Brad Down, Cargill’s Case-Ready Protein Operations Manager, highlights that CarVe aims to reduce injuries from repetitive motion and accidental cuts — common hazards in the demanding carving environment.
Addressing Labor and Supply Challenges
The beef processing industry has faced multiple disruptions in recent years. Notably, Tyson Foods plans to close its Lexington, Nebraska facility and JBS is shuttering its Los Angeles plant within months. Against this backdrop of tightening supply and high consumer demand, Cargill’s early investment in automation and AI positions it ahead of many competitors.
Their Factory of the Future program spans over 100 projects across 35 North American protein processing sites, incorporating smart saws, foreign object detection, automated packaging, and predictive maintenance technologies.
Commitment to Transparency and Employee Engagement
Cargill executives stress that CarVe is designed to support—not surveil—workers. Gillig notes that the company has worked closely with union leadership to clearly communicate how CarVe operates and the benefits it brings, ensuring transparency and addressing concerns about employee monitoring.
“We want to create the best environment possible for productivity and food safety,” Gillig says. “CarVe helps us do this while respecting our workers and preserving their dignity.”
As the beef industry adapts to evolving supply constraints and market pressures, Cargill’s Fort Morgan plant illustrates how innovative technology can improve efficiency, worker safety, and product yield. This blend of human skill and artificial intelligence represents a forward-looking model for meat processing facilities striving to meet consumer demand in a challenging landscape.
