Case Study — Food Processing
Eliminating Cross-Contamination at a High-Volume Meat Packing Facility
A Midwest meat packing plant with 48 wash stations needed USDA-accepted temperature control to meet HACCP protocols and eliminate pathogen risk.
The Challenge
The facility operated a high-throughput beef and pork processing line running three shifts per day, six days a week. USDA inspectors had flagged inconsistent water temperatures at washdown stations — some running below the 140°F minimum required to kill Listeria and Salmonella, others scalding workers at temperatures above 160°F.
The plant's existing mixing valves were manual and lacked thermostatic control. Operators adjusted temperatures by feel, leading to wide variation across the 48 stations. A single failed USDA audit could result in a production shutdown costing $200,000+ per day.
The facility also needed equipment that could withstand daily chemical sanitizer exposure, high-pressure washdowns, and the physical demands of a meat processing environment — without corroding or requiring frequent maintenance.
The Solution
Northeast Controls Inc. specified the SuperKlean Model 3600M-B-T thermostatic hot and cold water mixing station for all 48 wash points. The 3600M-B-T features a factory-set thermostatic cartridge that automatically maintains outlet temperature within ±3°F of the setpoint — eliminating operator adjustment and ensuring consistent HACCP-compliant temperatures.
The bronze body construction with stainless steel internals provided the corrosion resistance needed for daily chemical exposure. Each station was configured with a DuraFlow Classic DH150 spray nozzle rated for 150 PSI, providing the flow rate and spray pattern required for effective carcass and equipment washdown.
Installation was completed in phases over four weekends to avoid production downtime. Northeast Controls provided on-site commissioning, temperature validation documentation, and operator training for all three shifts.
The Results
The 3600M-B-T stations gave us the consistent temperature control we needed to pass USDA audits with confidence. Our sanitation team no longer has to manually adjust valves — the thermostatic cartridge does the work.
— Plant Sanitation Manager, Midwest Meat Processing Facility