Claire Thompson
Tyson Foods is the largest chicken processor in the US, with a market share of approximately 25%. The company has been involved in several controversies, including lawsuits regarding animal cruelty, environmental concerns, and employee welfare. Pilgrim's Pride, Perdue Farms, Koch Foods, and Wayne Farms are also key players in the US poultry industry, with Koch Foods starting as a one-room chicken processing company in 1973 and growing into a profitable business with locations in six states. However, the largest chicken processing plant in the world, Tar Heel, is owned by Smithfield Foods and located in North Carolina.
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What You'll Learn
Tyson Foods: largest chicken processor in 2019
Tyson Foods was the largest chicken processor in the US in 2019. The company produced an average of 200.47 million pounds of ready-to-cook chicken each week, with a market share of approximately 25%. This was a decrease from the previous year, with a 5.68% drop in pounds slaughtered.
Tyson Foods operates 140 chicken facilities, including 35 slaughter plants and 16 further-processing plants. They employ over 140,000 people across 24 states, including Alabama, Arkansas, Indiana, Iowa, Kansas, Mississippi, Missouri, Nebraska, South Dakota, Tennessee, Texas, and Wisconsin.
Tyson Foods encompasses several household brands, including Jimmy Dean, Hillshire Farm, Ball Park, Wright Brand, Aidells, and State Fair. The company produces a wide range of poultry products, including chicken, turkey, and duck, as well as beef and pork.
The closest competitor to Tyson Foods in terms of production is Pilgrim's Pride Corp., based in Greely, Colorado. Pilgrim's Pride slaughters an average of 30.3 million chickens each week and has 86 facilities overall, including 25 slaughter plants. They are a subsidiary of JBS and have a market share of approximately 20%.
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Pilgrim's Pride: second-largest chicken processor
Pilgrim's Pride is the second-largest chicken processor in the US, with a market share of approximately 20%. It is a multinational food company that produces chicken and other poultry products. The company has a presence in 12 states, as well as Mexico and Puerto Rico, and employs about 38,000 people. Pilgrim's Pride is majority-owned by JBS S.A., a Brazilian company that is the largest meat processor in the world by revenue.
Pilgrim's Pride has an extensive history in the poultry industry. Its origins can be traced back to a feed store opened in 1946 in Pittsburg, Texas, by Lonnie "Bo" Pilgrim and his older brother, Aubrey. Over the years, Pilgrim's Pride has made several acquisitions, including Gold Kist in 2006 and Gold'n Plump in 2016. The company also experienced setbacks, such as filing for bankruptcy in 2008 and facing food safety and animal welfare controversies. In 2025, Pilgrim's Pride contributed $5 million to the second inauguration of Donald Trump, drawing scrutiny from Senator Elizabeth Warren.
As one of the leading chicken processors in the US, Pilgrim's Pride has a significant impact on the industry and the economy. The company has the capacity to process about 36 million birds per week, resulting in almost 9.5 billion pounds of live chicken annually. Pilgrim's Pride supplies its products primarily through foodservice and retail outlets, serving millions of customers. The company's large-scale operations contribute to employment opportunities and stimulate local businesses.
Pilgrim's Pride's position as the second-largest chicken processor in the US comes with certain responsibilities and challenges. The company has faced scrutiny over its food safety practices, with a notable incident in 2013 involving the recall of 27.4 million pounds of sliced deli poultry due to Listeria contamination. This outbreak had severe consequences, including multiple fatalities and illnesses. Additionally, Pilgrim's Pride has been criticised for its alleged use of "inedible" chicken parts in cattle feed, a practice known as protein conversion, which is common in the poultry industry.
Overall, Pilgrim's Pride plays a significant role in the US chicken processing industry. With its large market share and extensive operations, the company influences the market and supplies chicken products to consumers nationwide. As the industry continues to grow, Pilgrim's Pride is likely to remain a key player in the US chicken processing sector.
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Smithfield Foods: owns largest plant
Smithfield Foods, Inc. is a Chinese-owned pork producer and food-processing company based in Smithfield, Virginia. It was founded in 1936 as the Smithfield Packing Company by Joseph W. Luter and his son. The company owns over 500 farms in the US and contracts with another 2,000 independent farms across the country.
Smithfield Foods owns the largest chicken processing plant in the US, the Tar Heel plant in North Carolina. The plant was originally built in 1992 by Murphy Family Ventures and was purchased by Smithfield Foods in 2000. It occupies 973,000 square feet (or 90,000 square meters) of space and employs more than 5,000 workers.
The Tar Heel plant is a vertically integrated facility, which means that all aspects of the production process are included in one location, from slaughtering to packaging and shipping. This integration allows for better control over quality and consistency throughout the supply chain. The plant utilizes advanced technology and automation to enhance efficiency and productivity, such as robotic carcass splitters, slicers, vision systems, and conveyors.
The Tar Heel plant plays a crucial role in meeting the demand for poultry products in the United States. With a capacity to process 35,000 chickens per hour or 1.25 million chickens per week, it is a significant contributor to the economy of the region. The plant's scale and production capacity make it a key player in the global chicken processing industry.
In addition to its economic impact, the Tar Heel plant is also recognized for its commitment to sustainability. It has implemented environmentally friendly initiatives, including a wastewater treatment system that produces biogas for electricity generation and a stringent waste management program to reduce its environmental footprint.
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Koch Foods: sixth-largest producer
Koch Foods is the sixth-largest chicken producer in the United States, with a 4% market share in the global chicken market. The company was started in 1973 as a one-room chicken processing operation and has since grown into a highly profitable business with locations in six states.
Koch Foods has been involved in several controversies and legal issues. In 2007, federal authorities raided one of its chicken processing plants in Ohio, detaining 161 undocumented workers. The company was fined $536,046 for violating federal immigration law and began using E-Verify to check employees' work eligibility. In 2019, federal authorities raided seven of Koch Foods' chicken processing plants in Mississippi, detaining 680 undocumented workers.
Koch Foods has also faced accusations of discrimination. The company was accused of discriminating against Black contract farmers in Mississippi, and USDA investigators found "evidence of unjust discrimination". In 2012, the U.S. Equal Employment Opportunity Commission filed a class-action employment discrimination lawsuit against Koch Foods, alleging harassment and discrimination based on national origin and race at its Mississippi plant. The case was settled in 2018, with Koch Foods paying $3,750,000 plus other relief.
In addition to its chicken processing operations, Koch Foods has expanded its business. In 2017, the company announced plans to build a $40 million feed mill in Alabama, but later changed the location to Attalla, Alabama, where it constructed a modern grain storage and distribution facility.
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Cargill Meat Solutions: largest poultry company
Cargill Meat Solutions is the largest poultry company in the United States, with $165 billion in sales and a market share of 22%. The company raises and processes poultry for sale to both consumers and food companies, and also provides food service solutions. Cargill's meat division was established in 1979 with the purchase of meat processor MBPXL (later Excel), and has since expanded into turkey, food service, and food distribution businesses.
Cargill Meat Solutions has grown significantly over the years through acquisitions and mergers. In 2003, it acquired Milwaukee Emmpak and merged it with Taylor Packing Co., which it had purchased in 2001. In 2006, the company further expanded by acquiring Fresno Meats. Cargill also has a large international presence, with operations in 70 countries and partnerships across the supply chain, from small family farms to global shipping lanes.
In addition to its poultry business, Cargill is involved in various other industries. The company trades, purchases, and distributes agricultural commodities such as grain and palm oil, and is active in the energy, steel, and transport sectors. Cargill also has a financial services arm that manages financial risks in the commodity markets. The company has made significant investments in sustainable practices and reducing its environmental impact, while also working to increase food security and help farmers and food producers succeed.
Cargill's presence in the meat industry extends beyond poultry. The company's three main brands of beef are Circle T Beef, Valley Tradition, and Meadowland Farms. Cargill also has a history of partnering with leading experts in animal welfare, such as Dr. Temple Grandin, who has narrated a video tour of a Cargill beef processing plant.
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Frequently asked questions
The largest chicken processing plant in the US is the Tar Heel plant, located in North Carolina. It is owned by Smithfield Foods.
The Tar Heel plant has the capacity to process 1.25 million chickens per week.
The plant covers 973,000 square feet (90,000 square meters) and employs over 5,000 workers.
Tyson Foods is the largest poultry producer in the US, with a market share of approximately 25%.
