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Representative illustration: A vertically integrated turkey processor tried to 'buy its way to profitability', and overhead ate the gains.

Case Study · Food & Beverage

A vertically integrated turkey processor tried to 'buy its way to profitability', and overhead ate the gains.

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1Challenge

Rising costs and competition led to heavy automation investment, but higher overhead eroded the gains.

2Approach

  • Tackled waste and variation behind downtime and lower yield
  • Improved workstation layouts and material flow
  • Closed maintenance gaps and trained yield-critical positions

3Results

$100M

Financial impact across all plants

1.4% | 15%

Fresh plant: yield | labor $/lb

6.1% | 34%

Cook plant: yield | labor $/lb

$8.1M at the pilot complex alone, with no new capital.

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© USC Consulting Group 2026 | Food & Beverage. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.