Background

Mountaire Farms is a rapidly growing leader in agricultural food processing, known for its high-volume fresh chicken products. Following a devastating grain explosion that destroyed existing receiving structures, Mountaire needed to rebuild and modernize its facility. WL Port-Land Systems Inc. was brought in to design and build the replacement infrastructure under a high-pressure, fast-track timeline to ensure the site was operational before the critical September grain season.

Recognizing the need for a world-class dust management solution to prevent future hazards, WL Port-Land reached out to Mideco to integrate Burnley® Baffles into the new site design.

Problem

The project centered on an existing 14’ x 18’ truck dump hopper that handles a variety of materials, including both dry and wet whole corn (14%–24% moisture) and soybeans (13%–20% moisture). The reconstruction presented several complex challenges:

• Safety & Compliance: Following the previous explosion, achieving 100% dust management was critical to mitigate combustible dust risks.
• Structural Integrity: Initial plans to retrofit the existing steel were scrapped after field inspections revealed the structure required a total replacement, further tightening the project schedule.
• Physical Constraints: The pit utilized three inclined 16” screw conveyors and 3”-deep grating bars. The new baffle system had to be custom-fitted to a new support structure while integrating with a locally sourced baghouse and dust collection hood.

Solution

Mideco provided a tailored Model 1 Burnley® Baffle system made of 1.6mm galvanized steel to withstand the abrasive nature of wet and dry grain.

To fit the new 4578mm x 4290mm intake area, Mideco designed a layout of 7 columns and a strategic mix of 49 components, comprising both full and half-baffles. This configuration ensured the entire surface area of the hopper was fully enclosed, even with the unique spacing of the new structural parts. The baffles trap the air displaced during unloading, preventing dust from escaping into the environment, as well as keep valuable product inside the hopper.

To help Mountaire achieve its 100% dust management goal, Mideco provided the minimum extraction volumes required for the local baghouse. This allowed the client to source a more efficient collector that works in synergy with the Burnley Baffles.

Result

Through proactive coordination with WL Port-Land, Mideco completed production in May 2022—well ahead of the September launch. The installation achieved an immediate 80% reduction in fugitive dust as a standalone system and served as the critical foundation for the site’s total dust containment strategy.

By restoring the facility with Burnley Baffles installed, Mountaire Farms enhanced site safety and effectively recovered valuable product that would have otherwise been lost, providing a cleaner, safer, and more profitable operation for the local grain season.

Is your facility undergoing a fast-track renovation or safety upgrade? Contact Mideco today for a custom-engineered solution.