In September 2025, Cargill Protein – North America made a bold operational decision: to temporarily shut down its Fort Morgan, CO beef harvest and cut facility for a full system overhaul. The goal? To improve safety, serviceability, and long-term sustainability of its ammonia refrigeration infrastructure—without compromising on budget or timeline.
A Complex Scope, Executed with Precision
Cargill contracted RC&S, a member of the IRPROS cooperative, to lead the project. The scope included:
- Safe evacuation of 185,000 pounds of ammonia with support from Airgas Ammonia Field Services
- Replacement of 86 critical valves, including LT and HT recirculators, pump valves, and make-up stations
- Upgrades to compressors, oil pumps, and coalescing elements
- Installation of new valve tags, insulation, and updated P&IDs
All of this was scheduled to be completed in just 10 days, from evacuation to system restart.
Challenges Met with Collaboration
Coordinating multiple subcontractors, managing a full facility shutdown, and executing around-the-clock shifts required intense planning and trust. Cargill’s confidence in RC&S and the IRPROS team was built on years of experience and a shared commitment to safety.
The project peaked with 59 professionals on-site, including construction crews, service techs, insulators, and scaffolders. Planning began in late 2024, with execution ramping up in September 2025 and full demobilization by October 17.
Budget Discipline and Operational Excellence
Using the COINS ERP system, RC&S tracked hours, materials, and expenses in real time. Leadership oversight ensured the project stayed on budget, with contributions from Chris Stacy, Joe Godberson, and PD Rosenbaum guiding financial and material coordination.
Impact Beyond the Facility
This shutdown wasn’t just about equipment—it was about people and community. By investing in safer, more serviceable systems, Cargill is reinforcing its commitment to worker safety, environmental responsibility, and long-term job support in Fort Morgan.
A Model for Future Projects
The success of this project highlights what’s possible when engineering, operations, and leadership align around a shared goal. It’s a blueprint for how industrial facilities can modernize safely, efficiently, and with purpose.
