Perdue Farms to dismantle Cofield feed mill after fatal explosion

USA –  Perdue Farms will dismantle its Cofield feed mill after a fatal February 21 explosion that killed one worker and injured two others, with the company determining the facility cannot be safely repaired.

The company said the decision followed consultations with engineers and independent experts, who concluded that structural damage to the mill was too severe to allow safe restoration. 

Dismantling is scheduled to begin on April 20 and is expected to take up to 12 weeks, with specialised contractors carrying out the work under controlled conditions.

While the cause of the explosion remains under investigation, such incidents in feed mills are often linked to combustible dust. 

Facilities handling grain, soybean meal, and other fine feed ingredients can accumulate dust particles that, when suspended in air under the right conditions, become highly explosive. 

A single ignition source, such as a spark from equipment, overheating machinery, or static electricity, can trigger a blast.

Feed mills are particularly vulnerable due to the combination of enclosed processing environments, continuous material handling, and the presence of flammable organic dust. 

Industry data show that dust explosions in grain and feed facilities, while relatively infrequent, tend to have severe consequences due to rapid pressure build-up and the potential for secondary explosions.

In the Cofield case, the explosion caused significant structural damage to the feed mill and disrupted nearby operations. 

Although grain receiving and oilseed crush facilities at the site were not directly affected, they remain temporarily shut due to their proximity to the damaged structure. 

Operations are expected to resume only once the site is deemed safe.

The company added that safety remains its top priority, both during the dismantling process and in ongoing site management. 

Crews will operate between 7 a.m. and 7 p.m., Monday through Saturday, with measures in place to control dust, reduce noise, and manage traffic. 

Fire suppression teams are also monitoring the site, particularly to address intermittent fires that have occurred beneath debris since the explosion.

“Our highest priority remains protecting those on site and supporting our associates and the surrounding Cofield community,” the company said.

The Cofield facility has been part of Perdue’s grain, oilseed, and feed operations since the 1970s, highlighting the long-standing role of such infrastructure in integrated livestock supply chains. 

The loss of the mill underscores the operational and supply risks posed by industrial accidents, particularly in regions where feed production is closely tied to the poultry and livestock sectors.

The incident also underscores the importance of preventive safety measures across the feed industry, including dust control systems, equipment maintenance, and monitoring technologies to reduce the risk of similar explosions.

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