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A Q&A with Lexy Shut of the Appalachian Producers Cooperative, who says the brand new facility has dramatically decreased processing wait occasions and will revive the realm’s native meat financial system.
By Isaac Wood
November 17, 2025
Flooring Lead Bart Harris (left) and High quality Assurance Coordinator Sage Rock trimming beef on the new farmer-owned Appalachian Producers Cooperative, in Telford, Tennessee. (Photograph credit score: Lexy Shut)
Farmland makes up half the full acreage in Washington County, Tennessee. However this rolling panorama within the foothills of the Appalachian Mountains doesn’t enable for straightforward planting or plowing, so elevating cattle—notably beef cattle—is widespread for farmers.
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Till lately, although, a dearth of high-quality native meat processors made cattle a pricey endeavor. The three small-scale processing facilities in close by Greene County lacked the capability for the amount of meat produced, and cattle farmers typically needed to wait greater than a yr for his or her animals to be processed. Consequently, many farmers offered their calves into commodity markets, which meant they shipped the animals to the Midwest for processing, after which the meat was despatched again to East Tennessee to be offered retail. All that transportation lower into farmers’ income.
In 2021, a gaggle of leaders within the East Tennessee agriculture group determined that Washington County would profit from a brand new meat-processing facility. The group managed to safe $10 million in native, state, and federal funds and opened the Appalachian Producers Cooperative (APC) facility in June 2025.
Lexy Shut, the executive supervisor at UPC. (Photograph credit score: Isaac Wooden)
The brand new slaughterhouse is the primary farmer-owned cooperative to be established within the state in additional than 50 years. It has already doubled the area’s USDA-approved processing capability. For the APC’s farmer-members, processing now not takes months; there may be at the moment zero wait time, and the entire course of takes simply two to 4 weeks.
To be a co-op member, farmers must be acknowledged by the IRS as a farm (which suggests incomes a minimum of $1,000 per yr) and, yearly, each pay a $50 charge and course of one head of beef or the load equal in different livestock. When the power is worthwhile, members will share these income based mostly how a lot they’ve used the power.
Lexy Shut has been engaged on this venture because it began in 2021. She wrote grants for it as a part of her position with the Appalachian Sources Conservation & Growth Council and began full time as the executive supervisor on the APC in August 2025. Shut recognizes the state wants a lot multiple facility in a single county, however sees APC as a superb step in the proper path. “We’re hoping that [it’s] serving to to construct a extra vibrant and worthwhile agricultural sector,” she stated.
In a dialog with Civil Eats, Shut mentioned how the co-op’s leaders overcame the challenges they confronted in getting the power constructed, their targets for the long run, and why they really feel the venture is a vital endeavor.
As is the case in a lot of the U.S., there’s a scarcity of small-scale meat processors in Appalachia. What share of cattle in Tennessee have been processed domestically earlier than the co-op opened?
There was three meat processors in Washington County again within the day, like 50 years in the past. Then there was none for many years, and now there’s us. Now, solely 6 p.c of the animals you see simply driving round [throughout Tennessee] are processed domestically. The opposite 94 p.c are [born here and] being despatched off to the Midwest. Within the newest agricultural census, there’s most likely about 400,000 cattle inside a two-hour radius of this facility in my county-by-county counting.
How does non-local processing have an effect on farmers?
Traditionally, many of the farmers listed below are what are known as cow-calf operations. The calves are with the moms till they’re about 600 kilos. They’re typically offered to the subsequent step within the chain, that are “backgrounders,” and people of us are taking these weaned calves and bringing them to 900 kilos. Then they’re promoting them [to processors in the Midwest]. Loads of native farmers are both cow-calf, or they’re backgrounders.
There’s often 1000’s of {dollars} of distinction between what they’re getting for that calf and the worth of that completed meat, lower and despatched to a grocery retailer. The aim was to chop out that intermediary.
Are you able to describe what the Appalachian Producers Cooperative consists of and the way it’s staffed? Additionally, what does the APC course of appear like for farmers?
It’s a 16,000-square-foot facility with tremendous state-of-the-art gear, and we provide customized—which is non-USDA-inspected—and in addition USDA-inspected slaughter and processing. There are a whole lot of labor-saving, high-powered, costly machines right here. On the kill ground, we now have hydraulic lifts so of us aren’t having to bend and raise. It’s nonetheless laborious work, nevertheless it’s loads much less strenuous.
We’ve a common supervisor. We’ve a manufacturing supervisor. There are 4 or 5 administrative and advertising of us. At full capability, we’ll most likely have 20 to 24 folks on the ground working full-time—we’re ramping up there. There’s not an abundance of expert labor—meat processing labor—simply laying round. We most likely have a couple of dozen of us proper now that we’re coaching up.
Farmers deliver the animal in, often the afternoon earlier than, so it has time to settle in. Then it goes by the power. It’d cling for per week or two [on a hook in a cold environment, to develop flavor]. Then it’s lower up, packaged, frozen, and accessible for pickup.
What number of animals are you at the moment processing every week, and what’s your hope for the long run?
We’re as much as 25 head per week, and we need to get, hopefully in January, as much as 40 head per week. The power is sized such that we may very well be processing 125 head per week, round 6,000 a yr. We hope to serve, after we’re at scale, between 200 and 500 farms a yr.
We’re attempting to work with some bigger producers—of us which might be promoting to greater nationwide grocery retailer chains. These chains require third-party food-safety audits. As soon as we’re licensed for a kind of audits, then we’ll be capable to get in of us which might be doing 20 or extra head per week.
The aim is to have some mixture of each this fee-for-service processing for farmers and in addition to be shopping for [from farmers] and processing our personal underneath our personal model.
Rudy Rodriguez, APC manufacturing supervisor, with freshly lower ribeyes. (Photograph credit score: Lexy Shut)
How will APC profit farmers as soon as it’s totally up and operating?
We’re in a position to produce a very high-quality product, and we now have entry to actually high-quality packaging choices. Hopefully having a very engaging product opens up extra markets and extra prospects for them.
Tennessee is likely one of the top states on this nation for farmland loss. There’s simply so many housing developments going up on farms, and all that topsoil is getting scraped away. That agricultural land is misplaced ceaselessly when that occurs.
We are attempting to assist help a rise in farm incomes. We’re providing high-quality processing, the place farmers are in a position to flip round and hopefully make more cash off of promoting their meat.
What made you need to open as a cooperative? What was the method for securing funding for the power?
There wasn’t sufficient revenue in meat processing to be engaging to a non-public investor or a single donor. However there was nonetheless an enormous want throughout the agricultural group for a brand new meat processing plant.
Loads of farmers, particularly the bigger ones doing beef cattle manufacturing, are members of the Washington County Farmers Co-op—the feed-and-seed retailer. They’ve already been collaborating on this cooperative construction. It wasn’t too far of an concept to then say, “We’re gonna function this as a producer-run co-op.”
We fashioned the cooperative in 2021, however there had been of us engaged on this venture since about 2017, and so they had truly labored with UT [University of Tennessee] Extension to get a feasibility research completed on the prices and the advantages of placing in a brand new meat processor in Washington County. The truth that we had that readily available actually put us in line to get a whole lot of grant funding.
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Throughout COVID and post-COVID, there was an enormous influx of money from the American Rescue Plan—it was like over a billion {dollars} focused only for new meat processing capability, as a result of it wasn’t simply right here that folks have been backed up. It was an enormous bottleneck all over the place on native meat processing.
Between a bunch of various federal and state packages, I feel we acquired about $6.5 million {dollars}, which allowed us to get some non-public loans for the rest.
Washington County invested a few of their sources, so there was native, too. It was an enormous deal to provide you with $10 million {dollars}. And folks have been actually excited that this was taking place and are actually pleased with what we’ve completed.
What are your hopes for the power? What would you want issues to appear like 10 years from now?
Personally, I need to see this fast lack of agricultural land decelerate. Not solely as a result of I feel there’s worth simply in that land being open, but in addition as a result of that’s land that we will use to supply our personal meals. If we as a nation aren’t satisfying most, if not all, of our meals wants, then we’re susceptible. We noticed that in COVID when provide chains collapsed.
So for me, it’s re-localizing meals. We used to feed ourselves. Within the ’50s, ’60s, ’70s, there was a whole lot of this processing infrastructure—not only for meat, however for dairy, grain, greens. In 1980, there have been like 100 working dairies in Washington County, and if there’s nonetheless two left at the moment, I’d be stunned. In 2009, the final native milk processing plant closed in Kingsport. It was the final one. That led to the collapse of the dairy farm trade in East Tennessee. We’re hoping that [the new processing facility is] serving to to construct a extra vibrant and worthwhile agricultural sector.
After I was writing these grants, it was actually pitched as a generational funding in our agriculture. My dream is, in 10 years we’re nonetheless right here—we’re nonetheless serving farmers, we’re nonetheless serving customers. We’re making it worthwhile for native farmers, for younger farmers, for brand spanking new farmers to develop meals for this area.
This interview has been edited for size and readability.
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Isaac Wooden is a author and podcast producer based mostly in East Tennessee. He was an inaugural member of the Christianity At the moment Younger Storytellers Fellowship and has reported for Christianity At the moment, Ministry Watch, and 100 Days in Appalachia. Read more >
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