Author: Staci Nichols – Chief Marketing Rebel

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Tyson Foods, a major player in the world protein market, relies almost exclusively on corn to feed its poultry and livestock. In fact, Tyson is the largest buyer of corn for animal feed in the US (Union of Concerned Scientists, 2022). Additionally, field corn, the kind Tyson buys, is one of the most heavily taxpayer-funded crops in the country, which shows that it encompasses some volatility. If Tyson were to diversify its supply chain to include alfalfa feed, which costs roughly the same as corn feed, and diversify its protein offerings to include plant protein, it would benefit US taxpayers, the planet, the animals, and decrease their reliance on one crop (World Wildlife Fund, 2022).

Feeding strictly corn to poultry and livestock, while it causes them to grow faster, is otherwise inefficient and unsustainable, creating several supply chain vulnerabilities (Navarré, Musto, & Nazareth, 2025). Chickens benefit from a varied diet that includes grass, while cows aren’t equipped to process corn at all. Tyson Food’s dependence on just a few centralized corn feed suppliers poses a serious supply chain risk and exposes them to price volatility, lack of substitutability, and supply shocks. If Tyson were to vary the feed given to their animals, such as by including alfalfa in their diets, this would reduce the amount of diseased animals and corn dependency.

Animal farming models typically exist on a spectrum between two extremes: highly concentrated, corn-fed feedlots and organic, free-range systems. Without disrupting their current facilities, Tyson Foods could offer a hybrid model where their animals remain concentrated in feedlots and CAFOs (Concentrated Animal Feeding Operations) but receive alfalfa half of the time or just at strategic times. By adding alfalfa to their animals’ diets, Tyson’s number of feed suppliers would grow, increasing their supply chain’s diversity and resilience, as well as a variety of other benefits.

Beyond resilience, another benefit of incorporating alfalfa into Tyson’s supply chain is the potential for reduced warehousing costs. Corn silos, for example, are expensive, high-tech buildings. Alfalfa, however, is typically stored in inexpensive pole structures with little more than a roof over the bales. It’s not uncommon for alfalfa to simply be covered with tarps, drastically reducing warehousing costs.

Tyson Foods could also reduce their grip on corn by diversifying the types of protein they sell. Adding additional plants as components further diversifies Tyson’s supply chain, reduces dependency on corn, and also eliminates much of the need for a reverse supply chain for food pathogen recalls. A shift away from animal protein towards plant protein would minimize the risks and costs associated with E. coli and Salmonella outbreaks. Beyond the cost of an E. coli recall itself, studies indicate that foodborne illnesses further burden food producers through fines, lawsuits, brand damage, and shareholder losses. One study showed a $109 million stock value loss within just five days of a serious recall (Pozo & Schroeder, 2016).

If Tyson Foods were to add a line of hybrid-meat products (50% meat, 50% plants), bringing in pea, grain, mushroom, or bean suppliers would add even more resilience to their supply chain. Other hybrid meat/plant protein products are already on the market: Applegate by Hormel, the Great Organic Blend Burger by Perdue Farms, and “Chicken Plus” Nuggets by the Blended Burger Project. Additionally, plant-based meats are still seen as premium foods, which can generally be sold at higher margins. However, in this case, hybrid animal-plant protein is a luxury good that would not appear to come with the usual increased logistical costs of top-shelf items.

Currently, Tyson Foods experiments with plant protein products under its boutique sub-brand Raised and Rooted. However, plant-based offerings under the Tyson name could be added at scale and still fit their down-home brand. For instance, Tyson could offer “Texas Chili Hamburgers” consisting of beef, chili beans, and chili seasoning or a hamburger that combines two barbeque favorites, baked beans and beef. A meat loaf patty featuring beans and grains might appeal to traditional Tyson customers. Tyson’s chicken nuggets could be infused with potatoes to create a hybrid “french fry nugget,” with onions for an “onion ring nugget,” or with jalapeños for the ultimate buffalo wing. By A/B split testing a variety of marketing campaigns, Tyson can determine if these hybrid animal/plant proteins appeal more as kid-friendly yet healthier school lunches or as fun fast food fusion, like a McRib or Crunchwrap.

Tyson Foods has been sued for making false claims about improving their supply chain’s sustainability (Animal Legal Defense Fund, 2024). For Tyson, modernizing their methods, products, and sourcing is as much about staying relevant as it is about phasing out an obsolete “one type of feed to make one type of protein” system. By adding alfalfa to their animals’ diets and diversifying their protein product line, Tyson can improve their sustainability, logistics, supply chain resilience, and rebuild consumer trust.

References

Animal Legal Defense Fund. (2024, September 18). Tyson Foods sued over deceptive “net-zero” and “climate-smart beef” claims. https://aldf.org/article/tyson-foods-sued-over-deceptive-net-zero-and-climate-smart-beef-claims/

Navarré, A., Musto, L., & Nazareth, T. (2025). Beyond meat substitution: A multifaceted review of plant-based and alternative proteins, from environmental impact to analytical technologies. Foods, 14(13), 2312. https://doi.org/10.3390/foods14132312

Pozo, V. F., & Schroeder, T. C. (2016). Evaluating the costs of meat and poultry recalls to food firms using stock returns. Food Policy, 59, 223–231. https://doi.org/10.1016/j.foodpol.2015.09.006

Union of Concerned Scientists. (2022, February 9). Tyson’s need for feed. https://www.ucsusa.org/resources/tysons-need-feed

World Wildlife Fund. (2022, October 25). As much as $2.6 billion of corn and soy never leaves US farms [Press release]. https://www.worldwildlife.org/press-releases/as-much-as-2-6-billion-of-corn-and-soy-never-leaves-us-farms