JBT Marel Enables Fully Integrated, Data-Driven Beef Processing

How Integrated Processing Systems Improve Efficiency at Zakrzewscy’s Beef Facility
Beef processors adopting smart production systems increasingly rely on integrated hardware, software and automated workflows to improve traceability, raw-material use and operational control. The Zakrzewscy Group’s purpose-built beef processing facility in Szczuczyn, operating since 2022, shows how a fully connected line can reshape daily production, workforce experience and sustainability outcomes.

Designed as a two-story, straight-line process from livestock arrival through slaughter, primary and secondary processing, the plant handles 58 head of cattle per hour and averages 50 tonnes of beef per nine-hour shift. High levels of automation were incorporated to support consistent output, improve ergonomics and enhance animal welfare. The location in the Mazury livestock region was chosen to minimize transport distance and reduce logistical pressures.

The Zakrzewscy family evaluated multiple technology partners before selecting JBT Marel to support long-term scalability. They prioritized environmental responsibility, reduced contamination risks, and the need for software and equipment that could evolve with future demands.




How End-to-End Traceability Strengthens Quality and Consumer Trust
Cattle are weighed and scanned upon arrival, with animal origin and feed history uploaded to JBT Marel Software to initiate a full-line traceability chain. Each meat portion receives a unique identifier linking batch, supplier, classification, operator, and production data. This enables precise auditability, faster inspections, transparent process documentation, and strong brand protection.

Traceability data supports rapid and targeted recall actions and simplifies labeling for both domestic and export requirements. Automated data collection across the line reduces errors and increases customer confidence, particularly in markets where transparency is essential.

Automation for Food Safety, Consistency and Production Control
The plant integrates automation throughout slaughter, chilling and cutting. Carcasses are transported overhead with minimal human handling, reducing cross-contamination risks. After evisceration and inspection, carcasses move through a pre-chill tunnel and into the chilled area via an automated system.

Primary cuts enter the StreamLine, which distributes work evenly across operators and provides on-screen instructions tailored to order specifications. This improves yield, reduces training time, and ensures consistent cutting quality. Real-time monitoring alerts operators to deviations in weight or quality, reinforcing robust food-safety practices.

Access to accurate, real-time data enables faster decisions on scheduling, production planning and resource allocation. The shift from historical reporting to live operational insight has accelerated corrective actions and improved strategic planning.




Workforce Retention Through Ergonomics and Safety
To address labor shortages and improve retention, all deboning, trimming and portioning stations feature adjustable ergonomic seating and clearly displayed task information. Employees benefit from transparent performance measurement and easier task comprehension.

Hand-wash and equipment-wash stations positioned near work areas improve hygiene, while enclosed walkways keep production zones isolated from office and visitor traffic. Staff facilities such as showers, a cafeteria and relaxation spaces contribute to a safer and more attractive work environment.

Maximizing Raw-Material Use and Reducing Overproduction
Tight margins in the beef industry require efficient raw-material utilization. Inventory management software allows production to align closely with orders, minimizing storage and preventing unnecessary stock buildup. Real-time updates delivered at each workstation improve communication and streamline cutting and packing decisions.

The system has contributed to fewer customer complaints and more accurate fulfillment of specifications. Cold storage now functions mainly as a logistics buffer rather than long-term inventory. Raw-material utilization has increased significantly, enabled by advanced planning tools and streamlined product flow.




Sustainability Embedded Into Facility Design
Environmental considerations guided every design stage, from water treatment systems that allow reuse for irrigation to solar panels that reduce reliance on fossil fuels. Automated equipment and optimized cooling systems from JBT Marel further reduce energy use and waste.

The family reports unexpected gains from integrating equipment and software throughout the operation, including simplified communication and fewer post-production analyses due to access to continuous, reliable data.

A Collaborative Approach to Digitizing Beef Production
The plant was developed through close cooperation between Zakrzewscy and JBT Marel, ensuring that software and equipment aligned with the facility’s long-term strategic goals. Joint floor evaluations shaped a digital setup tailored to real workflows, supporting rapid employee adoption and long-term operational resilience.

After three years of operation, the Zakrzewscy Group confirms that the facility’s integrated design, data-driven processes and automation have enabled higher productivity, improved safety, and a more sustainable approach to beef processing.

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