Three years of advanced operations at Zakrzewscy beef processing plant

From the beginning 

The Szczuczyn production plant is a purpose-built beef processing facility in the Mazury region of Poland, which utilizes automation and innovation to meet the changing demands of the industry. The facility currently processes 58 head of cattle per hour, with an average production rate on the beef cutting line of 50 tonnes per nine-hour shift.  

The two-story, 300-meter-long building is designed to allow a straight-line production flow from the unloading of livestock and slaughter on the ground floor, to primary and secondary processing and dispatch of end-product on the second floor. “We took maximum benefit from automation in this factory. It makes better working conditions for our employees and improves animal welfare,” said Dariusz Zakrzewski, Owner. 

When building their future-ready processing facility, the Zakrzewscy family considered every aspect of the development through the lens of their company values: environmental care and sustainability, high product quality, and social responsibility. They thought carefully about where to build their new processing line, choosing the Mazury region, a high-density livestock area of Poland, to reduce transport distances for animals and combat infrastructure challenges. They considered how the two-story architectural layout and high levels of automation would work together to minimize cross-contamination risks. And they went looking for a technology partner that could support their ambitions and grow with them in the future. “We considered various systems and suppliers, but JBT Marel best suited our needs. They offer comprehensive, scalable systems that can be flexibly developed as the plant’s needs grow. Another huge added value was the fact that it's an international organization with local service and implementation facilities in Poland,” said Paweł Zakrzewski, Board Member, Zakrzewscy Group.

Traceability = brand reputation and audit simplicity

Cattle arrive on site and are offloaded into a purpose-built, external enclosure designed to reduce stress. As each animal enters via a set of runways, they are weighed, and their ear tags are scanned. Data, including animal origin and feed history, is uploaded via JBT Marel Software and full-line traceability commences. 

"Each piece of meat is assigned a unique identifier linked to the batch, supplier, animal class, production date, and operator. Such detailed data not only facilitates audits and compliance with veterinary and quality inspection requirements, but also increases the trust of our customers – especially foreign contractors, for whom process transparency is a key condition for cooperation,” said Paweł Zakrzewski. 

Integrated, full line traceability system helps protect the Zakrzewscy brand reputation. Building customer and consumer trust in both food safety and quality. The system automatically collects and collates data as raw material moves through the production stages. The data is easily accessible, enabling quick searches of all products by batches, production line, or production date to be carried out if and when needed. This accuracy and speed means product recall procedures are fast and specific. Minimizing food safety incidents and facilitating cooperation with regulatory bodies. “Traceability is a fundamental tool for maintaining our reputation – it allows us to document the origin and parameters of a product, which is important not only in the context of audits, but also in terms of end customer expectations. Thanks to the transparency of our processes, we gain a competitive advantage and strengthen our position as a reliable business partner,” said Paweł Zakrzewski.

Traceability data not only helps track products recall; it also simplifies labeling for domestic and international orders. Detailed, accurate information can be automatically printed on end-product labels to meet regulatory requirements and customer preferences. “It’s not just export regulations that are getting stricter. Food safety is important locally as well. JBT Marel Software has made getting the best product to our customers easier,” Paweł Zakrzewski.

The system also supports quality control by automatically analyzing product weight, quality, and classification, using predefined parameters. If any deviations are detected, operators receive immediate notification, which enables quick and efficient intervention. Removing raw material that does not meet requirements from production boosting product safety, providing real support for the quality control department, and facilitating audit documentation.

“Access to true and up-to-date information is crucial. Thanks to the use of systems, we have this information here and now. We know what is happening at the plant, what is being produced, what has been produced, what will be produced, and this significantly speeds up the decision-making process.” Paweł Zakrzewski.

Improving workplace experience 

Each of the four deboning stations, 20 trimming and portioning stations, and eight final trim stations in the production plant in Szczuczyn are equipped with ergonomic seating, adjustable to suit the needs of employees. “It has increased work comfort, as well as a sense of control and understanding of one's own tasks. For many employees, it is also important that their performance is measured in a fair and transparent manner,” said Paweł Zakrzewski. 

Understanding the importance and difficulty of retaining a skilled workforce, Meat Plant “ZAKRZEWSCY“ (PL: Zakłady Mięsne Zakrzewscy) ensured all areas of the facility were built with a focus on workplace health and safety. Operators can wash their hands and equipment between each carcass with ease as hand and equipment wash stations are situated close to each workstation. Enclosed walkways ensure processing areas remain uncontaminated by office staff and visitors to the site. While staff have access to showers, a dedicated cafeteria and relaxation area. “Labor shortages aren’t going away,” said Dariusz Zakrzewski, “We wanted to build a workplace where the employees we have wanted to stay.”

Raw material utilization

Meat processors are feeling pressure from multiple sides, squeezing margins tighter and tighter. Due to increased margin pressure, beef has become a more expensive product for consumers. However, market trends also show consumers’ willingness to spend on premium products. The production plant in Szczuczyn operates utilizing inventory management software which allows them to plan production based on customer orders, optimize cutting and packaging processes. Thus, minimizing finished product being stored as inventory. On the floor, this translates to real-time monitoring and efficient communication with employees. “We can see today's production report on an ongoing basis. The system changes it on its own, and the employees immediately get the information; there’s a computer at each workstation. Thanks to this, we are very efficient and save a lot on the goal product.” Mateusz Marmola, Plant Manager, explained. Paweł Zakrzewski elaborated further, “There’s been a significant decrease in the number of complaints. Mainly due to the elimination of products that did not meet customer specifications at the sorting stage.”

Ongoing monitoring ensures that any product that is inventoried is used to maximize shelf life and quality. “We have almost completely eliminated overproduction, and our cold stores function more as a logistics buffer than a place to store inventory.” said , Paweł Zakrzewski. “We’ve increased raw material utilization to a level that was previously impossible to achieve without the support of advanced JBT Marel Software tools.”

Driving sustainable business practices

In their latest beef processing facility, the Zakrzewscy family prioritized reducing environmental impact at every design stage, from water treatment which allows water to be reused for irrigation, to solar panels that reduce fossil fuel reliance, and JBT Marel solutions which reduce energy use and waste. “Sustainability is one of our core goals as a company,” said Dariusz Zakrzewski, “the slaughtering and processing lines, and cooling solutions from JBT Marel help us meet this goal.”

While the Zakrzewscy family have long embraced the latest technology in their beef processing, even they were surprised by some of the unexpected outcomes of implementing integrated equipment and software to the complete production facility.

Three years after opening the production plant in Szczuczyn they’re still happy with the result. And not just on the production floor. “We’ve transformed our approach from one based on historical data to one based on real-time operations. Thanks to JBT Marel Software, we gained access to reliable data not only from the production floor, but also from a strategic perspective, which enables better investment, planning, and organizational decisions. It is also an important step towards full digitization, which in our opinion is not only a trend but a market necessity,” said Paweł Zakrzewski.

Collaboration is the key to quality results

A collaborative approach shaped the development and implementation of the Zakłady Mięsne Zakrzewscy facility,to result in a plant that ensures full traceability, better raw material utilization, and the real-time visibility needed to run efficiently.

When designing the software, the collaboration of both companies helped to define how digital tools could support the Zakrzewscy’s long-term strategy. As JBT Marel Software Sales Manager, Marek Rzepiński explains, the process was highly collaborative.

Improving workplace experience

“Every new plant comes with its own ambitions and challenges, and Zakrzewscy was very clear about where they wanted to go. From the start, our work together was very hands-on,” said Rzepiński. “We spent a lot of time on the floor, looking at real processes, understanding their goals, and shaping a software setup that truly fits the way they wanted the new plant to run. Projects like this work best when there’s trust and openness on both sides — and that’s exactly what we have. It’s been great to see how quickly the team embraced the system and how it’s already supporting their daily decisions. When we combine our experience with the customer’s day-to-day insights, we can build solutions that genuinely make a difference.”

Dariusz Zakrzewski couldn’t be happier with the Zakład Produkcyjny w Szczuczynie facility, “JBT Marel has worked with us every step. Not only in designing and building but the after-service they provide. We really feel like we’ve made something for the future.”

JBT Marel and the Zakrzewscy family share the common goal of creating a more sustainable meat industry by using innovative and integrated hardware, software and service technology to optimize yields, improve health and safety, and maintain high quality. We can’t wait to continue being their technology partner of choice long into the future. Together we are transforming the future of meat processing.

About Zakrzewscy Group

Zakrzewscy Group began its journey in 1994 with the establishment of its first company, Zakłady Mięsne Zakrzewscy. What started as a family-owned meat processing business has grown into one of Poland’s leading producers of pork and beef, serving customers across Europe and worldwide.

Today, the group employs over 1,200 people and operates through several specialized companies that complement each other to deliver a comprehensive range of products and services: 

• Zakłady Mięsne Zakrzewscy – the flagship company, focused on high-quality pork and beef processing for domestic and international markets.
• Zakłady Mięsne Stanisławów – specialising in traditional Polish meat products and cold cuts, combining authentic recipes with modern standards.
• Fento – providing innovative solutions for meat processing and packaging, supporting efficiency and sustainability across the supply chain.
• Wimax Artis – offering advanced freezing and storage services, with a daily freezing capacity of 120 tonnes and storage for 15,500 tonnes, ensuring optimal preservation and food safety through HACCP-certified processes.

The group’s success is built on a commitment to tradition, quality, and trust, while embracing innovation and technology to meet the evolving demands of the global meat industry. By integrating advanced processing systems, digital solutions, and sustainable practices, Zakrzewscy Group continues to strengthen its position as a reliable partner for retail, foodservice, and export markets.