Zanchetta upholds high standards

Frangoeste Tietê: modernization and expansion

Although the Frangoeste Tietê facility, bought in 2021, had outdated infrastructure, Zanchetta saw potential and modernized the cut-up department, not only to automate but also to increase capacity. Previously, the plant could cut just 50–60% of its production and debone just 10% of the breast meat. Today, it achieves 100% cut-up and approximately 70% breast deboning. “We wanted the final product to match the standard of our Boituva facility. That means two cut-up lines for every primary processing line,” emphasizes Carlos Augusto Zanchetta, Operations Director. The new cut-up and deboning area features two ACM-NT lines, equipped with two ALPINE systems for anatomic leg processing, followed by two AMF-i HD breast deboning systems. With this setup, the Tietê facility is now prepared to produce up to 400 tons of finished products per day, reinforcing its strategic role in supplying the domestic retail market.

Advanced performance

Zanchetta Group’s main facility in Boituva handles an average daily output of 900 tons of finished products, serving both the domestic market and exports to over 50 countries. The product mix consists of approximately 85% chicken pieces and 15% whole chickens, either fresh or frozen. This performance is made possible by advanced JBT Marel solutions implemented across two primary processing lines that cover all stages — from stunning to evisceration. The cut-up department includes four ACM-NT lines, fitted with three WingMaster modules for wing processing and five AMF-i HD systems dedicated to breast deboning, ensuring large-scale efficiency, consistency, and quality.

Maximize results with WingMaster

The addition of three new WingMaster systems from JBT Marel in Boituva has further enhanced the performance of the ACM-NT lines, supporting Zanchetta’s strategy to meet export demands with excellence. This upgrade allows the company to optimize performance year-round, despite seasonal price variations in chicken wings. “The decision to invest in the new wing cutter was driven by export market requirements. Wings are seasonal products — they’re more valuable in summer and less in winter. With a plant prepared for all scenarios, we can maximize results continuously,” says Carlos Augusto Zanchetta.

Partnership with JBT Marel

Zanchetta’s collaboration with JBT Marel began in 2007 with the installation of their first line. Since then, the JBT Marel team has maintained a constant presence, providing regular maintenance and support for new projects. “Both our teams understand each other’s way of working. We’ve never had issues. Whether it be line changes, plant expansions or new machine installations, we’ve always started and completed projects on time. There’s a strong level of trust between JBT Marel and Zanchetta. Having JBT Marel’s support team close to our operations makes a big difference. We can always count on JBT Marel’s support,” affirms Carlos Augusto Zanchetta.

A culture of pioneers

JBT Marel’s innovative solutions have positioned Zanchetta as a pioneer in adopting cutting-edge technologies in Brazil. “It’s part of our culture: any investment must be planned for the long term, ideally 30 years, without the need for major remodeling. This is how we operate daily. Often, we build larger structures than needed to allow future expansion without disruption or improvised additions,” explains Carlos Augusto Zanchetta. “That’s how we think: we look for the most advanced and efficient solutions on the market, evaluate whether they fit our budget and objectives, and carefully assess cost versus return. If the investment pays off over time—even if it’s substantial—we go for it. This culture is key,” he adds.

Commitment to innovation

This mindset led Zanchetta to become the first company in Brazil to adopt groundbreaking JBT Marel solutions such as the AMF-i HD, and more recently, the WingMaster and ALPINE systems, reaffirming the group’s commitment to innovation, efficiency, and production excellence. Ruud Berkers, Regional Sales Director Poultry for JBT Marel in Latin America, says, “Zanchetta has a solid culture of investing in cutting-edge technology. There is a true commitment to innovation. Our partnership is very strong, and it’s a great pleasure to work alongside the Zanchetta team.”