Boosting Machine Efficiency & Gizzard Yield at Mar-Jac Poultry (Jasper, AL)
Category: Consultation Services and Machine Maintenance
Case Study – Mar-Jac Poultry
About Mar-Jac Poultry
Mar-Jac Poultry, a fully integrated poultry production company, is headquartered in Gainesville, Georgia about 50 miles northeast of Atlanta. Established in 1954, Mar-Jac has consistently delivered high-quality poultry products and is a preferred supplier for the U.S. food service industry. With a global reach, Mar-Jac Poultry is known for its high standards and reliable production.
Learn more about Mar-Jac Poultry: https://www.marjacpoultryal.com
The Challenge
The Mar-Jac Poultry team at their Jasper, AL, facility, has over 60 years of experience in poultry processing. However, even seasoned operations face challenges. Mar-Jac encountered inefficiencies in gizzard yield due to machine misalignments and the wear on essential components, affecting both their production rates and yield quality. Recognizing the impact on their bottom line, Mar-Jac turned to DeLong’s for a solution that would boost efficiency and provide staff training for ongoing maintenance.
After conducting an in-depth inspection, DeLong’s team pinpointed the issues: worn-out parts and alignment inconsistencies affecting protein yield due to inaccurate cutting. Impressed with DeLong’s technical knowledge, Mar-Jac engaged DeLong’s team to optimize their machines and streamline processes.
The Partnership
In a highly collaborative partnership, DeLong’s teamed up with Mar-Jac to assess unique operational needs and implement tailored solutions focused on optimizing efficiency and maximizing gizzard yield. Earlier this year (2024), DeLong’s provided similar services to Mar-Jac’s Hattiesburg, MS location, building familiarity with Mar-Jac’s workflow and reinforcing confidence in delivering consistent value. This successful collaboration highlights both companies’ dedication to innovation and continuous improvement in the poultry industry.
DeLong’s inspection process generally includes thorough testing of all gizzard harvesters, de-fatters, manual repeel tables, eviscerators, and other essential processing units. Additionally, safety assessments are available upon request to mitigate potential hazards during equipment operation.
Learn more about DeLong’s Consulting Services: https://delongs.com/consulting/
The Solution(s)
To address Mar-Jac’s needs, DeLong’s implemented a two-pronged approach: equipment upgrades and comprehensive staff training.
1. Equipment Replacement and Realignment
DeLong’s provided replacement parts for critical components that had become misaligned over time, helping to improve processing power and increase protein yield. These improvements not only enhanced yield but also improved safety for the operators.
Learn more about DeLong’s Replacement Parts: https://delongs.com/products/
2. Staff Training
To ensure sustainable improvements, DeLong’s team provided comprehensive training for Mar-Jac supervisors and floor staff, focusing on optimal machine maintenance, adjustment techniques, and preventive measures. This cross-training helped staff become adept at identifying and correcting issues before they affected productivity.
To learn more about machine maintenance, check out DeLong’s Guide on Cross-Train on Machine Maintenance.
The Results
The impact was immediate. Mar-Jac reported significant improvements in both yield and processing speed, leading to less waste and more precise production. Moving forward, Mar-Jac expects to process an average of 168,000 birds daily with this optimized equipment.
The partnership yielded an impressive 70-82% improvement in yield within just 24 hours of implementing the necessary adjustments. Overall, the changes have helped improve the yield from 12 – 18%, according to Grimes.
In 2024, Mar-Jac ranked as the 15th largest broiler producer in the U.S., achieving an average weekly volume of 10.3 million pounds in broiler slaughter live weight. DeLong’s enhancements have been instrumental in supporting production at this scale.
Our Gizzard Harvest Went Up 12-18% Afterwards. Great Service And Price With Parts And Parts Rebuilds!
Looking Ahead
Following over four months of partnership and preparations for the holiday season, Mar-Jac has already observed notable advancements in efficiency.
DeLong’s remains dedicated to helping partners like Mar-Jac Poultry achieve operational excellence and safety, ensuring ongoing success across the poultry industry.
About DeLong’s Gizzard Equipment
DeLong’s Gizzard Equipment was founded in 1967 and is the leading global manufacturer of poultry processing equipment, specializing in precision-engineered rollers and solutions for poultry and gizzard processing. Known for their industry expertise, DeLong’s products meet or exceed industry standards for all major brands of processing equipment, making them the trusted choice in gizzard and poultry production.
Learn more about DeLong’s: https://delongs.com/