Frimesa powers new pork processing plant with JBT Marel technology

Located in southern Brazil, Frimesa is the largest pork processing company in the state of Paraná, and also produces dairy and processed food products. Founded 45 years ago and exporting since 1988, the company has a mission to provide high-quality food, with collaboration and sustainable development guiding every step of production.

Now, in the largest expansion in its history, Frimesa has launched a state-of-the-art pork processing plant in Assis Chateaubriand. This greenfield facility is equipped with advanced automation, robotics, and software from JBT Marel—a leap forward in both productivity and precision.

The new plant introduces a highly automated operating model designed to increase capacity, improve yields, standardize cuts, and reduce repetitive tasks. At the same time, it maintains the highest standards of animal wellbeing and microbiological quality.

Scaling up with consistency and predictability

To keep pace with rising demand and expand its global presence, Frimesa needed to boost industrial capacity—without sacrificing the control and standardization that define its operations.

The new Assis Chateaubriand plant was built with that goal in mind: to reach 12,000 slaughters per day in the first phase, expanding to 15,000 in 2026 and 23,000 by 2032, positioning it among the largest pork processing plants in Latin America. From slaughter to dispatch, the entire process is fully automated.

Scaling up wasn’t the only priority. Frimesa also set out to meet shifting consumer preferences, as more people look for smaller portions and products tailored to modern lifestyles, such as those living alone or in smaller households.

As Elias explains, “Consumers are looking for individualized products. This demand is already a reality and requires lines capable of fully meeting those expectations.” Meeting these expectations requires greater precision, full traceability, and optimized yield across every step of the production line.

Automation as the growth driver

The partnership between Frimesa and JBT Marel goes back many years, with successful experiences in other cooperative units. This trusted relationship played an important role when choosing technology for the new project. “Our target was 1,000 heads per hour—and we identified JBT Marel as the supplier capable of meeting the project’s requirements,” explains Elias.

Following technical visits to plants in the US and Europe, Frimesa made full mechanization and automation a core priority. This meant connecting every stage of production, from slaughter to cutting and deboning, through real-time software to ensure consistency, speed, and control.

JBT Marel’s ability to deliver complete and highly precise lines, backed by strong technical service and proven performance, reinforced the choice in technology. Elias is pleased with the outcome: “JBT Marel delivered as promised, and today we’re already operating beyond the planned nominal capacity.”

Enhanced animal welfare and carcass quality

Implementing the CO2 Stunning System was a major step forward in the initial processing stage of the new facility. By replacing traditional electrical stunning, the technology delivers major improvements in both animal welfare and carcass quality.

According to Gerson Luiz Elsenbach, Frimesa’s Meat Division Manager, the new method has “virtually eliminated fractures and reduced PSE occurrence, ensuring a cleaner and more efficient operation.” PSE refers to pale, soft, exudative meat, a common texture and color issue linked to electrical stunning.

The system also enables vertical bleeding with a smaller area of intervention, which increases yield and creates a more attractive final product. Splattering, often seen with the previous method, has been eliminated too, resulting in a cleaner, more uniform presentation for consumers.

Beyond product quality, the new process improves ergonomics and safety for workers and reduces the need for strenuous, repetitive jobs that are hard to fill and prone to high turnover.

Contamination has also fallen sharply—abdominal opening now shows near-zero contamination compared to rates of up to 1% during manual processing.

According to Gerson, automation has transformed both outcomes and confidence. With the robots, he explains, “standardization has improved, we have more high-value meat, and fewer trimmings at the end of the line.”

Vertical deboning redefines productivity and ergonomics

The DeboFlex Primal Cut vertical cutting system has brought precision and consistency to primary cutting, especially in high-value areas like belly and ribs. It reduces rework, improves flow to deboning, and ensures uniformity across all parts.

According to Gerson, the system’s stability and control directly enhance results. “We’ve achieved a very precise standard in the primary cut, with clear gains in belly and ribs. That’s more money in the bank.”

DeboFlex has streamlined daily operations by maintaining a steady pace and supporting ergonomic movements. Gerson notes that the ease of operation has strengthened both performance and team wellbeing: employees learn quickly, hit daily targets with confidence, and work with less stress and greater morale.

Processing is faster, yields are higher, and less meat is wasted. Improved workflow also helps preserve meat temperature and microbiological quality.

AXIN Software connects the process with real-time data and traceability

AXIN, JBT Marel’s food processing software, connects every stage of production from slaughter to dispatch. By digitalizing the workflow, it gives Frimesa precise, real-time visibility of performance, allowing managers to spot yield deviations instantly and adjust as needed.

The software also supports rail-based carcass classification in the chilling rooms, helping allocate cuts more efficiently and improve line performance. With full traceability, each batch is linked to its producer of origin, supporting workforce planning and meeting international market requirements.

According to Gerson, AXIN Software “allows us to act on the root cause of issues and sustain growth with control,” reflecting how digitalization is now central to Frimesa’s long-term strategy.

Long-term partnership focused on continuous innovation

With the Assis Chateaubriand plant now fully operational, Frimesa is looking ahead. The cooperative plans to further increase automation, expand software implementation, and gradually incorporate artificial intelligence into future stages of production.

The goal is to double capacity and increase exports from 23% to 30% of their production by 2028, while preserving efficiency and quality. “Not long ago, it would have been unthinkable to see robots handling carcasses at high speed. Today it’s a reality—and just the first step,” notes Elias.

JBT Marel will continue to play a key role as Frimesa moves into its next phase of growth. The partnership extends across the slaughter, cutting, and deboning lines, all connected through software that supports greater consistency and export readiness. Built on trust and proven performance, the collaboration remains focused on long-term innovation.

As Elias explains, “Choosing JBT Marel was a natural decision, thanks to its proven technology and experience. We continue together—and the expansion already includes new technologies under development.”

About Frimesa

Frimesa is a central cooperative in Paraná, Brazil, formed by five member cooperatives (C.Vale, Copacol, Copagril, Lar, and Primato) operating in pork and dairy production, as well as in processed and derived food products.

It is one of the most robust and integrated pork production operations in Brazil, responsible for 7.8% of national pork production and around 25% of Paraná’s output. Recognized as the fourth-largest pork processor in the country and one of Brazil’s leading exporters, Frimesa operates five industrial plants in western Paraná: in Medianeira, Marechal Cândido Rondon, Santa Helena, São Miguel do Iguaçu, and Assis Chateaubriand.