Mar-Jac Poultry

Primus is providing design-build-automate services for this 161,000 SF automated poultry processing expansion and modernization project for Mar-Jac Poultry in Gainesville, Georgia. The project is designed to increase production capacity, improve product flow, expand frozen storage capabilities, and support more efficient order fulfillment through advanced automation and cold storage technologies.

The expansion includes: 

• New VRT freezer
• Refrigeration room
• Controls room
• Shipping dock and shipping office
• Upgrades to four existing production lines 
• New production line

Conveyor systems were reconfigured to improve product flow and accommodate longer product queuing into and out of the VRT freezer, supporting higher throughput and operational efficiency.

A key component of the project is the integration of automated storage and material handling technologies. The facility includes:

• New ASRS freezer warehouse
• Conversion of a portion of the existing freezer to a high-density ASRS storage system with robotic layer picking
• Automated frozen stack-off area featuring robotic palletizing
• These solutions improve storage density, streamline order fulfillment, and reduce manual handling throughout the cold chain process.

When complete, the project will increase production capacity from 2.2 million chickens per week to 3.4 million chickens per week, representing a 65% increase in throughput. The expanded facility will provide Mar-Jac with the infrastructure needed to support continued growth while enhancing productivity, automation, and supply chain performance.