Central Bernard boosts throughput with Marel solutions

Les Viandes Central Bernard, a Montreal-based poultry processor, uses Marel’s StreamLine and AXIN software solutions to achieve real-time monitoring and labor continuity, leading to higher throughput and more predictable production. During Marel’s Software Knowhow event in Orlando, Florida, in October 2024, Danny Sedra, VP of Operations, discussed the challenges Central Bernard encountered, and explained how things have improved since the implementation.

Addressing challenges
As a prominent player in the North American poultry processing industry, Les Viandes Central Bernard faced significant challenges in market competition and operational production optimization. The company encountered issues with productivity and workforce reliability. “We struggled with consistency and throughput, especially with employee attendance being unpredictable from one day to the next,” explains Danny Sedra. In search of a solution, Central Bernard partnered with Marel and implemented the StreamLine system along with AXIN software in the deboning department. “We operate a 50,000-square-foot facility. Our throughput on finished product is about 80,000 to 100,000 kilograms per day and we employ a team of about 150 people. About three years ago, we took on this project to improve our processes. After that, together with Marel, we conceptualized the project. We installed two StreamLines with 20 stations each and implemented Marel’s AXIN software.”

Dramatic improvements
In addition to attendance issues, Central Bernard had to deal with significant variations in product size. “We looked at various options, and StreamLine offered the flexibility we needed to handle different product sizes without sacrificing yield.”

With StreamLine’s intelligent deboning and trimming line and AXIN’s real-time data capabilities, Central Bernard has seen dramatic improvements. "Since adopting StreamLine and AXIN, we've boosted our throughput, improved productivity, and ensured more stable attendance," Sedra notes. This upgrade allowed the company to plan more effectively, meet customer demands consistently, and reduce the need for outsourcing labor, all while boosting overall performance.

Transforming workforce engagement and productivity
Before integrating StreamLine and AXIN, Central Bernard’s deboning operators worked as a team and received shared production-based remuneration, despite uneven productivity. With StreamLine and AXIN, Central Bernard can now monitor individual productivity and pay employees based on their performance. “Now, employees see that they work for their own remuneration. They’re motivated, incentivized, and have taken ownership of their throughput.” This shift in mindset has increased engagement and raised wages, as employees now produce more and earn more.




From conservative to aggressive
Danny Sedra continues, “Before our project with Marel, we had difficulties planning daily production capacities. We didn't know on any given day how many deboners would be at work, and we could never predict the speed of their work, which made it difficult to commit to accepting orders. As a result, we adopted a very conservative approach in that regard and had to outsource our deboning capacity or buy in product to compensate, which costs money. When customers asked us, ‘We need these products in any given week,’ we couldn't do that.

But now that we've gotten consistent throughput, it really facilitates planning. We're able to calculate how much we can produce each day, and that's because the overall rate of production is very consistent. So we've adopted a more aggressive approach to order-taking. We commit to higher volumes and even look for more. In the end, the StreamLines have given us more capacity in the same square footage with the same labor force. They have certainly improved our business performance."

Better data for smarter decisions
The introduction of AXIN software has given Central Bernard real-time insight into productivity and yield. “Before StreamLine and AXIN, we had a reactive approach—too little, too late in terms of visibility,” Danny Sedra explains. “Now, we have live data sharing through dashboards that display KPIs, performance lights, and automated daily reporting.” With this data-driven approach, Central Bernard provides employees with a leaderboard showing individual yields, encouraging healthy competition and accountability. “When we started, the gap between the best and worst yields was 12-15%. "Now, we’ve compressed that to between 4-5%,” says Danny Sedra, crediting this improvement to the feedback and insights enabled by AXIN.

Futureproofing
With the consistent throughput and productivity gains provided by StreamLine and AXIN, Central Bernard is well-positioned to expand operations and take on higher order volumes. Danny Sedra states, “It allows us to futureproof our operation for the next generation, making us more competitive and resilient in the marketplace.”

A partnership built on trust
Central Bernard’s success with the StreamLine and AXIN solutions has been supported by Marel’s responsive and knowledgeable team. “Our Marel sales representative, David Lamontagne, has been there with us from the beginning and has been instrumental in our success,” Danny Sedra concludes. “When there’s an issue, we can easily call him, and he’s always there to help us out. It’s like a true partnership.”

With Marel’s support and technology, Central Bernard has positioned itself to continue providing high-quality, value-added poultry products while building on its legacy of innovation and excellence.