Beyond expectations: Morgan Beef’s journey with Marel software

Managing inventory in a large-scale meat processing operation is no small feat. Can you describe how Marel’s software has transformed your inventory processes?

“The most significant contribution from Marel’s software has been its capability to provide us with control over our stock. Previously, we had a hard time controlling the inventory, with a lot of loopholes. Secondly, we can now see real-time inventory holdings at all times, which is a game-changer for us, replacing stock counts at a specific time, which were only valid until our next transaction. A third benefit is that the software has enabled us to reduce our downtime. Previously, we were used to software-related downtime for days. This has come to a definite end, which is a massive gain for us.”

Efficient packing processes are crucial for any meat processor. How has Marel’s software enhanced the efficiency of your packing process?

“Marel’s software infrastructure is great to build upon with other components. It doesn’t restrict its application to pure Marel equipment. This opened up doors for us to work with different packaging options, different packaging SKUs etc. Our previous software would have had great difficulties making changes, such as adding extra label information. With Marel’s software, this was in production the very next day.

In terms of traceability, the software replacement was also a game changer. An FSSC 22000 audit has become a painless, effortless process thanks to the one-click, one-report output. Auditors were very impressed both with the speed and the quality of the report.”

Waste reduction is a significant concern in food processing. How has Marel’s software helped in reducing waste at Morgan Beef?

“The largest waste reduction is to see our inventory real-time. With Marel software, we are completely aware, even in our very large facility, of the production dates and expiry dates of all our products. Now, we can give our sales team a timely directive to sell that part of the inventory before it expires. This saves us a lot of wasted food.”

Order management can often be complex and error-prone. How has Marel’s software improved your order management process?

“The biggest improvement is the insight into the orders for everyone. We can now ensure that different salespeople don’t sell the same product to different customers. We can even sell the order to the customer who offers the best price. This is especially valuable for products that are scarce and in higher demand. Now that Marel software gives such good insight, we can manage what products are being sold to which customer. We can specifically target customers for particular kinds of products, so that they will always only get what they want, which reduces returns considerably.”  

Automation is often the key to efficiency. How has Marel’s software facilitated automation at Morgan Beef?

“The software from Marel has significantly improved control over integration compared to our previous software, addressing glitches and reducing problem-solving time, with ERP integration, for example. It focuses solely on being a stock system, combining with the ERP system when needed, but separate from the financial ERP tools. This approach minimizes discrepancies between systems and streamlines problem-solving.
The reliability and user-friendliness of Marel’s software integration have proven superior, eliminating the need for constant troubleshooting. Overall, our team prefers it for its intuitive operation and seamless integration.”

Beyond operational efficiency, what other advantages has Marel’s software brought to Morgan Beef?

“We’ve built a whole reporting framework on top of Marel’s software, giving the management team a detailed overview and the ability to drill down to specific transactions. The system offers insight into profit or losses from the point of order placement. The live reporting system has replaced the need for two dedicated people compiling daily reports and spreadsheets, providing real-time insights for everyone involved.

As for data security, the transition to Marel software has successfully resolved previous vulnerabilities. It provides comprehensive security features, addressing issues such as fake invoice creation and unauthorized access. The system ensures traceability of user transactions with individual logins for scales and computers, offering enhanced control and accountability. Unlike the old system with shared credentials, Marel software enables specific role assignments, limiting access to restricted data. This enhanced software security framework has proven invaluable in safeguarding business transactions.”

Effective support is crucial during any software implementation. How has the support from Marel been during this process?

“The support from the Marel team has been exceptional. Implementations inevitably come with challenges, and given that their helpdesk operates 24/7, Marel’s staff was constantly available, day or night, to promptly address and resolve any emerging issues.

Whether addressing our change requests or system modifications, the Marel team always demonstrated flexibility and responsiveness. They ensured the results aligned with our requirements, even when we asked for additional features or custom programming. Any issue was promptly addressed, so we never had to deal with line stops due to the software.”

The Covid-19 pandemic posed many challenges. How did Marel handle the implementation process during this difficult time?

“Despite challenges posed by the Covid-19 pandemic, the software implementation was successfully completed remotely over nine months. We had daily Teams meetings, in which the Marel team showcased remarkable support and ingenuity. Many great ideas emerged from the meetings and extensive testing was done remotely. The rapid changeover, from development to launch, marked a record time. After Covid restrictions were lifted, the Marel team was immediately on-site to address all floor-related issues. Within two weeks they implemented the software. It was a brilliant effort of the Marel team.”

Company website: morganbeef.co.za