Story Studio – Zajac Liquid Process Systems

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Zajac, LLC is a woman-owned company that provides turnkey solutions for clients in the Brewery, Dairy, Food, Beverage, Personal Care, and Pharmaceutical industries. The company was founded in 1975 by Bill and Sandy Zajac and has been providing top-notch services for over 40 years. In 2011, Laura Zajac took over as the president, which not only makes the company woman-owned, but woman-run. Zajac employs over 100 experienced specialists in designing, fabricating, and installing liquid process equipment. All of Zajac’s labor resources, including engineering, design, fabrication, automation, electrical, installation, and packaging, are in-house. The teams work together to deliver high-quality solutions to their clients. Zajac is a one-stop shop for clients who are looking for a reliable and efficient solution to their processing needs.

“Zajac has been doing essentially all of our process and control work here at the brewery for the last ten years. Their quality and professionalism have been phenomenal, and I really feel like they care about the final quality of our beer just as do all of our employees here at the brewery.”

-Rob Todd, Owner at Allagash Brewing Company

Brewery – Zajac has been an integral part of the craft brewery industry, providing innovative solutions to help small New England breweries grow into successful companies. Zajac specializes in designing, engineering, and integrating high-quality heating, cooling, and packaging systems and installing new brewhouses. Beer Packaging trends are constantly evolving. Brewers can now offer their products in smaller bottles, cans, variety packs, or personalized packaging. Zajac can be a valuable partner to help breweries identify and integrate the equipment required to meet their needs. While utility systems may not be the most glamorous aspect of brewing, they play a crucial role in ensuring a consistently high-quality product. One of the biggest issues faced by breweries is under-sizing utility systems. Electrical, glycol, steam, water, and waste all play important roles in delivering a repeatable product. Designing and installing utility systems that not only meet process needs but also incorporate vital safety elements can be a daunting task. Qualified integrators like Zajac can provide the expertise necessary to ensure that utility systems are correctly installed and maintained, allowing breweries to focus on producing exceptional beer.

“Zajac has been doing essentially all of our process and control work here at the brewery for the last ten years. Their quality and professionalism have been phenomenal, and I really feel like they care about the final quality of our beer just as do all of our employees here at the brewery.”

-Eric Meader, Parts & Inventory Specialist – Engineering Dept. at Allagash Brewing Company.

Dairy – Zajac has been in the dairy industry since 1975. Their primary expertise lies in their exceptional ability to swiftly adapt to the dynamic and ever-changing demands of dairy manufacturers. In 2023, Zajac completed a major project involving a number of new and repurposed tanks, a rebuilt glycol system, and a massive distribution valve cluster that they designed and fabricated. Using their in-house CWI (Certified Weld Inspector) ensured the quality of all work performed. Zajac’s Automation team created the functional design specification and handled the PAC software, HMI, data collection and reporting, automation simulation, commissioning, and start-up support operator training. Zajac offered a single point of accountability throughout the entire project cycle making the client’s experience streamlined and stress-free. As a true design-build integrator, Zajac excels at offering end-to-end services to its clients.

“I would like to thank the Zajac family for supporting me and my family over all these years and to thank everyone at Zajac for everything they have done for this plant over the past 30+ years. It was always the same great team. I cannot begin to count all the great things that were accomplished to keep us growing as a business and in technology. No project was too big or small that you could not accomplish it on schedule and on budget. Thanks for all the weekends, holidays, and late-night calls that were always answered. As a team, you always came through for us whether it was supporting maintenance, training, fast-paced projects, or stepping in on projects at the last minute when other vendors walked out on us.”

-Tony Cote, System Engineer at General Mills – Yoplait

Food & Beverage – Zajac understands sanitary equipment design principles and other certifications required for the production of food and beverage products ensuring consistency, safety, and quality. Zajac sets itself apart from most of its competitors not only by having all in-house process resource capabilities but also by having its own custom fabrication facility. Along with designing your production process, they can also design and build your platform decks, custom conveyor parts, prototype parts, and any custom signage using their state-of-the-art OMAX waterjet. The use of this equipment helps streamline their process and can help to reduce both costs and time.

“I’ve been at this Littleton, Massachusetts site for 49+ years and have dealt with Zajac for 20+ of these years. We have a great relationship with Zajac’s parts department as well as Zajac’s mechanical and electrical departments. One of the major reasons this relationship has been outstanding is the parts department. We’ve contacted Zajac’s parts department many times with minimum information and they’ve somehow bailed us out by helping us identify the parts needed and expediting them for us. I always feel comfortable leaving parts requests with Zajac’s parts department, knowing they will come through.”

-Fred Caissie the Maintenance Manager at Patriot Beverages.

Pharmaceutical – Zajac’s venture into the pharmaceutical industry in 1989 was a significant milestone in its journey. The company’s decision to design and install a large blood fractionation facility in the northeast was an ambitious move that has paid off in the long run. Whether Zajac is fabricating a modular system in its manufacturing facility or on-site, its team of Engineers, Designers, PMs, and Welders all meet the same cGMP standards, which is a testament to their commitment to quality.

The pharmaceutical industry is currently experiencing a significant transformation, with more regulations demanding higher standards than cGMP. As a result, pharma quality leaders are stepping up their game to stay ahead of the curve. Zajac is already ahead of the game, given its 30+ years of experience in the industry. Zajac has manufactured many different types of custom skids for pharmaceutical companies, including: Virus Reduction Systems | Chromatography Systems | Centrifugation Systems |Cell Disruption Skid | In-Line Dilution Systems |Paste Resuspension Systems |Water/Gas/Steam/Cooling Systems | Filtration Systems (MF/UF/DF/TFF) |Modular Valve Matrix |CIP Systems.

Zajac takes great pride in their role as equipment manufacturers for all their clients. They adhere to Good Documentation Practices (GDP) to ensure successful validation of their systems. Their Quality Team ensures that all materials are inspected and traced throughout the project and that all documentation is complete and easy to trace from receipt inspection through the final documentation package. Zajac’s systems are crafted with the highest level of quality and care ensuring compliance and customer satisfaction. After completing the design, fabrication, and delivery of API and depth filter skids at a biological facility in North Carolina, a customer representative shared their positive experience with Zajac:

arolina, a customer representative shared their positive experience with Zajac:

“I was blown away. The skids were nearly perfect…wonderfully built. Beyond that, the level of preparation was outstanding. I was particularly impressed with how the weld maps were displayed, making it easy for us to locate each weld, another sign of how Zajac goes above and beyond for the client. Beyond the technical expertise, everyone on the team has been welcoming, friendly, and quite frankly, fun, and funny. It’s been a pleasure to work with Zajac, and I gladly look forward to a future opportunity.”

-Confidential Pharmaceutical Client