Page 50 - FoodFocusThailand No.182 May 2021

SMART PRODUCTION

Into this dynamic environment, additional international standards based system’s advantages over a paper-based system include data
designed to ensure product safety (EC 178/2002, US Bioterrorism Act, consistency, speed of data analysis and improved recall management.
FDA, GMP, BRC, IFS, ISO 22000) are cropping up. A prerequisite to the An electronic system can also document processes, generate
traceability required is documentation of all relevant formulation and weighing and manufacturing reports, and print labels to identify goods-
weighing activities. A computer-guided and networked rather than paper- in-process. This type of system is also vital for transparent
based production system provides easily accessible production data. manufacturing processes and providing a proper decision base for
This article will address the benefits of investing in such a system streamlining processes.
as well as considerations that help to ensure the system enhances • System Components/Configuration
manufacturing productivity and quality in addition to providing traceability A standardized configurable system that has been tuned to
for safety regulations. manage critical weighing process parameters has many advantages
• Increasing Regulatory Pressure Requires Traceability over client-specific systems with custom programming.
From bird flu to bioterrorism threats, modern reality has forced both Standard interfaces allow a high degree of customization while
governments and food processors to impose new rules for food and offering expert system maintenance and support over the life of
allied product manufacturing. For example, the IFS (International Food equipment and software. The initial investment better maintains its
Standard) requires producers to guarantee traceability of goods flow, value and can secure optimal production performance well into the
as stated in IFS Version 6.1. Similar requirements are stipulated in the future.
BRC (British Retail Consortium) standard and in FSSC 22000 • Integrated Traceability
requirements. In every production step from goods entry to shipment, database
Aside from regulations, unpredictable supply-chain or customer entries correspond to in-process materials. In a computerized system,
events may require investigation into production steps. If defective barcode-reader enabled labels assist with component identification
batches appear, the root cause of the problem must be identified and and overall traceability during processing.
measures taken to ensure future product quality and safety. Essentially, Printers connected to weighing workstations can print labels at
food producers must document all processes – without gaps. This the point of identification that enable fast materials recognition.
includes recipe development, quality lab, production planning, monitoring, Label types include:
dispensing and packaging/distribution. A computerized and intelligently • Weighing labels: Dispensed materials for an order are marked.
networked formulation/weighing system is key. Order, batch and lot number help guarantee processors do not mistake
• Traceable Weighing/Formulation Is Computer-Based components.
Truly gapless traceability requires that all involved parties feed • Pallet labels: These identify a pallet and its contents, particularly
recipe-relevant data – ingredients, structures, work instructions, batch when materials are placed on a pallet before they are moved into
and production order information – into a centralized system. A computer- production.

Improve Production Yield

Process-Oriented Recipe Management

Food manufacturing companies are under increased pressure to improve plant productivity, product
quality and consumer safety. For all three, ingredient traceability and process tracking play central
roles.

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