Eliminating "Out of Spec" Batches can Save Food Processors 5-8% of Total Ingredient Cost


Advanced batch and lot tracking system enables consistent, repeatable, error-free batch results by eliminating operator errors

(Patchogue, NY) The Production Recipe Ingredient Management System (PRIMS) is a software-based automation solution that allows food processors to improve product quality and radically reduce the cost of wasted raw materials. It is based on the premise that the only way to prevent operators from making mistakes is to confirm and verify everything they pre-scale and add into the mixers, thereby removing their ability to deviate from the product recipe. With PRIMS installed, operators cannot make a batch that does not meet the recipe specification, in terms of required ingredients and proportions, as well as mixing time, speed and dough temperature.

After a food processor loads recipes into the product's database, the recipes are sent via a local area network to PLC-based control stations on the plant floor as needed to meet daily production schedules. The recipe software then "walks" the operator step-by-step through the recipe on a multilingual display at the control station which is connected to plant-floor equipment - mixers, scales, temperature probes and other devices.

If everything is according to spec, the system lights up a green "acknowledge" button and once the operator presses it, he is allowed to proceed to the next step. If anything is out of spec, the acknowledge button remains dark and the operator is prompted to correct the mistake. If an operator goes outside the prescribed recipe, the deviation is recorded by the system, along with operator ID, so management can take corrective action. Actual usage of all ingredients is recorded at each usage point in the plant.

Lot tracking for raw material traceability is also addressed by the PRIMS software. This is important for food safety in the event of a product recall, and for compliance with Title III of the Food Safety Bioterrorism Act. The software gives food processors the capability to quickly track raw material lots to specific batches, and to immediately identify other batches made with common raw material lot numbers. All of the data associated with the production of a batch is recorded by the PRIMS system, allowing easy manipulation of the production data to support management reporting and quality control processes.

For more information call 631-758-3629, email sales@focus-works.com or visit www.focus-works.com.

PROCESS EXPO is the premier worldwide trade show for leaders in the food and beverage industry. Held Nov. 1-4, 2011, at McCormick Place in Chicago, Illinois, the show will feature the latest processing technologies presented by 450+ exhibitors. A world-class educational program, including a full day of Spanish-language sessions, will provide much of the technical expertise to complement the practical applications seen on the show floor. PROCESS EXPO is produced by The Food Processing Suppliers Association (FPSA), a global trade association serving suppliers in the food and beverage industries. Register today at www.myprocessexpo.com.

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