Recipe Management Software
SI’s Recipe Management Software and Mixing Screen can eliminate human error in food recipe processing, that can lead to re-batching and even batch loss.
By using SI’s Mixing Screen and Recipe Management software, our customers digitalise, visualise and control multiple mixes from component ingredients, and provide for batch repeatability and bi-directional traceability. They are able to produce the most complex value-added products, ready meals and baked items with confidence.
With SI’s recipe management software and controls, customers can:
Plan daily mixes, complete recipe methods and product relationships.
Visualise multiple raw materials on the mixing screen, in the correct order.
Control user process workflow.
Accurately reconcile stock levels for raw material, delivering full traceability and silo management.
Manage raw material intake by scanning and validating the correct batches on the screen, whilst integrating weighing where required to achieve the correct tolerances.
Create part complete mixes with correct labelling, whilst mapping out combination specifications and tracking WIP stock items which are visible within the stock management system.
Track everything – from raw materials, costs, WIP, through to finished goods and packaging for traceability and accuracy.
Control costs, with all production costs measured against master specifications.
“By using SI’s software to validate recipe make up, we’re ensuring that the right ingredients, at the right quantities are issued to manufacture products. This results in greater consistency for quality and improved traceability.”
Finnebrogue Artisan
When is a recipe screen more than just a mixing screen?
Most recipe screens will scan raw material batches and validate that correct batches or raw materials have been scanned, according to recipe tolerances. SI’s recipe screen does all of this and so much more.
SI’s Recipe Mixing Screen shows how the product has been set up within the specification, the batch breakdown and the components for the recipe.
For each ingredient as it’s transacted, it down-dates raw material and quantities to keep stock accurate, maintaining this accuracy with real-time shop floor data capture.
It eliminates errors and wastage by validating that the right raw materials are being used for the right recipe. again, keeping stock accurate and providing complete traceability.
It transacts quantities into pot for traceability, in standard operating order, until mix is completed.
And for part-completed mixes, rather than locking the mixing screen, mixes can be set aside until you are ready to finish the recipe.
Managing incomplete recipe mixes
As batches are added, both the mixing screen and the recipe management software verify that the right raw materials are being added and manages all ingredient tolerances.
Then, the next instructions are issued for producing the mix. Based on what’s been issued into the mix, accuracy is always maintained within SI’s Recipe Management Software.
More than that, our software can also manage partially completed mixes. In the case of an incomplete recipe mix, perhaps due to an ingredient issue, there’s also an option to override the process and book it back into stock.
By choosing this option, a label will be produced with the run number, but it will not be booked as WIP. Once the ingredient issue has been resolved, then mix can be reintroduced and sent back to production for completion.
Minimising impact of operator errors
If an operator scans an ingredient or introduces a component to the recipe mix that’s incorrect, then simply select the “discard” option. (Discarding doesn’t return the product back to stock, it discards the recipe). And when working with scales, all ingredients can either be weighed out on one scale or multiple scales, and choose whether or not to reset tare.
Recipe Management Software and Mixing Screen – in practice:
Start by using cost modelling specifications to segregate the processes (products can be made using multiple processes). For example, in the case of sausages, processing of the meat mix could be handled in one room whilst the dry mix is finished elsewhere.
Against each component part, permitted percentage tolerances can be defined, above the required weight.
By integrating with stock and intake in real-time, your food manufacturing operations will have a complete visual about actual raw material availability. And for bulk ingredients, where intake is held within in silos meaning that precise traceability isn’t achievable, our software tracks stock according to “first in, first out” traceability.
Scan and validate raw material from the stock position:
- With stock allocated centrally in the system, if the wrong product is scanned, it immediately shows that it’s incorrect and won’t accept it into the mix.
- When the correct product is scanned, the screen immediately displays how much is available on stock.
- As the product is put on the scale, the weight is captured. The product can then be issued to production as part of the recipe.
- Once the full amount of the product is issued, it automatically moves on to the next product in the list.
- Once the product ingredient list has been completed then, by pressing “Accept” it will issue a work in progress (WIP) label, that is then visible within stock management system.
- If it’s not necessary to capture every weight (i.e. fixed weight items), batches can be scanned and, based on user permissions, any manual weights can be keyed-in.
At any point, progress can be reviewed against the recipe. The mixing screen shows all the product ingredients that have been correctly issued, together with a green tick symbol.
If recipes include in-line processes, these can be booked at the end of the line as separate process, using our OCM and labelling software.
