Recipe Management Software and Mixing Screen
For recipe-based food manufacturers, SI’s Mixing Screen digitalises and visualises control of ingredients and component recipes.
Raw material intake, silo and stock management, mapping out combination specifications, tracking WIP and scanning to batches – all are critical processes for recipe managed food manufacturing.
With SI’s recipe mixing screen and recipe control management software:
- Map out all your recipe managed products using SI’s cost modelling software. Cost modelling holds all BOM information together with all product relationships.
- Know how to make products, even when ingredients are unavailable available.
- Determine at what price your business needs to sell products to make a profit.
- Manage both reduction specification products and combination/recipe product.
- Manage tolerances of ingredients and WIP stock lists, even when production is already underway.
- Create works orders to make blends and WIP batches.
- Track everything – from raw materials, costs, WIP through to finished goods and packaging for traceability and accuracy.
- Scan and issue batches of ingredients/raw materials, on the shop-floor, to works orders and maintain traceability – tracked and reported on in real-time.
- Verify that operators are adding the right quantities and product codes.
- Produce WIP stock with real-time visibility and any track short list WIP stock.
And as our MES software is driven by our renowned shop-floor data capture, it every production process is controlled in real-time. From scanning, mixing and make-up, through to baking and cooking, cooling and finishing.
How it works
- 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.
- Next, scan and validate raw material from the stock position:
- If the wrong product is scanned, it immediately shows that this is the incorrect product.
- 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 for the Cumberland sausage mix.
For each mix, the recipe screen shows how the product has been set up in the specification, the batch breakdown and the component for the recipe. For instance, in the case of a 200kg Cumberland Sausage mix:
- Four batches of 50kg specified.
- The recipe components and quantities of each ingredient for the sausage mix.
- The prescribed order. Alternatively, it could be an open process.
In some cases, you might not want to capture the weight of everything, for instance in the case of fixed weight items. Instead, the batch can be scanned and, based on user permissions, a manual weight is 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, visually indicating with a green tick symbol.
When the recipe includes an in-line process, this can be booked at the end of the line as separate process, using our OCM and labelling software.
Managing incomplete recipe mixes
As batches are added, the mixing screen and recipe management software verifies that the right raw materials are being added and issues the next instructions for producing the mix. It also maintains accuracy for all stock information accurate, based on what’s been issued into the mix, and manages all ingredient tolerances.
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 into stock.
By choosing this option, a label will be produced, featuring the run number, but it will not be booked as WIP. Once the ingredient issue has been resolved, then mix can be reintroduced to 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.