Alga.Meat: business process optimization in the food industry
Are you a small or large business owner in the meat processing market? Existing software is not efficient enough, does not cover all areas of activity and you are looking for ways to improve absolutely all technical processes?
To your attention – the product of Algabas – Alga.Meat, a traceability system that is fully optimized for the tasks and needs of the Ukrainian market, and is able to systematize the entire work of the enterprise – from the receipt of meat products to the warehouse to the calculation of the cost of a batch of finished sausage, cutlets, etc.
How it works: product traceability system from Algabas
Alga.Meat is an operational unit that integrates into the existing accounting and management accounting system. Receiving certain data from the established control points of product traceability, it transforms them into full and detailed information, thanks to which:
- You can control all process stages of meat products from production – from the raw material supply to the production of finished products (according to the haccp system);
- Monitor all processes online, timely adjusting and coordinating them;
- Control the amount of incoming and used raw materials, excluding theft;
- Receive system reports on all technological and financial processes during production;
- Track product labeling, including the printing of labels and accompanying cards for pallets;
- Receive and register applications from customers;
- Create reports and track the cost of the final product.
- The product is based on the BAS ERP platform, which allows you to solve absolutely all the tasks facing the Ukrainian food business.
Please note: this program for identification and traceability in Ukraine works in accordance with the regulations of domestic legislation, as well as the requirements of international standards ISO, FSSC, IFS, BRC and Global G.A.P.).
Business automation with the help of the HASP system is an opportunity to bring the production process to a fundamentally new quality level! Join Algabas!
Food traceability
New!!! Automation of HACCP plan
The production control point of the MPP is the operator’s workplace, where the raw materials and finished products move between warehouses and workshops, where the operation of changing the raw materials state takes place and the batches are recorded at each production stage.
Automated workplace of the production point. Our product works on touch monoblocks and does not require a keyboard and mous
EXAMPLE OF CONTROL POINTS OF MPP PRODUCTION
1КТ. Raw meat reception from suppliers
2КТ. Moving raw meat from the refrigerator
3КТ. Raw meat output from the defroster
4KT. Raw meat output from deboning and veining
5KT. Spices
6КТ. Raw meat standardization
7KT. Complete set for stuffing
8KT. Stuffing and transfer to forming
9CT. Exit from the formation and frame registration
KT10. thermal processing
KT11. Exit from the cooling room
KT12. Exit from the buffer warehouse
KT13. Transfer to the packaging and warehouse of finished products
Resource specifications
Resource specification is a type of information that describes the production process parameters of manufacturing products and semi-finished products. This is a necessary and sufficient part of information for the production schedule formation by stages of production.
1.Products in the package
2. Product composition in the package
3. Raw material specification obtained after heat treatment.
4. Raw material composition transferred for heat processing (losses during heat processing)
5. Raw material specification that comes out of the syringes.
6. Raw material composition which is transferred to the syringes.
7. Raw material specification which is transferred to the cutter.
8. Raw material composition transferred to the cutter.
9. Completion of raw materials for mixing.
10. Raw material set for mixing.
Example implementation by control points:
1КТ. Raw meat reception from suppliers
At this point, the storekeeper accepts raw materials from suppliers. A photo is taken from the web-camera to record the fact of the raw material delivery. The storekeeper clicks on the “Save and print” button. At the same time, information for the batch is entered in accordance with the HACCP standard.
- Date of the batch;
- Expiration date;
- Humidity;
- Temperature;
- Variety;
- Packaging condition;
- Manufacturer, etc.
At the same time, the system forms a new batch of raw materials and prints a batch passport. After weighing, the batch passport is placed in a box or pallet. And labels are automatically printed.
2КТ. Moving raw meat from the refrigerator
At this control point, raw materials are transferred from the refrigerator. The storekeeper scans the barcode from the batch passport. The internal document formed with the filled in parameters of the batch and weight is automatically opened. Here is the fact of fixing losses from the refrigerator. If the transferred weight differs from the original, but the batch is transferred as a whole, the storekeeper presses the “Close batch” button to register losses. And a new batch is formed, the old batch is closed to account for losses.
At this control point, you can use the MOBILE CONTROL POINT – MOBILE APPLICATION OF RAW MATERIAL SCREENING
3КТ. Raw meat output from the defroster
The storekeeper scans the batch barcode from a passport, the system automatically opens a new document and fills in the details of the batch and weight. According to the production norms, the system fills in the parameters with the norms of losses during defrosting. At this control point, the losses are fixed and a new batch is formed.
4KT. Raw meat output from deboning and veining
The operator scans the barcode of the outgoing batch. A new document is automatically opened with the filled in batch details and containers. At this control point, the batch is controlled and new batches are created.
5KT. Spices
Prepared sets of spices, assembled for mixing, are marked with thermal checks. The barcodes of the thermochecks are checked during the spice sets transfer to the production in order for the system to register their transfer from the spice packing area.
You can see the work of the control point in more detail – MES ERP FOR SPICES ACCOUNTING
6КТ. Raw meat standardization
The operator scans the batch barcode on the raw material container. If a raw material is selected that is not included in the recipe, the system informs about it.
If the raw material is included in the recipe, the system checks the compliance of the batch weight and the weight in the recipe for this type of raw material.
If the weight of the scanned raw material batch is less than the weight required by the recipe, the system includes the raw material container in the set. In the recipe line, the system shows:
- How much of this raw material is required by the recipe;
- How much is already included in the set;
- How much is still needed;
- The operator transports the containers to the set formation area.
7KT. Complete set for stuffing
The operator loads the required amount of raw materials into a new container. At the same time, the scales on the form show the weight in real time. As soon as the required amount of raw material is loaded into the container, a green frame appears around the weight field. A red frame is shown around the weight field if the operator has poured more raw materials than required.
After all types of raw materials are collected according to the recipe, the operator prints labels for the entire set and attaches them to all containers with raw materials.
8KT. Minced meat and transfer to the forming
To perform the processing of raw material sets for stuffing, the corresponding resource specifications must be filled in. The operator selects the equipment (Cutter) in which the kneading will be carried out.
Next, the operator selects the production stage, according to which the minced meat should be kneaded.
The recipe appears on the screen.
The system informs about the recipe.
If the raw material is included in the recipe, the system checks the compliance of the batch weight and the weight in the recipe for this type of raw material.
If the weight of the scanned batch of raw materials is less than the weight required by the recipe, the system includes the container with raw materials in the set. In the recipe line, the system shows:
How much of this raw material is required by the recipe;
How much is already included in the set;
How much is still needed;
9KT. Output from the formation and registration of frames
To control the fermentation time, the “Fermentation Monitor” is used, which is a form with a table that displays the batches of raw materials put on fermentation, their weight characteristics, as well as the dates and times of putting on fermentation and the planned completion of fermentation.
KT10. Thermal processing
The operator selects the production stage for the ” Thermal processing ” subdivision for which the process will be carried out.
The operator takes the weight from the scales by clicking on the “Take weight” button. To register the thermal processing losses, the operator presses the “Close batch” button.
KT11 Output from the cooling chamber
The operator indicates the number of the cooling chamber in which the frame with unfinished products will be placed next.
The operator takes the weight from the scales by pressing the “Take weight” button. To register losses in the chamber, the operator presses the “Close batch” button.
KT12. Output from the buffer warehouse
The system has a mechanism for fixing losses in the buffer warehouse – this is displayed on the buffer monitor, which shows which stacks should be transferred first from the buffer warehouse.
The buffer warehouse monitor shows:
- Nomenclature;
- Frame number;
- Date and time of entry into the buffer warehouse;
- Actual time spent in the buffer warehouse;
- Net weight.
KT13. Transfer to the packaging and warehouse of finished products
This checkpoint is described in ALGA.PACKING ORDERS
In a broad sense, traceability is a tool that determines the path of a product from its source to the direct recipient and is a system of recording information about all steps in the supply chain of this product.
The form and content of traceability depend on the food product, production operations and other factors. This explains the lack of a single definition of the traceability system.
However, the universal concept is that the traceability system consists of three basic elements:
1). supplier traceability (external traceability, step back);
2). process traceability (internal traceability);
3). buyer traceability (external traceability, a step forward).
Recording information about the product and the ability to provide it if necessary are integral components of each of these elements.
Most legal requirements focus on the need to ensure external traceability. The introduction of internal traceability in the enterprise is regulated by the business itself by including this requirement in international and most private standards, for example, ISO 22 000, FSSC 22 000, BRC, IFS1.
The main purpose of including traceability provisions in legislation is to ensure the possibility to carry out the most accurate product recalls and to quickly provide information to the relevant state authorities in case of food safety problems. As a rule, the requirements for mandatory implementation of traceability apply to all market operators involved in the food chain, namely:
- market operators of primary production;
- market operators that store food products;
- brokers and traders;
- transport companies;
- distributors;
- retailers;
- public catering establishments;
- market operators – manufacturers.
- process traceability (internal traceability);
- buyer traceability (external traceability, step forward).
