9 replies to this topic

[Zolita]

Just working on a new batch number and traceability system for a bakery
in South Africa, anybody have a fool proof system including the reworking of dough?

[Simon]

Can anyone help new member Zolita with this query.

Welcome to the forums Zolita.

[Simon]

Take a look at this case study; although it’s marketing material for a software provider it does give you a step by step view of how they achieve traceability in an industrial bakery.

Formula Control & Lot Traceability in a Baker (PDF)

Hope it helps.

Regards,
Simon
 

[D.R. Tirtasujana]

Hi Zolita,

Just wanna share a simple thought about traceability. Perhaps it could help.

1. You need to make sure when you buy materials or when the materials come from the supplier, they consist of no more than 2 lot number for each receiving material, if possible

2. Record the lot number and quantity for each incoming material. If there is no lot/batch code from the supplier, you could use the expired date or receiving date, or you could also generate internal lot number (code). If you use internal code, make sure you associate your internal code with supplier lot number/expiry date/receiving date or any other identification which could make you easy to tell the supplier the certain material in the future

3. Separate (phisically) each specific lot of material. If you have enough space in your material storage, use different pallet/place for different lot number. If not, you can stack them in the same pallet/place with clear identification to distinguish between lot numbers

4. When materials are taken from the storage for preparation or production process, make sure the FIFO/FEFO system is applied. Finish the oldest lot before using the next lot. Record the amount and the lot code of each material taken from the storage.

5. In preparing the material for production (e.g. weighing ingredients for each production batch), apply label of identification for those materials. The information in the label shall contain the lot code or any code associated with the checksheet where the lot code is recorded

6. In the production process, each production steps (e.g. mixing, forming, filling, proofing, baking, finishing, packing) shall have checksheet where you could record each lot code of material used in each production batch. You could also record a code associated with the checksheet of material preparation (where the lot codes are recorded)

7. If there is a semi finish product which is needed to be reworked (e.g. dough), a specific code for it shall be generated and recorded. When it is then used in the next production batch, it shall also be recorded in the new batch checksheet as one of material used in the that batch.

8. Assign production code/or any code to print on the packaging of the finish product. This code shall be recorded in the checksheet of the last process (e.g. packing)

9. Each code of finish good is stored separately from the other codes

10. When delivering the finish good to customer, record the quantity, code, and customer name in delivery checksheet

11. Test your traceability system by:
a. Pick up a random finish product code, and trace where (customer) the product was delivered
b. Pick up a random finish product code, and trace when it was produced, what materials in it, and what is the code of each materials (including packaging)
c. Pick up a random material code, and trace what products were made of that specific code of material and where the product was delivered

Hope it is useful

Regards,
-Rizki-

[Simon]

Thank you so much for your detailed explanation D.R. Tirtasujana.

Did this help you Zolita - please comment.

Regards,
Simon

[dv8dawn]

Thank you Tirta! 

 

I really appreciate the way you explained traceability process step by steps… 

[Charles.C]

Thank you Tirta! 

 

I really appreciate the way you explained traceability process step by steps… 

 

Hi dv8dawn,

 

And equal Compliments to yr search capabilities ! 

[Ekivlen]

Well said and very thorough. The auditing component will be crucial for you, especially in the infancy of this process. Start at a heavy frequency of auditing and back off once you've established control / feel confident that the staff understand.

Another recommendation is the use of Microsoft Excel to calculate your formulations. Once you've established a recipe specification, you can calculate percentages to any batch size you may need. This will give measurements for staff to pick and grid lines for adjacent placement of lot codes. If you need an example I can provide.

Integral to your success will be the training you provide at the outset. This is a very complex task and increasingly important. I have found that having select people pick ingredients is best - don't overwhelm the masses. At times we had one person whose primary job was collecting ingredients and documenting for the next day's production. It is very difficult to keep up with the speed of production as well as batching recipes and documenting lot codes and amounts. Unfortunately, one of the first things to slip is typically the paperwork. 

Good luck and let us know what the end result is!

[expl73xavier]

si es correcto

[dv8dawn]

Hi Ekivlen,

 

Your point is well taken and you are right as it’s stereotypically paper work with lot of dedication. But we will have to make a dedicated kitchen team to log all the ingredients & batch no of each production in each shift.

 

All the recipes are developed but still, kitchen staff doesn’t bother to follow the same even after giving them relevant trainings.  As you said, there I could appoint a dedicated person particularly for this task in each shift and let me see the outcome.

 

Thank you for your guidance,

 

Dv8.