Calise & Sons Bakery, Inc. Implements Batch Control & Lot Tracking System from SG Systems LLC. This post explains how Calise & Sons Bakery, Inc (Calise) eliminates bad batches, removes paper traceability and imports recipe data from JustFood ERP.
Quality! For over 100 years, the Calise family has been baking and delivering the freshest, best tasting bread and rolls, earning a reputation as the highest quality specialty baker in the Northeast. Calise manufactures over 140 varieties of baked, par-baked, and frozen bread and rolls. The Calise brand has grown to be one of the strongest and best known brands in the Northeast USA.
Due to the amount of SKU’s Calise produces, being on target with scaling and lot traceability is a major concern. Calise was experiencing lost dough
issues due to inaccuracies in scaling. They also wanted to streamline their traceability procedure to meet GFSI guidelines more efficiently than with a paper system. SG Systems has extensive knowledge and experience in the area of formula control scales, ingredient traceability & inventory management (raw ingredient and finished product). For this reason, Calise Bakery contacted SG Systems.
The Batch Control & Lot Tracking System installed at Calise Bakery provides Ingredient Lot Traceability from received & labeled ingredients through the production formulation process, enabling paperless lot and batch control & traceability. In the centralized Minor Ingredient Weighing area is a Vantage Touch Screen Terminal connected to a weighing platform with a barcode label printer.
The tightly controlled formulations are exported from JustFood ERP and automatically imported into the SG Systems database. This removes the need to manually enter or double handle data relating to ingredient, formulations, sequence, locations and target weights. Bulk ingredients present in the formula are automatically flagged to allow the scaling operator to focus on the relevant part of the formulation.
The manufacturing plan is setup using a desktop PC Management license, allowing the Production Manager to schedule the required amount of batches from a remote PC on the network. The system has virtually eliminated time consuming paper based production and Ingredient Traceability records.
Michael Calise, Calise Bakery President comments “During the research process is was very important that we selected a Batch Control & Lot Tracking System partner with experience in handling data from our existing JustFood ERP System. SG Systems imports our formulas automatically which minimizes error and saves us time. The weighing tolerances on the scale system has removed ingredient over weighing and improved our batch consistency.”
The Batch Control & Lot Tracking System provides an effortless and very simple to use production formulation process. The large touch screen prompts the operator through the recipe as each ingredient is added; using management set green / red tolerances and a speedometer weighing display. The system will not allow the operator to continue if the incorrect ingredient lot is selected or the wrong amount added. Detailed instructions relating to product characteristics are also flagged up to ensure adequate HACCP / SOP requirements are met.
The end result is a Batch Control & Lot Tracking System which can trace an ingredient through the manufacturing process. In the event of an ingredient recall, Calise Bakery can provide their customers with the assurance that they have 100% visibility of which ingredient has been used, how much and when. This is critical in today’s bakery market and enforced by many customers.
SG Systems’ comments “SG is a company who pride themselves on thinking outside of the box to deliver solutions to eliminate paperwork and provide customers with a return on investment. The team at Calise Bakery is forward thinking, innovative and appreciate that lot traceability can be turned from being a paper-based headache into something which can be used to deliver real business value.”