Established in 1927 in Dallas TX, Family owned Illes Seasonings & Flavors (Illes Foods) is a manufacturer of liquid and dry food ingredients. Their products provide features like flavor, texture, aroma, and appearance to meat, food, and beverage products. These ingredients are sold to food manufacturers and beverage distributors to be used in their products or mixed with their food or beverage formulations.
In order to achieve the tightest possible control over their production formulation and traceability processes, Illes has recently upgraded their old RFS batching system to the very latest Enterprise V5 Formula System, developed by SG Systems.
Ross / Aptean Integrated Batch Production
The system provides an interface with their existing Ross (Aptean) ERP system to capture ingredient traceability information from batching events which take place on the production floor. Bills of Materials, Production Schedules and Inventory are exchanges between the two systems.
The V5 Formula Systems connect to their existing scales (3 scales of differing manufacturers and capacities to each V5 Terminal) to control the weighing process and regulate the exact amounts of ingredients used within the blends, ensuring target weights are achieved and inventory is downgraded in real time.
7 V5 Formula Systems have been installed, replacing their entire previously installed RFS batch system. After each ingredient is weighed, labels are generated through mobile wireless network label printers to identify the ingredient lot number, name and the job which the ingredients relate to. This information is then captured at the mixer using mobile tables pc’s with integrated scanners to provide a ‘zero mistake culture’, enabling batch validation for the hand added & bagged ingredients.
Director of Materials Handling, Joel Dennie comments “With the V5 Formula System in place overtime hours are down considerably. Before we implemented the V5, operators were weighing 50 batches per day – now we have V5 they’re producing up to 125 batches per day. That’s a significant increase in production output”
A single V5 Formula System is also installed into their offsite liquid ingredients blending facility and the database is linked to their main facility through VPN to provide a central point of data storage and retrieval.