Mass Balance in Food Processing – Precision Built Into Every Gram

V5 from SG Systems Global enables food manufacturers to monitor every gram of input and output—delivering complete mass balance visibility across the production process. Whether you’re producing baked goods, beverages, prepared meals, or bulk ingredients, V5 captures raw material usage, process loss, rework, and finished output with digital precision.

This isn’t just inventory tracking—it’s enforcing traceability, minimising waste, and unlocking actionable yield insights. With real-time traceability and production enforcement, V5 helps food processors meet regulatory expectations and operate lean—without the uncertainty of spreadsheets or manual reconciliation.

“Before V5, we couldn’t explain our losses. Now we can trace every pound—input, waste, rework, and what left the line.”
— Plant Director, Food Manufacturer

Digital Mass Balance for Regulated Food Production

In regulated manufacturing environments, mass balance is critical. Whether for internal efficiency, external audits, or compliance with standards like GFSI, ISO 22000, or 21 CFR Part 117, producers must prove that what enters production matches what leaves—factoring in loss, yield, and rework.

• Track all raw materials by batch, weight, and lot number
• Monitor key loss points—mixers, ovens, conveyors, etc.
• Record waste, overfills, and off-specification product
• Integrate rework directly into production workflows
• Match finished goods against recipe targets and live yield

V5 connects to scales, PLCs, barcode systems, and MES touchpoints to automate and verify each mass movement on the production floor.

Yield Visibility and Waste Accountability

Undetected yield loss is a hidden cost across food factories. V5 eliminates this blind spot by tracking actual weights at key points—before, during, and after production. This provides dashboards and reports that expose underperformance, overuse, or unnecessary loss in real time.

• Live dashboards for shop floor, QA, and leadership teams
• Automated yield reporting by product, line, or shift
• Threshold alerts when yield drops unexpectedly
• Direct integration with QMS for investigation and corrective action
• Audit-ready trails with time, user, and machine stamps

“Precision built into every gram.”
— SG Systems Global

Industry Applications: From Dough to Dairy

Mass balance is essential in every food category—but how it’s applied varies. V5 adapts to your product type, from flour-to-dough ratios in bakeries to solids tracking in liquid and chilled food processing.

• Bakery: Monitor flour loss, scaling variance, and packaging waste
• Dairy: Track solids, fat, and water losses across tanks
• Frozen meals: Match ingredient portions to packaging weights
• Snacks and bars: Control overfills and track excess giveaway
• Bulk ingredients: Balance tanker offloads with batch demand

V5 supports flexible site configurations, ensuring the solution fits your process—not the other way around.

Audit-Ready, Always Accurate

Every movement tracked in V5 is logged to a digital record with timestamps, user validation, and equipment verification. Whether you’re being audited, handling a product complaint, or managing a recall, you’ll have full accountability from intake to despatch.

• Digital signatures compliant with 21 CFR Part 11
• Built-in SPC and process variance analysis
• Integrated batch and traceability records
• Exportable reports for internal or external review
• Reconciliation down to individual weight entries

V5 removes the guesswork. You’ll know exactly what went in, what came out, and where any loss occurred—supported by data, not assumptions.

Discover how V5 from SG Systems Global can help your team enforce mass balance, reduce loss, and meet the highest expectations for food manufacturing control—whether in the UK, US, or globally.