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SG Systems has supplied a food traceability, formulation control and ingredient recall solution for Dallas-based Illes Seasonings and Flavors, a manufacturer of liquid and dry food ingredients.

Illes Seasonings and Flavors creates products that provide features such as flavour, texture, aroma and appearance to food and beverage products.

In order to achieve tight control over its production formulation and traceability processes, Illes has recently installed the Vantage Formula Control and Traceability System from SG Systems in its dry ingredients facility.

The system has been developed to provide a direct interface with the already installed Ross ERP system to capture ingredient traceability information from real events that take place on the production floor.

All data is backed up to a high-end server that is protected against power surges and power failure (through a UPS).

In the event of an electrical fire in the server room, the airtight room fills with inert gases to prevent fire spreading until help arrives.

In addition to achieving tight production control, the Vantage Systems connect to the scales (three scales of differing capacities to each Vantage) 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.

This is achieved via a direct interface to the Ross ERP System.

In turn, this control provides perpetual inventory control.

Training time for the production operators took less than a day before the operators could work without supervision and were producing at the same rate as before, but with improved accuracy and reduced time with batch paperwork.

Five Vantage touch-screen controllers have been initially installed.

After each ingredient is weighed, labels are generated through mobile wireless network label printers to identify the ingredient lot number, name and the job that the ingredients relate to.

This information is then captured at the mixer and validated by Ross to provide a ‘zero mistake culture’.

A single Vantage touch-screen controller is also installed into the offsite liquid ingredients blending facility and the database is linked to the main facility through VPN to provide a central point of data storage and retrieval.

SG Systems

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