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Two Vantage touch-screen terminals from SG Systems have improved traceability at the Original Bagel Company’s facility in West Caldwell, New Jersey.

Original Bagel produces traditional water-boiled bagels at its scratch baking operation and cold storage facility.

As all bagels are prepared largely by hand and require a number of different ingredients, it can be difficult to keep track of the individual amounts used and to ensure that the correct quantities are added to deliver a consistent product.

The installation of the Vantage systems has resulted in ingredient savings for Original Bagel.

Mark Wolfson, the company’s director of quality assurance, said: ‘We’re more streamlined in how we do things and know if any waste is occurring; previously we weren’t keeping those numbers.

‘Now that we can record those figures, our guys are more aware of what they are doing.

‘With the waste now eliminated, dollars are saved,’ he added.

The system installed at Original Bagel provides traceability from receiving ingredients through the production formulation process to enable complete lot and batch traceability.

The two Vantage touch-screen terminals are connected to weighing platforms and label printers that enable the manufacturing plan to be communicated with the production team.

The system has virtually eliminated time-consuming paper-based production and traceability records.

The formula for particular products is entered into the PC server via the recipe formulation management software.

The system enables management to enter and determine the exact recipe characteristics, including individual ingredient tolerances and how the products are added.

For instance, recipes may be a mixture of weighed ingredients and bagged ingredients – both of which are weighed to tight tolerances (enforced by the system) to produce a consistent taste and texture to the bagel.

The system calculates the amounts of individual ingredients needed and downloads the order to the relevant station, providing a simplified formulation process, with the large screen prompting the operator throughout as each correct amount of ingredient is added.

The system will not allow the operator to continue if the incorrect ingredient is selected or the wrong amount added.

Detailed instructions relating to product characteristics are also flagged up to ensure that adequate HACCP requirements are met.

Once the final product has been cooked and packaged, the finished box count is entered into the system.

The finished-product inventory system is then updated to provide real-time visibility of exactly how many boxes have been produced.

The final piece of software is a customer sales-order processing system.

This software enables customer-specific orders to be entered into the system and then the orders are sent to the receiving and shipping terminal for the operator to ‘allocate’ the inventory.

The end result is a system that can trace an ingredient through the manufacturing process to a finished product.

In the event of an ingredient recall, Original Bagel can provide its customers with the assurance that it has 100 per cent visibility of which, how much and when ingredient has been used.

SG Systems

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