This can be as simple as monitoring the shipment of fresh vegetables from a farm to a grocery store. On the other hand, it can be quite complicated if there are multiple sub-recipes used to create a single finished product. You are well aware of ingredient lists that fill up 80% of the label. Well almost.

These ingredients come from multiple suppliers with multiple lot codes and variable quantities. Dry products. Wet Products. Products stored in a warehouse, in a silo, in a cooler, in a freezer, just in time, etc.. There are many variables that go into creating a lot tracking program to meet your requirements. One that fits your procedures and one that is inclusive of all your ingredients, your food contact ingredients and your products. It keeps track of your vendors and the manufacturer of the ingredients, as well as customers and their distributors.

A Lot Tracking solution that gives you the information about the product and all the ingredients that were used in that product. A solution that goes one step further and gives you all the products that each of those ingredients were used in addition to the one of interest. A total count of cases produced, the inventory amount and a list of all customers that received the product and how much they received and when they received it.

All at the click of a mouse button. A solution that ties everything together for you so that you do not have to go find each detailed piece of information.

Automated Data Collection

One of the keys to a good lot tracking program is automated data collection so that it is not necessary to have manual data entry for every step of the process with the inherent data entry errors that occur.

Automated data collection can be started at your supplier's place of business so that you have a head start on data input. This can be in the form of using a code 128 barcode which includes all the information desired from vendor name to lot code to date of manufacture to site of manufacture to shelf life and the list goes on and on.

It can be in the form of an email that is decoded and the lot codes entered into your lot tracking program. It can be in the form of a fax that an OCR program reads the lot codes and enters them into the lot tracking program. It can be in the form of a web page that permits the data to be entered and then updates the lot tracking program. The use of RFID is considered by some.

Whether it is barcodes, RFID or a program that interprets the dates of production for FIFO management that selects ingredients to be used, monitors their use and records the necessary information to create a tie between ingredient and finished product.
 

Inventory Accountability with a ScaleDAC

Once the ingredient data is in the system at Receiving, it must be maintained as a part of Lot Tracking so it can be accounted for if the need arises. This is one of the problems that occurs when data is maintained on paper and even with MRP's if data entry is dependent upon a person to supply their information. Even worse, if the MRP depends on what has been scheduled by the MRP for use by lot code and weight without a verification step. This is why there are often so many inventories done as well as cycle counts.

A FoodHorizon system accounts for the lot codes and quantity of each product coming into the facility in different automated means as necessary for the situation. It then uses an actual weight based on a lot code to deplete inventory. A ScaleDAC (DAC = Data Acquisition) is attached to scales so that the exact amount weighed is depleted each time it is weighed. This provides Real-Time inventory control as well as eliminating the theoretical weights assumed with formulas and batch weights. In addition, it provides a positive step for lot code identification.

This single step also facilitates using the correct lot code of ingredients. A pick list generated by the FoodHorizon scheduler module that uses FIFO or other desired procedures for designating which lot code and quantity of ingredients to use. Barcodes and RFID tags on ingredient containers can be verified automatically at the ScaleDAC and those not on the Pick List will be rejected and require further review.

A ScaleDAC also assures that the correct weight of each ingredient is put into each and every batch. This eliminates the errors of mis-weighing because the ScaleDAC can be set to prevent an incorrect weight from being entered. Whole containers such as 50# bags, 10# containers, etc. can be entered as a full bag without weighing that allows more rapid throughput.

FoodHorizon systems provide accurate, rapid and logical procedures that can be used for quality procedures, food safety procedures and production procedures. A ScaleDAC can be used for batching and for Statistical Process Control (SPC). Both are important steps in providing consistent, uniform products within the limits of the specifications. This provides sensory quality attributes to the finished product as well as assuring an economic benefit with strict weight control.