For Always Bagels it began in 1985 with one retail bakery in Port Jefferson, NY, accompanied by three additional bakeries in years to follow. Family owned and operated for over twenty-five years our commitment to excellence has allowed us to provide our customers with the finest boiled bagels possible.
Today Always Bagels has grown into two state of the art production facilities with a combined 92,000 square feet and 160,000 for future expansion.
These facilities have enabled Always Bagels to consistently deliver excellence in quality and value. New signature and specialty items as well as custom formulations are constantly being developed for continuous customer satisfaction. Through technical support and dedication to quality we have impressively increased sales for all our customers.
To compliment their New York factory, and introduce electronic traceability and advanced batch control for bulk and minor ingredients, Always Bagels made contact with Matrix Controls. They made a well informed choice and purchased the latest V5 Formula System from Matrix Controls.
V5 Formula System
With recent food traceability scares affecting thousands of food companies (all food processing facilities) – food companies like Always Bagels are faced with a choice as to how to address the traceability legislation from the incoming raw ingredients of products to their mixing, batching & blending process, through to the labeling of finished and repackaged goods. This can be an expensive and brand damaging problem to address if companies take the traditional and inadequate paper-trail route.
The Traceability System is a combination of hardware and software designed to bridge the gap between the production floor weighing and labeling processes and the management team. All incoming raw materials are booked in at Goods Inwards onto the Inventory Control module and allocated to precise locations within the site giving real time inventory levels which highlights shortages before commencing production.
When the daily production requirements have been established, the pick list for daily inventory is generated and communicated with V5 Formula System Terminals (designed and built by SG Systems LLC). This schedule provides the V5 Formula System Terminals with information relating to production orders, items ordered and inventory lot numbers to deduct from.
When the operator selects the relevant production order from the industrial touch screen display, the system details how many batches of a particular product have been scheduled. Each formula is then weighed to a target weight (forcing the Operator to weigh accurately and work to weight tolerances set by management). Only when each element of the formula is exactly within the management set weighing tolerances will the system allow the operator to progress to the next ingredient ensuring product consistency is always maintained.
All ingredient lot codes are validated and recorded for full traceability. As many of the formulations have ‘blends within blends’ the system is configured to allow for a multi-level recipe structure providing traceability across the liquid yeast formulations which are combined to form the finished product.
After the mixing, batching and baking process the product is either frozen or sold fresh. Always Bagels has dozens of finished product SKU’s each with specific label formats descriptions, the latest GS128 Barcode Symbology, Ingredient Declaration and a Finished Batch Number which is fully traceability).
Finished products are scanned at the shipping dock using wireless tablet PC’s (Running SG Systems WMS Software) which allow the picking and shipping process to take place in a very efficient manner. FEFO is imposed to create automatic inventory rotation, ensuring scanned products transfer the order correctly while depleting inventory accurately.
The Tightest Possible Production Control & Traceability
Being based on the well proven Traceability System , the reporting package has the ability to pinpoint which Lot Numbers have been delivered to which customers and when – all in real time. Simply enter the Lot Number into the PC and it will generate an Ingredient Traceability Report providing shipping details in the event of a product recall.
The reports package also enables visibility of operator performance, production throughput, and production yield while generating no additional workload for the site staff. The system provides traceability to comply with the most stringent food safety legislation and enables our process to score highly with the retailers requiring traceability.
The system guarantees a reduction in the waste caused by a conventional scale system
Lenny Tyc, Northeast Foods
With the waste now eliminated, dollars are saved
Dave Harris, Original Bagel Company
The System provides total control over our production process and gives us 100% Traceability - Absolutely brilliant
Gareth Franks, Dominos Pizza
Tolerances on the scale system removed ingredient over weighing and improved our batch consistency
Michael Calise, Calise & Sons Bakery