Established in 1927 in Dallas TX, Family owned Illes Seasonings & Flavors is a manufacturer of liquid and dry food ingredients. Their products provide features like flavor, texture, aroma, and appearance to meat, food, and beverage products. These ingredients are sold to food manufacturers and beverage distributors to be used in their products or mixed with their food or beverage formulations.
In order to achieve the tightest possible control over their production formulation and traceability processes, Illes has recently upgraded their old batching system (installed 2010) to the very latest Ross ERP Integrated V5 Formula System, developed by SG Systems LLC.
The system is developed to provide a direct interface with their already installed and well proven Ross ERP system to capture ingredient traceability information from real events which take place on the production floor. All data is backed up to high end server which 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. For a food production facility, this setup rivals the pharmaceutical sector in terms of the investment in technology and redundancy.
In addition to achieving the tightest possible production control, the Ross ERP integrated V5 Formula Systems connect to the scales (3 scales of differing manufacturers and capacities to each V5 Terminal) 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 utilizing the SG systems developed ‘Gateway’ CSV interface to their Ross ERP System. In turn, this control provides automated perpetual inventory control.
The multi lingual shop floor interface (supports all knows languages by default) ensures operators can easily relate to the system and are not alienated by technology, which is often a problem with software companies attempting to control production floor operators. Training time for the production operators took less than a day before the operators could work without supervision and were producing batches quicker than using their old batch system, but with improved accuracy and reduced time with batch paperwork.
7 V5 Formula Systems have been installed, replacing their entire previously installed batch system. After each ingredient is weighed, labels are generated through mobile wireless network label printers to identify the ingredient lot number, name and the job which the ingredients relate to. This information is then captured at the mixer using mobile tables pc’s with integrated scanners to provide a ‘zero mistake culture’, enabling batch validation for the hand added & bagged ingredients.
A single V5 Formula System is also installed into their offsite liquid ingredients blending facility and the database is linked to their main facility through VPN to provide a central point of data storage and retrieval.
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
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