PC-JUN09-PGS8.OK:PC-JUN09-PGS8.OK.qxd 01/06/2009 14:30 Page S8
Feature Food processing & packaging
Streamlining ice cream production
Marco’s TRAC-IT MES is playing a pivotal role at the
Unilever UK ice cream plant in Gloucester, from the driver
operated pit weighbridge through to raw material stock
holding and recipe make-up
U
nilever operates ice cream fac- Gloucester’s SAP administrator Neil
tories throughout the world, Drew recognised that the mixing room
and sells its ‘heartbrand’ prod- presented a ‘black hole’ regarding
ucts in over 40 countries. Its accurate data. Recipe make-up was
‘hand-held’ impulse products include based around an outdated manual
iconic names such as Cornetto, entry system that was susceptible to
Magnum and Solero, whilst the ‘in- human error and provided inadequate
home’ range includes Viennetta and cross checking. By the time data
Carte d’or. arrived at SAP it was historic and
Seasonal variances no longer affect often inaccurate. This in turn had a
today’s ice cream manufacture, and direct impact on raw material usage
Unilever’s Gloucester factory operates and stock control.
Datamaster termi-
requirement, the bill of materials
throughout the year. Overall plant con- TRAC-IT MES is able to help solve
nal screens provide
(BOM) for the manual assembly of sub
trol at the site is provided via this issue by continually updating sys-
clear operator
mixes is sent to the appropriate TRAC-
Unilever’s SAP ERP system. Although tems such as SAP with live data from
instructions for the
IT Datamaster terminal. The terminal
there is a high level of automation critical control points on the factory
manual assembly of
screens provide clear operator instruc-
within the main factory, make-up of floor via Marco’s Datamaster terminals.
sub mixes
tions and associated bar code scanners
the batches that feed the lines with Through discussions and presentations, check that ingredients are added in the
raw materials relies heavily on accu- Marco was able to demonstrate this correct order. Any errors are automati-
rate manual assembly within the capability to Drew and his colleagues, cally flagged up, preventing further
mixing plant. hence the contract was awarded. progress without supervisor interven-
Marco’s TRAC-IT MES factory floor Now during recipe make-up in the tion. As each ingredient or sub mix is
efficiency system focuses on the mixing plant, SAP acts as the master, collated, individual barcode labels are
mixing plant and incoming bulk raw with conformity cross checks taking printed to accompany them en route to
materials – this is the first phase of an place with the TRAC-IT Technical the mixer.
ongoing project to improve control, Specification Module (TSM). In typi- Manual additions are directly con-
visibility and efficiency at the plant. cal batch mixes ingredients vary from trolled via TRAC-IT, whilst the mix
The installation also includes a driver- bulk inputs such as water, milk and plant systems control the semi-auto-
operated weighbridge, Datamaster oils, to manual additions of fractional matic bulk material additions. TRAC-
recipe control stations and pit- colorants weighing a few grams. IT checks that all the required
mounted bulk weighing floor scales. When a planned work order is ingredients and sub mixes for a partic-
Before the installation, Unilever raised by SAP for a specific batch ular batch are added to the mixer. On
completion of the bulk dispensing, the
A soft landing helps meatballs stay whole
mix plant system transfers the results
to TRAC-IT where this real time infor-
S
wedish food manufacturer Dafgård has been able to achieve gentle
mation, together with the manual
and accurate weighing of meatballs into bags at the speed required
assembly data is checked against the
following the installation of an Ishida multihead weigher.
works order and passed back to SAP.
“Our target speed is 100 bags per minute but it is vital that the
As raw materials are withdrawn
integrity of the meatballs – which can break apart during handling – is
from stock ready for mixing, SAP auto-
maintained,” explained assistant plant manager Christoffer Sundberg.
matically downgrades stock levels
“Many of the suppliers we talked to could not guarantee this essential
based on actual usage. TRAC-IT holds
combination of speed and delicacy in handling. Only Ishida could pro-
in limbo records of these materials
vide a suitable solution for all product sizes. During tests, the machine
until the ingredients have actually
been placed in the mixer.
achieved speeds of up to 120 bags per minute, far outstripping the
“TRAC-IT has given us an environ-
required capacity.”
ment where we now have total control,
The Ishida CCW-M-214 has been designed to handle food products
total reportability, less mistakes and
that require gentle and controlled handling. A low angle, reinforced dis-
one where every action is logged. This
persion table with concealed fixings, semi-flat radial feeder troughs
clearer operational visibility has
with waterfall end and safe edges, and double opening hoppers with
enabled us to reduce our raw material
cushioned, easy down inserts ensure that the product moves quickly stock holding levels,” said Drew. “We
through the weighing machine without the risk of damage. In addition, are now in the process of bringing
the gentle slope configuration of the discharge chutes, along with a set other areas within the factory under
of metal guides, serve to reduce the fall speed of the product and pre- the TRAC-IT umbrella.”
vent the meatballs from colliding, thus allowing a quick product trans-
fer into the integrated VFFS bagmaker.
Marco
Ishida Europe T: 0121 607 7700 www.ishidaeurope.com Enter 232
T: 01342 870103 Enter 233
www.marco.co.uk
S8 JUNE 2009 Process & Control
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