Award-winning cheese processor installs Integreater to capture and track live stock data
The firm based in Lancashire, UK, produces a range of cheese for retailers, wholesalers and food service businesses including Traditional Lancashire, Blacksticks Blue, Red Leicester and Double Gloucester, as well as hard and soft goat and sheep products.
Lean manufacturing objectives
Gillian Hall, owner, Butlers Farmhouse Cheeses, told FoodProductionDaily Integreater will manage all aspects of the cheese making process from activity at its diary in Inglewhite, to the cut and pack processes of the despatch plant.
“The software will help Butlers to drive its lean manufacturing objectives, capture and track live stock data, as well as grading, maturity, yield and giveaway information,” she said.
Integreater is a range of food productivity software to help manufacturers see, measure, simplify and improve their business. It includes stock control, despatch, quality assurance, weighing and labelling, tracking and monitoring, forecasting, planning, sales and purchase order processing, packaging waste and yield management.
Rob Stephens, managing director, Systems Integration, said its client base has doubled since launching Integreater in 2010 and to maintain its customer support service it has hired 60% more staff.
“More food processors are recognising the importance of the right business management software. Over the past few years the recession has put a strain on already tight profit margins in the food sector and to make matters worse, processors have faced a backdrop of food scares, as well as increasing customer and legislative demands,” he said.
“Despite this, we’ve experienced our fastest period of growth during this time. This is because our software not only enables users to quickly and easily demonstrate traceability; it provides them with the live tools they need to maximise profitability, even during tough market conditions.”
Vantage US retailer Ahold
Established in 1992, Systems Integration has partnerships with food manufacturers across the UK and North America including Vantage Foods which uses its Production Planning software at its Camp Hill site in Pennsylvania, US.
The factory is one of the largest case ready meat plants in North America and is managed by Vantage for retailer Ahold.
"We have hundreds of products in our range, some of which are made from the same raw materials but have to be processed on different production lines and at different times,” said Kerri Castillo, scheduler, Vantage.
“Our delivery vehicles also depart at various times to reach depots in different parts of the country. This means we may have to stagger production accordingly. To add to the pressure, we often receive last minute changes and top up orders.
"Unfortunately, spreadsheets become out of date as soon as they are created. Production need updated plans every time there is a change. With Integreater I can see my entire plan on one screen and have complete visibility of Forecast, Pre and Final orders. I can add forward production or adjustments easily. I can also click on any item for detailed associated data such as which stores' orders contribute to a product's production figure."
The firm also works with South Caernarfon Creameries dairy co-operative in North Wales, which has nearly 150 members that manufacture 10,500 tonnes of cheese and 12 million litres of milk a year.
It uses Integreater’s enterprise manufacturing execution system, e-MES to automate the creamery's grading and quality assurance system, updating entire batch records with sample test results on their 37 acre site to reduce labour costs.
