Software created after BSE crisis turns new tides

The software controls all purchasing and intake processes, production and critical yield points such as head removal, deboning and filleting.

By using data capture and bar code scanning, JCS has automated its factory floor processes in Grimsby, in the UK, to eliminate human error and create a single point of collection for all departments to work from.

Perishable food industry​

Rob Stephens, managing director,Systems Integration, told FoodProductionDaily, its system was introduced to the market over 20 years ago and is continuously evolving due to the dynamic nature of the perishable food industry.

“We experienced significant growth in the meat sector when traceability legislation was introduced following the BSE crisis​,” he said.

“In 2010, we launched our Integreater brand and started to acquire customers in other food sectors​.”

Louise Coulbeck, director, JCS Fish said the business has grown steadily, expanding year on year since the company was established in 2000 and it wants to focus on improving production processes, traceability and real-time business information to make decisions.

'Think outside the box'​

“JCS is a proactive business that values team effort from factory floor staff through to the MD​,” she said.

“We aren’t afraid to try new things and think outside the box so we can continue to diversify and grow in an ever-changing climate​.”

The software is used by more than 85 food processing sites across the UK and North America, including Butlers Farmhouse Cheeses, Falfish, Seachill, South Caernarfon Creameries and Vantage Foods, a North American meat processor.

Stephens added the firm is looking forward to launching a food specific production planning software in the New Year.

Under pressure​

“Raw materials and wages are significant costs for food manufacturers. Our software allows users to plan daily production - including labor, raw material and packaging requirements​,” he said.

“Management can set crewing levels against jobs and lines and it will automatically calculate the combined crewing level across production​.”

He said the main challenges for food processors today was facing pressure to produce quality, fresh products at low cost.  

Customer satisfaction​

“Having worked in the food processing industry, our senior management team developed software that saves time, improves accuracy and provides visibility across the business so improvements can be made​.

“It also includes functions that predict product cost variation and order fulfillment​.

“The fast-paced environment of food processing is made worse by having to demonstrate complete traceability to meet legislation and retailer demands. With Integreater, users can find the information they need in seconds​.”

The software includes a live view of production, it can highlight delays and shift production runs onto different lines to meet total daily production requirements.

Coulbeck added its factory has become faster, leaner and paperless which has increased operator productivity.

“We now have full control over our production processes. It gives us complete forward and backward traceability,​” she added.