Managing allergens isn’t just a case of ticking a compliance box, it’s essential for safeguarding consumer health and maintaining a good reputation. With increasing awareness around food allergies and stringent regulations in place, manufacturers must ensure that their processes minimise the risk of allergen cross-contamination.
This is where advanced software solutions like Opcenter APS can make a significant difference, helping businesses to improve their allergen management and keep consumers safe.
Streamlining production scheduling
One of the major challenges in allergen management is dealing with the complexities of production scheduling. Allergens, such as nuts or dairy, require thorough cleaning between production runs to prevent cross-contamination. This cleaning process can be time-consuming and costly, often resulting in downtime and reduced efficiency.
Opcenter APS addresses this challenge by intelligently scheduling production runs to minimise the need for frequent changeovers. By grouping similar products together or arranging allergen-containing products at the end of a production run, the software helps reduce the frequency of clean-downs. This approach not only cuts down on cleaning time but also ensures that machines spend more time in production rather than idle. In turn, this improves overall efficiency and productivity.
Coding and tracking ingredients
A key feature of Opcenter APS is its ability to code all products and ingredients based on their allergen content. This detailed coding system allows the software to consider allergen attributes when scheduling production. By having a clear view of which products contain allergens, the system can plan the production flow in a way that avoids the risk of cross-contamination.
For instance, if a product containing nuts is scheduled to be produced, Opcenter APS ensures that the subsequent runs are allergen-free, or at least not containing the same allergens, to prevent any potential cross-contact. This approach is helpful in maintaining a safe production environment and protecting consumers with allergies.
Alerting planners to potential conflicts
Even with the best planning, conflicts can still arise. Opcenter APS helps prevent potential allergen issues by alerting planners to any conflicts between successive production runs. For example, if a product containing an allergen is followed by a product that must be allergen-free, the system will flag this as a potential issue. This early warning system allows planners to make adjustments before problems occur on the factory floor, reducing the likelihood of allergen cross-contact and ensuring smoother operations.
Ensuring full traceability
Traceability is vital when it comes to allergen management. If an allergen issue is discovered in a product after it has been shipped, manufacturers need to quickly identify and address the problem. Opcenter APS provides full traceability of batch-level production details, making it easier to trace the product forward or backward through the production process.
With detailed records of each batch’s production history, manufacturers can quickly pinpoint where an allergen might have been introduced and take corrective action. This traceability not only helps in resolving immediate issues but also supports long-term improvements by identifying patterns or recurring issues in the production process.
Learning from historical data
Another significant advantage of Opcenter APS is its ability to learn from historical data. As the system gathers information on scheduling constraints and allergen management, it can refine its scheduling strategies based on what has worked well in the past. This continuous learning process helps improve scheduling accuracy over time, further reducing the risk of allergen cross-contamination and enhancing overall production efficiency.
Addressing short shelf-life and emergency runs
Food products often come with short shelf-lives, adding another layer of complexity to production scheduling. In cases where a special order or emergency run is required, manufacturers might need to adjust their schedules on the fly. Opcenter APS can adapt to these changes and update the production schedule accordingly, ensuring that urgent orders are fulfilled without compromising allergen management practices.
However, these emergency runs can sometimes result in additional cleaning down times. While manufacturers might face extra costs associated with this, the software helps mitigate these impacts by enhancing the overall schedule to minimise downtime as much as possible. The goal is to maximise production efficiency while still adhering to allergen management protocols.
System compatibility and integration
When adopting a system like Opcenter APS, compatibility with existing manufacturing processes and equipment is crucial. Opcenter APS is designed to integrate smoothly with various manufacturing systems, ensuring that it can work effectively within your current setup. This compatibility helps avoid disruptions and ensures that allergen management processes are seamlessly incorporated into your existing workflows.
Ready to see how Opcenter APS can help your business? Contact us today. With our years of expertise and skills, we’re able to help give tailored solutions for your business. We even have experience working with big brands, so you can be confident that you’re in safe hands.
