Manufacturing traceability and compliance
Food processors focus on compliance and traceability initiatives for a number of reasons, which ostensibly will keep them competitive and in business. More specific reasons, according to a study from AberdeenGroup entitled Compliance and Traceability in Manufacturing, include compliance to regulatory mandates, adherence to internal policy guidelines, mitigating risk of product recalls and building customer trust.
The report, which surveyed more than 650 manufacturing executives, also says companies are increasingly focused on reducing manufacturing costs, and particularly the cost of poor quality with end-to-end traceability of product and processes. According to the report, best-in-class manufacturers are more likely to adopt technology solutions for their traceability initiatives at the enterprise level.
Best-in-class manufacturers respond to non-conforming shipments up to 44 hours ahead of laggards (see table, “Top performing companies earn best-in-class status”). Best-in-class manufacturers are 89% more likely than laggard manufacturers to integrate product and process data collection across the supply chain, resulting in a 36-minute response time to non-conforming shipment. Best-in-class companies manufacture 98% of their product in compliance with their process, as compared to 85% for laggard manufacturers. Best-in-class manufacturers realize 95% first-pass yield, as compared to 74% laggards. Best-in-class manufacturers realize 96% on-time delivery as compared to 89% for laggard manufacturers.
(A complimentary copy of the report is available for a limited time. It can be found at http://www.aberdeen.com/summary/report/benchmark/4138-RA-compliance-and-traceability.asp.)
Top performing companies earn best-in-class status
|Definition of Maturity||Mean Class Performance|
Top 20% of aggregate performance scorers
| 98% products in compliance
95% first pass yield
36 minute response time
96% on time delivery
Middle 50% of aggregate performance scorers
| 94% products in compliance
91% first pass yield
8 hour response time
91% on time delivery
Bottom 30% of aggregate performance scorers
| 85% products in compliance
74% first pass yield
45 hour response time
89% on time delivery
|Source: Aberdeen Group, December 2007|
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Enzymes replace emulsifiers and other chemicals
The battle between enzymes and emulsifiers is intense in the bakery industry. Enzymes such as amylases are increasingly replacing emulsifiers such as DATEM and mono and diglycerides. Enzymes perform the same functions as emulsifiers, including crumb-softening, anti-staling, starch complexing and extension of shelf life at relatively lower concentration that emulsifiers.
Enzymes, being organic in nature, do not have to be listed on the label as additives, hence the “clean-label” showing fewer additives. Currently enzymes are replacing emulsifiers at the rate of 5 to 10% in bakery applications.In the wine-making industry, the enzyme market grew at a rate of 4.3% in 2006. And in fruit juice production, the chemicals used for depectinisation have been replaced by enzymes such as pectinases. Enzymes break open fruit tissues to release more juices.
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