Paramount 21 Limited, a family owned frozen food manufacturing company and a leading name in the seafood sector, has chosen Stevens Group Limited to implement a factory-wide paperless traceability system, delivering substantial material efficiencies and cost savings.

Paramount 21 needed a complete factory process control system that would control and manage the food manufacturing process, from raw material received to finished product. This required the scheduling of works orders to each line in the factory, and then recording the use of recipes and raw ingredients in the creation of each product to provide visibility of production quantities, along with traceability information to meet various quality standards. An interface with Paramount 21’s MRP system (Pegasus Opera) was also required.

Ingredient Receiving & Labelling Process

Stevens Receiving Software is installed on a PC and connected to a label printer, removing the need for a paper based booking-in system. The integration with Pegasus Opera allows cross referencing with purchase orders to ensure supplier compliance while providing price information for later job costing analysis.
Receipt of the stock is confirmed to Opera, which returns a confirmed ingredient cost once an invoice relating to the purchase order and delivery is received. Stevens Receiving Software allows Paramount 21 to control use of ingredients throughout the factory process, saving money through ingredient rotation.

Weigh Up and Ingredient Mixing
Paramount 21 installed the Stevens Vantage RFS (Recipe Formulation System) to control the weighing accuracy of ingredients used to make up processed mixes. The mixes (sauces, spices and other processed ingredients) are weighed up on scales connected to the Vantage Terminals. The easy to follow screens utilise simple dial displays and guarantees the elimination situations of ‘too much or too little’.

Assembly Lines
Two ‘multi line’ Vantage terminals are located at the production lines to display line specific production orders. The terminals allow completed batches to be combined with other ingredients used during the assembly process, providing complete costing for the jobs and 100% traceability. At this point the ERP System is provided with accurate job costing which in turn can be used for accurate P&L accounting.

The ‘drill down’ reports allow easy navigation through the newly developed reports suite. The reports allow production summary information, batch specific data and even lot number reports to enable the viewer to see ‘where, when and how’ for all of the ingredients used through the production process.

Paramount 21’s Financial Director, Jon Phillips, comments on the Stevens Solution: “We compiled a detailed project requirement to enable us to streamline our processes, expand our ERP to the production floor and achieve complete factory floor traceability. Stevens demonstrated their proven solution and modified their existing software to work with and meet our needs 100%. Their attitude and support is second to none and we are delighted with the implemented solution.”
Stevens manufacture a range of weighing solutions which include Recipe Formulation, Average Weight and In-Line Product Inspection Systems.

Please visit www.stevensgroupltd.comfor further details