To find out more and explore our many food productivity modules and services,
simply click on the links below.

Performance & Improvement
View Modules

Dashboard

The problem

Management need a detailed view of productivity for each process under their control, as well as an overview of their department. Similarly, every CEO wants to know what’s going on in their business – without having to spend time on the factory floor.


The solution

Integreater’s dashboard tool allows managers in each part of the production cycle to easily monitor process-specific performance. It can be configured to measure whatever data is most important to each department and features a ‘drill down’ function for detailed analysis.

The dashboard also provides CEOs with highly visible and consolidated information. This ensures that they always have an accurate, real time overview of their business’s performance – wherever they are.


The result

Integreater’s dashboard tool gives management complete visibility across the processing cycle. This means that problems can be easily identified and resolved, improving productivity. Owners and board members also have an accurate view of the factory floor, enabling them to focus on long term objectives and strategy.

Download Dashboard factsheet

Business Analysis

The problem

Management understand the importance of business analysis, but rarely get chance to undertake this critical task.

Business analysis is not traditionally viewed as being part of the processing cycle. It’s often performed on an ad-hoc basis, usually a last minute scrabble around audit time – or on the rare occasions when management have a spare moment.


The solution

Integreater® ensures that this important task becomes part of the processing cycle. It works by integrating with your production network to automate the continuous measurement and analysis of essential data.

Processors are able to quickly and easily dissect any measured result, including yield, throughput, product giveaway and pack-fill. Information can be viewed in real time, or for a specific date/time range.


The result

Integreater® takes all the hard work out of business analysis, providing management with the knowledge and visibility to make informed decisions and set realistic objectives.

Download Business Analysis PDF

Overall Equipment Effectiveness (OEE)

The problem

Downtime is a major difficulty for any manufacturer because it has a negative impact on productivity. It is particularly problematic for food processing businesses as it cuts into already small profit margins.

Most businesses are aware that there are issues causing downtime, but it’s difficult for the reasons to be singularly identified to site management or engineers. Even if a section is being monitored, collating the information into a meaningful set of data is very time consuming.


The solution

Integreater® gives you the knowledge and visibility to identify exactly what is causing production downtime. It provides a detailed view of productivity on a machine, process and departmental level.

The e-MES enables management to set business-specific targets, then records production data to assess performance against these criteria.

Electronic data management allows operators to quickly and easily record any issues or problems, as well as the reason why they occurred. Management can then identify and rectify any inefficiencies, enabling them to streamline their production process.

Integreater® can be programmed to capture whatever information is most relevant to each business, including the line number, stop/ start time and reason. A simple chart then displays the amount of production time being lost at each stage of the processing cycle. This enables management to easily identify any trends in faulty machines or processes.


The result

Management are able to minimise downtime and maximise productivity. This will optimise order fulfilment and service level, as well as profit margins

Download OEE factsheet

Key Performance Indicators (KPIs)

The problem

Although management are always looking to improve performance, measuring productivity is often retrospective and undertaken separately to the processing cycle. This can be time consuming and prone to error.

Despite being an extremely important function, monitoring performance can be ad-hoc. It often takes a back seat to seemingly more pressing issues, such as meeting last minute order changes.


The solution

Integreater® enables food processors to continuously monitor productivity. Management set key performance indicators for their business and the e-MES then integrates with the processing cycle to measure the relevant data.

Information is presented in real time using simple colour-code technology. This allows operators to easily identify and rectify any issues that are affecting performance.


The result

Management have an accurate, up-to-date view of performance and are able to identify any trends. In order to understand the reasons behind performance issues, the KPI module can also be used in combination with Integreater’s Business Analysis and OEE tools.

Download KPI factsheet

Benchmarking

The problem

We all know that we have the potential to achieve greater productivity – but in a busy food processing environment, management rarely have the time to accurately benchmark their performance.


The solution

Working in conjunction with our KPI measurement tool, Integreater’s benchmarking software allows processors to set business-specific targets to measure their performance against. Management are able to continuously assess productivity and if benchmarks are not being met, this tool can be used with Integreater’s OEE software to identify the reasons why.


The result

Management can measure and benchmark the data that is most important to their business, allowing them to easily spot any problems. This reduces the potential of future issues and improves long term performance.

Download Benchmarking PDF

Browse Modules
Dashboard
Business Analysis
Overall equipment effectiveness (OEE)
Key performance indicators (KPIs)
Benchmarking

“We’ve now got one version of the truth; there’s now one place we can go to get all that information and it’s providing a more efficient way of working”
DB Foods

Customer Service and Management
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Quality Control

Need to be confident that everything is traceable and compliant?

If you’re reliant on manually recording quality assurance data you will appreciate how this can hamper your operation. Any investment in ERP should consider how it will better enable TQM and support Right First Time methodologies, to both save time and improve accuracy. Whilst data capture will track the progress of your products, you need the rigour within quality assurance checks to track specifics such as moisture levels at different stages.

Integreater has been specifically designed to excel at shop floor data capture. Data can be readily captured across a range of devices – from touchscreens, laptops, tablets through to handheld devices and PDAs – integrated with 3rd party products, and transferred wirelessly to a server so that you have a complete picture. With flexible, interlinked reports, customised to reflect your own procedures, with Integreater you will achieve traceability of QA results your way.

As Rob Stephens, SI’s Managing Director explains, “In terms of QA, with each and every process there are many different checks that have to be performed. Many factories are reliant on check sheets; the QAs use these forms to record status at different times of day when they walk the floor. Inevitably, this results in piles of paperwork to wade through whenever they get audited and it can take days to prove that all the checks have been performed and that whenever there’s been a non-conformance, they’ve done something about it. It’s a very reactive way of doing things. Filling in forms doesn’t indicate whether their processes are going well or badly, or if they are doing the correct number of checks at the right time.”

“Our software electronically collects and stores the same information and automatically flags up any issues. It shows how many checks are being performed, when they are happening and identifies any non-conformances. It becomes a very proactive way of managing QA; it provides a clear view of what’s being done, whether there’s anything that can be improve upon and, in terms of real traceability and looking at what you do, everything is instant because the information is already in place and available to be viewed.”

“It’s a very proactive way of managing QA and ensuring real traceability.”

Download Quality Control factsheet

Margin Manager

The problem

Having full control and understanding of costs is essential in such a price- sensitive sector. Unfortunately, businesses find it difficult to account for all the fluctuations, complexities and variants associated with food processing.

Analysing costs when supplying different specifications to a number of customers can often leave processors guessing their margin. The tracking of credit back values need to be considered, as well as other factors, including waste, promotional activity, price adjustments, new product development and specification changes. This leaves little time for cost analysis, meaning problems are often identified when it’s too late and profits are dented, or losses have been made.


The solution

Integreater® provides a detailed breakdown of costs, automating calculations to ensure that processors have continuous, accurate and up-to- date information.

Product specific benchmarks can also be set to measure and compare results against. This helps processors to avoid overspending, allowing them to understand if and where they can make cost savings.

The application works by using a hierarchal structure to include prices from the initial raw material, right through to multiple finished products. This incorporates each stage of the processing flow, as well as credit back values.

Ingredient prices, packaging prices and product specifications are simply imported. This allows users to view existing price and cost, matched to actual and forecast sales volumes. Additional specifications or costing models can be easily created and users can also view margin by product and product group. Sales price, costs and margins for both their actual or forecast sales volume can also be easily analysed. This gives the overall weighted average margin of the business, as well as the weighted average margin by customer and product group.

Integreater® allows users to easily adjust margins to their desired position, enabling them to view the sales price that will need to be charged in order to achieve their goal.


The result

Management gain complete understanding and control of all their costs. They are able to identify where they are making a profit or loss and understand the reasons why. Integreater® provides a total understanding of the implications that any changes will have on overall margin. This is particularly useful when negotiating prices and planning promotional activity.

Download Margin Manager factsheet

Cost Modelling

The problem

Having full control and understanding of costs is essential in such a price-sensitive sector. Unfortunately, businesses find it difficult to account for all the fluctuations, complexities and variants associated with food processing. Inaccuracy is a common problem that leads to losses in a surprising number of cases.

The solution

Integreater’s modelling tool provides a detailed breakdown of costs, automating calculations to ensure that processors have continuous, accurate and up-to-date information.

Product specific benchmarks can also be set to measure and compare results against. This helps processors to avoid overspending, allowing them to understand if and where they can make cost savings.


The result

Management gain complete understanding and control of all their costs. They are able to identify where they are making profit or loss and understand the reasons why. This is an essential tool for businesses operating in an industry renowned for price-based fluctuations and notoriously tight profit margins.
Browse Modules
Quality Control
Margin Manager
Cost Modelling

“We operate a BRC accredited plant. This means we are always looking at ways to improve quality and efficiency. I’m confident that Integreater® will gve us complete visibility and control.”
Dansko Foods

Production Control
View Modules

Problems with shortages or surplus of stock for your raw materials as a result of poor data?


Sales order processing is critical to food processors but all too often disparate systems result in poor communications, mistakes, duplication of effort and delays. Mainstream solutions are unlikely to deliver the depth of information or functionality that your business needs.

Consider the following when evaluating any sales order processing solutions:

  • Is it comprehensive enough to handle EDI, web orders, as well as manual data entry?
  • Does it have a comprehensive CRM, integrate with your preferred accounting solution and able to hold multiple price lists per customer?
  • Can it analyse data such as order history, who’s buying, who’s not buying, type of orders?
  • Will it create and process your sales orders with ease and accuracy, for instance with drag & drop order tools, easily amend orders in real-time and when they are already in progress?

Download Sales Order Processing factsheet

Purchase Order Processing

Need complete visibility of your orders?

Our Purchase Order Processing (POP) software is designed purely for the challenges of the food productivity environment and provides complete visibility of what is being ordered throughout your operations. When used in combination with Integreater’s Stock and Order solution, the purchase order processing module will register any shortfalls in raw material or packaging and automatically generate the necessary purchase orders.

Paper based purchase order systems are time consuming and susceptible to error and duplication, particularly when department place orders separately. And without complete visibility, accurately verifying deliveries at good-in is unnecessarily complex.


The solution

Integreater® uses electronic data management to centralise your purchase order function. Operators are able to match deliveries against invoices and accurately check what should have been received. This saves a great deal of time and significantly improves accuracy.

Businesses are also able to centrally manage the prices that they pay for raw materials and packaging, as well as any goods received notes.

With recently enhancements, as well as providing the ability to create standard purchase orders for raw materials and dry goods items, the interface also offers:

  • Colour codes status indicators
  • Generic and supplier prices
  • Copy order
  • Chase dates
  • Draft Purchase Orders
  • Emailing of Purchase Orders direct to suppliers
  • Auto Complete on full receipt
  • Min and Max stock levels display
  • Current On hand Stock Levels per area
  • Re-order levels
  • Purchase Order templates

The result

Integreater® creates an organised purchase order function that ensures complete visibility for staff across all departments. Buyers have more control over the purchasing process and operations staff have the visibility they need to optimise productivity.

Download Purchase Order Processing factsheet

Livestock Suite

The problem

Strict and extensive legislation is one of the toughest challenges currently facing abattoir management. As it is essential to demonstrate complete traceability, slaughter houses must ensure the accurate identification, selection, weighing, grading and labelling of all livestock and carcasses. It is also vital that they correctly record and disclose any veterinary conditions.


The solution

Integreater’s Livestock Suite ensures that traceability becomes part of the business cycle in any abattoir. It enables real time monitoring, capturing livestock data from delivery right through to despatch.

Integreater’s web based Livestock Tracker measures important factory floor data, ensuring that management have complete visibility and control of the slaughter process. To support operations, the Bookings, Management and Payments system automates complex and time consuming administrative tasks.


The result

Integreater® ensures that management have an accurate view of their Kill Line, alerting operators to any potential issues. This enables staff to act quickly and contain any problems, minimising disruption.

Integreater® has been developed to ensure that businesses meet important industry legislation, helping them to avoid penalties and fines.

Electronic data management enables abattoirs to easily provide evidence to relevant authorities, even within short time frames. Integreater® is also compatible with most commonly used business software, ensuring information is provided in a suitable format.

Download Livestock Suite factsheet


What our customers say…

“We are now 100% sure that MHS health information gathered is accurately attributable to the correct animal (let alone the correct batch of animals, as is required by the legislation). In conjunction with other systems which we had in place already, this allows our producers to benchmark performance of healthy animals against animals which have perhaps had some health issues, primarily fluke, which is a massive issue for producers in our catchment area.”
John Craig, Operations Director, A.K. Stoddart

Outer Case Marker (OCM)

The problem

Food processors produce cases of product which need to be weighed, labelled and shipped efficiently. They need an affordable solution which is easy to maintain, but can cope with their specific business requirements.

In terms of functionality, management need to be able to set product selection screens to their own specification. Users also need to be able to add and remove products, as well as group them into colour coded categories and produce high quality labels.


The solution

Integreater’s OCM is high quality and durable. The standard model comes with a variable-height frame, mast, load cell and touchscreen, as well as a printer and scale indicator. The unit is provided fully assembled and can be tailored to your specifications. For example, you may want additional printers, an IP65 rated printer garage, or a swing arm for the screen.

The touchscreen is used for running Integreater’s OCM software, which will provide you with all of the functionality that you need. Once we have built the unit and configured it to your specifications, we will design any labels that you require and set up your products on the system. The unit will then be shipped to you and one of our engineers will install it, test it and provide training at both operator and administrator levels.


The result

Operators are able to accurately weigh and label products, with speed and ease.
Production quantities for each product are sent to the OCMs on the factory floor. This information is grouped by run number, so that target quantities and progress can be displayed on the touchscreen. Operators will now know how many cases are outstanding for each run, as well as what has been completed. This enables your business to improve traceability, organisation, productivity and efficiency.

Download OCM PDF

Production Tracker

The problem

Food processors face a series of unique challenges that make production control difficult. Management have to deal with short product life and tight operating margins, as well as the numerous complexities associated with each customer and product.

A time-pressured production environment often means that problems are only identified once orders have been despatched. If processors fail to effectively track production, it can ultimately lead to fines, product recalls, damaged customer relationships and negative press.


The solution

Integreater® enables processors to monitor and control each stage of the production cycle. It automatically provides information on what has been received, issued or returned in the raw material area – as well as what has been booked into stock or finished goods. The tracking tool monitors product giveaway, comparing actual or ‘catch’ weight to fixed-weight specifications.

Integreater® enables processors to view results in real time, or for a specific time/date range. Production run numbers also enable management to precisely pin-point any issues, providing them with the knowledge and understanding to rectify problems as soon as possible. This promotes a proactive management culture and significantly improves reaction lead-times.


The result

By monitoring critical data for each processing function, Integreater® enables businesses to have complete visibility of their production cycle. Its tracking tool provides processors with the knowledge and understanding to effectively plan. This ensures management can make improvements to achieve greater accuracy, efficiency and profitability.

Download Production Tracker factsheet

Production Monitoring

The problem

Monitoring the production cycle is a challenge for any food processing business. Producers have to deal with short product life and lead times – whilst accounting for differing raw materials, customer specifications and product variants.

Poor visibility of the processing cycle can mean that management fail to identify inefficiencies and inaccuracies. If problems are left to escalate, this has a negative impact on productivity, order- fulfilment and costs.

Poor production monitoring can cause small issues to escalate, which can lead to product recalls and fines, damaged customer relationships and negative press.


The solution

Integreater’s monitoring tool ensures visibility across the production and despatch functions. It enables processors to view essential data on produce that has been issued to the production floor, as well as any returns. Management can also monitor quality conformance and raw material receipts.

Integreater® ensures that management have a real-time view of each function within the processing cycle. Its monitoring tool continuously records and analyses performance data, ensuring that operators have an accurate view of production. This enables processors to measure results against business-specific benchmarks and plans.

Operators are alerted to any problems, enabling them to take immediate action to minimise disruption. Complete traceability ensures that processors can pin-point exactly which products will be affected by a quality control issue, significantly reducing upheaval, waste and cost.


The result

Integreater® ensures complete visibility and traceability throughout the production cycle. This enables processors to monitor each function within their business, measuring the data they feel is most critical to performance. Electronic data management ensures producers have the knowledge to effectively identify, isolate and rectify any problems. This enables them to achieve greater accuracy and efficiency.

Download Production Monitoring factsheet

Despatch & Tracker

The problem

The need to remain responsive to customer demands can put dangerous pressure on a despatch team. In this time pressured environment, poor visibility of collation makes fulfilment difficult, especially with last minute order changes. Mistakes in rotation and shelf life management can quickly damage profit and customer relationships.

The solution

Our Despatch & Tracker software works by interfacing with other Integreater® modules and third party solutions. This means that orders can be manipulated in a number of configurable formats, including order/picking sheets and tracker views. Reports can then be received by the despatch department in print or electronic format, either through a PC or wireless PDA device.

Integreater® allows despatch operators to remain mobile by continually feeding real time updates to their PDA devices. Information includes the correct stock to pick, its location (based on product description) and shelf life availability.

To improve accuracy and efficiency, products are assigned to an order through barcode scanning. Integreater® has a function which enables operators to despatch whole pallets by simply scanning one barcode. Individual units can also be transferred from these pallets, retaining their unique trace code.

To meet your individual business needs, responsibility for order releases can be restricted and despatch documentation can also be customised.


The result

Total control enables processors to achieve complete accuracy and efficiency, helping management to improve service levels and minimise losses. The order processing and despatch cycle becomes visible, accessible and easy to manipulate. This results in accurate despatch against orders, less internal wastage and reduced delivery claims.

Despatch & Tracker software allows management to monitor and respond to issues proactively and accommodate any sudden changes. In addition, despatch operatives are able to manage everything from their pocket PC devices, making them more efficient.


What is a Tracker?

A tracker is a web-based tool which allows operators to
view data from anywhere using an internet connection. Please see below for some of the benefits of this feature:

  • Can be used to review business performance when
    away from site
  • Real time updates for complete visibility
  • Most information is available on one screen for easy
    access
  • Data can be exported to Microsoft Excel

Despatch & Tracker is used to display the progress of picking against orders due to be shipped. Working in real time, the system is continually updated so you have full visibility of where you are in the order assembly and despatch cycle. To access further information, users can simply drill into the item to view the detail of the despatch note, loadout information and related order data.

Download Despatch & Tracker factsheet

Stock Tracker

Transform your business operations with an instant view of on-hand stock, available stock and shelf life status

In the perishable goods processing business, the accuracy of stock management data is essential. Profit margins will be quickly compromised without data to understand the nature of all short shelf-life products, stock rotation and the specialist levels of care required.

Companies traditionally apply significant and costly manual resources to collect a snapshot of the stock at a particular point in time, the benefit of which is degraded by the effect of continual fluctuation. This makes stock data expensive to collect, quickly redundant, prone to inaccuracy and with regards to profit margins, self defeating.


Our Stock Module is a powerful tool to enable accuracy and a clear view across stock management: from intake, raw materials, work in progress, finished and dry goods, through to shelf and least life validation and soft allocation. It can be updated in real-time through the use of wireless devices, such as touchscreens and PDAs. You are assured of the relevance and reliability of stock inventory data and the collection process. Users can validate stock by scanning pallet and item barcodes, making better use of labour resources.

“With a live stock view our customers always know exactly what they’ve got in stock, how to rotate it correctly and ensure product doesn’t go out of date.” Rob Stephens, Managing Director, SI

Integreater® Tracker provides an instant view of on-hand stock, available stock, stock shelf life status: you know the exact age of all stock and where it is. This enhanced ease and accuracy of stock management delivers significant time and cost savings allowing our customers to improve output.

“Our stock tracker solution has transformed many of our customers’ business operations.” Rob Stephens, Managing Director at SI explained. “Typical results includes a vast reduction in the number of claims made, in terms of deliveries not matching what was on the paperwork, and a greatly improved ability to get the product out the door faster. With a live stock view they always know exactly what they’ve got in stock, how to rotate it correctly and ensure product doesn’t go out of date.”

Download Stock Tracker PDF

Dramatically reduce the margin for error

Our shop floor data capture solutions enable food processing businesses to gather essential data from the factory floor quickly, efficiently and accurately. Through the use of fixed and mobile data capture points your operation can become paperless and gain access to real-time information and reporting.

When combined with our management tools, including Production Tracker, Stock Tracker and Despatch Tracker, your business will gain unparalleled visibility of key data throughout your operations.

Integreater® works by capturing information throughout the process, giving us complete forward and backwards traceability. We now have the ability to find product history and information in seconds.”
Louise Coulbeck, Director, JCS Fish.

Automate your shop floor data capture through our wide choice of barcode scanners (wireless and corded), touchscreens, label printers, scales & indicators and intelligent software. Track all your processes, from purchase order receipt right through to stock take.

  • Purchase Order Receipt
  • Direct Receipt
  • Stock Movements
  • Auto (Live) Stock Booking
  • Stock Issues & Returns from Production
  • Dry Goods Issues and Returns
  • Product Snap Yield
  • Batch/Production Run Traceability
  • Outer Case Marking (OCM)
  • Weigh Price Labelling
  • QA Paperless Systems
  • Finished Goods Despatching
  • Despatch ASN Label (SSCC)
  • Stock Taking
For more information on any of the following or any other shop floor data capture requirements you may have, please call us now on +44 1543 444555
Browse Modules
Sales Order Processing
Purchase Order Processing
Livestock Suite
Outer Case Marker (OCM)
Production Tracker
Production Monitoring
Despatch & Tracker
Stock Tracker
Shop Floor Data Capture

“With Integreater we are now able to establish fully operational profit margins, our stock turnover, our stock availability and our stock traceability”.
DB Foods

Planning & Management
View Modules

Stock & Order

When customers want to increase orders, it’s imperative to understand whether the right raw materials are available to fulfil the order. And when orders are decreased, processors will need to determine what to do with the surplus stock. With the real-time data capture within Integreater® you will be able to analyse the intelligence, make informed decisions; you will understand whether to order more stock, if you need to sell the excess stock to another business and how cut wastage to a minimum.

With Integreater® your fresh produce business will have the data transparency to deal with all your customer orders, no matter how much notice you are given. Every part of your business will be connected so that everyone has the information they need, whenever they need it and in a way they prescribe.

Download Stock & Order factsheet

Available To Sell

The problem

Poor vision and planning at food processing plants can result in surplus and shortage of stock in both the raw material and finished goods warehouses.

Over stocking leads to wastage, forcing processors to freeze produce. This significantly lowers sales value and increases storage costs, both of which reduce already small profit margins.

Under stocking also increases costs, as processors cannot afford to negotiate the best prices when purchasing raw materials at the last minute. Operators may also fail to fulfil orders on time, which can be very damaging to customer relationships.


The solution

Integreater® ensures that management have an immediate, real-time view of what stock is available to sell based on fulfilled orders and raw material availability.

The system uses simple colour-code technology to ensure 100% visibility of stock volume, location, age and value. It is also possible to analyse and segregate production using run numbers, enabling operators to isolate any problematic batches with ease. Management have far more control and disruption is contained, reducing any negative impact on the production cycle.

Electronic data management promotes informed decision-making, planning and forecasting. This is supported by touch-screen technology, enabling processors to easily view information on live and future stock, as well as the actual and unconfirmed orders to be satisfied.


The result

Food processors have the vision and knowledge to achieve effective planning and stock management. Operators can instantly view what raw materials are on site and the sales team always have an accurate view of stock availability. Businesses are able to optimise order fulfilment and be best prepared to cope with last-minute order changes.

Download Available to Sell factsheet PDF

Production Planning

The problem

Retail packers receive numerous orders every day, usually with very short delivery deadlines. Many food processors are working with perishable raw materials that have a short shelf life. If they over stock, surplus will go out of date and if they under stock, they won’t be able to meet orders. In order to reach different customer depots on time, delivery vehicles have to depart throughout the day. If a vehicle is late, it could be turned away and if they don’t achieve 100% service level fulfilment, processors may be fined.

Planning in this environment is very difficult. In addition to short delivery deadlines, last minute changes and top-up orders are common. This means that any plans quickly become out of date. Raw materials and wages form the majority of overheads for a food processing business. This means it’s important to ensure the best possible use of these resources.

Achieving this, while trying to meet orders in an ever changing, fast paced environment, is a huge challenge. As a precaution, processors often overstaff in order to ensure that they fulfil customer orders. Labour is a significant cost for food businesses, so overstaffing eats into already tight profit margins.


The solution

RunMaster allows users to plan daily production in seconds – including labour, raw material and packaging requirements. It automatically calculates what needs to be produced by accounting for the finished goods that are already on site. There’s no need to manually calculate raw material and packaging requirements either, this is also automated.

Planners can set crewing levels against jobs and lines and it will automatically calculate the total crew requirement across production. Users can easily set planned breaks, wash downs, scheduled maintenance and change overs. They can also log machine breakdowns with a click of the mouse.

RunMaster accounts for the scheduled departure times of depot delivery vehicles and identifies if the current production plan will meet these important deadlines. This is live, so the effects of any delays are immediately visible. If necessary, planners can easily split production runs between lines so that orders can be despatched on time.


The result

RunMaster simplifies the complex planning process so that a daily plan can be produced in under a minute. Planners are able to easily make updates with a click of the mouse and can instantly see the knock-on effects that any changes will have. RunMaster will also suggest corrective actions.

Production supervisors and crew have a live view of the plan and their progress. They are also immediately alerted if there are any changes or problems. This kind of visibility enables management to have complete control in the fast paced, ever changing production environment of food processing.

Download Production Planning factsheet

Packaging Waste Manager

The problem

The government has challenged retailers to reduce their carbon footprint. To meet legislation, they are required to monitor their packaging waste levels and provide evidence to regulators.

Retailers therefore need detailed and accurate information regarding the packaging used for their stock.This data is often required within short time frames and unfortunately for their suppliers, the manual collation of paper records can be time consuming and susceptible to error.


The solution

Integreater’s Packaging Waste Regulation Manager has been designed to allow processors to systematically track the packaging they supply to their retail clients. The programme uses electronic data management to automate the analysis, collation and distribution of all necessary information.


The result

Retailers are able to comply with legislation and suppliers benefit from a reduced carbon footprint.

As the environment is an issue which is set to grow in importance, Integreater® allows processors to demonstrate that they are prepared to meet any future challenges with ease. It also gives retailers the reassurance that suppliers are investing in their relationship. This is particularly important for businesses operating in such a highly competitive sector.

Download Packaging Waste Regulation Manager factsheet

Dry Goods Management

The problem

An extensive product range, specification changes and promotional activity can be problematic for the dry goods team at any food processing business. There is no accountability of lost stock or issued quantities. It is also hard to predict delivery forecasts in alignment with production demands.

These conditions mean that trying to manage the dry goods function can prove costly, as it often requires additional labour, last minute adjustments and sourcing.


The solution

Integreater® enables the dry goods and packaging functions to be easily managed. The software accounts for existing stock position and forecasted deliveries. It also uses expected finished goods sales to predict ongoing requirements.

Integreater® allows operators to issue product in real time, so that stock is displayed online. In addition, the stock take facility can be implemented to create weekly usage figures. Multiple warehouses, locations and sites are also catered for – including product transfers.

Unlimited reporting means that management have access to detailed information regarding dry goods and packaging materials. This includes a feature which enables users to visualise the amount of packaging ‘shrink’.


The result

Integreater® enables food processors to gain total control of their packaging and dry goods functions. This is achieved by enabling operators to have complete visibility of stock levels, location, age, when an item is due to be despatched, what has been under-delivered against supplier, where and when an item was issued and by whom.

Integreater® works by applying the bill of materials to finished or inprocess products. This means that accountability of stock is available, whatever its physical state may be. This is then referenced against projected sales that are based on finished products, enabling users to return packaging commitments in accordance with wastage regulations.

Download Dry Goods Management

Need to reduce giveaway on fixed weight products, improve yield and achieve better scheduling?

The accurate measurement of product yield is critical for any food processing business. Unfortunately, tight profit margins mean that even a slight miscalculation can lead to a loss, with large production runs often magnifying the problem.

A time pressured processing environment also means that issues are often only identified once orders have been despatched.


The solution

Integreater® has been designed to measure yield for your entire product range, accounting for all variants and complexities. It also allows management to set yield specifications for each product. Performance is then measured by comparing actual results against these criteria, immediately alerting operators to any discrepancies.

Management have a real-time view of all transactions on their system, allowing them to identify where profit and loss is being made on individual or grouped items. This enables them to target any inefficiencies and resolve problems as soon as possible. They can also easily correct any errors that may have occurred whilst issuing and returning raw materials to different groups and areas.


The result

Effective yield management optimises the use of raw materials, thereby reducing waste and maximising profit margins.

Yield management is fully integrated with the production cycle, allowing operators to closely monitor results in real time and rectify any problems as soon as they arise.

Download Yield Manager factsheet

Forecasting

The problem

Effective forecasting is a critical task for any food processing business. Unfortunately, it is made difficult by short product life and last minute order changes.

To effectively meet demand, management need to ensure that they have enough raw materials, packaging and labour resources. This can only be achieved if they are able to accurately predict upcoming orders.

Inaccurate forecasting means that buyers will either purchase too much raw material, or not enough. Both situations can cause serious problems for food processing businesses. For example: if processors overstock raw materials, they have to freeze any surplus. This significantly reduces sales price and increases storage costs.

Similarly, failing to order enough raw material forces buyers to make last minute purchases. They cannot negotiate the best prices and if stock shortages are left to escalate, processors may fail to meet orders on time. This damages customer relationships, which can be particularly problematic in such a competitive industry.


The solution

Integreater® systematically predicts demand based on sales data, which is continuously measured to ensure the most accurate forecasting.

The e-MES will take into account the effects of promotional activity and cannibalisation. For example: if sirloin steaks are on promotion, Integreater® will automatically predict the impact that this will have on sales of rump steak.


The result

Effective forecasting means that buyers are able to make informed purchases several weeks before customer orders are finalised. They can then negotiate the best price for raw materials.

Similarly, operations staff are able to achieve the most efficient use of resources, minimise waste and ensure that orders are met on time.

Download Forecasting factsheet

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Forecasting

“Integreater allows staff, from the factory floor to the board room, to run real time reports quickly and easily, maximising the chances of identifying and rectifying any problems as soon as they arise.”
Seachill