STEVENS in action!

10143j-043e‘On A Roll’ Sandwich Company invests in ‘Vantage’ Factory Wide Ingredient Control System from Stevens Group Ltd and Achieves ‘A Grade’ BRC Accreditation… first time!!

Once again Stevens Group Ltd is helping companies to increase yields and reduce product giveaway, this time at ‘BRC Grade A’ Food Company ‘On A Roll’ Sandwich Company.

‘On A Roll’ Sandwich Company, makers of the “Pick of the Pantry” sandwich range, specialises in the manufacture of delicious upmarket sandwiches and rolls to many of the hotels, football clubs, colleges and hospitals in the northeast area of England.  This report details how ‘On A Roll’ have utilised the ‘Vantage’ Factory Wide Ingredient Control & Traceability System to go above and beyond the BRC Traceability requirements.

On A Roll Sandwich Company, owned by husband and wife team James and Helen Stoddart, moved to new premises on Riverside Park Industrial Estate, having outgrown the base where they launched the business in 2007. The business has produced ‘over budget’ performance each year and the company has an efficient operation where its products are produced by over 70 committed staff. James and Helens’ zero mistake culture manufacturing facility has the tightest possible control and electronic traceability available.

“As we started growing our business, the need for improved ingredient control became apparent. In addition, as we grew, the need for very high manufacturing practices meant that the time had come to invest in the Stevens ‘Vantage’ Ingredient Control System,” James Stoddart said.

The fact that all sandwiches are prepared by hand and require a number of different ingredients, can pose difficulties in keeping track of individual amounts used and that correct quantities are added to ensure a consistent product. Stevens Group has extensive knowledge and experience in the area of formula control and inventory management (raw ingredient and finished product).

On A Roll is a customer who has seen the ingredient savings by installing the system: “We’ve found that it made us become a better company.  We’re more streamlined in how we do things and know if any waste is occurring; previously we weren’t keeping those numbers. Now that we can record those figures, our employees are more aware of what they are doing. With the waste now eliminated, money is saved,” James Stoddart said

The system installed at On A Roll provides traceability from receiving ingredients through to the finished inventory. Along the process are seven ‘Vantage’ Touch Screen Terminals connected to weighing platforms and label printers which enable the manufacturing plan to be communicated with the production team. The system has virtually eliminated time consuming paper based production and traceability records as well as providing up to the minute stock control and “touch of a button” mass balance on all raw materials and packaging.

10143j-035eThe formulas for sandwich fillings are entered into the PC Server via the recipe formulation management software. The system allows management to enter and determine the exact recipe characteristics, including individual ingredient tolerances and how the products are added. For instance, recipes may be a mixture of weighed proteins and salad-based ingredients – both of which are weighed to tight tolerances, enforced by the system, to produce a consistent taste and texture to the finished sandwich.

The system installed at On A Roll provides traceability from receiving ingredients through to the finished inventory. Along the process are seven ‘Vantage’ Touch Screen Terminals connected to weighing platforms and label printers, which enable the manufacturing plan to be communicated with the production team. The system has virtually eliminated time consuming paper based production and traceability records as well as providing up to the minute stock control and “touch of a button” mass balance on all raw materials and packaging.

The formulas for sandwich fillings are entered into the PC Server via the recipe formulation management software. The system allows management to enter and determine the exact recipe characteristics, including individual ingredient tolerances and how the products are added. For instance, recipes may be a mixture of weighed proteins and salad-based ingredients – both of which are weighed to tight tolerances (enforced by the system) to produce a consistent taste and texture to the finished sandwich.

The end result is a remarkable system, which can trace an ingredient through the manufacturing process to a finished product. In the event of an ingredient recall, we can provide our customers with the assurance that we have 100% visibility of which ingredient has been used, how much and when.

Stevens Group’s Commercial Manager, comments, “Stevens is a company who pride themselves on thinking outside of the box to deliver solutions which eliminate paperwork and provide customers with a return on investment. The team at ‘On A Roll’ are forward thinking, innovative and appreciate that traceability can be turned from being a BRC headache into something which can be used to deliver real business value. Above all though, they make an excellent sandwich and we always enjoy our lunchtime visits to their factory!”

The STEVENS Group

Tel: 01254 685200

www.stevensgroupltd.com