By John W. Chlopek

Pick up any major newspaper and you’ll see the case for food plant traceability technology is right there - literally in black and white. Food safety crises involving everything from processed meats to peanut butter have drawn full attention from consumers and government regulators. Moreover, both groups demand product processing and distribution details -and they want them immediately. Clearly it’s critical that food processors ensure they have both a solid quality process and an equally strong traceability process. Ideally, processors can take a preventative - rather than reactive - approach to traceability.
To get started, it’s important to realize traceability is simply a material identification process. The key components to any traceability concept are the same: data capture and information accessibility. That said, the manner in which you capture data and the ease with which you can do so depend upon your environment. For example, you’ll start with a few decisions to make in regard to your approach: direct or indirect and manual or systemic. The “Direct Traceability” flow chart on page 32 denotes the process in relation to this approach. Simply put, you capture material data each step along the way - eventually tying all components to the finished product or batch.
Alternatively, you may utilize an indirect approach, as shown in the flow chart on page 33. This concept calls for assigning material data to master production orders - as opposed to the individual process steps. In either case, it is beneficial to have the process managed via an integrated system. This greatly reduces the opportunity for errors that may result from capturing the information manually, in addition to providing data access via a central data repository.
An integrated solution, developed specifically for the food industry, can supply the required functionality. It is important to remember that a “traceability” system is not a stand-alone solution, but rather an integrated component of your overall business management solution. As a process, traceability extends throughout the entire “external” supply chain. This is important when considering your internal plant material flow. The traceability process typically begins at receiving, although there may be information gathered in relation to the purchase order entry process in specific circumstances (i.e. grower harvest date, feed lot data, etc.).
Let’s assume that the traceability process begins at material receipt and that you’re using an integrated solution. It is important to note that you can gather the traceability data as a by-product of your general business process. The information you gather throughout your process is utilized for inventory control, costing, etc., in addition to traceability. Depending upon your supplier network, you may have the option to scan a bar code label supplied by your vendor. Ideally you can utilize this approach with (1) all your vendors, (2) at least a majority of your vendors or (3) your primary vendors. This process can be managed via one of three platforms: a workstation and wireless serial scanner, a radio frequency handheld device or manual steps.
The process of scanning a vendor label will provide all of the vital data required (i.e. vendor, lot date, use by date, etc.). By tying this data directly to the purchase order number, you now have the ability to track costs as well. In the event that you are not able to scan a label, you always have the option to enter the information manually and print your own label, which can be utilized throughout the remainder of your process. Assuming that you follow this process for all raw material receipts, you can now identify all materials that make their way to the production floor. Regardless of the traceability concept that you implement, direct or indirect, you will be able to assign all raw materials to a finished good, batch or master production order.
The production exit process will, of course, entail the labeling of finished goods (package, case and pallet). These labels will contain your designated lot code, which can be systemically tied to the materials utilized in production. The final internal process step will be assigning the package, case or pallet to an outbound sales order. The traceability concept that you implement should provide the capability to access the required information - including lots assigned to a sales order, vendor lots utilized per internal lot, etc. In an integrated solution environment, this step should be as simple as entering a lot (internal or external) and subsequently having the ability to review where that lot was utilized and/or assigned.
In summary, material identification throughout your entire process is critical in relation to traceability and otherwise. Take the time to review your current traceability approach. Perhaps you can introduce enhancements that can solidify your capabilities.
You can find additional information on the topic at www.gs1.org and www.usda.gov.

Without a trace