Notes for owners · Industry-Specific Software Guides
Where a Food Manufacturing Unit Loses Money Between Recipe and Dispatch
Most of the leak sits in four places: yield that drifts from the recipe, rejected pouches nobody counts, old batches returning near expiry, and claims approved unchecked. Each one shows up once the batch number travels from raw material inward to dispatch. GullySystem’s Manufacturing Production Management Software holds that batch record.
Ganesh HS, Strategy and Technology, GullySystem · · 3 min read
Yield that drifts from the recipe
Every recipe says how much oil, spice and flour a batch should take. On the floor, the issue often runs a little over. Nobody sees it until the monthly margin looks thin, and by then the cause is weeks old.
The remedy is a batch sheet that sets recipe quantity beside actual issue. The supervisor records the difference and the reason on the same day. Read it weekly. A pattern by operator, shift or ingredient tells you where to look first.
- Recipe quantity and actual issue on one sheet
- Yield and wastage worked out per batch
- Operator and shift named on every batch
- A reason written against each deviation
Pouches that fail and go back for repacking
Pouches that fail weight or sealing go back for repacking. Film is lost and product is handled twice. The count is rarely written against the batch, so yield reads worse than it was, or better.
Record rejection, rework and scrap at the stage where each one happened. Weight, seal and moisture readings belong on the same batch record. The loss then has a place and a count.
Old batches hiding behind new ones
In a crowded godown, the newest cartons sit nearest the door. Loaders pick what they can reach. The older batch waits, and it leaves later with little shelf life left.
Hold finished stock by batch and best-before date, and let the dispatch screen show the oldest batch first. Review near-expiry stock every week rather than when a distributor sends it back.
- Finished stock held by batch and best-before date
- Oldest batch shown first at dispatch
- Returns logged by batch and by reason
Scheme and damage claims nobody checks
Distributors raise claims for schemes, damages and returns, often after the scheme period has closed. Checking each line against what was announced takes time. So accounts approve the claim and move on.
Keep every scheme on record with its period, products and terms. A claim can then be matched line by line before it is paid. Damage claims should name a batch, so a pattern by batch or route becomes visible.
This is slow at first. It speeds up once the scheme record exists.
A short weekly review
Most of these leaks can be caught with a short look each week. The review needs four lists, each drawn from the batch record rather than from memory: over-issued batches, rejections by stage, stock close to best-before and open claims.
A unit making one product in a few batches a week may manage with a ruled register. Once several products, pack sizes and distributors share the floor, three separate files stop agreeing with each other.
Batch leak tracker
Rule a single page into one row per batch. Columns hold recipe quantity, actual issue, packs passed, packs repacked, best-before date and any claim raised later. Fill it for a month, and the column with the most entries is where to start.
Open a blank worksheet to printQuestions owners ask
Does tracking batches make a unit FSSAI compliant?
No. Compliance comes from your process, licence and testing, and your food safety consultant can say what applies to you. A batch record only helps you answer questions about a batch quickly.
Can we keep Tally for accounts?
Yes. Tally stays for accounts and GST. The production system is not linked to it in the standard set-up, and a Tally export is quoted separately once your ledger heads are fixed.
Will software cut our yield loss on its own?
Not on its own. It shows where actual issue differs from the recipe, and by how much. Someone still has to read that list each week and act on it.