Every pack code traced back to its batch and its ingredient lots.
Follow ingredient and packaging receipt, recipes, batch records, line checks, pack coding and dispatch on a single record. Every pack code leads back to its batch and to the ingredient lots behind it. Buying, kettle room, quality and dispatch see the same page. A lot of xanthan gum can be searched forward to every customer who received it.
- Recipes, ingredients, pack formats and shelf lives entered as you make them
- Suppliers, stock and customers migrated
- Changes to recipes and check sheets handled by GullySystem staff when asked
Ingredient receipt, recipes, batch records, line checks, pack coding and dispatch for packaged food makers run in one system built and hosted by GullySystem. A code on each pack leads to the batch and its ingredient lots. A lot can also be searched forward to pallets and customers.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Ingredient and packaging receipt
Deliveries are booked by lot and supplier with expiry dates and certificates of analysis. Goods stay in quarantine until the incoming checks, such as tanker seal and temperature, are done.
- 2
Production planning
Orders and forecasts become batches by recipe and line. Shortages of an ingredient, a film reel or a corrugated carton show before the day starts.
- 3
Batch making
Operators weigh to the recipe and scan each lot issued. Kettle temperatures, kill step times and hold times are logged against the batch as they happen, with the operator named.
- 4
Filling and coding
Packs are filled, seared or capped, and sealed. Each gets a batch code and a best before date from the inkjet. Checkweigher rejects and metal detector test-piece results are kept for the run.
- 5
Release and storage
Release follows passed line checks and a signed pH or brix reading. The batch then moves to chilled or ambient stock by pallet.
- 6
Dispatch and trace
Pallets are picked against the order, and delivery notes list lot codes. A trace runs from an ingredient lot to the customer in one search.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Goods Receipt (GRN)
Deliveries are booked by supplier, lot and expiry date, then held in quarantine until the incoming checks on the lot, such as tanker temperature, are passed.
- Bill of Materials
A recipe lists ingredient weights and steps, and revisions are kept so each batch can show which version was used.
- Production Planning
Batches are planned by recipe and line from orders and forecasts, and shortages of oil, premix or film are shown before the shift.
- Batch and Serial Tracking
Each batch lists the ingredient lots issued, the line and the operators, so a pack code leads to everything behind it.
- Quality Control
Kettle temperatures, hold times and detector results are entered at the line, and a reading outside its limit holds the batch from release.
- Barcodes and Labels
Batch codes and dates are laid out per product and printed with each fill run, along with case and pallet labels.
- Vendor Management
Approved suppliers carry their certificates and expiry dates, and complaints are logged against the batch concerned.
- Warehouse Management
Chilled and ambient pallets are held by location and days remaining, and picking follows the oldest date first.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For goods inward staff
Book each delivery by lot, record expiry dates and hold anything unchecked. When you reject a lot, the reason sits on the supplier file for the next audit.
For production planners
Turn orders into batches by recipe and line, and see shortages of ingredients, film or cartons before anyone is on the floor.
For line operators
Follow the recipe on the tablet, scan each ingredient lot into the batch, and record temperature and hold times at the kettle or retort.
For quality teams
Review line checks, release batches, manage supplier certificates and run a trace when a retailer calls.
For sales and dispatch
Take orders, pick by lot and date, and send delivery notes carrying the right codes.
The numbers the owner asks for.
- Batches by recipe, line and result
- Ingredient lots used by batch
- Finished stock by days to best before date
- Line check results by shift
- Customer orders shipped by lot
- Complaints by product and batch
Who this is built for.
- Makers of sauces, ready meals and soups for retail and food service
- Producers of jams, pickles, dairy products and desserts in sealed packs
- Manufacturers of cereals, noodles and dry mixes
- Private-label food makers filling for supermarkets
- Co-packers running recipes owned by other brands
When it is not the right choice.
- A small kitchen selling a few jars at a local market can keep batch notes on paper.
- Snack makers frying and flavouring product may prefer Snack Manufacturer Management Software.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- Barcode and label printing
- Scale and checkweigher data import
- EDI or order portal import
- Accounting export
Questions owners ask before a demo.
Can a returned pack be traced to its ingredient lots?
Yes. The code on the pack leads to its batch record, which lists the ingredient and packaging lots issued. A search can also start from one ingredient lot and list every batch, pallet and customer.
How are recipe changes handled?
A revised recipe keeps the old one on file. Each batch records the version it used, so a later question about salt or xanthan weight has a clear answer from the record.
Does it hold allergen declarations?
Yes. Declarations are stored against each ingredient and recipe, and the label text follows the recipe in use. Your quality team decides how each declaration is applied on the pack.
Can chilled stock be separated from ambient?
Yes. Each product carries its storage type and shelf life, and stock is listed by pallet with days remaining. Picks follow the oldest date.
Can line checks be filled in on a tablet?
Yes. Operators open the check sheet for the batch on a tablet and enter readings as they take them. A reading outside the limit is flagged on the spot, and the batch stays on hold.
Can it print retailer case labels?
Yes. Case and pallet labels can be set up with the codes each retail customer asks for. Layouts are agreed during implementation.
Can we pack for another brand?
Yes. Recipes and labels can be tied to the brand owner, so private-label runs stay apart from your own products.
Who owns the batch records?
You do. The format for handing records back is stated in the quotation.
What does the quotation depend on?
Cost depends on lines, users and modules. We start by learning your recipes and customers, then show your own products on screen, and a written figure follows that session.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Packaged Food Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
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