A leading pet food manufacturer partnered with NorthWind to address an operational challenge: preventing cross-contamination during raw material unloading. The facility was experiencing recurring issues with unloading trucks into incorrect silos, resulting in quality control problems and potential product contamination. NorthWind implemented an advanced material validation system that not only eliminated these errors but also digitized the company’s reporting processes, bringing greater efficiency and accountability to their operations.
Without a robust validation system in place, operators would occasionally unload raw materials into incorrect silos, leading to:
- Cross-contamination between different product ingredients
- Quality control failures requiring costly rework or disposal
- Production delays and inefficiencies
- Compliance risks with food safety regulations
- Paper-based documentation that was time-consuming and prone to human error
These challenges were not only impacting operational efficiency but also potentially compromising product quality and safety—critical concerns in the pet food industry where ingredient integrity is paramount.
- Pet Food Manufacturer
- Minnesota, USA
NorthWind met with the customer to understand the current process and began development on a material validation system that would put safeguards and constraints on the unloading process while still providing operational flexibility. The solution centered around integrating barcode scanning technology with their control systems, creating a foolproof method for ensuring materials were directed to the correct silos.
We integrated barcode scanning technology with the facility’s existing control system using Ignition Vision HMI Platform to create a robust validation process. When operators prepare to unload a truck, they are required to scan a barcode from the milling company that contains a unique identification number. The software searches through a material database to identify the specific material associated with that ID. The system then automatically verifies whether the selected silo destination matches the scanned ingredient information.
If the destination does not match the scanned material, the system prevents the unloading process from being enabled, effectively eliminating the possibility of cross-contamination. This hard stop in the process ensures that materials can only be unloaded into appropriate silos containing matching products.
- Ignition Vision HMI platform
- Tag historian for data logging and analysis
- OPC UA communication protocol
- Barcode scanners for material validation
The system was designed with operational flexibility in mind. Operators can clean out silos when material levels fall below configurable setpoints, allowing for smooth transitions between materials. For situations where level scanners might not be functioning correctly, supervisors have override capabilities to clean out destinations when they know a silo is empty despite sensor readings.
Additionally, supervisors can manage the material database directly through the system, adding new materials as they enter the supply chain. This ensures the validation system remains current with all ingredients used in the production process.
NorthWind also digitized the manufacturer’s paper-based reporting system by implementing digital reports within Ignition. The new system automatically tracks and records:
- Silo destination for each material transfer
- Product name and specifications
- Lot number for traceability
- Trailer number for logistics tracking
- LPN (License Plate Number) for inventory management
This digital transformation eliminated the need for manual witness signoffs, as all information is now scanned into the system at the time of unloading. The data is logged to a database and can be queried, with records maintained for up to a year, significantly enhancing traceability and compliance capabilities.
The implementation of NorthWind’s material validation system delivered immediate and significant benefits to the pet food manufacturer:
- Complete elimination of cross-contamination incidents from incorrect silo loading
- Improved product consistency and quality
- Reduced risk of costly product recalls or rework
- Streamlined unloading process with clear validation steps
- Elimination of time-consuming paper-based documentation
- Reduced production downtime from contamination incidents
- Comprehensive digital records of all material transfers
- Enhanced traceability from receipt to production
- Ability to analyze material handling patterns and identify optimization opportunities
- Improved documentation for food safety compliance
- Enhanced traceability for audit requirements
- Digital records accessible for inspection and verification
The manufacturer reported high satisfaction with the solution, noting that the system has not only resolved their cross-contamination issues but also improved overall operational efficiency. The digital transformation of their reporting process has provided management with greater visibility into their material handling operations, supporting better decision-making and continuous improvement initiatives.
Learn more about NorthWind’s Solutions the Pet Food Industry or reach out to schedule a walk through of a system.
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