Sealord Group Ltd
Mass production and processing
In the packaging
Check weighing the product
Packages ready for gluing and folding
Through the metal detector
Once Frits and Nick are confident that the materials and processes are well enough adjusted and that the product will meet specifications, a full production trial will take place. All the materials required to produce the crumbed scallops are noted in a bill of materials. Using the bill of materials as her ordering base, Sally, the company production scheduler, orders packaging, materials and frozen seafood. She must accurately forecast the lead times for the supply of the various materials. Lead times for some items, such as the seasoning for the batter, can be as much as to eight weeks, so products are scheduled up to three months in advance. Sally is included in the planning loop from the early stages of the development of the crumbed scallops.
The process guides ensure that total quality management procedures can be followed throughout the manufacturing of the product. They tell production staff what to do to make the product safely and consistently right first time. The guide contains details that are specific for the processing of the crumbed scallops, and links the quality checks to the requirements of the product specification. Initial checks include the recording of batch numbers and use-by dates for all the raw materials.
Battering and crumbing
During battering and crumb application mixing instructions are given, and viscosity tests are carried out on the batter to ensure that consistent quantities are applied. The consistency of the batter application is crucial to the even crumbing of the product and the weight accuracy of the scallops. Checks are made on the temperature of the batter. Temperature control is important to maintain viscosity and comply with food safety requirements. All this data is recorded at frequent intervals on process control sheets.
Temperature
The temperature of the cooking oil (over 180o C) and the temperature of the spiral freezer (-28o C) are constantly checked. The retention time the product spends in the freezer is also checked.
Packing and weighing
Weighing all products is an essential part of quality control. Inner cartons of product are weighed individually prior to packing in the outer cases. The weighing machine rejects under-weight packages. The net weights for every package produced are recorded and retained by the weighing machine. Also checked and recorded at this stage are use-by dates, the batch codes of trays and cartons, net weights; there are also metal detector checks, carton and case sealing checks, micro sampling and auditor checks. The palletising method is also precisely specified e.g. 15 cartons per layer x 4 layers (60 cartons).
The information is recorded accurately and legibly on the process guides. These guides are collected and checked to ensure that the crumbed scallops are produced within specification.
COP Outcome development and evaluation
Expert analyst / customer evaluations of the scallops
Sealord employs consumer analyst experts such as Colmar Brunton to provide reliable consumer evaluation of its products. This is extremely important when a new product is launched, and to give feedback about existing product and complete the evaluation loop. Quality products and customer satisfaction ensure the company of continued success in the market. This consumer feedback may result in Frits co-ordinating minor adjustments in the seasoning used in the batter for the scallops.
