Careers Contact Downloads |

Food Processing Software Solutions

Pork

Home / Archives for Industry News / Pork

Farmer Bookings & Feedback via Livestock Portal

Farmer Bookings & Feedback via Livestock Portal

A new web-based appointment booking and feedback system, reduces paperwork, facilitates easier appointments, and provides transparent feedback to producers and farmers in real-time and accurately

Feb 2022

The supply of livestock from the producer to the meat processor is underpinned by the consistent supply of livestock of the correct quality, correct inspection and optimal grading of these animals while processing in meat processing factories. This is applicable to Beef, Lamb and Pork/hog producers and processors. 

This relationship can now also be built-upon and strengthened with the use of a transparent data transfer from the processor back to the producers via a new Emdyex web-based appointment booking and feedback system. This is achieved via Emydex standard APIs that interact directly with Emydex factory floor MES Solutions running on Kill lines in Abattoirs and Slaughterhouses around the world. 

 

Animal Health Feedback 

Farmers could have the ability to make bookings and appointments, receive Health feedback information, download their financial information, as well as receive their remittances digitally through the Portal, reducing unnecessary paper documentation and helping both sides work towards their sustainability goals.

To facilitate the seamless exchange of producer/Processor data, Emydex has developed a comprehensive suite of secure web APIs. These are designed to simplify the livestock supply from producer to processor and offer the ability to surface kill line and grade data about the supplied livestock back to the producer.

 

Farmer Appointments & Bookings

Authorised agents and suppliers can book appointments to supply their livestock to the processor directly using the API calls embedded in a web portal which can be run via a web browser on a desktop PC or mobile device. This makes the process of selling livestock to the processor far simpler than initiating a booking via other means, eliminating double handling of data and reducing the opportunity for errors in the process.

The Emydex Supplier WebAPI Module consists of several API endpoints that can be called to perform various operations, such as registering new suppliers and livestock delivery appointments directly within Emydex, providing details of any generated payments and retrieving relevant data collected on the Emydex kill line. 

 

Visibility of Grading & Quality Data

This can include the data from the Emydex veterinary inspection stations, grading data and if applicable data from chiller grading processes (MSA). The data retrieval from the kill line via the APIs can be performed at a per delivery or lot level or down to the individual sides of the carcasses forming part of a particular delivery or lot. This offers much greater visibility of the grading and quality data registered to each carcass by the processor and provides comprehensive feedback to the supplier on the condition of the livestock supplied to the factory. How each carcass was graded informs how each carcass was ultimately priced for payment. This can assist the supplier in improving the quality of supplied livestock to meet the producers’ requirements.

By combining the Emydex Kill Line, Central Animal Payments System and Livestock API modules in one wholistic solution, Beef, Lamb and Pork livestock suppliers and processors can achieve a higher level of digital integration when considering the supply of animals to the plant and also receiving performance feedback on the quality of supply and pricing calculations applied to the delivery.

Request a Demo

Emydex CAPS off year with Livestock Payments System

Emydex CAPS off the year with a new Livestock Settlements System

For most Meat processors, the procurement of raw materials, especially Livestock, is by far the largest variable cost for the business to manage. Therefore, being able to ensure the Accurate andTimely payment for this stock is a key requirement. Many Meatprocessors choose to differentiate themselves from their competitors based on the speed and accuracy of payment to their suppliers. Emydex’s recently redeveloped Central Animal Payment System (CAPS) is designed to meet this requirement specifically, as well as to provide functionality that provides parameter-driven flexibility to meet all current and future requirements.

 

Calculating Animal Settlements

The key to the success of the system is the ability to design animal payment ‘methods’ that can be added to the system as a component to suit individual customer needs without modifying the existing system. This means that if there is a requirement for a new way of paying a supplier, whether it be based on a contract, supply volumes, average market process, or a complex grid-based system, these can be developed and ‘locked in’ to the existing system as a snapshot for later retrieval.

As standard, the Animal Payment System caters to multiple payment grids where any data from the kill floor or kill ‘lot’ (delivery) can be incorporated into multiple axes of a grid to generate a payment.

This might be a weight range and fat score or a meat marbling score and dentition range i.e. virtually any combination of data elements that can be measured as part of livestock processing.

Multiple grids can be used to accumulate values such as a supplementary ‘bonus’ value or to allow a record to pass to a second grid if the criteria for the first grid e.g. a carcass that is too heavy or old for the first payment grid. This ‘fall through’ process can be repeated until a grid that matches is finally found.

 

Cattle Payment Invoicing and Adjustments

The system is capable of producing recipient-created tax invoices (RCTI) for suppliers (farmers), third-party agents, commissioned livestock buyers, transport companies and service or contract kills (an accounts receivable transaction rather than the usual accounts payable).

User-defined adjustments, again using virtually any of the data in the system, can apply adjustments to this invoice to either deduct money for items such as carcass faults, levies, transport costs etc. or apply a rebate such as a ‘skin’ or hide credit. These can be applied automatically using pre-defined ‘settlement schemes’ (groups of adjustments) or added manually on a case-by-case basis.

 

Carcass Costings

As a carcass is produced, the system can calculate the cost for the carcass per kg (or lb) by running each carcass record through the various livestock settlement processes to generate the total cost, so not only is the cost of the purchase from the supplier included but also the cost of freight, commissions etc.

Costs that do not appear on any invoice such as a kill fee can also be included if required. This allows for carcasses to be costed before the payment is finalised so if the carcass is disposed of via a sale or boning process, the cost can be reported as part of the input to the process for accurate costings. Alternatively, carcass costs can be updated once the payment is finalised.

 

Animal Payment Reporting

Invoice and costing data can be updated to an in-house or 3rd party provider ERP or Financial system for payment with full audit trails and costing audits available in the CAPS system. Standard reports are available and data from the payment system can be surfaced using the in-built Emydex Business Intelligence (BI) tool.

Kill data can be from Emydex kill floor systems or up-uploaded from multiple sources and sites to allow for a centralized system for consolidated processing and reporting.

 

Centralised Payments catering for large Enterprises

Given the flexibility and extensibility of the system, current and future needs can easily be met with an ‘out of the box’ system. Once configured the system can generate payments, email all parties involved and update costs and financial systems at the push of a button. Payment processes that would traditionally take hours can be streamlined and the labour requirements significantly reduced.

Accurate costings allow for true profitability costing as the input costs to sales and further processing are readily available.

With the ability to run as a centralised process taking data from many sources, both large enterprises to single site operations can all gain tremendous advantages from the new system.

 

If you want to learn more – contact Ireland, Australia, New Zealand, South Africa, or North America offices.

Request a Demo

SunPork scales new heights

How Emydex helped SunPork expand their Swickers Kingaroy operation to become the biggest, fastest, highest quality pork processing operation in Australia.

Meet the client

Through Swickers Kingaroy, SunPork is the largest pig processor in all of Australia, handling 900,000 pigs every year to produce 18% (42 million kilos) of the nation’s pork. The group is proud to be Australian farmer-owned and a direct employer of 1,400 people across the country.

In addition to the domestic market, SunPork exports 7 million kilos of pork to seven other countries and creates 140 million meals worldwide annually. They do this through 37 Australian farms in three states and six New Zealand farms on the two islands. They also have three feed-mills, a directly owned abattoir, major interest in a second facility, as well as two value-add facilities.

The opportunity

Following the rebuild of the Export Boning Room after a fire at SunPorks’s Swickers abattoir in Queensland, the group began an additional AUD$ 64m (Euro €40m) investment in a new state-of-the-art facility in 2016. It set out to become the most efficient pork processing line in Australia with a capacity to process up to 750 pigs per hour, whilst maintaining a relentless focus on quality.

In December 2019, the SunPork Group completed the Swickers abattoir expansion in Kingaroy, located three hours outside Brisbane, Queensland, creating more than 200 jobs in the process.

“Over the past 18 months Swickers has constructed the most advanced pork abattoir in Australia, and certainly one of the best in the world. Many producers and wholesalers will rely on the efficiency and quality standards in our plant to maintain and develop their business well into the future. This facility is a cornerstone of the SunPork business and we now have foundations that will underpin our long-term growth strategies.”

Dr Robert van Barneveld, SunPork Group CEO and Managing Director

So how do you become the fastest and most efficient pork processing facility in the country? You bring in one of the world’s leading providers of factory floor software for food processors. You bring in Emydex.

What we did

The Sunpork project began with the design and development of a new state-of-the-art, fully automated kill line system for the Swickers processing plant, in line with Smart Manufacturing (Industry 4.0) best practice. 

The main goal of this project was to interface the Emydex MES to an automated factory floor system consisting of a network of RFID readers and sensors, as well as multiple (20) in-line automated machines, connected to Emydex via the PLC layer. This meant integrating with equipment supplied by Frontmatec, Denmark, that included a carcass opener, automated splitting, AutoFom grader and a carcass stamp printer. 

Other equipment included a PorkScan grader, automatic track scales as well as LED/Light and gate control systems, in addition to other devices to manage routing. The use of multiple real-time vet inspection and grading stations also controlled the flow and routing of carcasses.

RFID integration required the design and build of standard integrations (APIs) to interact with RFID tracking systems on the kill floor. The RFID system provides real-time carcass identification and tracking, enabling full traceability of the carcass throughout processing.

As part of the project, the Emydex engineering team also designed and built a new centralised communication service, called the Data Communication Interface (DCI). DCI eliminates the need for individual terminals to have direct communication with the various integrated hardware and allows terminals to receive the data input in a unified format via this single central communication point. 

The project also delivered additional new innovative systems for stock delivery and pen management, automated carcass routing and an automated chiller sortation system based on configurable business rules.

Going Live

The system began commissioning at the SunPork Swickers plant in July 2019.

The results

The effects were immediate, and the system keeps improving day by day.

“The new kill line is significantly more efficient than the previous line, and it will continue to improve as we move forward. Manpower has reduced in terms of two shifts to one, while the new floor will allow us double output. There are two real and obvious benefits that Emydex has brought to SunPork. One, we have more data points where we can collect manufacturing information from around the floor and two; we have replaced many manual tasks such as populating spreadsheets.

Geoff Miller, Group CFO and Company Secretary

“What makes the Swickers plant unique is that it not only processes product on behalf of SunPork, but also provides a service kill for other companies in the pork industry and so had to have a lot of flexibility not usually found in normal processing facilities. The need to meet the requirements of each customer utilising the service provided by the plant meant Emydex had to deliver a system that could not only operate at very high speed, but also deliver the ability to change the way each customer’s pigs were prepared and to signal this in real-time to the operators on the production floor”

Ian Carson, Technical Sales Director, Emydex Australia

What’s next?

The next phase is to refine and perfect Emydex’s ‘Factory of The Future system’ on the ground at Swickers and then roll Emydex systems out to further processing functions at Kingaroy and SunPork’s other facility in Queensland.

In other's words

“We gave Emydex a very tough ask to design and build a system for a kill floor that itself had not even been physically designed yet. Many other system developers would have walked away at various points in the project when things got tough but Emydex regularly went above and beyond the call of duty and I have huge respect for them for that. Their guys were out here working seven days a week and were as invested, committed as we were. It was a new world for both of us and I can’t fault them at all.”

Geoff Miller, Group CFO and Company Secretary

“The Emydex team has been superb… from the beginning showing a willingness to understand the requirements and design a custom solution for us… (there are) different demands here in Australia to those plants in Europe. The difference it has made has been terrific: for example, we used to have two data collection points on the kill floor and now we have 20. The throughput was 300 pigs per hour and now we’re processing between 700 -750 per hour. The value the Emydex team is adding is fantastic. Support is brilliant, with clear concise and well-presented analysis of issues reported, coupled with mitigation, solutions and actions to monitor and implement fixes. Live dashboards will broadcast information to the right people throughout the group worldwide in real-time. We’re very happy to be working with them and would recommend Emydex to any manufacturer anywhere.

Iestyn Thomas, Group IT Manager, Sunpork Group

I would absolutely recommend Emydex because they have invested their time and resources in our business… it means as much to them as it does to us. Some of their guys came out and spent a month working at the coal face and we couldn’t ask for more commitment than that.

Geoff Miller, Group CFO and Company Secretary

 

For more on Emydex's Products, or contact Sales in any of our Dublin, Brisbane, South Africa or Toronto offices

Request a Demo

Emydex North America Market Update

Emydex Technology, a Dublin company specialising in Traceability Software for the food processing industry, have secured its third customer in the North American market. This contract brings to 120 the number of processing plants using Emydex software worldwide, in 14 countries. The company secured its first North American contract in Canada two years ago with pork processor Donald’s Fine Foods and has since closed a deal with Canadian Fishing Company (Canfisco).

Emydex was established in 2004 by co-founders James Grennan and Redmond Burke to offer fish and pork producers and food processors an integrated production management system tailored to their needs.

Now led by chief executive David McMahon, Emydex employs more than 50 people at its Dublin headquarters and overseas offices in Canada, Australia and South Africa. The company’s factory- floor software is aimed primarily at large-scale processors. The software combines production control with traceability and quality reporting, yield analysis, stock and food safety management.

“We’ve now moved into the Saas (software as a service) space,” said McMahon.

“We are very focused on our three export markets: Africa, Australia and North America.

“We have spent 12 years developing solutions for 60 customers, with 120 plants around the world, and the question then became ‘what else do they need from us?’.

“We’ve spent the last two years building an online quality management system and that’s been really successful. We then went back to our customers with ten other products we were thinking of building and asked them ‘how interested are you?’.

“They came back and offered to help us with design and testing. So, we’re now working on three new products, two of which are Saas, for group production planning group animal payments and Factory of the Future.”

An export-led company, Emydex has customers in South Africa, Australia, New Zealand, Canada and Namibia. The firm targets countries with strong meat exports, a relatively low concentration of large-scale processors and a strong regulatory framework for food traceability.

Emydex is a client company of state agency Enterprise Ireland. “They have helped us with R&D grants for new product development and internationalisation grants to help market entry into our key new markets,” said McMahon.

Written by Elaine O’Regan – Sunday Business Post

The Business Post

Request a Demo

Traceability enabled in Ireland’s Largest Pig Processor

Rosderra Irish Meats Group is the largest pork processing company in Ireland. The group processes over 1.5 million pigs per annum across its two state-of-the-art processing facilities at Edenderry, Co. Offaly, and Roscrea, Co. Tipperary. In addition, Rosderra has a speciality Meat Ingredients facility in Clara, Co. Offaly, a Pork-Curing facility in Jamestown, Co. Leitrim, and a Cooked Meats facility in Stradone, Co. Cavan.

Rosderra approached Emydex in 2014 to replace their existing traceability and production control systems operating across the group approaching end-of-life. After winning a competitive tender, Emydex was awarded the contract to supply a new factory floor data capture IT solution that operates door-to-door across the group’s four main operating plants. All production processes were to be covered, including weighbridge integration, lairage, grading, primal deboning, further processing, packing, order picking and dispatch, stock, yield management and traceability reporting.

Split into eight distinct project phases, the project also included implementing Emydex’s Cold Store system into Rosderra’s Cold Store facility in Jamestown and tight integration with third-party warehouse management systems operating in external cold stores utilised by Rosderra’s production plants.

As part of the initial project phases, Emydex worked with Rosderra’s IT integration partner to build robust interfaces to the group’s SAP system. Integration points were built using AS2 and XML transfer files to allow Emydex to pull products, materials, and customer files from SAP, as well as Customer Sales orders destined for both Rosderra production sites and third-party cold stores, and later send updated Stock data back to SAP for stock valuation and available-to-promise purposes.

After completing the roll-out of Emydex’s Packing and Warehouse Management systems to Rosderra’s four operating plants in early 2016, the focus shifted to the Boning Hall operations in Edenderry and Roscrea. These project phases included implementing Emydex’s boning hall systems for cutting, boning, further processing, and Yield Control. Yield Reporting from Emydex includes Carcass chill loss, Cutting yield, chill loss/cutting summary and Boning Hall yield reports.

Presently, the project is in its final phase, which covers the Abattoir operations at both Edenderry and Roscrea, including a centralised slaughter plan and livestock appointments system, weigh-bridge integration, lairage bookings, bulk sequencing, and detained and pig grading stations. Reporting will include a real-time slaughter line monitor program that will accurately display the status of the slaughter with analysis by lot. Slaughter line analysis can be displayed in both tabular and graphical reporting formats.

Commenting on the project, David McMahon, Emydex CEO, said, “We are now well into the final stages of a two-year Emydex systems roll-out across the Rosderra group, covering door-to-door processes as well as integrations to back-office ERP, 3rd party cold stores and suppliers as well as factory floor machinery. Looking back over the two years, I see the project has run smoothly. Both the Emydex and Rosderra project teams worked well together to plan and deliver each project phase on schedule without any major disruption to operations. Rosderra is now reaping the benefits of having a robust factory floor data capture Production control system installed, with Emydex providing group and plant managers and supervisors with real-time and accurate reporting on their Production Yields, Stocks and Traceability.”

Louis Ennis, Rosderra Group Finance and Emydex project sponsor added, “Rosderra Irish Meats Group chose Emydex as an end-to-end solution to replace our legacy system. The installation, which is currently ongoing, will be completed over multiple phases across multiple sites, with all implementations running smoothly and with minimum disruption to the business. The first implementation was the warehouse and packing modules, and, through added interfaces with our ERP system, brought immediate benefit to the business through greater visibility on orders, improved data validation and reduced administration, especially around our cold store loads where manual input has been greatly reduced. Overall, the system greatly improved real-time information and offered ease of use and improved flexibility when making changes”

Request a Demo

Arthur Mallon’s fully operational with Emydex

Mallons Brand

Arthur Mallon Foods specialise in the production of fresh, frozen and cooked sausages. They supply fresh and frozen pork, to the major Irish retailers and export frozen pork sausage to Holland. Mallon’s sausages have won multiple awards in Ireland, UK and France and have achieved two Great Taste Awards in 2012. They operate from a purpose built modern production facility in Hilden, Co. Monaghan.

Arthur Mallon Foods identified a requirement to upgrade their existing production management systems to a single production management system that was scalable and flexible to meet with growing demands for specific industry, customer and supplier requirements. They required a single system to manage and report on order control, stock control, recipe formulation, traceability, quality control and yield control. With these objectives in mind they contacted Emydex in 2012.

Phase 1 – In order to minimise disruption to normal day operations, the project was split into a number of smaller project phases. Starting at the end, in Phase 1 Emydex customised their Packing & Processing module to suit Mallon’s particular needs including features such as Unit, Box and Pallet Labelling. Packing stations allow operators to work to Packing Work Orders whilst enabling them to switch quickly between Work Orders.

As part of this same project phase, Emydex’s Warehouse Management module covering Dispatch was implemented ‘off-the-shelf’ with only a few tweaks required to meet their particular requirements. “The key point about Emydex software is the standard module offerings are very comprehensive and cover almost everything we need, and if they don’t have specifically what we need, it’s not a major hassle to change it” said Paul Kearney in Arthur Mallon Foods.

In parallel with the Emydex factory floor install

Mallons also upgraded their ERP system, and Emydex integrated seamlessly with this. Sales orders are keyed into their financial system and then sent directly to Emydex for order picking and dispatching. Purchase orders are generated within Emydex, and then exported to the financial system upon receipt of goods.

Phase 2 of the project covered Raw Material and Dry Goods Intake, as well as Issuing Stock into Production via handheld scanners to ensure stock levels are accurately maintained.

Phase 3, Emydex’s Recipe formulation system is currently being implemented, and about to go-live. This module will track and control the levels of ingredients being issued to recipes as well as the calculating yields from finished recipes. Implementing the recipe system will assist Arthur Mallon’s with Quality Control and Traceability reporting, as well as provide key information in real-time to the floor managers as to the performance of the line.

“Already we are seeing the advantages of having Emydex as well as the capabilities and possibilities for the future. With the software and the excellent backup and service from all the staff in Emydex we feel we have the complete package.” Paul Kearney
For more information on the Emydex system click here or contact Emydex on +353 1 8855990

Request a Demo