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BatchMaster Software Solutionsfor the Pet Food IndustryHelping you keepour pets healthyand activeProcess Manufacturing Software
IntroductionBatchMaster Software offers an industry specific ERP solution that helps you streamline your operationsand bring your products to market, faster and more cost effectively, while complying with ever morestringent FDA and FSMA regulatory mandates. Whether you private-label, co-pack or produce your ownline of food products, BatchMaster ERP for Food supports your unique manufacturing requirements inproduct development, production, quality, costing, and compliance, while supporting all of your sales,accounting, warehousing and distribution needs.Overcome Industry ChallengesToday, many of pet food manufacturers are appealingto a more health conscious public that wants toprovide healthy foods to their pets. Always underpressure to innovate their products, pet foodmanufacturers seek to incorporate new ingredientsthat add flavor and nutritional value to their recipes,while reducing and eliminating artificial ingredients andpreservatives– all with consideration to maintainingtheir products' pet appeal and reducing product costs.Product development is important to those pet foodmanufacturers who want to quickly develop andintroduce products to their retailers, grocery stores,restaurants and end consumers. With the rising costsof meat, vegetable and grain ingredients, havingvisibility to product costs from the time of conceptionthrough production is one key to controlling productmargins. Federal regulations for pet food must becomplied with, and in some areas are stricter thanhuman food regulations. With just these objectives inmind, it's no wonder that forward thinking pet foodmanufacturers are upgrading their software systems toaccelerate product development, scale up production,reduce costs, and ensure quality and compliance.Let's address a few challenges that were faced andovercome by many food manufacturing customersemploying BatchMaster ERP:Bring New Products to MarketManufacturers want to quickly and accurately adjustthe ingredients of their base intermediates and finishedgoods recipes to meet their physical, nutritional andcost target property values.Run High Volume, Continuous ProductionHigh volume manufacturers with national and regionalretail chain and food distributor customers typically runrelatively small selection of products throughautomated production lines. They want to release largebatch runs then monitor products and equipment alongtheir automated lines in order to adjust their equipmentsettings. Their goal is to keep the continuous processflowing with minimum user involvement, such asstarting and closing batch jobs at each step or processcell.Control Inventory LevelsIn order to optimize their resources, manufacturerswant more granular, yet easier to use demand planningand production scheduling tools that will consolidatedemand, calculate the correct number of batchproduction orders, and help one balance inventorylevels for raw materials, finished goods andintermediates or bases that can yield a variety offinished goods. In addition, they look for assistance inmaking better informed raw material procurementdecisions, such as automating the generation ofpurchase requisitions.Reduce Waste and Improve YieldsFood manufacturers want better accountability tominimize stales, spoilage and other losses, as well asavoid over production. Improved reconciliationreporting of production of yields at blending and mixingthrough packaging is desired in order to track andreconcile losses at each step. In addition,manufacturers need accurate demand planning andproduction scheduling information in order to makemore informed raw material procurement decisions.Ensure Product Freshness onRetail ShelvesThose manufacturers that produce refrigerated goodswant better control over their stored ingredients andshipped finished goods, including mandated QCinspection of received ingredients and stability tests ofstored base inventory and finished goods. 2016 BatchMaster Software. All Rights Reserved.BatchMaster Software Solutions for the Pet Food Industry2
Comply with FDA and FSMA mandatesLot traceability is of major concern to those companieswhose products have longer shelf life or containingredients that are historically subject to recall. Thecreation and assignment of lot numbers at the time ofreceiving and production is a challenge to manymanufacturers, so automating these processes isdesirable. When performing a product recall, the abilityto quickly track and trace suspect products fromsuppliers to customers, from customers to suppliers oranywhere within production in minutes, not in days, isa requirement.Generate Product LabelsSome manufacturers want to generate ingredientstatements on demand, so if these ingredients areidentified in USDA or Genesis, the software shouldhave access to these ingredients' physical andnutritional values.Increase Margins and ProfitabilityTo increase the bottom line, companies need toanalyze their expected vs actual costs from conceptionthru production to customer shipments. Managers wantbetter visibility to raw material costs, based upon lastpurchased, standard and projected prices, andaccurately capture and track the static, scalable andtiered costs associated to labor, energy, water andother resources. In addition, purchasing wants tonegotiate better terms for those raw materials for whichdemand planning has determined there is aconsolidated demand. And to increase the top line,sales recognize that they can retain existing customersand gain new ones with demonstrated predictability,scalability and compliance across their company’soperations.Lab and SamplesNew product requests from internal and externalsources can be managed from product developmentthru production to acceptance, including internal andcustomer approval workflows and communications.With access to USDA , Genesis and user defined itemphysical and nutritional information, the systemidentifies those ingredients that cause intermediatebase or finished good products' property values to beoutside the tolerances for protein, fat, fiber, moisture,ash and taurine levels. And when necessary,theoretical ingredient property values can be used inthe recipe calculations.Separate Recipes and Packaging Bills ofMaterialIn BatchMaster ERP, recipe specifications andpackaging bills of material are managed separately.Expected losses and gains expected during productionare defined within the recipes. Product developers canperform what if analysis scenarios against a recipe andthen compare multiple recipes against each other, sideby side. QC tests, special manufacturing instructions,direct and indirect costs can all be assigned to bothrecipes and packaging BOMs. With visibility to allfinished good specifications, one can createintermediate base recipes, which can be made to stockor made to order. Multilevel workflows expedite thereview and approval of recipe and packagingspecifications across departments.InventoryBatchMaster ERP captures, manages and reports oninventory levels in terms of weight, volume and units,as well as quality statuses, expiration dates, lotnumbers, and strengths. An item's organic, non GMOand other certification documentation are maintainedwithin the item record.Planning and SchedulingKey Manufacturing FeaturesBatchMaster Manufacturing for Food supports productdevelopment, production, quality, costing, compliance,planning, scheduling and mobile warehousing. Foodmanufacturing capabilities can be quickly added totoday's leading financial applications, specificallyQuickBooks, Sage 100 & 300, Microsoft Dynamics GPand SAP Business One. 2016 BatchMaster Software. All Rights Reserved.Standing orders, sales orders and forecast entries canbe used as finished goods demand inputs; inventorylevels, batch production jobs, and receipts can be usedas supply inputs. An accurate, detailed plan for batchproduction orders can be generated down to thevarious production steps or process cells within theproduction lines. Planning and scheduling takes intoaccount the rates and capacities of mixers, fillers,packagers or other process cell equipment. Real timeproduction adds and cuts, as well as equipmentmaintenance and changeovers, can easily be enteredand managed using the graphical scheduling tools. Toensure these batch jobs yield their expected results,demand planning can generate the required purchaserequisitions to avoid shortages or rescheduling.BatchMaster Software Solutions for the Pet Food Industry3
Productioncreation and movement of suspect products, fromdelivery to shipping, shipping to delivery, andanywhere within production. BatchMaster ERPgenerates GFSI and FDA related documents,customized recall reports and personalized customerletters. In terms of production labeling, ingredientpanels that address protein, fat, fiber, moisture, ashand taurine percentages plus organic and non GMOclaims can be generated on demand. From an ITperspective, all key transactions are maintained inhistory logs for auditing purposes, including recipeapprovals, batch job changes and QA releases.BatchMaster ERP aggregates demand for finishedgoods, creates the optimal number of batch jobsacross the production stages or process cells,allocates the best inventory and back schedules thebatch jobs. Recipes can be dynamically adjusted tocompensate for available inventory characteristics (e.g.protein, fat, fiber, moisture, etc) in order to meetspecified target characteristics. Batch job releasesand completions can be managed on an individualbasis, which initiates all the necessary inventory pulls,QC tests and manufacturing instructions. Certainbatch jobs can be linked together and back scheduledor sequenced using the Super Batch feature.Manufacturers can manually capture inventory usageor automatically back flush inventory when closingbatch jobs, as well as capture actual costs and otherbatch job data.Warehouse activities that support receiving throughproduction to shipping tasks, including manufacturingrelated inquiries, QC related inspections andinstructions can be executed via mobile devices.QualityDashboards and ReportingSystem libraries for sample inspections, QC tests,checklists and special manufacturing instructionsagainst recipes, finished goods, equipment andprocesses can be established. Received goods maybe quarantined until associated vendor samples arereleased by QA. In terms of ensuring the freshnessand stability of certain stored ingredients, users can bedirected to check intermediate and finished goodinventory in storage. Some procedures may just beinformative in nature, where others require anacknowledgement or simple data entry. QC tests formicrobial, pH, specific gravity, and other conditionsrequire data collection and validation, and may result infurther retesting or reworking. In all situations, themanual or system assignment of quality statuses toinventory will determine its disposition and availability.Customizable COAs are generated upon batch jobcompletions.Customizable role-based screens provide visibility tocritical manufacturing data, including inventoryconsumption and balances, actual versus expectedyields and costs, and quality control results and trends.MobileCostingRaw materials costs based upon last purchase price,standard costs, or projected costs are rolled up alongwith fixed, tiered and scalable labor costs. Costestimates can be managed during productdevelopment of product recipes, including intermediatebases, and packaging BOMs. Actual costs, yields andother KPI's are captured during production, and can becompared against projections in a variety of analyticreports.Compliance - Food Safety, Lot Traceabilityand LabelingLot number information is captured or auto generatedat the time of receiving, auto generated forintermediates and finished goods, and then validatedduring finished goods distribution. A bi-directional viewof lot controlled inventory enables users to track the 2016 BatchMaster Software. All Rights Reserved.BatchMaster Software Solutions for the Pet Food Industry4
Key Front Office FeaturesRecognize These BenefitsAvailable as a total financial and manufacturing ERPsolution, BatchMaster ERP for Food adds a tailoredfront office suite, including CRM, to its processmanufacturing suite. Front office modules include:By gaining greater control over product developmentand production, improving planning and scheduling,balancing inventory, and reducing costs and variances,pet food manufacturers employing BatchMasterSoftware solutions are increasing their profit margins,gaining market share and improving their bottom line.Accounting and Financials:Capture, measure, analyze and report the cost ofdoing business, specifically the cost of intermediatesand finished goods from the lab through to customershipment.Sales:Convert sales quotations into customer samples, thentrack and report on the status and profitability of everycustomer campaign, quote and order shipment,including their discounts and promotions.Purchasing:Employ economies of scale to purchase raw materialsfrom approved, certified vendors to feed planned batchproduction jobs created from demand planning.Maintenance:Plan, schedule, and execute predictive and preventivemaintenance activities against production line andwarehouse equipment to optimize equipmentavailability and utilization.Distribution:Effectively manage store replenishments, inbound andoutbound activities across one or more facilities, aswell as inter warehouse transfers.Rapidly Develop New Products:To satisfy consumer desire for more health consciouspet food products, ones that are protein and nutritionalvalue, without unwanted additives and preservatives,your team of product developers will have the tools tospeed their development processes. Advancedprogramming reduces your time spent on tedious,error-prone manual calculations in designing, updatingand approving products that meet your targetedphysical, nutritional and financial target propertyvalues.Better Inventory Control:Accurate, granular demand planning and productionscheduling optimizes your procurement and productionof raw materials and finished goods, respectively,which will give you better control over inventorybalances and space utilization within your plants.Quickly Scale Up Production:Automation of your batch and continuous flowproduction processes reduces the need for manualintervention. Dynamic recipe adjustments, auto sizingand scheduling of batch job all work together tostreamline production, while reducing the delays, risksand costs of operational downtimes. The establishmentof a comprehensive, online quality program allows youto improve current processes, keep production lineequipment settings at their optimal settings and ensureyour manufacturing processes can meet the increasedin demand.Avoid Customer and Industry Fines andPenalties:Keep compliant with industry specific and federalregulations, in terms of ingredient declarations, lottraceability and recall requirements. Bi-directional lottracing enables you to report on suspect products inminutes, not days - minimizing the scope of the recall.You can now establish effective mock recall programswith your suppliers and customers. By establishing acomprehensive quality program, you can avoidcustomer chargebacks, buy-backs and returns due toorder shortages and shelf life issues. And with athorough and easily accessible audit trail of keybusiness transactions, you will be in compliance withyour auditors' record-keeping requirements. 2016 BatchMaster Software. All Rights Reserved.BatchMaster Software Solutions for the Pet Food Industry5
Reduce Costs:Increase Sales:Development tools that run recipe cost “what if”scenarios and comparisons help you control productcosts for both intermediates and finished goods.Demand planning and production scheduling reducethe costs of excessive labor and inventory, as well asthe costs associated to equipment clean-downs andchangeovers. And with a quality program enacted atthe time of receiving thru customer shipments, you willreduce the cost of spoilage and stales.Leverage the system's advanced quality, traceabilityand compliance capabilities to not only retain yourvaluable customers, but to gain new ones.Improve Management Reporting and Analysis:Customizable role-based screens provide you withaccurate, real-time visibility to those key metrics thatwill help you to make better informed decisions, faster,and maintain your competitive edge.Take The Next StepBatchMaster Software's solutions for the pet food industry give you greater control over your business, from sales,procurement, and manufacturing to accounting and customer service. Deployed as either an add-on to your existingfinancial solution or as an end to end, financial and manufacturing solution, you gain system adaptability,accountability, reliability, scalability and traceability – all the system abilities you need to profitably grow yourbusiness.As an industry focused solution provider, BatchMaster Software is ready to help you meet your business objectives,so please contact us today to discuss your business requirements:BatchMaster SoftwareTel: 1 949.583.1646 x266Email: info@batchmaster.comwww.batchmaster.com 2016 BatchMaster Software. All Rights Reserved.BatchMaster Software Solutions for the Pet Food Industry6
BatchMaster Software Solutions for the Pet Food Industry Helping you keep our pets healthy and active Process Manufacturing Software
