REDUCING CHEESE LOSSES

2013 INTERNATIONAL DAIRY SHOW

TRACKING AND REDUCING CHEESE LOSSES IN CUTTING AND WRAPPING OPERATION

TO WHOEVER OPERATES A SEMI-AUTOMATIC OR AUTOMATIC CHEESE CUTTING AND WRAPPING OPERATION. PARTICULARLY LINES INCLUDING A CHECKWEIGHER.

J.Denis Bedard, P.Eng.COPRODEV PLUS

BOOTH557

REDUCING CHEESE LOSSES

1 – Cheese is like GOLD!

It’s Color is golden?

REDUCING CHEESE LOSSES

It takes 10 pints of milk to produce 1 bl of cheese

90% of the milk is converted into whey (lactoserum) - Filtered through reverse osmosis - or evaporated to produce whey powder

Both of these technology are expensive to purchase and maintained. They also require large quantity of energy to operate.

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

RAW MATERIAL LOSSES (Penalty = $8.00/KG)

• Cheese that ends up on the floor and cannot be resold

• Cheese that ends up in catchpans that are contaminated

• Metal contamination• It can account to as much as 1% of tonnage

REDUCING CHEESE LOSSES

The source of raw material losses

1. Mostly from wire cutting equipments

2. Manual handling of the cheese

3. Bad conveyors transitions4. Improper conveyor

transport chains

REDUCING CHEESE LOSSES

How to reduce your raw cheese losses?

• Measure and track you cheese losses –Target less than 0,1%

• Sensibilise the production personnel

• Install catchpans throughout the entire production line

• Do regular dry cleaning

• Consider ultrasonic cheese cutting

• Automate

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

TRIM GENERATED BY THE CUTTERS (Penalty = $2,00/KG)

TIPS to REDUCE IT

1. Measure and Track your Trim2. What can you do to improve

the squareness of your blocks?

3. Do you have to trim so much?4. Revisit your product

dimensions, Evaluate your cutting volumetric efficiency.

5. Evaluate new technology.6. Don’t forget your the owner of

the company, you can call the shot!

REDUCING CHEESE LOSSES

NEW TEHNOLOGY =CHANGE IN CUTTING CONFIGURATIONAND IMPROVECUTTING VOLUMETRICEFFICIENCY

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

SCALE REJECT % VS PRODUCT GIVE-AWAY ($2,00/kg Penalty) ($8,00/kg Penalty)

RECALL: THE RULES

1. The average weight of the sampling lot must be larger the declared weight

2.Samples with weights below the MAV (Maximum Alowable Variance) are illegal

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

SAMPL NO.

TARGET WEIGHT, grams

ACTUAL WEIGHT, grams

1 454 456,82 454 453,53 454 458,14 454 455,95 454 453,76 454 4557 454 449,48 454 459,69 454 454,6

10 454 454,411 454 448,812 454 457,613 454 45614 454 456,515 454 459,8

7308 454 454,4AVG 455,2

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:446

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[446

:449

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[449

:452

[

[452

:455

[

[455

:458

[

[458

:461

[

[461

:464

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[464

:467

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[467

:470

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[470

:473

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[473

:476

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[476

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[479

:482

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[0

200

400

600

800

1000

1200

1400

1600

1800

2000

FROMTO # UNITS Probablity

425428 9 0,12%

428431 15 0,21%

431434 16 0,22%

434437 22 0,30%

437440 49 0,67%

440443 76 1,04%

443446 169 2,31%

446449 378 5,17%

449452 1006 13,77%

452455 1778 24,33%

455458 1891 25,88%

458461 1156 15,82%

461464 452 6,19%

464467 177 2,42%

467470 62 0,85%

470473 27 0,37%

473476 12 0,16%

476479 8 0,11%

479482 2 0,03%

482485 3 0,04%

7308 100,00%

DW = 454GM MAV = 19,9GM

REDUCING CHEESE LOSSES

SAMPL NO.

DECLARED WEIGHT, grams

ACTUAL WEIGHT, grams

1 454 456,82 454 453,53 454 458,14 454 455,95 454 453,76 454 4557 454 449,48 454 459,69 454 454,6

10 454 454,411 454 448,812 454 457,613 454 45614 454 456,515 454 459,8

7308 454 454,4

AVG 455,2

Variance, grams

-1,61,7

-2,9-0,71,50,25,8

-4,40,60,86,4

-2,4-0,8-1,3-4,60,8

grams

σ =

1,61,72,90,71,50,25,84,40,60,86,42,40,81,34,60,8

9,2

𝟐√𝒊−𝝁

=

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

REDUCING CHEESE LOSSES

How do you compare two production lines running different product?Line 1: 454gm, Sigma= 9,2gmLine 2: 907gm, Sigma= 16,7gm

You standardize the standard deviation:Line 1: Standardize Sigma = 9,2/455,2 = 0,0202Line 2: Standardize Sigma = 16,7/912,4 = 0,0183

REDUCING CHEESE LOSSES

SUMMARY

PRETEND YOU ARE THE OWNER

MEASURE AND TRACK YOUR LOSSES

DONT JUST CHECK AVERAGE WEIGHTDOCUMENT AND TRACK YOUR STANDARDDEVIATION

REDUCING CHEESE LOSSES