REDUCING CHEESE LOSSES
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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
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REDUCING CHEESE LOSSES
1 – Cheese is like GOLD!
It’s Color is golden?
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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.
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REDUCING CHEESE LOSSES
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REDUCING CHEESE LOSSES
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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
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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
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REDUCING CHEESE LOSSESHow 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
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REDUCING CHEESE LOSSES
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REDUCING CHEESE LOSSES
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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!
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REDUCING CHEESE LOSSES
NEW TEHNOLOGY =CHANGE IN CUTTING CONFIGURATIONAND IMPROVECUTTING VOLUMETRICEFFICIENCY
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REDUCING CHEESE LOSSES
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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
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REDUCING CHEESE LOSSES
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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
[425:4
28[
[428:4
31[
[431:4
34[
[434:4
37[
[437:4
40[
[440:4
43[
[443:4
46[
[446:4
49[
[449:4
52[
[452:4
55[
[455:4
58[
[458:4
61[
[461:4
64[
[464:4
67[
[467:4
70[
[470:4
73[
[473:4
76[
[476:4
79[
[479:4
82[
[482:4
85[
0
200
400
600
800
1000
1200
1400
1600
1800
2000
FROMTO # UNITS Probablity425428 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
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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
=
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REDUCING CHEESE LOSSES
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REDUCING CHEESE LOSSES
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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
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REDUCING CHEESE LOSSES
SUMMARY
PRETEND YOU ARE THE OWNER
MEASURE AND TRACK YOUR LOSSES
DONT JUST CHECK AVERAGE WEIGHTDOCUMENT AND TRACK YOUR STANDARDDEVIATION
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REDUCING CHEESE LOSSES