Streamlining Manufacturing Operations at Cooper Farms

“The installation was smooth and well-planned so we didn’t miss a beat during the changeover,” says Eric Ludwig, plant manager at Cooper Farms-Cooked Meats.

The Challenge: Seeking a fully integrated plant-floor solution

Cooper Farms-Cooked Meats, a division of Cooper Hatchery, Inc., supplies cooked deli and sliced turkey products to private-label customers and national restaurant chains across the U.S. Plant Manager Eric Ludwig sought a modern solution to upgrade outdated equipment and improve operational control. He needed a system that could manage:

• Accurate barcode labeling
• Finished product inventory control
• Real-time yield tracking
• Enhanced recall efficiency
• GMP (Good Manufacturing Practice) control

Additionally, Ludwig required a solution that could communicate seamlessly with the Defiance, Ohio, warehouse and distribution center. “We also needed a system the operators could easily use,” he noted.

After reviewing several proposals, Cooper Farms chose CAT Squared’s smart-manufacturing solutions, specifically designed for ready-to-eat and ready-to-cook plants.

The Solution: A Seamless Integration of Hardware and Software

To eliminate the costs associated with traditional wiring, CAT Squared’s implementation team utilized radio frequency (RF) equipment, including portable barcode printers and RF interfaces for scales and other plant equipment. This setup enabled system access from anywhere within the plant.

CAT Squared’s Further Processing Solutions collected data from every process on the production floor, integrating intelligent labeling, barcode scanning, and live scale weighing. This allowed real-time monitoring and analysis of yield and production data, providing Cooper Farms with total management capabilities based on real-time insights.

Core Capabilities of the CAT Squared System

1. Production Planning
   The Further Processing module converts customer orders into detailed formulations, generating bills of materials for packaging and ingredients, which are then split into mix lots according to machine capacities. The system prints preparation sheets with complete instructions for meat and spice mixing, ensuring precise execution of production plans.
2. Receiving
   As raw meat and spices arrive, the system assigns unique receipt numbers, captures weights, conducts HACCP checks, and prints labels for easy tracking. Real-time inventory management of raw materials, including shrinkage tracking and spice pre-mix controls, ensures comprehensive oversight.
3. Mixing
   Preparation sheets are scanned to load mix requirements into RF hand-held devices. The system validates all scanned ingredients against product specifications, with allowances for approved substitutions. Weights are recorded automatically, ensuring consistency and compliance.
4. Racking and Cooking
   Cooked products are tracked by batch using metal barcode tags, with weights recorded pre- and post-cooking for accurate yield calculations. Post-chill weight measurements track further losses, accounting for additional processing steps like stripping and browning.
5. Pack-Out and Palletizing
   The in-line check-weigher and auto-apply labeler manage batch runs, while a mobile scale and printer combination handle special packaging requirements. Each case is labeled with a serialized barcode, linking it to its production history and facilitating seamless dispatch.
6. Tracking and Recall
   CAT Squared’s system provides bi-directional traceability from raw materials to final product. During an independent audit, the system demonstrated its recall capabilities, identifying all rework within 35 minutes, showcasing its efficiency and reliability.
7. Dispatch and Warehouse Management
   The Warehouse Management System (WMS) module integrates with dispatch and inventory control, minimizing handling costs and ensuring accurate product flow. The WMS supports the dispatch of pallets or individual cases, enabling precise lot tracking and streamlined order fulfillment.

Results: Improved Efficiency and Real-Time Control

The six-phase implementation of CAT Squared’s monitoring, recall tracking, and process control systems at Cooper Farms-Cooked Meats was done in fewer than six months. The entire installation was completed without disrupting operations, and no additional personnel were required. Eric Ludwig appreciated the system’s performance, saying, “I like the system because I’m able to generate information in reports I could never track before.”

By leveraging CAT Squared’s comprehensive data tracking and process control capabilities, customers can significantly enhance their operational efficiencies, reduce waste, and improve product quality. These improvements lead to reduced costs, higher yields, and faster response times, directly contributing to increased profitability and a stronger competitive position in the market.