Grupo Bimbo

New York Bakery MARCO customer case study bagels

MARCO Limited have installed the first stage of a Trac-IT MES weighing and traceability system, with the implementation of their Recipe Formulation Module, for the New York Bakery Company at their new plant near Rotherham. The Trac-IT system plays a key role in New York Bakery’s Six Sigma ‘doing things right’ philosophy at the site, focussed on quantitatively understanding and consistently meeting critical customer needs by minimizing waste throughout the entire value chain.

Canadian owned New York Bakery Co make bagels at the site – lots of them! With a capacity of over 60,000 fresh and frozen bagels an hour, the company is Europe’s largest producer of this iconic American snack, supplying all the major supermarkets and retail outlets with private and New York Bagel Co branded goods.

The System

Trac-IT MES starts work when goods arrive at the stores. Here all raw materials are checked in against outstanding orders and labelled. The system automatically checks that the supplier is approved and that the use by date is appropriate. The system generates a barcode for each individually packed product and pallet module. Stacked items are stored in ‘use by’ date order so that the products for current use are at the bottom of the racks as part of the strict FIFO (First In First Out) regime. Any de boxing is recorded within the system ensuring a traceability continuum, throughout.

The next stage of the project will integrate the bulk flour and water weighing systems as well as further integration with New York Bakery Co’s ERP software system.

The current installation is already bringing measurable improvements to our process and has initiated an important traceability chain. We are confident the completed Trac-IT MES (Manufacturing Execution System) will further ensure that the factory floor data is optimised in real time to provide a dynamic measure-control-improve environment. This will continue to minimise waste through spoilt or inconsistent batches and optimise equipment efficiency.

Charlotte Wood – New York Bakery Company

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