Editor's Choice


Integrating HACCP management in manufacturing execution systems

October 2024 Editor's Choice

Why HACCP is important in the food industry

Hazard Analysis and Critical Control Points (HACCP) is a systematic approach designed to identify, evaluate and control hazards throughout the food production process, providing a robust framework for safeguarding public health across various food industries, including meat, seafood, vegetables, and fruit processing. HACCP principles are applicable across all sectors of the food industry, from production and processing to distribution and service. These principles have gained universal acceptance among government agencies and trade associations, highlighting their importance in safeguarding public health. By systematically applying HACCP principles, food producers can enhance safety and quality in their operations, ultimately benefitting both consumers and the industry as a whole.

Maintaining readily available, accurate and up-to-date records is crucial to prove the execution of monitoring HACCP activities and to demonstrate compliance with regulatory requirements. Documentation serves as evidence of the effectiveness of the HACCP plan and supports communication between all the operational teams, including production, food safety and quality. Essential records include hazard analyses, critical control point (CCP) monitoring logs, and documentation of corrective actions taken.

Why MES is important in the food Industry

In tandem, manufacturing execution systems (MES) monitor and manage manufacturing processes, facilitating real-time data collection, and enhance operational efficiency. At its core, an MES is designed to track and document the transformation of raw materials into finished products through the different processes and equipment involved in this transformation. It accomplishes this by collecting data directly from equipment and operators on the shop floor, offering a transparent view of the manufacturing process by making the information available in real-time through dashboards and human machine interfaces (HMI).

An MES, depending on the specific company and its processes, can include functionalities such as scheduling, order execution, production reporting, labour management, quality management and maintenance management. Through these capabilities, an MES provides critical information that supports informed decision making at all organisational levels.

One of the significant roles of the MES in a company is its ability to integrate data from various manufacturing systems such as scada, HMI and quality management systems (LIMS and QMS), and make it available within context to the company enterprise resource planning (ERP) system. By functioning as a central hub for data integration, an MES provides a comprehensive view of the production process, enabling manufacturers to identify inefficiencies and streamline operations. This real-time data monitoring allows for preventive maintenance and quick responses to production issues, ultimately enhancing operational efficiency and reducing downtime. In addition, the data collected, transformed and made available at this level also provides critical information needed by the ERP system for profitability calculations and by executives for decision making.

Why is integration important for food producers

Integration between these two critical systems aims to streamline compliance with food safety regulations while optimising production efficiency and reducing costs, making it particularly valuable in today’s competitive food market. If we think back a few years, a whole brand of food products disappeared from South African retail shelves almost overnight, due to a lack of readily available food safety data and a failure in HACCP practices.

One of the primary benefits of integrating HACCP management into an MES is the improvement in operational efficiency and the increase in data accuracy. By automating data collection and real-time monitoring, manufacturers can reduce manual data entry errors and improve data reliability. This streamlining leads to faster response times and shorter production cycles, ultimately lowering costs and increasing productivity. It can also enable earlier identification of potential issues and allow for preventive measures to be taken, as opposed to reactive corrective action only after major issues become apparent.

By leveraging MES software, manufacturers can effectively monitor CCPs, automate data collection, and improve traceability throughout the production process, thus ensuring adherence to stringent food safety standards. In addition, integration fosters better collaboration among stakeholders and facilitates continuous improvement in food safety protocols, which is essential for maintaining compliance in an increasingly regulated environment. Integration results in a more interconnected understanding of food safety risks, enabling producers to adopt a proactive approach to compliance. A unified system simplifies the process by consolidating various standards into a single framework, allowing businesses to focus on comprehensive compliance rather than navigating multiple individual standards at different points in the process. Furthermore, properly defined and integrated traceability systems can improve transparency throughout the supply chain, enabling rapid identification and containment of safety issues.

What is the challenge for food producers?

Despite its benefits, the integration of HACCP with the MES presents certain challenges. The complexity of integrating disparate systems can lead to difficulties in setup and configuration, which in turn leads to the need for complex technical training to ensure successful implementation. Additionally, issues such as data silos and inconsistencies in data formats complicate the integration of HACCP within the MES, further impeding successful implementation. In addition, a lack of standardised processes within companies may hinder implementation and scalability, potentially resulting in additional manual data entry, increased deviations and longer release times. To mitigate these challenges, it is recommended that companies engage cross-functional teams to assess and prioritise their integration needs, thereby ensuring a comprehensive decision-making process.

After the technical challenges have been addressed, companies also have to overcome the people issues such as resistance to change and mistrust of technology. Many South African enterprises face systemic issues related to workforce development, underscoring the need for comprehensive training programmes tailored to the specific needs of their employees. Enhancing access to training and education programmes for food handlers and processors is vital for promoting a culture of food safety and compliance. Improved awareness and knowledge enable stakeholders to implement better food safety management systems and reduce contamination risks, ultimately enhancing food safety outcomes.

Collaborative efforts among regulatory agencies, industry associations and educational institutions can promote the development of effective training initiatives, but this is unfortunately not happening in a practical sense.

What is next for food producers?

As the food industry evolves, the fusion of MES and HACCP principles will continue reshaping operational practices, driven by technological advancements such as artificial intelligence (AI), machine learning (ML) and the internet of things (IoT), and also an increasing focus on sustainability and quality control measures. The adoption of cutting-edge technologies such as AI, ML and IoT is poised to redefine how MES and HACCP systems operate and interact. These technologies will enable real-time monitoring and data analysis, allowing food producers to respond rapidly to safety hazards and operational inefficiencies. In addition, AI and ML solutions will combine historical real-time and transactional data into models that can predict process, quality and hygiene outcomes, thus highlighting and preventing adverse conditions for food safety occurring in the process.


About Gerhard Greef


Gerhard Greef.

Gerhard Greeff has qualifications in chemical engineering, production management and quality management. He has been involved in manufacturing since 1987 and with software development and integration in the manufacturing operations management (MOM) field since 1999. Gerhard believes that a properly designed and implemented MOM system will improve operational effectiveness and efficiency and can add tremendous business value for any manufacturing company.

For more information contact Gerhard Greeff, Implementation Manager, TransLution Software, +27 11 803 5854, [email protected], www.translutionsoftware.com


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

The future of industrial automation: fieldbus and industrial networking
LAPP Southern Africa Editor's Choice
As a global leader in integrated solutions in the field of cable and connection technology, LAPP recognises that fieldbus and industrial networking technologies are pivotal in shaping the future of manufacturing and production processes.

Read more...
AI-driven innovations with CCTV and cyber security
RJ Connect Editor's Choice Fieldbus & Industrial Networking
The fast progress of artificial intelligence (AI) and video analytics is redefining the rail surveillance landscape. Advancements have bolstered proactive event detection, predictive maintenance and enhanced situational awareness.

Read more...
Taking control of your warehouse stock is no walk in the park
TransLution Software Data Acquisition & Telemetry
Most companies focus on their production operations as a pain point. This is a mistake, as scheduling, moving, tracking and reporting on inventory at the operational level can have a major impact on production efficiency and profitability.

Read more...
Loop signature 27: SWAG tuning of simple integrating processes.
Editor's Choice
The chief control engineer of one of the largest petrochemical refineries in South Africa once sent me an email after a course at his plant. He wrote that he had found the section on SWAG tuning of simple integrating processes one of the most informative of the whole course.

Read more...
Harnessing industrial AI agents for reliable automation
Editor's Choice IT in Manufacturing
The excitement around generative AI (GenAI) has been undeniable, promising wide-ranging changes across industries. However, for those of us in the world of industrial control and automation, the realities of implementing these powerful technologies are a little more nuanced.

Read more...
Futureproof your industrial network security with OT-centric cyber security
RJ Connect Editor's Choice
To achieve digital transformation, industrial operators must first address the daunting task of merging their information technology (IT) and operational technology (OT) infrastructure. In this article, we focus on the importance of strong OT network security and provide some tips on how to strengthen cybersecurity for industrial operations.

Read more...
The symbiotic relationship between OEMs and SIs
Schneider Electric South Africa Editor's Choice System Integration & Control Systems Design
While businesses tend to turn directly to original equipment manufacturers OEMs or vendors when embarking on IT projects, the role of the SI as a key facilitator and partner cannot be overstated.

Read more...
Case History 196: Unstable condensate level control.
Michael Brown Control Engineering Editor's Choice Level Measurement & Control
The operators in a petrochemical refinery were having great trouble in trying to stabilise the condensate level in a vessel, and this was adversely affecting other loops downstream. Several unsuccessful attempts had been made to retune the controller.

Read more...
Big themes for 2025
Editor's Choice News
2024 was a year of unprecedented innovation and global upheaval. As we look ahead, Amy Webb, CEO of the Future Today Institute asks which technologies will reshape our world in 2025?

Read more...
SAIMC: MESA Africa 2024 summit
TransLution Software SAIMC
The SAIMC Computer Engineering Council, also known as MESA Africa, recently held its annual summit. The two days were jam-packed, with an excellent balance between theory, thought leadership, and practical case studies. The general consensus among the delegates was that the insights gained were incredibly valuable.

Read more...