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Emydex Door-to-Door in Junee Lamb, NSW, Australia

Emydex complete the system implementation with new customer in Australia, Junee Lamb, NSW

 

Meliomar traceability tagging

Junee Lamb is one of New South Wales’ leading sheep meat processors and exporters. With a focus on high quality chilled lamb for the domestic market as well as having significant export sales, Junee process over 3500 head of lambs daily. Junee also provides a service kill and boning operation for other customers such as major supermarket chains who wish to market their own product. All product is certified Halal and some product is processed as organic lamb.

Factory Floor Production Control System

Junee Lamb had a requirement to upgrade their existing factory floor production control system at the plant in Junee, as well as their Sydney wholesale and further processing systems, to a modern, flexible, user-friendly system which fully integrates all processes required for the procurement, slaughter, processing and sale of meat products.

Previously the company were operating with two separate factory floor data collection systems that were disconnected, and the company realised it would be more beneficial to their business to upgrade these systems to a single production management solution, offering one version of the truth, that could be tailored and customised to suit their specific business requirements.

Junee Lamb needed a system that would integrate with their existing back-office financial system, and also needed to incorporate an off-the-shelf label design system that allowed for the integration of foreign text in multiple languages, such as Arabic and Chinese.

Over the past 12 months, Emydex software engineers based in Australia, installed their Manufacturing Execution System (MES) across the entire business operations, including the lamb factory and wholesale centre. Emydex software modules implemented includes the Emydex Kill line & Payments module for stock procurement and payment, Carcass Management Module, Processing & Packing Module used for boning room production management, and the weigh-labelling of product, as well as the Emydex Warehouse Management module, used to manage and report on all factory stocks.

Many benefits have accrued from the implementation of Emydex, including the ability to cost stock purchased prior to processing, to determine a forward selling price. Another benefit is providing detailed costings reporting once skin returns, credits as well as all purchasing costs are known. Feedback to service kill operators and suppliers can be produced as soon as a lot is complete and emailed to customers.

For the domestic trade, the ability to quickly enter orders, and to produce consolidated production requirements and picking sheets, allows the orders to be accumulated during the day. Hanging product is weighed across an Emydex terminal, so invoices can be produced by delivery run from the terminal, as soon as loading is complete. This ensures accurate documentation is produced with invoices travelling with the deliveries. Similar functionality in the Sydney operation has allowed for significant growth with continued customer satisfaction.

Junee are a market-driven company who enjoy a reputation for top quality product and are seen as a market leader, especially into to the Asian market where the Junee Gold brand is recognised as one of the premier Australian brands. Consequently, virtually all stock is produced to order and is often labelled with customer order information (such as port marks) and often have complex, multi-language multi-label requirements.

Centralised Specification System

A key benefit of the system is having one centralised ‘specification’ system, where labels designs are stored with foreign text generated from the product specifications ‘real time’ using the actual text and thus not requiring images or conversion codes. All customer production requirements can be entered into a plan, which in turn generates the daily works orders, touch screen product buttons, all of which are linked to sales orders and labelling requirements. Order requirements eliminate costly over-production, and allow order fulfilment and shipping to be easily managed.

End to End Solution

By providing a fully integrated, ‘end to end’ solution Emydex have provided a platform where efficiencies have been gained in all areas of the business and allow for information to be readily available. Ease of use has ensured user acceptance has been high with minimal impact on the day to day running of the business as the system was rolled out. With 24-hour support in place, Junee can be assured that support is available 24x7 to provide comfort as the company goes ahead with plans to greatly expand the business over the next 12 months.

‘Having run the business across a number of disjointed systems previously, with little by way of fast-responding support, the business has greatly benefitted from have one, fully integrated, easy to use system. Testament to this is our recent and continuing smooth expansion, maintaining our reputation for top quality products and service. The Emydex system has provided significant benefits from its flexibility, ease of use and ability grow as we do. With Emydex now managing our ‘pasture to plate’ processes we feel confident we can meet the challenges as we expand into the future’.
Heath Newton, Managing Director - Junee Lamb

For enquiries contact sales@emydex.com or call Emydex on contact us

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Traceability enabled in Ireland’s Largest Pig Processor

Rosderra Irish Meats Group is the largest pork processing company in Ireland. The group processes over 1.5m pigs per annum across their two state-of-the-art processing facilities at Edenderry, Co. Offaly and Roscrea, Co. Tipperary. In addition, Rosderra have a specialty Meat Ingredients facility in Clara, Co. Offaly, a Pork-Curing facility in Jamestown Co. Leitrim, and a Cooked Meats facility in Stradone, Co. Cavan.

Rosderra approached Emydex in 2015 with a view to replacing their existing traceability and production control systems operating across the group that were approaching end-of-life. After winning a competitive tender process, Emydex was awarded the contract to supply a new factory floor data capture IT solution that operates door-to-door across the group’s four main operating plants. All production processes were to be covered including weighbridge integration, lairage, grading, primal deboning, further processing, packing, order picking and dispatch, as well as stock, yield management and traceability reporting.

Split into eight distinct project phases, the project also included implementation of Emydex’s Cold Store system into Rosderra’s Cold Store facility in Jamestown, as well as tight integration to third party warehouse management systems operating in external cold stores utilised by Rosderra’s production plants.

As part of the initial project phases, Emydex worked with Rosderra’s IT integration partner to build robust interfaces to the group’s SAP system. Integration points were built using AS2 and XML transfer files to allow Emydex to pull products, materials and customer files from SAP, as well as Customer Sales orders destined for both Rosderra production sites as well as 3rd party cold stores, and later to send updated Stock data back to SAP for stock valuation and available-to-promise purposes.

After completing the roll-out of Emydex’s Packing and Warehouse Management systems to Rosderra’s four operating plants in early 2016, the focus shifted to the Boning Hall operations in both Edenderry and Roscrea. These project phases included implementation of Emydex’s boning hall systems for cutting, boning, further processing, Yield Control. Yield Reporting from Emydex includes Carcass chill loss, Cutting yield, chill loss/cutting summary and Boning Hall yield reports.

Presently the project is in final phase, that covers the Abattoir operations at both Edenderry and Roscrea including a centralised slaughter plan and livestock appointments system, weigh-bridge integration, lairage bookings, bulk sequencing as well as detained and pig grading stations. Reporting will include a real-time slaughter line monitor program that will accurately display the status of the slaughter with analysis by lot. Slaughter line analysis can be displayed in both tabular and graphical reporting formats.

Commenting on the project, David McMahon, Emydex CEO said “we are now well into the final stages of a two-year Emydex systems roll-out across the Rosderra group, covering door-to-door processes as well as integrations to back-office ERP, 3rd party cold stores and suppliers as well as factory floor machinery. Looking back over the two years, the project has run smoothly. Both the Emydex and Rosderra project teams worked well together, to plan and deliver each project phase on schedule and without any major disruption to operations. Rosderra are now I believe reaping the benefits of having a robust factory floor data capture Production control system installed, with Emydex providing group and plant managers and supervisors with real-time and accurate reporting on their Production Yields, Stocks and Traceability.”

Louis Ennis, Rosderra Group Finance and Emydex project sponsor, added “Rosderra Irish Meats Group chose Emydex as an end to end solution to replace our legacy system. The installation which is currently on-going will be completed over multi phases across multi sites, with all implementations running smooth and minimum disruption to the business. The first implementation was the warehouse and packing modules and through added interfaces with our ERP system brought immediate benefit to the business through greater visibility on orders, improved data validation and reduced administration especially around our cold store loads where manual input has been greatly reduced. Overall the system greatly improved real time information and offers ease of use and improved flexibility when making changes”

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Emydex Live in World’s Largest Ostrich Processor

OUDTSHOORN – SOUTH AFRICA:

World’s Largest Ostrich Processor

Established in 1985, Klein Karoo is the world’s largest Ostrich processor, producing 65% of all Ostrich related products found on international markets. Klein Karoo represents more than 800 local farmer members, and produces ostrich meat, leather and feathers. Klein Karoo supplies Ostrich (Poultry) meat, including the famous ‘fan fillet’ to the local South African market, as well as to a growing number of export markets including the UK, Denmark and Sweden where Klein Karoo’s pre-grilled Ostrich meat is today available in five of the largest retailers in Europe.

With its head-quarters in the town of Oudtshoorn, located on the garden route in South Africa, the company operates a large number of processing factories in the region including three separate Ostrich Slaughter and deboning plants located in Oudtshoorn, Graaff-Reinet and Swellendam, as well as a number of other processing facilities including value-added processing, pet treat, pre-grill and Biltong processing operations.

Working in conjunction with a South African Industrial Engineering Company (iPlan Global), Klein Karoo invited Emydex to tender in July 2015, for a factory floor software solution to replace their existing production control systems that were deemed to be end-of-life. Klein Karoo sought to adopt a “leapfrog” strategy in the selection of their new software system i.e., a technological solution appropriate for 2016 and beyond. They also requested a centralised enterprise system in order to maintain one “single version of the truth”. Finally, the system they sought needed to be agile and flexible so as to allow for scale and speed to incorporate business change such as acquisitions.

Kill Line Software Live in Three Plants

Following a thorough tender process, including a project discovery and scoping exercise in South Africa, Emydex were awarded the Klein Karoo contract in January 2016. A team of Emydex developers working remotely from Dublin in close collaboration with Klein Karoo in South Africa, commissioned and configured Emydex software systems for Klein Karoo’s three Abattoir operations, boning halls and value added operations for both Local and Export Markets. A team of Emydex Senior software engineers implemented Emydex systems into the groups three plants over the Summer months of 2016, such that by the end of August all Emydex systems were live and in operation across all processing plants, without any major issues. In tandem, Emydex integrated with Klein Karoo’s new back-office ERP system, Syspro, that was implemented in parallel by iPlan Global.

Commenting on the system go-lives Karoo’s project manager said “The operators at both Graaff-Reinet and Swellendam had a positive experience with Emydex following go-live, and the general consensus is that Emydex seems much simpler and faster to use than their current system. Also taking into account the fact that the users at Swellendam saw the screens for the first time on the morning of go-live, and had no major issues transacting. So overall a positive experience from an end-user’s perspective. The Emydex developers were very helpful during their visit and didn’t shy away from finding on-site solutions or the long hours.”

Full Traceability Reporting

Commenting on the perceived benefits for the business following the system go-live, Cobus Pretorius, Production & logistics Co-Ordinator with Klein Karoo said “The Emydex program interface is really user friendly, and makes navigating through the system very easy, and also the filtering option on all Emydex client screens, make lookups quick and easy. The suite of full traceability reports are easy to navigate, and will save us a lot of time. In addition, the fact that all information and reporting can be extracted to Excel also has a lot of benefits for our business.” Commented Pretorius

He went on to add “from a Warehousing perspective the full scanning throughout the Emydex system is a big step forward for our company, we can already see the huge benefits this gives us in terms of proper stock control. Also by fully integrating with our new financial system, Emydex has eliminated all the work that we had to manually duplicate before. Naturally the human error with regards to these manual duplicated transactions has also been removed.

The automatic integration between our Graaff Reinet & Swellendam plants in terms of carcass shipments to our primary processing facility in Oudtshoorn has also saved us a lot of time and trouble. Lastly, the way labels are set up, and the ability we have to change them with little or no input from Emydex, as well as the fact that we can preview the labels before we have to actually print, is something that I rate as one of my top three system improvements!”

Recipe Formulation Software

“Finally, the Emydex Recipe system, which is something new to Klein Karoo, works really well and we can see that it actually gives the factory workers a sense of pride in actually “measuring” what they are doing and not just blindly mixing bathes. This also ensures that the correct products are used in the correct quantities for all the recipes. The last benefit I would add is that having the ability to be able to trouble-shoot quickly by being able to connect to the actual floor pc’s have made life much easier!” added Cobus Pretorius.

Reflecting on the project’s success, Charl du Plessis, Managing Director of Klein Karoo International said “to incorporate Emydex slaughter, de-boning and recipe functionality into a single business entity in such a short time-frame was great achievement in my opinion”. David McMahon, Emydex CEO added “the Klein Karoo project was definitely one of the most ambitious and potentially challenging projects we have ever had to tackle. The fact that the go-lives went so smoothly, over the various project phases coming in quick succession over the Summer, is down to the hard work and many months of preparation and testing invested by Klein Karoo, iPlan and Emydex working in partnership as a unified team”.

For more information on our Poultry Processing Software click here

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Beef Processing Software Live in MeatCo Namibia

WINDHOEK – NAMIBIA:

The Emydex implementation team returned to Ireland after the latest phase of Emydex system deployments at MeatCo’s two main production sites located in Windhoek and Okahandja, Namibia. At this stage Emydex’s factory floor data capture and production reporting software is now operational from factory door-to-door in both of MeatCo’s main beef primal processing plants, from Kill line through to boning hall processing & packing, sales order picking & dispatch.

In addition to their main primal processing plants, Emydex is now also installed in two further processing plants on the MeatCo Windhoek site that are the Wholesale and Cannery processing plants. Current plans are for MeatCo’s IT staff to themselves complete the Emydex systems roll-out to its other two beef processing plants located North of the veterinary fence in Oshikati and Katima Mulilo. Both deployments will be supported remotely by Emydex’s Implementation team of developers based in Emydex’s HQ in Dublin, Ireland.
At this point there are just under 100 Emydex data capture devices (consisting of PC terminals and hand-held scanners) installed across MeatCo’s four plants operational with Emydex, that include a number of Animal Health and Quality Assurance inspection stations on both Kill line systems, as well as Industrial PC stations covering Dentition, Grading, Primal labelling, Carton Packing, VET Seals, Recipe formulation and Dry Goods stock management.

The Emydex system in MeatCo also provides functionality for 3rd party carcass intake, carcass splitting as well as dispatch. The system is fully integrated to MeatCo’s group wide-ERP system (Sage X3), and has interfaces built to a number of 3rd party Cold Stores in both Africa and Europe.

Having tested and implemented the Emydex kill line & payments system in the Okahandja plant, the same kill line system was later installed in Windhoek over a weekend, going live the following Monday. A fast paced install. “The MeatCo kill line is unique compared to our European kill line systems”, said Emydex CEO David McMahon, “Grading is carried out over two separate stations for example, one per side, allowing different destinations to be associated with each side of an animal, allowing for condemnation or part condemnation of only one side of an animal.”

Commenting on the completion of this main phase of the Emydex project that took just over 12 months to complete, McMahon said “MeatCo have been the ideal customer for Emydex to work with. Highly professional and organised with regard to working with our development and implementation teams on the planning, testing, training and go-live phases of the project. The project ran smoothly over the past 12 months, and we’re delighted to hear now that MeatCo feel they have the sufficient knowledge, in-house capabilities and confidence to continue themselves with completion of our system roll-out to their two remaining processing plants. Our support team will be on-hand to support them 24/7 should it be required.”

Nico Weck, MeatCo’s Group Chief Financial Officer said “Now that the Emydex installation is complete in both our main processing operations, we have a robust Traceability control and reporting system in place that provides our management team with real-time feedback on our production processes. The flexibility that is inherent within Emydex means we can quickly and easily add additional reporting as it is required by the business. ”
For more information on our Beef Processing Software click here

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Euro Quality Lambs are live with Emydex Kill Line & Payments System

SHROPSHIRE-UK:
Euro Quality Lambs Ltd (EQL) is a lamb and sheep abattoir capable of processing 12,500 carcasses a week with onsite boning and further processing facilities. The majority of EQL production is sold in carcass form, both to the UK and throughout Europe.

EQL is one of the largest specialised and dedicated Halal meat processors in the UK.

In 2014 EQL recognized that their ageing production management system was in need of updating in order to satisfy both customer and legislative quality, traceability and veterinary requirements. After a detailed review of market suppliers of meat processing software in both the UK and Ireland, Emydex Technology were chosen to supply a new Lamb kill line system to EQL.

Installed over a number of separate project phases, the Emydex software installed was configured specifically for EQL, by tailoring the Emydex standard Lamb kill line system to deliver functionality from livestock procurement right through to carcass & box dispatch.

Hardware costs were kept to a minimum by reusing the existing scales, printers and barcode scanners. The only new hardware installed (supplied by Emydex industrial hardware partner MWS Ltd) being three new industrial touch-screen computer terminals. A single OCM was supplied to enable labelling of boxes (both offal and primals).

Rizvan Khalid (Senior Director) of Euro Quality Lambs commented “having met the Emydex team and seen all of the product development, project delivery and customer support teams based in Dublin, we felt confident that we could work with Emydex. Since then our project has been implemented in a timely manner, and has met and in some cases surpassed our expectations.” Khalid added “One differentiator with Emydex over the other factory floor systems we evaluated was the ability and ease with which the Emydex system can be modified and configured to work in line with our existing EQL business processes. We had many new ideas that we wanted to incorporate into our new system. The flexibility inherent in Emydex means everything is possible”

Commenting on the installation, David McMahon CEO with Emydex in Dublin said “Rizvan and the management team in EQL had a very clear vision of their system requirements from the outset of the project, that was the automated collection of production data from factory door-to-door, enabling accurate reporting on production yields, quality and traceability information in real-time.”
For more information on the Emydex system click here or contact Emydex on +353 1 8855990

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Emydex live in MeatCo, Namibia

WINDHOEK – NAMIBIA:
Emydex today announce that their factory floor Data Capture, Production Reporting and Traceability system is now live and operational in MeatCo (Namibia)’s main beef processing plant in Windhoek, the capital of Namibia.

The beef primal deboning system in Windhoek is the first of an eight phase project that will see Emydex systems rolled out across MeatCo’s six beef processing operations in four separate locations in Namibia, as well as integrating Emydex to the Table Bay Cold Store in South Africa.

The two year, Euro 300k contract includes system rollout to Meatco’s two export approved slaughter and boning plants in Windhoek and Okahandja. Both plants are capable of slaughtering up to 1500cattle per day. The naturally grass fed Beef for which Namibia is famous is supplemented with Beef from Meatco’s own feed lot at Okapuka.

The Meat Corporation of Namibia (‘MeatCo’) also operate two further non-export abattoirs owned by the Namibian government but managed by Meatco, in Katima and Oshakati, which will both see Emydex installed. Finally a Wholesale beef processing plant and a cannery (both on the Windhoek site) will operate Emydex’s production management system.

Having pre-configured MeatCo’s customer specific business requirements in Dublin during February, Emydex staff were onsite in Windhoek during the Months of March and April, further configuring and customising the Emydex system to comply with the local market requirements of Meatco’s main export plant.

Phase one of the Windhoek project covered the carcass chills, carcass dispatch, boning hall, primal and carton packing, finished product stock, carton dispatch and integration to Meatco’s Sage X3 ERP system. Emydex are currently working on the Meatco Wholesale plant in Windhoek, soon to be followed by the Cannery and finally the Windhoek Beef slaughter line.

The company are targeting September 2014 as a likely roll out date for Windhoek system into Meatco’s second export plant in Okahandja.Due to the inherent flexibility and usability of the Emydex system Meatco are planning to roll out the Emydex system in the Oshakati and Katima abattoirs themselves,with remote support from Emydex as needed.

Commenting on the first phase of the Emydex system roll-out, AndriesTaljaardt,Meatco’s Windhoek Plant Manager said

“While slaughter continues uninterrupted, system upgrades are currently being effected at our Windhoek abattoir to improve the effectiveness of operations and maximise output in order to cater to growing customer demands.

Because of these demands, and the fact that preferences and specifications are continuously changing, we have to move into the direction which the market is moving. We have installed a new Production Management Software System (Emdyex) and layout in our Windhoek abattoir deboning department, which allows for a lot of value addition to our products. The Emydex system controls the volumes and all the information on the deboning floor and is responsible for the production recons and the labelling of products.

With the new layout, we have introduced an additional vacuum line and an additional frozen line. With that, we can now put up to 420 carcasses through deboning per day within normal working hours. For May, we are looking to put more than 6600 carcasses through deboning. Round about June, once the system is fully implemented, the number of carcasses we want to put through deboning is about 7000.”

In addition Andries said “We chose Emydex given it is a highly technological system that is used in many international abattoirs that adhere to European Union standards. Meatco is a pioneer in quality standards compliance in Namibia and is one of the first companies to achieve certification for international standards like ISO 9001 and HACCP.”

Commenting on the Emydex system roll-out, Nico Weck, Group Chief Financial Officer at the MeatCo group said “since implementing Emydex’s shop floor barcode labelling and scanning system at our Windhoek primal deboning operations, our managers now have instant access to accurate reporting on our Yields, Stocks and Traceability”.

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