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Food Processing Software Solutions

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Ireland

Home / Archives for Ireland

Irish Casings

3rd February 2022

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Ashbourne Meat Processors

8th July 2020

Ashbourne Meat Processors
Case Study

One of Ireland's largest chilled beef exporters

A leader in the supply of quality Irish beef products

Beef
Ireland | EU
Multi-Site

Ashbourne Meat Processors is one of Ireland’s most successful exporters of premium chilled beef products. Founded in 1985, the company exports high-quality products all over the world and is proud to be recognised as a family whose expertise and knowledge is passed down from one generation to another. There are nearly 200 people in the company family working in two facilities in the centre of Ireland – Roscrea (slaughtering and cold-storage facilities) and Naas (deboning and cold storage).

Ashbourne Meat Processors is a firm believer in leveraging advanced technology and production facilities.

Emdyex-Client-Logo-Ashbourne-Meats
What Ashbourne Meat Says

“The savings in administration were immediate – we saved a labour unit in the office immediately – and the piles of paperwork and stacks of files are a thing of the past. We’re almost paperless now, except for the cheques which some of our more traditional farming suppliers prefer over electronic payments. I estimate that actual physical paperwork has decreased by 95% and that’s a huge achievement.”

 

PJ Butler, Roscrea Plant Manager, Ashbourne Meat Processors

Challenge

Ashbourne Meat Processors’ two plants were essentially working in isolation from each other on outdated systems that required a lot of manual input and data entry. The abattoir in Roscrea would take in livestock and create the relevant paperwork. When the carcasses were transferred to Ashbourne Meat Processors’ facility in Naas (and to other facilities operated by the company’s clients all over the country), new paperwork would have to be created. This was extremely inefficient and left the company open to human error, duplication and lack of visibility and control.

There were also issues with compliance as the legacy systems used in both operations were not integrated with the Department of Agriculture systems and so there was a need for even more data entry.

Solution

Emydex is the acknowledged leader when it comes to process development for the food industry and when Ashbourne Meat Processors decided to overhaul the IT infrastructure and embrace the latest processing technology, they called Emydex.

Following a project scoping exercise, the team agreed to divide the job into two phases – one for the slaughter plant in Roscrea and the other for the Deboning operation in Naas. Connecting the two facilities was an obvious but important improvement.

In phase one, The Naas Deboning operation was upgraded by Emydex to deliver an end-to-end factory floor solution. Today Emydex handles the entire processing procedures within this plant, from Intake, Into / Out of Boning, Packing, Dispatch and Warehousing. Emydex also generates all the appropriate Dispatch Documentation, transfers traceability data to customers and allows for full forward and backward traceability. Prior to Emydex’s introduction, Work Orders were paper-based and were phoned down to the operators. Now this is all controlled within Emydex which means there is less likelihood of human error and the whole process is now more streamlined and controlled.

In phase two, the abattoir and cold storage facility 100 kilometres away in Roscrea, County Tipperary, was completely overhauled with everything from animal intake, supplier POs, inter-company paperwork and all procedures – from processing to packing, including sales picking – newly streamlined and automated. Labelling from boning through storage and out in orders was part of the specification as was the automatic electronic generation of all documentation. Real-time data is now updated constantly between the two plants and a new dispatch system created.

Outcome

Animal intake at the abattoir is now seamlessly and automatically integrated with the Government’s veterinary body, AIMS. Ear tags are scanned and all animal data is confirmed and registered and the Department of Agriculture is notified automatically. This improvement alone saves thousands of man-hours every year and completely eliminates human error at the intake point.

There used to be two separate systems and all sorts of mistakes were created by so much manual data entry. This led to delays in cattle payments and problems in registering the passport details of some animals. Now there is just one system and those errors have been eliminated.

Everything from animal intake to carcass dispatch and box generation is automated, tracked, reported and visible all the way from start to finish.

Overall, and almost immediately, efficiency was improved, paperwork virtually eliminated, errors drastically reduced, and profitability increased throughout the company.

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Staunton Foods

6th June 2020

Staunton Foods
Case Study

Pork
Ireland

A pork abattoir and cutting plant in Ireland

Pork Industry
Ireland | Europe
Single-Site

Staunton Foods is a privately owned pork abattoir and cutting plant in Timoleague, West Cork. Founded in 1950 Staunton Foods is now one of the main pig meat processors in Ireland. Since opening the purpose built factory in 1996, Stauntons have been supplying quality Pork and Bacon products for over 60 years both to domestic and export markets.

Subsequent expansion of the factory in 2005, 2008 and again in 2012 has allowed Staunton Foods to grow to become one of the main pig meat processors in Ireland.

After the factory expansion in 2012, Staunton Foods chose to implement Emydex’s Pig Kill Line and livestock payments system in their abattoir operation.

The system provides real-time reporting on kill line throughput, grading, destinations, suppliers, as well as a kill line yield analysis.

Emdyex Client Logo Stauntons
Working with Emydex

Emydex handles the slaughterhouse operations from data entry of intake to the Lairage, through to pig grading and supplier payments. Emydex exports invoices to their existing financial accounting system.

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Slaney Foods

6th June 2020

Slaney Foods
Case Study

Beef
Ireland

One of Ireland's largest beef processors

Beef Industry
Ireland | Europe
Single-Site

Located in Co. Wexford, Slaney Foods is one of Ireland's largest beef processing operations, processing over 2,500 cattle per week.

Emdyex Client Logo Slaney-Foods
Working with Emydex

In April 2014, Slaney Foods upgraded to the Emydex Kill Line system incorporating Beef Lairage, Ear-tag (Sequencing), Batching and Weigh/Grading stations located on their kill floor. The Emydex kill line system is integrated to Slaney Meat's existing Kill payments system.

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Rosie & Jim

6th June 2020

Rosie & Jim Case Study

Poultry & Processing
Ireland

A rapidly growing processing company in Dublin

Poultry & Processing

Ireland | Europe
Single-Site

Rosie & Jim is an Irish food production company established in 1997 when award-winning Craft Butcher Jimmy McLoughin established Quality First Limited. He began producing gourmet chicken products for supply to butcher shops and restaurants. Before long, the rapidly growing business moved to larger premises in Inchicore, Dublin 8. At this point, Rosie joined to assist with running the business.

Rosie and Jimmy McLoughlin are a husband and wife team who share a passion for wholesome quality food.

Rosie and Jim supply distributors to the retail, food-service and catering trades with ready to cook chicken products such as Breaded fresh & Frozen Chicken products, Wraps & Pasties.

Rosie and Jim approached Emydex in 2016 with a view to implementing a factory-wide Production Control and Traceability Reporting IT system door-to-door. The company had no existing factory floor IT system in place, operating manual processes instead, which meant excessive recording of internal processes manually on paper, which was both laborious and time-consuming, and offered little by way of real-time production control and traceability reporting.

The company had no real insight into the quantity or value of their existing stocks, resulting in procurement planning issues. Unsure of what current stocks were available to fulfill production orders, often resulted in over-ordering of stock, and the holding of excess stock of raw materials, dry goods and ingredients on-site than was needed.

Emdyex-Client-Logo-Rosie-and-Jim
Working with Emydex

“By the end of the first week most of the production team using the system were already comfortable with using it. You could visibly see them speeding up when going through the individual screens... Overall, I feel the project was a successful implementation, and the new system has been well received by our production team, operators and supervisors.”

 

Peter Turner, Financial Controller, Rosie & Jim

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Rockabill

6th June 2020

Rockabill Case Study

Seafood
Ireland

A family-run seafood company in Ireland

Seafood Industry
Ireland | Europe
Single-Site

Rockabill Seafood Ltd is a privately owned Irish company formed in 1984. Its owners, the Price family, have a tradition in the fishing industry going back many generations. The family-run company operates its own fleet of trawlers, refrigerated trucks and a number of processing plants located in Ireland and the UK.

The products they supply include, frozen and fresh Scampi, live and frozen razor clams, monkfish, velvet crab, cooked and live brown crab, cockles, whole fish and fish fillets, as well as a number of other seafood products.

Rockabill seafood specialises in 'Fresh & Frozen' seafood products and invests time, capital and management effort to ensure the integrity of its cold supply chain. The company's goal is to attain a seamless connection between the seabed and consumers so as to ensure that 'Fresh Frozen' is fresher than fresh and that our fresh product is the freshest.

Emydex was implemented at all the company’s production facilities.

Emdyex Client Logo Rockabill
What Rockabill Says

“Emydex has become a crucial and integral part of our organisation. They have reshaped the way we implement solutions throughout our production facilities. There are so many matrices involved with the processing of fish and shellfish, and Emydex have simplified all of these to make our lives easier.”

 

Alan Corcoran, Financial Controller, Rockabill

Challenge

  • Fast growing/Export focused seafood processor
  • Manual/Paper-based Production system
  • Over-reliance on a few key individuals inc. Stocks, Traceability, Yields, Operator Performance

Solution

emydex-customer-rockabill-fish

Outcome

  • Intake Stations x 3 (Prawns, Tails, Fish)
  • Cold Store Management
  • Prawn Packing Management
  • Finished Product Palletising
  • Real-time Production reporting on: Intake, Stocks, Dispatch, Traceability (backwards & forwards), Batch Yields, Operator Performance
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