TRACEABILITY IN THE
PRODUCT CONTROL

by marketing on 13 de November de 2023

The importance of traceability

More and more manufacturers need to control each of the steps involved in the manufacture of the products they make, from the quantity of raw materials, ingredients or packaging used to palletisation, so that the entire process is recorded so that, if necessary, a specific product or batch can be located quickly and easily.

It is traceability that allows us to take into account all these variables: the origin, the history of processes, the transformations, the controls to which it has been subjected, its final destination and its distribution chain, among many other things.
This concept is very important in sectors where counterfeiting may occur, such as the pharmaceutical industry. In these cases it is necessary to have complete traceability, audit-ready and also taking into account all the requirements of 21 CFR Part 11.

Traceability is also becoming increasingly important in the food market, with the aim of being able to identify batches and thus quickly resolve any unforeseen issues that may arise during the manufacturing or distribution of the product.

A ROBUST TRACEABILITY SYSTEM ON THE LINE IS THEREFORE ESSENTIAL TO ENSURE THE SAFETY AND QUALITY OF THE PRODUCTS, AS WELL AS TO FACILITATE THE IDENTIFICATION AND RESOLUTION OF PROBLEMS IN CASE OF INCIDENTS.

According to the AECOC Food Safety Committee: Traceability is understood as the set of pre-established and self-sufficient procedures that make it possible to know the history, location and trajectory of a product or batch of products throughout the supply chain at a given moment, through specific tools.

A good traceability system

Given the importance of a good traceability system in production, it is important to have suppliers who have a research and development department that adapts the traceability systems of the equipment that will go on a line according to the needs or requirements of each case. traceability systems of the equipment that will go on a line according to the needs or requirements for each case.

But, in general terms, what are the characteristics that a good traceability system must fulfil?

TRACKING FROM START TO FINISH

The system must be able to trace each stage of the production process, from the initial raw material to the final product delivered to the consumer. This allows any point where contamination or problems may have occurred to be identified.

Varpe equipment is able to identify the product at the start of a checkweigher or inspection system and know where it has ended up (rejected, correct, sorted, etc.).

UNIQUE IDENTIFICATION

Each batch or unit of product must have a unique identification, such as a barcode, QR code or batch number, which allows its origin and route to be traced at all times.

Varpe equipment is capable of incorporating readers to identify the batch or product that has been weighed or inspected using the customer's serial number system, incorporating weight information, x-ray equipment and/or rejects and transmitting it for storage.

DETAILED LOG

The system must record and store detailed information about each stage of the production process,
including dates, locations, suppliers, ingredients, processing methods, personnel involved and any other relevant data.

Varpe's equipment can provide statistical information on production, individual weights, rejects, x-ray images, etc. for further traceability and control.

AUTOMATION AND ADVANCED TECHNOLOGY

Utilizar tecnologías como sensores, RFID (Identificación por Radiofrecuencia) y sistemas de gestión de datos automatizados puede mejorar la precisión y eficiencia del sistema de trazabilidad.

Se pueden incluir sistemas de visión a los equipos Varpe para un control exhaustivo mediante código de barras o QR.

DATA INTEGRATION

The system must be able to integrate with the company's quality and production management systems,
allowing for a continuous and accurate flow of information.

Thanks to Varpe's wide range of communications, the checkweighing and X-ray inspection equipment is able to communicate with the customer's MES (Manufacturing Execution System) systems, providing a continuous and accurate flow of information. 

ACCESSIBILITY AND SPEED

Traceability information should be readily and easily available in case it is required, be it for auditing purposes, product recalls or any other type of investigation.

Varpe systems record all changes to parameters that affect the machine, such as format changes and editing, speed parameters or various adjustments, always recording both the time and the operator who made them, so that a record can be kept of what happened in a production run.

DATA SECURITY

Dado que la información de trazabilidad es crítica, el sistema debe contar con medidas de seguridad robustas para proteger los datos contra accesos no autorizados o manipulación indebida.

Todos los sistemas Varpe tienen una alta seguridad en los datos que gestionan. Además, incorpran un gestor de niveles de usuario para poder definir y gestionar permisos.

TWO-WAY TRACKING CAPABILITY

The system must allow tracking both forward and backward in the supply chain backwards and forwards in the supply chain.

That is, it must be possible to trace ingredients and components entering the components entering the process and also where the finished where the finished products are shipped to.

STANDARDS COMPATIBILITY

The system must comply with the traceability standards and regulations set by the competent authorities in the food or pharmaceutical industry.

Varpe takes into account all regulations that apply to its customers, such as 21 CFR part 11, and adjusts its equipment to assist with compliance.

EFFICIENT SETBACK CAPABILITY

In the event of a product recall, the system must allow for accurate identification of the products concerned and their location in the supply chain for a quick and effective recall.

STAFF TRAINING

It is crucial that staff are well trained in the use of the traceability system and in the importance of keeping accurate and up-to-date records.

Traceability requires prior research to understand the specific needs of each customer and industry, but as we have seen, any traceability system must ensure consumer safety, comply with regulations and standards, and maintain confidence in the quality of products.

EARLY WARNING CAPABILITY

A good traceability system must be able to generate real-time alerts if deviations or anomalies are detected in the production process, allowing corrective action to be taken in a timely manner.

Varpe systems have intercommunications with the MES systems to trigger real-time alerts if a problem occurs in any of the equipment.

In addition, the proprietary VIT4 data management software generates preventive maintenance alerts to avoid unwanted downtime.

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