Easy Production and Quality Management
From the tanker at the plant gate to a released, traceable batch: weighbridge and reception, recipes and run plans, batch tracking, pouch packing, QC approvals, lab logs and FSSAI traceability, all on one database.
Plant reception and weighbridge
Every tanker and vehicle is weighed in and out, QC-tested and accepted into production before a litre is used.
Bulk arrivals: QC test and production acceptance
Bulk-vendor and chilling-centre tankers are tested on arrival. Only milk that passes QC is accepted into production, and the acceptance carries its quality record forward.
- Tanker-wise receipt against despatch
- Quality captured with the receipt
- Accepted quantity flows to the silo
Weigh Bridge Desk (Windows) and plant in/out integration
The Weigh Bridge Desk records every vehicle entering and leaving the plant and passes the weights straight into the ERP, so nobody retypes a weight.
- Gross, tare and net captured automatically
- In and out for milk, materials and products
- Weighbridge Reports 01 and 02
Weighbridge photo proof and material balance cross-check
A photo is stored with each weighbridge entry for every material, and material balances are cross-checked against weighbridge weights so gaps show up the same day.
- Image stored per weighment
- Material balance vs weighbridge
- Proof ready for audits and disputes
Total solids matched from village to plant
Fat and SNF sent from villages and chilling centres are matched every day with what the plant received, despatched and had acknowledged.
- Purchase vs despatch vs acknowledgement
- Plant-level TS MIS for several plants
- Full detail on the TS matching page
Production planning and processing
Recipes, run plans and batches describe exactly what was made, from which inputs, on which equipment, by whom.
Recipe master with BOM costing
Each product has a recipe with its bill of materials, and the recipe cost is worked out from current material prices. Ingredient utilisation reports compare planned and actual use.
- Recipe master and BOM
- Recipe costing
- Ingredient utilisation report
Run plans and multiple run plan job cards
Plan each production run, record what goes in (Run Plan In) and what comes out (Run Plan Out 1 and 2), and issue job cards when several runs share a shift.
- Run Plan, Run Plan In, Run Plan Out
- Multiple Run Plan Job Card
- Output by machine
Batch master and batch tracking
Every batch gets its own record. Batch tracking shows who did what, on which equipment and at what time, and IoT can add machine parameters automatically.
- Batch master
- Stage-wise monitoring
- Batch-wise equipment usage for maintenance
Supports all plant equipment
Silos, PHE, separators and tankers are set up as equipment, so every movement and run is tied to the equipment that handled it.
- Silo, PHE, separator, tanker
- Transport CIP records
- Utilization report
Mass balance and variety-wise production
The Mass Balance Report checks that inputs and outputs balance for each batch, and Variety-wise Production Details show quantities by product for any date range.
- Material balance per batch
- Variety-wise production chart
- Utility consumption against production
Stock visibility from silo to dispatch
Stock is visible at every point: silo, finished goods, cold room (MCR) and dispatch. Store stock and production-area stock are kept separately and moved with stock transfers.
- Silo → FG → MCR → dispatch
- FG and SFG stock correction with approval
- Stock transfer updated on both sides
Packing and pouch management
Pouch packing is accounted for pouch by pouch, so leakages, flush milk and overfill are measured instead of guessed.
Single pouch tracking with leakages and flush milk
Every pouch is accounted for: good pouches, leaked pouches and flush milk are recorded per run, and handling loss is logged with a reason.
- Leakage and flush milk per run
- Handling-loss log
- Log Details Report
Pouch counts from the packing machine
Pouch counts are taken from each packing machine per variant and shift (this needs an extra hardware counter), then entered against the run.
- Pouch input entry per machine
- Milk Packing Log Details
- Machine, shift and product views
Milk pouch yield
Pouch yield shows how much milk went into how many pouches, so yield is checked every day for every variant.
- Packing pouch yield
- Pouch costing report
- Variant-wise view
Production-to-sales pouch matching
Pouches produced are matched against pouches sold and returned, so stock gaps between the packing hall and sales are visible.
- Sales pouch vs production stock
- Pouch-wise matching
- Feeds TS matching up to dispatch
Pouch weight monitoring
Sample pouches are weighed at the filler on a connected scale, with hourly deviation reports per head. See the CCP and pouch weight page for details.
- Average excess over target
- Hourly deviation per head
- Shift-wise packing performance
Plant QC, lab and FSSAI
Quality is recorded and approved at every stage, and any batch can be traced in seconds for an FSSAI or customer audit.
Quality of all incoming and outgoing material
Quality parameters are recorded for every material that comes in or goes out, including inter- and intra-company transfers.
- Incoming milk and materials
- Outgoing products
- Transfers between units
QC approval at each level and real-time batch clearance
QC enters results as tests finish and approves each stage before milk moves to the next, so batches are cleared without waiting for paperwork.
- Stage-wise approval
- Real-time QC entry
- QC activity sheet and acknowledgements
Lab tests, chemical and microbiology logs
Lab tests are recorded with the sample source (dispatch tanker, received tanker, route sample or vendor), lab type (chemistry, microbiology, milk plant lab, QC lab), result and attachment.
- Chemical Analysis Log
- Microbiology Analysis Log
- Results in %, KG or MBRT hours
Instant batch traceability for FSSAI
Batch number-wise traceability links raw milk, run plans, QC results and dispatch, with Traceability Reports ready for an FSSAI audit.
- Batch-wise quality records
- Traceability Reports 01-03
- Every quality log in the system, not on paper
Live batch results and Certificate of Analysis on web
Approved batch results are published on the web as soon as they are released, and customers can download the Certificate of Analysis for their batch.
- Dynamic publishing of results
- CoA download by customers
- Food Safety Management (FSMS) records
Walk through every function in the guided demo tour
Short cards for each screen and report, with links to the step-by-step Docs.
Related pages
Built for dairies, by a dairy software team since 2015
Every plant screen shown here runs on the same database as procurement, sales, stores and accounts, so a batch, a pouch or a GRN is never re-entered.
When you have seen enough, we are happy to show it to you live on our sample data: book a demo or call +91 94880 59495.