Optimal Strategy for Freezer Management and Other Areas Often Neglected in Meat Plants

10 Feb 24
Eben van Tonder

Introduction

Efficient feedback loops are the lifeblood of any meat plant, ensuring seamless operations across departments. From production to sales, and quality control to food safety, the entire focus of management revolves around optimizing these processes. As someone deeply engaged in managing a meat operation in Nigeria, where resource optimization is paramount, I’ve come to appreciate the importance of utilizing every aspect of the carcass efficiently. This echoes the sentiments of industry pioneers like Phili Armour, who famously remarked that nothing should go to waste in meat processing except the squeal (in the case of pork production; David Graaff’s Armour – A Tale of Two Legends). However, in reflecting on past experiences, I’ve identified a significant area of neglect: the handling of unwanted materials namely the freezers, work-in-progress chillers and re-works.

At Woodys we packed trim away for years which we wanted to use at some future date and never got around to doing that. Same with fat from cutter-bellies we imported.  At Van Wyngaardts in Johannesburg, I found even the blast freezer was used as a storage area for junk. Work-in-progress chillers were packed with sausage fillings that had not been filled and blended ham mixtures, mostly in the location for days and even weeks, seriously affecting the end-product quality. The reworks chiller is another area of huge concern. I dealt with the mistakes we made in this regard at Woody’s in Reflections on a Journey: From Memories to Mission. Here I develop a system that will prevent these mistakes.

Utilizing Matrix Software for Optimization

Implementing the Matrix Software system presents an ideal solution to address this issue. By utilizing its capabilities to track and manage every aspect of production, we can ensure that nothing goes to waste. Collaborating with experts like Pierce and Arno from Meat Matrix, we can design systems to effectively manage freezers and chillers, minimizing the storage of unwanted materials and maximizing efficiency. More important than the software is the thinking and the processes that must be designed and implemented. The software is a tool, but the work must begin with us!

Requirements and Specifications

In detailing my requirements for the Matrix Software system, I emphasize the need for comprehensive tracking and management protocols for freezers, blast freezers, work-in-progress chillers, and rework chillers. Each aspect must be meticulously documented, including recipes, production timelines, storage conditions, and responsible personnel. Drawing on studies such as “Optimal Storage Practices for Beef Bones: Ensuring Quality for Future Processing” and “Comprehensive Guidelines for Freezer Maintenance,” we can establish best practices to ensure product quality and safety (Smith, J., 2020; Jones, R., 2018).

I write the following to capture my own thoughts on the matter while it is fresh in my mind and to give to Pierce and Arno from Matrix Sofware so that I can see what capabilities the system have at the moment to accommodate what I require with the relevant daily and weekly reports along with some direction on what can be future QC and management direction in this matter. The power of their system is that every item is tagged, its ability to create batches and combine and take things apart from a single carcass tag, make multiple tasks for the product of deboning and portioning and keep full control and traceability by placing every item in an appropriate cost centre and new location.

Here are my requirements:

Freezers: In terms of freezers: everything that goes into the freezer must have

Blast Freezers: In terms of the blast freezer.

  • How are the products packed?
  • what went in
  • why did it go in
  • how was it packed? (best method for quick freezing)
  • at what temperature must it come out
  • How are we going to control the freezing time/ monitor it?
  • Who is responsible for this?

Work in Progress Chillers: The following applies.

  • what is going in?
  • why is it going in?
  • how long must it stay there?
  • FIFO??
  • how are the items packed?
  • airflow (how can products be guarded against excessive airflow and possible negative impacts such as drying?)
  • who is responsible for managing the chillers?

Rework Chillers:

  • traceability
  • expiry dates
  • salt content and other ingredients such as preservatives
  • what is the intended recipe attached to everything in the chiller?
  • intended time frame to be clearance from the chiller (what is the SOP)
  • who is responsible for the chiller 
  • should it be a chiller or a freezer?

Creating Standard Operating Procedures (SOPs)

Furthermore, these requirements must be translated into Standard Operating Procedures (SOPs) to provide clear guidelines for staff. SOPs will outline procedures for inventory management, temperature monitoring, and product rotation, ensuring consistency and adherence to quality standards (EarthwormExpress, 2023).

Feedback Loops and Optimization

While feedback loops typically exist in areas like sales and production, creating feedback mechanisms for freezer management is equally crucial. Through the Matrix Software system, we can establish feedback loops to monitor and optimize freezer usage, minimizing waste and maximizing profitability.

Time Frame and Efficiency

Setting a time frame for clearing unwanted stocks is essential, with a focus on weeks rather than months. Understanding key ratios, such as the 10% rule for formulation adjustments, allows for efficient utilization of resources and minimizes waste (EarthwormExpress, 2023).

Conclusion

In conclusion, my journey in the meat industry has taught me valuable lessons about efficiency, optimization, and the importance of leveraging technology to maximize productivity. As Wynand Nel from Eskort once welcomed me to work every morning at 5:45 when I reported for work, when we worked together at Stcoks Meat Market with the words “Welcome to the real world!”, I’m reminded that true wisdom lies in mastering both the technical aspects of the trade and the intricacies of human behaviour in line with the right focus areas. Freezers and chillers are a key focus area for profitability as is planning, SOPs and standards!