Bakery Reduces Ingredient Waste and Bad Batch Costs by Over $39,000

A large national baking company realized that improving the performance of their minor ingredient scaling could lead to a significant impact on their profitability. Additionally they were averaging one bad batch a week due to errors in the minor ingredient hand adds. They looked to Doran Scales to provide the solution to reduce costs from wasted ingredients and bad batches.

THE SOLUTION was a Doran FC6200 Formula Control Scale. A Doran FC6200 is installed at the ingredient scaling station. Ingredient batching is automated, stepping the user through the formula and ensuring the correct ingredients are accurately scaled every time. Formula Loader software is installed on a PC. This recipe software is used to create and maintain minor ingredient batches. Recipes, formulas and production schedules are then uploaded to the FC6200 through USB flash drive or through an Ethernet connection. Increase accuracy is achieved through user programmable ingredient target weights and tolerances giving management effective control of the batching operation. Multi-tasking Operators who are distracted by other production responsibilities can now return to the partially scaled formula assured that the scale will pick up right where they left off, prompting them through the remainder of the formula without error. Ingredient Lot Numbers are automatically recorded for traceability during formula scaling while ensuring each ingredient meets the desired weight tolerance.

Mushroom Grower Increases Production Output By 5000 lbs a Day

A large Mushroom grower needed a way to ensure that the tills of mushrooms were being filled to the proper weight and a means to verify the productivity of each employee. Since whole mushrooms vary in weight and size, the tills of mushrooms were filled by hand. They knew the weight of the bulk mushrooms and the total weight of all the mushrooms packaged that day and they realized that almost 4% of product was lost or unaccounted for during the packaging process. This needed to be improved to keep a healthy profit margin for this company.

THE SOLUTION involved the Doran 2200CW Checkweigh Scale with Ethernet and Excelerator Data Collection.

10 Doran 2200CW Checkweigh scales with wired Ethernet were installed in each production line (Seven total lines). They were connected to a PC with Dorans CW Setup program which contained a library of all products with over and under tolerances. The scales require the operator to log in with an employee ID; this allows all of their packaging for the shift to be recorded. The line leader enters the product to be run in the CW Setup program which then uploads this information and over under tolerances to the 2200CW scales on that line. After the 2200CW scales are setup with the product information and tolerances the Doran Excelerator program starts to collect the data on each weighment from each scale and each packer.

No Network Available for Data Collection? No Problem.

Over the past several years Doran Scale has become a leader in scale communication and data collection applications. With the new advanced features on the 2200 series this system now offers more flexibility in real world data collection applications. While collecting data using Ethernet and a Local Area Network (LAN) is ideal in many instances, there are times when this is not practical because of complexity, facility restrictions or cost. An ideal solution when a LAN is not available is the Doran 2200 Scale with the Bluetooth option utilizing data buffering.

The 2200 with the Bluetooth option (EXOPT205 ) is set up with an appropriate data string which could include Product ID, Description, User defined fields for Lot ID, Employee ID or Location and scale information. Data buffering is enabled in configuration and the data output method is selected. This could be a manual output by pressing the PRINT button or one of several automatic outputs. When weight is on the scale and data is output manually or automatically, the configured data string is Continue reading

Check Out the Latest Advanced Features of the Doran 2200 indicators

Doran listens to their distributors and their needs.  Along with the 2200’s standard features such as Gross, Net, Tare, multiple product ID’s, full numerical keypad, accumulator, eight setpoints, two RS232 ports, Doran recently released the latest offering of advanced features for the Doran 2200 Indicator which include: Continue reading

What you don’t know about your food manufacturing process could cost thousands of dollars

Add one of our Doran Bakery Scales to your process to improve efficiency. Bakeries, snack food processors, foodservice, makers of cakes, muffins, brownies, tortillas, pizza dough, and donuts are realizing cost savings from adding digital portion scales to their process. Just read a few of the case studies about everything from Mushrooms to Margarine.

From scaling and mixing areas for minor and major ingredients, to the manufacturing and finishing area and to final packaging and shipping, these high quality Doran Continue reading

Doran Scales New Bluetooth Option is fast and simple data communications for scales

Take scale communication to a whole new level with Bluetooth.Bluetooth is Simple
The Bluetooth Option is a complete wireless communication system. The kit includes an internal scale module (no external antennas) and a USB adapter for your PC. There are no cables to run, or connectors. No need to involve the IT department, it’s that easy.   A great addition to your Doran 2200 digital weight indicator.

Bluetooth is Fast
Factory installed and configured, it’s ready to go right out of the box. You will be quickly communicating with up to seven scales at distances up to 300 feet with the high-powered Class 1 device. Data is pushed from the scale to the PC which is a faster method of data communication than RS-232 and a multiplexer that slowly polls or gathers the data from the scales. You will be amazed at how fast the data is imported into an Excel spreadsheet with Excelerator Software.

Bluetooth is Affordable
With a list price that’s less than half of the price of the Wireless Ethernet Option, the Bluetooth Communication kit is a cost-effective, wireless data communication option. Continue reading