Halfpenny production and distro Flashcards
How many days a year is the production facility in operation?
360
What are the batch sizes?
800g loaves - 2500
400g rolls - 2500
Therefore each batch of loaves requires twice as much bread dough as a batch of rolls (2:1 ratio)
What are the 5 departments within the production facility?
- Mixing and kneading
- Shaping and proving
- Baking
- Cooling
- Packaging
What are the 4 service departments that support production?
- Raw materials stores
- Machinery maintenance
- Facilities maintenance
- Employee canteen
What are the details of the raw materials stores?
- Flour stored in large silos
- Salt and seed stored in smaller silos
- Yeast stored in large sealed bags into empty silos
- Silos cleaned before delivery
- Next door to mixing and kneading department
What are the details of the mixing and kneading department?
- Silos attached via pipes into mixing & kneading machines
- Each machine capable of a single batch (2500) of loaves or rolls
- Weighing of ingredients a computer process, fed into machine
- Machine mixes and adds right amount of water
- Dough kneaded by machine, rested for 15 mins before moving on
What are the details of the shaping and proving
- Machine divides dough into pieces suitable for 1 loaf or 1 roll
- Shaped to fit either a loaf pan or roll pan (6 rolls)
- Pans moved into proving machine
What are the details of the baking?
- Cooked for 15 to 20 mins
- When done, pans removed by machine
What are the details of the cooling?
- Cooling machine cools pans for 2 hrs
What are the details of the packaging?
- Loaves sliced regularly or thick
- All items packed
- Date labels attached and sent to distro centre
What are the details of flour?
- 3 types used; white, wholemeal and coarse grain wholewheat
- Each type sourced from specialists in milling, 2 white, 2 wholemeal and 1 coarse supplier
- All 4 suppliers located within 50km of producrion
- Payment terms 20-30 days
What are the details of yeast?
- Use fast action dried yeast
- Sourced from single supplier (used for 20 years +), purchased in bulk
- Payments terms 30 days
What are the details of grains and seeds?
- Sourced from multiple suppliers, depends on cheapest one
- Payment terms 30-60 days
How is the proximity of the distro centre beneficial?
- Freshly baked batches easily transferred to distro centre throughout the day
- Each type of product has its own area
What is the aim of the production centre?
- Dispatch products within 2 days of production
- Requires careful rotation of inventory in date order
What is the use by date on products?
2 weeks
How does halfpenny deliver?
- Uses own fleet of trucks and drivers
- Eco friendly as schedule aims to minimise distance travelled
Where are deliveries made to?
- Majority of supermarket deliveries made direct to stores
- Some to depots
- Local convivence have deliveries made to central depot
- Independent stores have deliveries direct to store
What is the split of employees/
Production - 827 (37.5%)
Distro - 1156 (52.4%)
Head office - 225 (10.1%)
