Blast Freezer Workflow

Note #

Before initiating the Blast Freezer process, ensure the following prerequisites are met:

1. Vacuum Film Availability:
   Ensure sufficient vacuum film quantity is available in the Production And Processing > Vacuum > Check In section.
2. Operational Production Line:
   The vacuum role must be loaded into the vacuum line to make the production line operational in Production And Processing > Vacuum > Vacuum Controls section
   Reference: Learn how to check-in and control vacuum packing.

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Steps for Blast Freezer Workflow #

1. Adding a Pallet #

Navigate to Production And Processing > Blast Freezer > Record and fill in the required fields in the Add Pallet section:

• Basket Size:
  Select the appropriate size for the basket:
  • Small (48 pieces capacity)
  • Large (60 pieces capacity)
• Processing Line:
  Select one of the four available production lines. The system will deduct from the running batch on the selected line.
• Select Product:
  • If associated with a sales order, the product list will display items from the sales order.
  • For products without a sales order, select Home Order to access the list of vacuum-packed products.
• Physical Pallet:
  Select Yes or No to include pallet weight in the total weight during check-in and checkout.
• Add Pallet:
  Click the Add Pallet button. The newly added pallet will appear in the pallet list.

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2. Pallet Actions #

Once the pallet is added, the following actions are available:

1. Print Pallet Label:
   Print a label for pallet identification and tracking.
2. Check-In:
   Submit the pallet to the freezer by clicking the Check-In button.
   • Check-In Modal Details: Enter the Weight and select the Freezer where the pallet will be stored.
3. View and Update Record:
   • Edit Quantity:
     Update the basket quantity for the pallet directly from the Quantity column in the pallet list. Click the pencil icon, which opens a modal to:
     • Specify the total number of baskets.
     • Enter the number of pieces for each basket based on the basket size (e.g., 48 for Small, 60 for Large).
   • View Modal:
     Access the View Modal by clicking the eye icon. This displays:
     • List of all baskets in the pallet.
     • Edit Button: Allows updating the quantity of pieces for a specific basket. Note: New baskets cannot be added from this modal—this must be done through the Quantity column.
   • View Vacuum Batch Details:
     View details of the vacuum batch used and its usage history.

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3. Freezer Management #

Once the pallet is checked in, it will appear in the Freezer section.

• Freezing Time:
  By default, freezing time is set to 720 minutes. This can be extended as needed.
• Freezer Status:
  • Red: Freezing is in progress.
  • Green: Freezing is complete, and the pallet is ready for checkout.
• Freezer Table Details:
  The freezer table displays the following information:
  • Status: Indicates freezing progress.
  • Pallet: Pallet number.
  • Basket Quantity: Total quantity of baskets.
  • Check-In Date/Time: Timestamp of pallet check-in.
  • Check-In Weight: Total weight (including or excluding pallet/basket weight based on configuration).
  • Batch No.: Corresponds to the running batch.
  • Product Code: Displays the product code.
  • Processing Line: Indicates the associated production line.

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4. Freezer Actions #

Manage pallets in the freezer using the following actions:

1. Move to Freezer 4
   • Transfer the pallet to Freezer 4 (IQF) for additional processing or long-term storage.
   • Select the pallet and click the Move to Freezer 4 button in the Action column.
   • Enter the required Weight and Quantity in the modal that appears.
   • Confirm the transfer by clicking the Move button.
2. Move to Other Freezers
   • Relocate pallets to freezers other than Freezer 4 for operational flexibility.
   • Select the pallet and click the Move to Other Freezers button in the Action column.
   • Choose the desired freezer location from the dropdown and confirm by clicking the Move button.
3. Checkout
   • Initiate the Checkout Process:
     • Click the Checkout button in the Action column of the freezer table.
     • The Checkout Modal will appear with the following fields:
       • Location: Select the destination location where the pallet will be moved.
       • Weight: Enter the final weight of the pallet or material being checked out.
   • Confirm Checkout:
     • After filling in the required details, click the Check Out button to finalize the process.
   • Post-Checkout Availability:
     • Once the checkout is completed, the material becomes available in Live Production > Blast Freezer > Check Out Material for subsequent packing operations.