On The Job with Country Maid: Automation Makes Pastry Factory's Production Processes Easy as Pie

CLIENT: COUNTRY MAID INC.  |  LOCATION: WEST BEND, IA

Sometimes the best things come in small packages. Country Maid Inc.’s Butter Braid brand pastries are a perfect example. The West Bend, IA, company has been rolling out delicious dough products for the fundraising industry since 1991, and these tasty pastries have helped non-profit groups raise over $280 million and counting. To keep up with demand, and Food and Drug Administration (FDA) regulations, Country Maid leaned on Van Meter Inc.’s automation expertise.

CHALLENGE: INCREASING EFFICIENCY WITHOUT SACRIFICING CONSISTENCY

Country Maid has come a long way since doing everything by hand in founders Ken and Marlene Banwart’s basement. When it grew into a state-of-the-art production facility, it was looking for a way to increase efficiency without losing product consistency. It also needed to remain in compliance with FDA regulations, like the Food Safety [Modernization] Act.

Country Maid’s VP of Engineering and Technology, Marc Banwart explained that a lot of their regulations are governed through the FDA. After they passed the Food Safety [Modernization] Act, Country Maid (and similar food and beverage manufacturers) needed to be able to produce records of batch history.

SOLUTION: AUTOMATING RECIPES AND COMPLIANCE CERTIFICATION

Van Meter knew exactly which automation solutions would give Country Maid the results it was looking for. Over the years, Country Maid has worked with Van Meter to automate multiple skids. Once the infrastructure was in place, Country Maid was ready to improve efficiency in two ways – automating its recipes and simplifying certifications and FDA compliance.

Van Meter recommended Rockwell Automation’s recipe management software products: FactoryTalk Batch, FactoryTalk Historian and Studio 5000 and pulled in integration partner, Interstates Control Systems Inc., to help bring the system to life.

The software allows the equipment to work together so Country Maid can benefit from a continuous-flow process. Prior to the software, they performed processes like measuring out recipe materials and keeping records of batches manually. But now the fully automated system moves material over a scale and weighs it to determine just the right amount to add to a batch. This has allowed Country Maid to achieve an incredibly consistent product.

The system also creates an electronic record with detailed batch information, time and date stamping, and electronic signature. When a product needs to be pulled off the shelf, Country Maid has FDA-required information readily available. The electronic record has cut routine FDA inspections from hours to minutes.

RESULT: HIGHER PRODUCTION OUTPUT WITH HIGHER QUALITY

With the Rockwell Automation software, Country Maid witnessed an increase in efficiency, between 83-86% on average. It led to a substantial increase in pastry production output. With the same number of people in the same amount of time, Country Maid went from producing 6,800 pieces per day to almost 22,000 pieces per day. Replacing manual production processes with automation allowed Country Maid to focus on how to improve the quality of its product rather than how to perform the processes it takes to make it.

"Country Maid went from producing 6,800 pieces per day to almost 22,000 pieces per day."

IMPROVE YOUR EFFICIENCY WITH AUTOMATION

Do Country Maid’s challenges sound familiar? How could automating manual processes help you increase production output and do it more efficiently? As a Rockwell Automation Authorized Service Provider, Van Meter has the essential supplies, effective solutions and expert support you need to reach increasing goals with fewer resources. Reach out to your Van Meter account manager with challenges you are facing or use the form below to get in touch with an automation specialist.

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