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5. The Production Process

Sonneveld products are produced with the greatest possible care. Products are supplied in a variety of physical forms and therefore produced in various different ways.
We distinguish between:

  • Bread improvement agents and bread and pastry mixes in powder form
  • Bread improvement agents in powder form and liquid improvers
  • Proson bread improvement agents in block form
  • Liquid release agents.

5.1 The processes

Depending on the physical form of the product it may be produced in one of a range of factories: The Powder Factory for products in powder form, the Paste/Release Agent Factory for products in paste form and release agents and PALIPRO for products in paste form, liquid improvers and Proson blocks. The general process is however the same in all the factories (see the diagram below): weighing, mixing, dosing/filling/block forming, packaging and storage.

The weighing of the ingredients takes place systematically, with the use of barcodes. The barcode must initially be scanned before the ingredient in question can be weighed. This barcode will be scanned again when the ingredient is added to the product. The production process, weighing, mixing and dosing, takes place in an enclosed system, preventing contamination from outside.

Production takes place in accordance with a set production process. The process parameters are recorded in a process report. All information relating to the raw materials used together with the relevant weights and mixing times are set down in a batch protocol. A sample will be taken against each batch number for physical assessment. Samples of products will be retained for the retention period specified for the product in question. Further checks will be described in Section 5.3.

5.2 Critical check points

Sonneveld has created three Critical Check Points (CCPs) in the production process, namely screening, metal detection and CIP.

Raw materials are passed through a variety of screens ranging from 0.2 to 10 mm. Depending on their packaging, powders are passed through a metal detector either before or after packaging. The metal detection system is checked daily. Because of the aluminium in their packaging, Proson and home bake products are passed through x-ray equipment.

No use is made of water for cleaning, because of the hygroscopic properties of powders. The equipment is therefore brushed and vacuumed clean. The paste, liquid, Proson and release agent production installations are wet cleaned (manually and using CIP) with the aid of cleaning and disinfection agents.

5.3 HAI

The process control parameters are documented in HAI.

HAI*QPM is a fully web based program.

The advantage is that all paper will disappear in the production unit.
- Controle lists of the production unit
- Charge protocols of each charge which is produced
- OEE rapports for the productive output
Also it is possible to see " real-time" by all stakeholders in the organization and to follow the production in their field of action, making monitoring easier and faster. It can also generate reports for managers and QA department.

See the attached diagram of the production process, including the Critical Check Points.

CCP's  Explanation of CCPs Method Frequency
CCP1 screening (in line) various dimensions , dep. on product visual weekly/ 1x shift
CCP2 metal detection Ferrous: 3,5 mm 
Non Ferrous: 5 mm
Stainless steel: 4 mm
visual 1 x per shift

5.4 Quality control on finished product

Physical inspection of the product takes place on the production line. A representative sample of the batch is taken for assessment. Products are also checked for weight, packaging and labelling. The weighing scales which are being used, are calibrated once annually in accordance with a set schedule. Standards have been specified for every product and are required to be met. This takes place by means of quality checks carried out by the operators (flow behaviour, consistency, colour measurements) or the Application Centre (technical baking quality approval). Where non-conformities are detected, the product is immediately quarantined and an investigation is carried out. Quality documentation is retained for 3, 5 and 10 years.

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