How to make Pepperoni in a Plant
By: Trina Davis
Table of Content
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Table of Contents
Table of Contents......................................................................................................................................................................... iii
Introduction ................................................................................................................................................................................... v
Material Ordering Process ......................................................................................................................................................... 3
Step 1: Order Created from Customer .............................................................................................................................. 3
Raw Materials Ordered ........................................................................................................................................................... 3
Materials Received and Stored .............................................................................................................................................. 3
Production Process ....................................................................................................................................................................... 6
Grind Room.............................................................................................................................................................................. 6
Cook Room............................................................................................................................................................................... 7
Drying Room ............................................................................................................................................................................ 8
Chiller Room............................................................................................................................................................................. 9
Slice Room ................................................................................................................................................................................ 9
Shipping Process ......................................................................................................................................................................... 13
Boxed Pepperoni.................................................................................................................................................................... 13
Shipped Pepperoni................................................................................................................................................................. 13
Introduction
v
Introduction
The objective for this manual is to provide the user with instruction on how to process pepperoni
in a manufacturing plant. There are several critical steps that must be followed in the plant in
order to produce pepperoni that will be saleable to customers in the food industries. This manual
is to inform users the simplest form for making pepperoni. The user must be trained on the
equipment before it is used to prevent any safety issues.
Material Ordering Process
Material Ordering Process
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Material Ordering Process
Step 1: Order Created from Customer
When a customer is ready to restock their
inventory they call their local supplier and place
the minimal ordered required. Customer enter the
order into their system. The plant scheduler puts in
what material he needs into the ERP system and
from there it gives them an estimate of what ingredients he will need to order. He creates a
process order for production so they will know how many pounds are needed to complete the
customer order.
Step 2: Raw Materials Ordered
The scheduler places the orders for all the raw
material needed to be produced. The receiving
supervisor will receive a manifest listing dates and
times to expect the material for production. Once
those ingredient have been order an estimated receive
date is given to the supplier. The estimated time to
deliver raw meat is within seven days. The spice
ingredients normally takes about seven to fourteen
days.
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How to make Pepperoni in a Plant
Step 3: Materials Received and Stored
When the raw material are delivered to the dock
door a material handler verify the paperwork with
the truck driver and if everything checks out he
begin to verify the weighs. A quality assurance
technician inspects the product to make sure the
material are within the customer specification and
approve for production. When QA release the
truck the receiving clerk enter those weighs and
the number of containers into the computer system
into their correct location.
A dock worker unload the trucks and
the product are place in inventory. A
pick ticket is generated and a list of
ingredient are handle by a material
handler whom gather the ingredients and
bring them to production. The
Production scheduler turns the process
order to the production supervisor so
they can prep for the production run.
Production Process
Shipping Process
How to make Pepperoni in a Plant 6
Production Process
Step 1: Grind Room
The forklift driver delivers the raw material to the grind to be process. The formulator looks at
his pick tickets to see what ingredient needed.
Step: 2: The pepperoni recipe includes the following:
15.93 lbs. Beef Extra Fine Trim
14.05lbs. Pork Cheek Frozen
44.97 lbs. Pork 72 Fresh
18.74 lbs. Pork Lean
0.32lbs. Water
0.01lbs Culture Starter
0.12lbs Cure Prague Powder
3.38lbs. High Purity Salt
2.49lbs. Seasoning with Paprika
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Step 3: Cook Room
When the all the raw material have been measure
up they are put into a blender that holds up to
forty five hundred pounds at one time. The
product is blended and sample are taken to the
chemistry lab to check the fat content. The beef
and pork percentage needs to be + fifty percent
either way. Once the batch is blended it is place
on a conveyor belt and goes through a meat pump
to pump the meat into the plastic casing to form
the pepperoni stick. This process is repeated until
there are enough sticks to fill the rack of one
hundred and eighty hooks.
.
Shipping Process
How to make Pepperoni in a Plant 8
Step 4: Drying Room
The utility worker load the racks with one hundred and eighty sticks and the forklift operator
takes the rack to register the weight of the rack. The operator then takes the racks and load them
into the ovens until it is filled. This process is repeated until all the ovens are full or until the
production run is over. The racks sit into the ovens and smoke for twenty four hours before they
are remove. The sticks are monitor to make sure they are drying at the level and speed that is
required per the customer specification. If this process fails then the product must have to be sent
back to the grind room for rework product.
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Step 5: Chiller Room
The forklift operator remove the racks after smoking in
the ovens for twenty four hours. The forklift operator
transfer the racks to the chiller room where each stick
have to sit and dry for twelve to fourteen days before it
can be further process. Some of the sticks takes longer
to dry then others. It may depends on the size of the
sticks. Larger stick weigh anywhere between twelve
hundred to fourteen hundred pounds takes a lot longer
than sticks that are much smaller.
Step 6: Slice Room
After the pepperoni sticks have completely dried the
forklift operator transfer all the racks into the slice room.
The utility workers remove each stick and place the stick
on the casing inflator to remove the casing. Once all the
casing have been remove they are place on the conveyor
belt and taken up to the slicer and the machine operator
places six to eight stick on the table and the sticks are
run into the slicer to be slice at a with specific to the
customer requirements.
Shipping Process
How to make Pepperoni in a Plant 10
Once the pepperoni has been sliced it is place on a conveyor belt and transfer to the eagle
triangle. The eagle has about 50 triangle and the slice bulk pepperoni makes it was to the
available triangle to be place in the plastic bag and sealed. The plastic bags can hold up to five to
twelve pounds per bag. When the appropriate weigh is meet the eagle seals the bag. The bag is
dropped back on the conveyor belt where it goes through a metal detector to be clear of any
foreign objects. If the metal detector keeps the product back the product goes on hold until that
batch can be verify by a quality assurance technician. If everything checks out the product is
ready to be place in a box.
Metal Detector
Pouch Packing
Shipping Process
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Shipping Process
Step 1: Boxed Pepperoni
Once the product have been placed in the box from
production it goes through the auto box machine where it
seal the box and place it on the palletizer. This process is
repeated until the pallet is full. The pallet is shrink rapped
to keep the boxes stable. The forklift operator takes the
pallet and place it in inventory in the correct bin. It will sit
in inventory until the product is release from a three day
microbiology hold.
Final Step: Shipped Pepperoni
When the product is release off micro. hold a pick ticket is created from the order that was put in
the system by customer service at the beginning. The material handler pulls the product from its
current location and the forklift operator load the product onto the truck where it’s taken to the
company’s distribution center until the customer need the product.
When the product is shipped out of the distribution and Invoice is automatic created and is
submitted to the customer via electronic document invoice online.
Packaging Machine
s
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