In the world of industrial baking, maintaining line efficiency and ensuring the longevity of bakeware and their coatings are paramount to delivering high-quality products consistently. American Pan’s SMART Pan Tracking® System helps protect the product and the pan, with actionable information.
The key to efficiently achieving great products on an industrial line includes using good quality coatings and pans that are optimized for the product and the production line, material, size and configuration. A comprehensive tracking system ties together all these aspects, to optimize the bakeware use, the system’s operation and the final results.
American Pan developed a SMART Pan Tracking® System providing data monitoring and insights concerning both the coating status and the line efficiency. “The pan tracking system is designed to provide actionable insights into these critical areas, ensuring streamlined operations and proactive maintenance,” states Jason Bowman, President of American Pan Europe & MENA.
Jason Bowman,
President of American Pan Europe & MENA
The SMART Pan Tracking® System is built around a straightforward record-collection framework, gathering the information necessary to continuously adjust operations for efficiency. Namely, it is gathering the following records:
1. Scanning time – The exact time each pan is scanned on the line.
2. Barcode identification – Unique barcodes on each pan for precise tracking.
The records are then analyzed to compile insights based on the measurements. These reports can immediately be used by operators to optimize coating usage, identify trends, and predict maintenance needs, ultimately reducing costs and downtime.
Smart installation, smart tracking
Incorporating the SMART Pan Tracking® System into a production plant is a straightforward implementation. The system comprises a processing unit that can have up to three cameras, depending on the pan type and operation scale. This adaptable setup is designed to accommodate a wide variety of pan designs and baking operations. “Whether a facility manages a high- or low-volume production line, the system’s flexible installation ensures it meets diverse operational needs,” American Pan notes.
Real-time alerts: proactive maintenance and quality control
To help bakeries stay ahead of potential issues, the system can be set to issue customizable alerts. They can include:
+ High coating usage: Signals when the coating begins to show signs of wearing down.
+ Low read alerts: Indicates difficulties in reading barcodes, often caused by debris or wear.
+ Predictive Recoating Alerts: Notifies users when coating on pans is nearing end of life based on cycle counts and current usage rate.
The preset values for alerts can vary by coating type and bakeware, ensuring precise monitoring tailored to specific operations.
The system evaluates operation efficiency and predictive maintenance through indicators – coating stock usage and historical data trends. “Uneven usage or residue buildup can signal the need for maintenance. By leveraging these insights, operators can establish maintenance schedules, minimizing downtime and preserving product quality,” American Pan explains.
Flexibility in access and records display
The SMART Pan Tracking® System is designed to provide system records as needed. To ensure data safety and convenience in accessing it, the information is available via a secure cloud login, which also makes it accessible from any location, regardless of the proximity to the line itself, or the facility. “Registered users can access an overview map of multiple facilities, with the ability to drill down into specific pans, production lines, or trends,” an American Pan specialist explains.
The system can automatically identify new pans when they are introduced into production without requiring an initial registration process. It adjusts its tracking parameters and compiles insights based on production volumes and types. “This adaptability allows the system to grow alongside production needs, providing comprehensive tracking across diverse operations,” American Pan specialist highlight.
Further enhancing its utilization flexibility, the SMART Pan Tracking® System is compatible with a wide range of baking operations and types of pans (leveraging the manufacturer’s pan manufacturing know-how), by using standard Matrix barcodes. The system adjusts to various sizes, shapes, and coating types; in this way, the need for extensive customization is virtually eliminated. Moreover, the system can be incorporated into production lines of widely different capacities, for the same benefits in tracking efficiency and cost savings.
In time, as production volumes increase or new pan types are introduced, the SMART Pan Tracking® System also scales up, together with the operation: “A one-time configuration enables the system to recognize and optimize tracking for new types of pans, ensuring smooth integration and continued efficiency,” the specialist illustrates. Together with bakers, American Pan designs tailored versions of the SMART Pan Tracking® System, to fit their unique needs. Some challenges, however, are shared by all operations, such as barcode maintenance, for instance. Over time, barcodes may become scratched or dirty, which interferes with the machine’s ability to read properly. American Pan can provide expert advice: “Our team provides guidance on optimal barcode placement and maintenance techniques, ensuring reliable tracking and long-term usability.”
The SMART Pan Tracking® System
+ Provides detailed information on cycles/bakes, pan gaps, coating life, and theoretical yield
+ An intuitive dashboard displays data in charts, graphs and analytics
+ Is compatible with any operation and type of pan
+ Is mobile device-friendly
+ Can be used to provide a complete view of multiple pan sets, production sites and bakeries
+ Issues useful alerts and notifications when actions are (soon) required
Tracking and more
When quality control and/or automation need to be heightened even more, the system can also come with optional features such as automatic pan rejection. This functionality ensures that pans failing to meet specified criteria are removed from the line, reducing human error and maintaining consistent product quality. Single and dual tags can also be implemented, to optimize the performance of various conveyor configurations. Data from multiple lines can be used, through an IoT unit, for even more insights and added control options.
All its features make the American Pan SMART Pan Tracking® System benefits extend beyond those of a simple tracking tool. “It’s a comprehensive solution for enhancing efficiency, maintaining coating quality, and enabling proactive maintenance. By integrating advanced monitoring and flexible features, this system empowers baking facilities to optimize operations, reduce downtime, and uphold the highest quality standards,” its manufacturer explains.
Data precision and smart use lead to measurable results improvements and welcome savings, proving that information is an extremely powerful tool in bakeries.
