Roadmap ERP: Pioneered Operational Excellence at 360° for Food Processing Industry

Read the latest blog to learn how Roadmap ERP system enables the digital transformation of India's top-notch popcorn company-from the outset of cultivating their own corn to the packaging of premium popcorn.

Introduction: With the idea of having premium and high-quality popcorn for the people of India, our client, the country's leading gourmet popcorn manufacturer, established in 2014 in Andhra Pradesh, took a giant leap in partnering with the world's top-class popcorn manufacturer in the USA. The client had initially imported kernels from the overseas vendor to provide the most delicious popcorn for moviegoers across the nation. Later in 2018, they started procuring seeds from them and cultivating corn crops indigenously through contract farming with the help of regional farmers in many villages/townships of Andhra Pradesh, India. These farmers will buy corn seeds from the client, sow on their land, and harvest them as wet corncobs. These wet corncobs will be processed into several stages and delivered products as Ready-to-Cook (Premix)/Ready-to-Eat popcorn. The client supplies their popcorn products to the largest cinema chains and food courts at shopping malls and airports in India.

  

In the competitive gourmet popcorn industry, efficiency and quality control are critical factors for success. Roadmap ERP System acts as a cornerstone by digitalizing the client's business operations from farm management to the packaging of premix and ready-to-eat popcorns. 

Farm Management: The journey begins with the issuance of high-quality seeds, pesticides, and fertilizers to farmers ensuring a consistent and superior popcorn crop. Roadmap ERP Farm Management capabilities enable crop planning, resource allocation, and yield forecasting. Field assistants from the client's company assist farmers in making data-driven decisions regarding planting schedules, irrigation, and fertilization. Moreover, real-time monitoring and reporting functionalities enable the client to track key performance indicators (KPIs) such as yield per hectare, water usage, and resource utilization and also facilitate continuous improvement and optimization. Roadmap ERP's farm management module tracks seed distribution, monitors growth stages, and schedules harvests for optimal yield.

Harvesting: As farmers harvest the wet corn cobs, the ERP system records the quantities and quality, scheduling deliveries to the processing plant. This data helps in forecasting and planning for the subsequent stages.

Drying and Sorting: Upon arrival at the processing plant, the wet corn cobs undergo drying. Roadmap ERP meticulously logs the data of drying times and temperatures to achieve the perfect moisture content of corn for popping. The dried kernels are sorted based on size and quality to ensure the preferred kernel type proceeds to the next phase of the process. All these processes are effectively managed and processed through Roadmap ERP system.

Manufacturing Ready-to-eat/Premix Popcorns: With the flexibility of the Roadmap ERP system, we can tailor Bill of Materials (BOMs) to accommodate variations in ingredients, flavors, and packaging according to the product requirements. It also equips the client to meet diverse customer preferences while maintaining efficient production workflows.

Packaging:  The final step is packaging, where Roadmap ERP system shines by tracking inventory levels, managing orders, and automating the packaging lines. Whether it's for premix or ready-to-eat popcorn, Roadmap ERP ensures that the right product reaches the right customer, fresh and delicious.

Reports: Roadmap ERP's Reporting application helps the client to generate Farm Management summary reports, harvesting summary reports, and costing reports gaining valuable insights and real-time analytics from the data.

On a final note, living in the era where food safety and traceability of food products are paramount, Roadmap ERP system holds immense potential in integrating every aspect from farming to processing gourmet popcorn products while maximizing operational efficiency and transparency in food production procedures, ensuring compliance reporting of safety and regulatory standards, real-time inventory management, and cost reduction across the entire value chain of the company.

By harnessing the power of centralized data management and comprehensive data insights of the ERP system, farmers and the food processing industry can overcome challenges, seize opportunities, and meet the evolving needs of consumers in a rapidly changing world.  In this way, Roadmap offers clients flawless ERP solutions that meet their unique business needs and allow them to leverage the growth potential in the market.