From raw material to shipment,
complete traceability at every step.
Implemented at Duru Bulgur's Karaman factory, the Product / Box / Pallet Traceability system tracks the entire process from packaging to shipment on a single digital platform, operating fully integrated with ERP.
New standard in food safety
Duru Bulgur's Karaman factory produces bulgur and pulse products. The project was implemented to ensure product, box, and pallet level traceability across the entire process from packaging to shipment on the production lines.
The established system aims to eliminate shipment errors while improving inventory management accuracy in the food supply chain.
Tracking difficulties and error risks
The lack of tracking for packaged food products in the box and pallet hierarchy posed operational risks.
- 01Manual Tracking RiskManual tracking of product, box, and pallet relationships after packaging created a traceability gap.
- 02Shipment ErrorsLack of visibility on which product was loaded onto which pallet could lead to shipment errors.
- 03Recall DifficultyIn case of potential quality or contamination issues, target-specific product recall was extremely difficult.
Product, Box, and Pallet Traceability
The Product | Carton | Pallet traceability application was successfully implemented on production lines at Duru Bulgur's Karaman factory. Product – Box – Pallet – Warehouse – Customer steps were made traceable and manageable on a single platform based on the unique serial number.
Product Marking
During the packaging stage, products are uniquely marked and gain a traceable identity.
Box & Pallet Association
Which product goes into which box, and which box onto which pallet is fully recorded (Aggregation).
Warehouse Transfers
Internal warehouse transfer movements between different locations are instantly recorded using handheld terminals.
Customer Shipment
Shipment transfers made to customers are recorded, completing the end-to-end data chain.
Field and data management infrastructure
PLC field automation
PLC structure managing field automation and production line workflow.
SCADA application with C#
Custom C# application for operator interface, label matching, and process monitoring.
Industrial Barcode Readers
Industrial scanners that read product, carton, and pallet barcodes/labels with high precision.
Handheld Terminal Application
Recording warehouse transfers, inventory movements, and customer shipments on-site via handheld terminals.
OnSuite Trace Platform
Central software layer where traceability and process management are controlled.
ERP integration
Bi-directional sharing of transfer data and stock status integrated with the ERP system.
Bi-directional integration with ERP
The traceability application runs fully integrated with Duru Bulgur's existing ERP system: field data, stock movements, and transfer info are instantly pushed to the ERP.
End-to-end digital control
End-to-end traceability
The entire chain from packaging to customer became traceable end-to-end based on the unique product serial number.
Zero manual errors
Product-box-pallet relations and warehouse/customer movements are auto-recorded, eliminating manual tracking errors.
Fast recall capability
In case of a potential recall, precise backward tracking capability maximized shipment accuracy and operational safety.
Meet Our End-to-End Traceability Solution
OnSuite Trace allows you to manage all your production processes from a single platform. We provide end-to-end digital traceability for your business with the motto "Continuous Control, Zero Defects".
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