Material Balance & Yield Analytics
Accounting for every kilogram, not only the finished ones
Comparing raw input with finished-product weight produces a number, but not an explanation. Mass leaves a food process by many routes, and some of those routes are normal conversion, some are revenue, and only some are loss. A plant that treats the whole difference as waste will investigate the wrong things. A plant that absorbs it into a standard allowance will miss the part that deserves attention.
Yieldstem closes the balance run by run. Each stream is classified by what happened to it and by the evidence behind it, and whatever remains is reported as an unresolved discrepancy with its size in plain view.
Input minus finished weight
8,520 kg
An apparent 35.5% loss. It looks alarming and says nothing about where to look.
Reconciled material balance
480 kg
2.0% is genuinely unexplained. The remainder has a known destination, a known record, or a physical reason.
- Finished-product recovery15,480 kg
- Saleable byproducts3,120 kg
- Moisture and process mass change3,600 kg
- Documented losses1,320 kg
- Unresolved discrepancy480 kg
- Byproducts
- Pomace, bran, peel and trim sold as feed or ingredient have a destination and a price. Counting them as waste misstates both the loss and the economics.
- Rework
- Material returned to the process can be counted twice if it appears as output in one run and is not recognized as input in the next.
- Moisture changes
- Evaporation, cooking, blanching and tempering change mass without losing product. A solids or dry-matter basis separates this from real loss.
- Work-in-progress
- Material left in tanks, hoppers and lines at the close of a run looks like loss in that run and like excess yield in the next.
- Rejects
- Whether a reject is scrapped, downgraded, repacked or reprocessed determines what it costs. A single reject figure hides that.
- Inventory adjustments
- Stock corrections posted days later often describe an earlier run. Left unattributed, they distort the period in which they are booked.
Bring us the systems you have today.
We can look at how your production, quality and inventory records are kept, and whether they can support this kind of analysis. A technical conversation with your operations and IT teams is often the most useful first step.