How to implement packhouse traceability
Packhouse traceability works when nobody has to think about it. Build it into receival, packing and dispatch, and test it with mock recalls before an auditor does.
Key points
- Map every point where product changes identity: receival, storage, batching, packing, dispatch.
- Make scanning the only way to move or use stock.
- Choose recall keys in advance: supplier, lot, packaging lot, room, PO, invoice, dates.
- Run a mock recall in week one and again before every audit.
Step 1: Map the critical tracking events
List every step where product is received, moved, transformed or shipped. FSMA 204 calls these critical tracking events (harvesting, cooling, initial packing, receiving, transformation and shipping), and they are a useful checklist even outside the US.
Step 2: Identify every lot at receival
Create a lot for each delivery with supplier, field or block, variety, quantity and date, and print a barcode label before storage. Purchase orders link the lot to the supplier record.
Step 3: Scan inputs into batches
Packing and processing batches must record which lots – and which packaging materials – went in. Outputs inherit those links, so every carton traces back to multiple suppliers if needed.
Step 4: Scan pallets at dispatch
Scan each pallet (or case) onto the order. The dispatch record then ties lots to customer, invoice, PO, carrier and delivery date.
Step 5: Define recall keys and test
Producepak can trace by supplier of produce or packaging, storage location, invoice, purchase order, customer reference, dispatch, delivery or pack date and more. Run a mock recall, time it, and fix any gaps.
Timeline
With Producepak, traceability is built into every process, so a full packhouse implementation typically takes one to two weeks. Clients report auditors requesting unusual trace methods and receiving answers in seconds.
Frequently asked questions
Do we need new hardware?
Usually only tablets or phones, barcode scanners and a thermal label printer. Existing PCs work for office tasks.
Can we trace packaging materials too?
Yes. Packaging lots are scanned into batches like produce, so recalls can start from a packaging supplier.
