3rd Shift Bakery - Process Controller

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Full Time Manteno, IL, US

4 days ago Requisition

Salary Range: $18.50 To $20.70 Hourly

As a Bakery Process Control Operator, you will play a critical role in ensuring that dough, crusts, and finished bakery products consistently meet food safety standards, customer specifications, and Urban Farmer’s net-content requirements. This position supports bakery production by performing on-line weight and quality inspections, verifying ingredients and formulas, monitoring equipment performance, and documenting all findings. You will work closely with Mixing, Sheeting/Press, Oven, and Packaging teams to ensure products meet all regulatory and quality expectations from raw ingredients through finished goods.

• Develop, maintain, and update SPC weight sheets for dough balls, pressed crusts, baked crusts, and finished goods.
• Conduct weight checks at required intervals (e.g., every 30 minutes or as outlined in SOP).
• Ensure weights fall within specified upper and lower control limits and take action when results fall outside those limits.
• Trend data to identify recurring issues such as dough inconsistency, improper divider settings, or press variation.
• Adjust or recommend adjustments to divider settings, press thickness, and dough hydration levels based on SPC findings.
• Perform scale calibrations prior to shift start and throughout shift as required by SQF/QA guidelines.
• Confirm proper functioning of dough height gauges, thermometers, moisture meters, timers, and metal detection verification tools.
• Document calibration results and immediately report any equipment malfunction to Maintenance, QA, and Supervisors.
• Verify metal detector checks at required intervals and document pass/fail results.

• Verify ingredient lot codes match the formula and recipe sheet.
• Confirm ingredient weights in batches fall within tolerances.
• Record dough temperature, mixing time, and dough consistency.
• Check dough ball weights and ensure uniformity between stations.
• Inspect divider blade condition and dough ball formation quality.

• Verify crust diameter, thickness, and shape meet spec.
• Check for signs of sticking, tearing, or uneven pressing.
• Confirm oven-ready crust alignment and transfer integrity.

• Document oven temperatures, bake time, and belt speed.
• Inspect baked crust color, height, texture, moisture level, and bubble formation.
• Identify under-bake or over-bake issues and notify Production/QA.

• Confirm crusts reach required cooling temperature prior to packaging.
• Monitor cooling conveyors for debris, build-up, or foreign material risks.

• Ensure correct film, labels, and allergen identifiers are used.
• Confirm net weights, label accuracy, and seal integrity on packaged items.
• Verify case codes and batch codes match production schedule.
• Check that all ingredients staged for the shift match the approved BOM (Bill of Materials).
• Ensure correct allergen controls are followed (e.g., gluten‑free, dairy‑free areas).
• Confirm proper FIFO rotation and documentation of lot codes.
• Identify any incorrect or expired ingredients before production enters mixing.

• Record all test data weights, temperatures, measurements, bake checks—into electronic tablets in real time.
• Ensure accuracy, clarity, and completeness of digital entries for QA review.
• Upload photos (if needed) of discrepancies, product defects, or out‑of‑spec observations.
• Maintain organized digital records for audits.

• Analyze trends in weights, dough performance, bake consistency, and finished goods quality.
• Prepare shift reports summarizing:
  • Out-of-spec weights
  • Bake quality issues
  • Ingredient discrepancies
  • Equipment calibration issues
  • Process deviations
• Communicate findings to Production Management, QA, and Maintenance.

• Immediately…