3rd Shift Bakery - Process Controller

JOB SUMMARY

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.
• 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 notify Production Supervisors and QA of any non‑conforming product or potential food safety hazard.
• Hold or stop production when necessary until corrective actions are completed.
• Assist with rework decisions, hold tags, and product disposition documentation.

• Follow…