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Technical guidelines for material balance management in food production
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GB/T 43812-2024: PDF in English (GBT 43812-2024) GB/T 43812-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 67.040
CCS X 01
Technical Guideline for Material Balance Management in
Food Production
ISSUED ON. MARCH 15, 2024
IMPLEMENTED ON. MARCH 15, 2024
Issued by. State Administration for Market Regulation;
Standardization Administration of the People’s Republic of China.
Table of Contents
Foreword... 3
1 Scope... 4
2 Normative References... 4
3 Terms and Definitions... 4
4 Basic Principle... 5
5 Material Balance Factors... 5
5.1 Actual product output... 5
5.2 Amounts of consumption... 6
5.3 Sampling volume during process... 6
5.4 Theoretical output... 6
6 Material Balance Management... 6
6.1 Management system... 6
6.2 Management plan and control... 6
6.3 Implementation... 7
6.4 Inspection and improvement... 8
Appendix A (Informative) Calculation Method of Material Balance... 9
A.1 Calculation of material balance rate... 9
A.2 Method for determining material balance limits... 9
A.3 Calculation of yield... 10
Technical Guideline for Material Balance Management in
Food Production
1 Scope
This Document provides the basic principles of material balance management, factors of
material balance, and guidance for material balance management in food production.
This Document is applicable to material balance management in food production.
2 Normative References
There are no normative references in this Document.
3 Terms and Definitions
For the purposes of this Document, the following terms and definitions apply.
3.1 Material in food production
Various substances and materials that are put into and circulated during the food production
process.
NOTE. Including raw and auxiliary materials of food, food packaging materials, as well as semi-finished
products, reusable defective products, waste products and finished products produced during food
processing and storage.
3.2 Material balance
The state in which the mass conservation is achieved between the material input and output.
NOTE. Input includes the amounts of raw and auxiliary materials; output includes the actual output of
the product, the amounts of by-products, the amounts of consumption and the amounts of process
sampling. When the production is not fully completed, the output also includes the amounts of products
under production, which includes the sum of the online products on the production line.
3.3 Material balance rate
The ratio of the sum of actual product output (including estimated output of product under
production), the amounts of consumption and the amounts of process sampling to the theoretical
output.
3.4 Yield
The ratio of the actual qualified output of a product to its theoretical output.
3.5 Material balance limit
The acceptable range of material balance rate under normal production conditions.
4 Basic Principle
4.1 Food production enterprises should implement food production material balance
management and establish a scientific material input and output mass balance relationship. By
calculating the material balance rate and considering the material balance limit, the adverse
effects on food quality caused by the introduction of undue substances and deviations, errors
and other abnormalities in the process, feeding, operation and other aspects of food production
shall be prevented. According to the yield, material balance management measures shall be
optimized to improve the production efficiency of the enterprise.
4.2 Food production material balance management should carry out various activities in
accordance with the basic principles of mass management.
4.3 Food production material balance management should be based on objective information
and real and effective data; comprehensively consider raw materials in different states such as
solid, liquid, semi-solid, and different processes such as physical, chemical, and biological
methods; and build a management model that meets the food production process requirements
and material balance limits.
4.4 Food production enterprises should calculate the material balance rate when new products
are developed, put into production, or when processes, raw materials, and equipment change;
and carry out corresponding material balance management according to production
management needs.
5 Material Balance Factors
5.1 Actual product output
The actual product output refers to the actual output of all finished products, including qualified
finished products, unqualified finished products, finished product sampling and testing, and
retained samples. If the material balance rate needs to be calculated during the production
process, the estimated output of semi-finished products and other products under production
shall also be included in the actual product output. The output of products can be estimated
based on the completion rate or experience rate of the same batch of finished products.
material balance management plan should include the selection of material balance
management objects and range, the determination of material balance calculation methods, etc.
6.2.2 The objects of material balance management should include raw and auxiliary materials
of food, packaging materials, finished products, etc. The objects of material balance
management can be a single material or all materials.
6.2.3 Food production enterprises should determine the range of the material balance
management process based on the feeding method, raw material turnover or loss status, process
parameters and requirements, daily production and product verification status, etc.
6.2.4 Food production enterprises should determine the appropriate material balance calculation
method. Under the premise of compliance, the material balance rate should be calculated
according to the characteristics of raw and auxiliary materials, production process, operation
method and production cycle, etc., as well as according to the production batch or the set
feeding amount. The calculation method of material balance rate is shown in A.1 of Appendix
A.
6.2.5 Material balance management can be carried out in stages according to the food
production process, or it can cover the entire production process. For simple processes such as
solid and liquid and physical methods, all raw materials should be included in one time for
accounting and management; for complex production methods such as chemical methods,
biological methods, multiple feedings, solid-liquid conversion, etc., accounting and
management can be carried out in stages according to the process and feeding method.
6.2.6 Food production enterprises should scientifically and reasonably determine the material
balance limit. See A.2 for the method of determining the material balance limit.
6.2.7 Food production enterprises can quickly calculate the material balance rate or evaluate
production efficiency based on the yield. See A.3 for the yield calculation method.
6.3 Implementation
6.3.1 Food production enterprises should compare the actual material balance calculation
results with the set material balance limits to ensure that the material balance rate meets the
material balance limits.
6.3.2 When the material balance rate does not meet the material balance limit, food production
enterprises should analyze the causes based on the actual situation. Common problems are as
follows.
--- Irrational setting of material balance limits;
--- Insufficient research on fixed consumption data;
--- Deviation in measuring instruments;
--- Differences in net weight or content of incoming materials;
--- Irrational setting of production process parameters or operational errors;
--- Mixed products from different batches;
--- Intentional or mis-operation to introduce other materials;
--- Incomplete collection of the amounts of consumption.
6.3.3 Based on the found problems and the analyzed causes, food production enterprises should
take corrective measures for the production process.
6.3.4 Food production enterprises should implement material balance management in
combination with procurement, production, logistics or traceability management systems to
achieve data intercommunication and sharing, and ensure that the quantity of terminal products
corresponds to the batch and processing of raw and auxiliary materials.
6.3.5 Food production enterprises should establish material balance management records,
including production plans, raw and auxiliary material input, packaging material input, the
amounts of consumption, semi-finished product quantity, process sampling and testing quantity
and retained sample quantity, qualified finished product quantity, unqualified finished product
quantity, finished product sampling and testing quantity and retained sample quantity, as well
as deviations from material balance limits, deviation causes, corrective measures and other
records.
6.4 Inspection and improvement
6.4.1 Food production enterprises should conduct material balance inspections regularly to
confirm whether material balance management is effectively implemented and compliant.
6.4.2 Food production enterprises should determine the purpose, content, method, frequency
and person in charge of material balance inspections.
6.4.3 Food production enterprises should implement material balance inspections at the
prescribed frequency, which should be no less than once a year.
6.4.4 Food production enterprises should evaluate the results of the material balance inspection
and put forward the evaluation conclusions.
6.4.5 When problems are found in the material balance inspection, food production enterprises
should formulate corrective and improvement measures.
6.4.6 Food production enterprises should record and preserve the inspection, evaluation and
improvement records of material balance management.
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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