A production run can look complete while its quantities tell a different story. Input stock may have been issued at one weight; several saleable cuts, retained trim and non-food material may leave at different weights. The result needs both a material explanation and a link from each output lot back to its inputs.
Use this review for one bounded run. Keep the physical quantity question separate from quality release, legal classification and the later sale or dispatch of the output. A tidy percentage does not answer those decisions.
The material equation
Balance weight without hiding an exception.
Start with measured input weight. Subtract all measured food outputs, including those on hold, and separately measured non-food material. The remainder is a difference to investigate, not automatically approved process loss. Saleable yield is a separate ratio: saleable food output divided by input.
Synthetic run: 100 kg in
These figures are fictional and illustrate the arithmetic, not a normal yield, permitted waste level or customer result. The 9 kg has already been separately classified by the operator for this example; the worksheet cannot classify it.
- Measured input
- 100 kg
- Saleable cuts
- 68 kg
- Food trim retained
- 18 kg
- Separately measured ABP
- 9 kg
- Recorded output and material
- 95 kg
- Unexplained difference
- 5 kg
- Saleable yield
- 68 ÷ 100 = 68%
The 5 kg is a finding. Check scales, tare, timing, omitted output, moisture or process loss, and duplicate or mistaken entries. Preserve the original readings and record the accepted explanation with an owner. Do not edit a category merely to make the equation equal 100 kg.
Reusable run review
Eight checks before the output becomes available.
Copy these prompts into your own run review. Record the actual value, evidence reference, status and named owner for each row; mark a check not tested when the evidence is missing.
Swipe the worksheet sideways to read each decision prompt.
| Check | Evidence to record | Decision prompt |
|---|---|---|
| Run boundary | Production order, product, date, line and start/end point | Which physical work is included? |
| Inputs | Source lot, issued net weight and unit for every input | Is this measured input, not merely planned stock? |
| Food outputs | Each output lot, net weight, unit and intended use | Are saleable, trim and held outputs each counted once? |
| Quality state | Held, released or rejected decision for each output | Does a mass balance conceal a product still on hold? |
| Non-food material | Separately weighed material and its operator-approved classification | Is an ABP category and movement record required? |
| Difference | Input minus all measured outputs and separately measured non-food material | What remains unexplained, and who investigates it? |
| Lineage | Input-to-output lot references and any downstream use | Can an affected output be found from its input lot? |
| Decision | Reviewer, evidence links, finding, owner and retest | What must be resolved before output is released? |
For each row: value ___ · source ___ · complete / review / not tested ___ · owner ___ · retest date ___. Keep the original finding when a correction is made.
Different decisions
A balanced run can still be unfit for release.
Material variance
Agree an internal review threshold for this process and investigate differences outside it. That threshold is not a universal legal tolerance or proof of food safety.
Quality and traceability
Keep input-to-output lot links and the relevant quality decision. A matching weight total does not clear a held output or prove that every batch record is complete.
Animal by-products
Competent staff must classify, segregate, document and arrange movement or disposal under the rules that apply to the site. An ERP weight category cannot make that decision.
Where software fits
Keep the run evidence together, then validate the site workflow.
Larder can link a yield session to a production order and record input, output and waste weights. Completing that production order can create linked output lots that await quality review. This does not mean every physical weighing, label, device or approval step is ready at a particular site.
Creating new animal by-product waste records and recording their disposal remain unavailable; existing records can be reviewed. Merge, repack and relabel workflows also remain unavailable. Agree the real process and test its evidence before relying on it. This worksheet does not certify compliance or replace the operator's food-safety and ABP responsibilities.
Primary guidance
FSA and FSS describe internal process traceability as best practice alongside legal supplier and business-customer traceability. Defra and APHA explain ABP categories and records for England, Scotland and Wales. Confirm the current rules for your establishment, products and jurisdiction with the relevant authority or qualified adviser.