3rd Shift Bakery - Process Controller at Urban Farmer LLC – Manteno, Illinois

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.

Essential Duties and Responsibilities:

Statistical Process Control (SPC) & Weight Monitoring

• 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.

Equipment Calibration & Verification

• 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.

In-Process Quality Inspections (Raw to Finished Goods)

Mixing

• 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.

Dividing/Portioning

• Check dough ball weights and ensure uniformity between stations.
• Inspect divider blade condition and dough ball formation quality.

Pressing/Sheeting

• 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.

Baking

• 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.

Cooling

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

Packaging (when applicable)

• 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.

Formula & Ingredient Verification

• 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.

Data Entry & Digital Documentation

• 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.

Data Analysis & Reporting

• 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.

Quality & Compliance Escalation

• 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.
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GMP, Food Safety & Safety Compliance

• Follow all GMP rules, including handwashing, PPE, and allergen control procedures.
• Adhere to SQF, HACCP, FDA, and bakery-specific food safety regulations.
• Report any food safety, sanitation, or safety concerns immediately.
• Participate in internal audits, mock recalls, and maintenance walk-throughs when requested.
• Participate in root-cause analysis for quality or process deviations.
• Perform additional tasks requested by Production, QA, or Management.

QUALIFICATION REQUIREMENTS:

• High School Diploma or equivalent is required.
• Self-motivated with strong leadership skills and the ability to work independently with minimal supervision.
• Proficient in using test equipment such as Quantum meters, Bostwick meters, weight scales, calipers, thermometers, rulers, and calculators.
• Capable of performing basic math calculations with the aid of a calculator.
• Excellent organizational skills with a demonstrated ability to analyze, interpret, and graph data on SPC documents.
• Strong oral and written communication skills to ensure compliance with quality standards and effective issue resolution.
• Basic computer skills, including proficiency in using tablets and familiarity with MS Word and Excel. Bilingual (English/Spanish) is a plus.

PHYSICAL DEMANDS:

1. Ability to regularly lift and carry product samples weighing up to 20 lbs.
2. Capability to perform tasks in varying working conditions, including hot and cold environments.
3. Must wear assigned personal protective equipment (PPE) and adhere to sanitation procedures.
4. Ability to stand or walk for at least 8 hours to reach workstations.

WORK ENVIRONMENT:

This position works in a manufacturing environment with variable temperature and loud noises from machinery and equipment alarms. The incumbent will be exposed to loud noises and alarms from equipment and machinery