← Hub — VFFS Program Portal
v10.0
VFFS Program
Brand System v10.0 — VFFS Portal
Vertical
Form Fill
& Seal
Fill. Seal. Pack. Ship.
End-to-end VFFS packaging line management for retail-ready cheese, snack packs, portion cups, and sauce packets. Real-time line monitoring, film inventory, quality control, and production scheduling across GFS packaging operations.
Bag Forming Gas Flush Seal Integrity Weight Control Retail Pack
FORM MAP GAS 70/30 PKG/HR 2,400
VFFS Portal
Facility Hermitage PA
Lines 3 VFFS Lines
Products Shreds, Snack Packs, Cups, Sauce
Pack Sizes 2 oz – 2 lb
System NetSuite WO + Line PLC
V1 VFFS Dashboard KPIs, Line Status, Real-Time Monitoring
Lines Running
2 / 3
Line 3 maintenance today
Units Packed Today
18,640
+8.2% vs. target
Efficiency %
91.3%
+1.2% vs. last week avg
Film Usage (ft)
4,820
0.4% waste rate
Downtime (min)
42
+18 min vs. target
Reject Rate
0.18%
Below 0.25% target
Line Status — Real-Time
Line 1 — Hermitage PA
4 oz Shredded Mozz
Running
Speed: 42 pkg/min  |  Batch: 8,400 / 12,000  |  Film: Roll #14
70% complete — ETA 14:20
Line 2 — Hermitage PA
Changeover
Idle
From: 8 oz Cheddar Shred → To: 2 oz Snack Pack  |  Est: 35 min
45% — Film threading in progress
Line 3 — Hermitage PA
Maintenance
Down
Seal jaw replacement  |  PM-2026-0319  |  Tech: R. Nowak
60% — Est. back online 16:00
■ Line status updates every 30 seconds via PLC data feed. Downtime tracked automatically by line controller.
V2 Production Schedule Weekly Calendar, Gantt Timeline, Changeover Windows
Line Timeline — Week of May 19, 2026
LINE
MON 19
TUE 20
WED 21
THU 22
FRI 23
Line 1
4oz Shred Mozz
CO
8oz Cheddar Shred
CO
16oz Mozz Shred
Line 2
CO
2oz Snack Pack
CO
4oz Portion Cup
CO
2oz Snack Pack
Line 3
Maintenance
Sauce Packet 1oz
CO
2lb Shred Blend
Shredded Cheese Snack Packs Sauce / Specialty Changeover Maintenance
Rush Orders
OrderProductQtyCustomerNeed DateStatus
SO-2026-2104 4 oz Shredded Mozz (24ct case) 800 cases NYC DOE Dist 12 2026-05-21 Rush
SO-2026-2118 2 oz Snack Pack Cheddar (48ct) 400 cases Good Eats Dist. 2026-05-22 Expedited
■ Schedule updates daily at 05:00 from NetSuite production planner. Rush orders flagged for priority line assignment.
V3 Product Configuration VFFS Product Setups — Bag Size, Film, Seal, Gas Flush, Label
4oz Shred
8oz Shred
16oz Shred
2lb Shred
2oz Snack
4oz Cup
1oz Sauce
Bag / Pouch Specs
Bag Size4 oz (113g)
Bag Width5.5 in
Bag Length7.0 in
Film TypeOPP/Met-PET/PE
Film Width11.0 in
Film Gauge2.5 mil
Gusset1.5 in side
Seal & Fill Parameters
Vertical Seal Temp285°F
Horizontal Seal Temp295°F
Seal Dwell Time0.4 sec
Fill Weight Target4.02 oz
Fill Weight Tolerance±0.08 oz
MAP Gas Mix70% CO2 / 30% N2
Residual O2 Target< 0.5%
Label & Case Pack
Label TemplateLBL-SH-4OZ-01
UPC0 72820 00412 8
Case Pack24 bags / case
Case Weight6.2 lb
Cases / Pallet80
Shelf Life120 days
Storage33–40°F
Machine Speed Reference
ProductBag SizeBags/MinFilm (ft/min)Gas Flow (L/min)Line
Shredded Mozz4 oz422812Line 1
Shredded Cheddar8 oz363214Line 1
Shredded Blend16 oz283616Line 1
Shredded Mozz2 lb224018Line 3
Cheddar Snack Pack2 oz482210Line 2
Portion Cup4 oz38N/AN/ALine 2
Sauce Packet1 oz6018N/ALine 3
■ All seal temperatures verified at quarterly PM. MAP gas mix compliant with FDA 21 CFR 101.100 for modified atmosphere packaging.
V4 Film & Packaging Inventory Film Rolls, Labels, Cases, Reorder Alerts, Waste Tracking
Film Roll Inventory
Film TypeWidthRolls on HandRolls AllocatedAvailableReorder PointStatus
OPP/Met-PET/PE (4oz shred) 11.0 in 48 12 36 20 OK
OPP/Met-PET/PE (8oz shred) 14.0 in 32 8 24 15 OK
OPP/Met-PET/PE (16oz shred) 16.5 in 18 6 12 10 OK
OPP/Met-PET/PE (2lb shred) 18.0 in 8 4 4 6 Reorder
PET/PE (2oz snack) 8.0 in 56 14 42 25 OK
Foil/PE (1oz sauce) 6.0 in 22 10 12 10 Low
Packaging Supplies
Label Stock
14,200
labels remaining
35% allocated · 45% available · 20% safety stock
Cases (Corrugated)
3,840
cases on hand
40% allocated · 35% available · 25% safety stock
Tray Liners
620
liners remaining
PO-2026-3891 inbound Wed 5/21 — 2,000 units
Film Waste — Rolling 7 Days
Startup Waste
0.22%
Changeover Waste
0.11%
Misprint / Splice
0.05%
Total Film Waste
0.38%
Target < 0.50%
■ Film suppliers: Printpack (shred film), Bemis (snack/sauce). Lead time 10-14 business days. Reorder alerts auto-generated at threshold.
V5 Quality Control Weight Checks, Seal Integrity, Metal Detection, Lot Verification
Weight Check Log — Line 1, 4oz Shred Mozz
#
Time
Target
Actual
Deviation
Result
1
06:12
4.02 oz
4.04 oz
+0.02
PASS
2
06:42
4.02 oz
4.01 oz
-0.01
PASS
3
07:12
4.02 oz
4.05 oz
+0.03
PASS
4
07:42
4.02 oz
3.92 oz
-0.10
FAIL
5
07:48
4.02 oz
4.03 oz
+0.01
PASS
6
08:18
4.02 oz
4.00 oz
-0.02
PASS
Check #4 triggered scale recalibration at 07:45. Weight restored within tolerance. CAR not required (isolated event, <3 consecutive).
Quality Checkpoints — Today
Seal Integrity
48 / 48 100%
Vacuum decay test every 30 min. All pouches holding ≥22 inHg for 10 sec.
Metal Detector
0 rejects Clear
Sensitivity: Fe 1.5mm / Non-Fe 2.0mm / SS 2.5mm. Last test piece challenge: 06:00 PASS.
Lot / Date Code
Verified OK
Lot: L260519-H1  |  Best By: 09/15/2026  |  Plant: Hermitage PA
Retain Samples — Today
LotProductTime PulledStoredDisposition
L260519-H14 oz Shredded Mozz06:15Retain Cooler #3Hold 120 days
L260519-H28 oz Cheddar Shred10:30Retain Cooler #3Hold 120 days
L260518-H32 oz Snack PackYesterdayRetain Cooler #3In Retention
■ Weight checks every 30 minutes per SOP-QC-024. Metal detector calibrated daily at start-of-shift. Retain samples held for product shelf life duration.
V6 Line Performance OEE, Downtime Categorization, Waste, Shift Comparison
OEE — Overall Equipment Effectiveness
Line 1
92%
OEE
Avail: 96% × Perf: 98% × Qual: 97.8%
Line 2
84%
OEE
Avail: 88% × Perf: 97% × Qual: 98.5%
Line 3
70%
OEE
Down for maintenance — PM-2026-0319
Downtime Breakdown — Week of May 12
CategoryLine 1Line 2Line 3Total% of Total
Planned Maintenance1.5 hrs2.0 hrs8.0 hrs11.5 hrs52%
Changeover2.8 hrs3.5 hrs1.2 hrs7.5 hrs34%
Unplanned Mechanical0.5 hrs1.0 hrs0.0 hrs1.5 hrs7%
Film Break / Splice0.3 hrs0.2 hrs0.4 hrs0.9 hrs4%
Material Wait0.2 hrs0.5 hrs0.0 hrs0.7 hrs3%
Waste by Category — May MTD
Film Waste
142 lb
0.38% of total film
Product Waste
88 lb
0.12% of bulk cheese
Label Waste
210
0.4% of labels used
Mechanical Reject
34 pkg
0.02% of total packs
Shift Comparison — Last 5 Days Avg
ShiftAvg Units/HrAvg OEEDowntimeReject RateCrew Size
Day (06:00–14:00)2,52093.1%12 min0.14%8
Swing (14:00–22:00)2,38089.4%22 min0.19%7
Night (22:00–06:00)2,21086.2%28 min0.22%6
■ OEE target: 85% minimum per line. Changeover time improvement initiative targeting 15% reduction by Q3 2026.
V7 BOM & Costing Bill of Materials, Cost Rollup — Bulk to Retail Package
BOM — 4 oz Shredded Mozzarella (SKU: GFS-SH-4MZ-24)
Component
Qty / Unit
Cost / Unit
Extended
Source
% of Total
Bulk Mozzarella (lb)
0.252 lb
$1.82/lb
$0.4586
Bongards
62.4%
Film (OPP/Met-PET/PE)
0.67 ft
$0.082/ft
$0.0549
Printpack
7.5%
Label (pressure-sensitive)
1 ea
$0.018/ea
$0.0180
Multi-Color
2.4%
MAP Gas (CO2/N2 blend)
0.28 L
$0.032/L
$0.0090
Linde
1.2%
Corrugated Case (1/24th)
0.042 ea
$0.86/ea
$0.0361
Int’l Paper
4.9%
Subtotal — Materials
$0.5766
78.4%
Direct Labor (per pkg)
—
—
$0.0680
Hermitage
9.3%
Overhead (per pkg)
—
—
$0.0414
Allocated
5.6%
Packaging Labor (per pkg)
—
—
$0.0495
Hermitage
6.7%
Total Cost Per Package
$0.7355
100%
Cost Summary — All VFFS Products
ProductMaterialLaborOverheadTotal/PkgCase CostMargin
4 oz Shredded Mozz$0.577$0.118$0.041$0.736$17.6628.4%
8 oz Shredded Cheddar$1.024$0.132$0.048$1.204$14.4531.2%
16 oz Mozz Shred$1.892$0.148$0.055$2.095$25.1426.8%
2 lb Shred Blend$3.610$0.165$0.062$3.837$46.0424.1%
2 oz Snack Pack$0.318$0.092$0.035$0.445$21.3634.6%
4 oz Portion Cup$0.490$0.105$0.038$0.633$15.1929.8%
1 oz Sauce Packet$0.142$0.068$0.028$0.238$28.5638.2%
■ Cheese cost based on current CME block/barrel + Bongards contract pricing. Film costs updated quarterly per supplier agreements.
V8 Customer Orders Orders Driving VFFS Production, Priority Queue, Fill Rate
Active Order Queue — VFFS Products
SO #CustomerProductCasesNeed ByPriorityFill Status
SO-2026-2104 NYC DOE District 12 4 oz Shred Mozz (24ct) 800 05/21 Rush
65%
SO-2026-2118 Good Eats Distribution 2 oz Snack Pack (48ct) 400 05/22 High
0%
SO-2026-2095 Sysco Long Island 8 oz Cheddar Shred (12ct) 1,200 05/23 Standard
40%
SO-2026-2131 US Foods Northeast 16 oz Mozz Shred (8ct) 600 05/26 Standard
0%
SO-2026-2089 Binghamton CSD 1 oz Sauce Packet (200ct) 150 05/28 Standard
100%
Fill Rate — VFFS Products, Rolling 30 Days
Overall Fill Rate
96.8%
On-Time Delivery
94.2%
Orders Completed
142
Short Ships
4
■ Priority queue auto-sorted by need date and customer tier. Fill rates tracked per SO line and aggregated monthly.
V9 Changeover Management Procedures, Allergen Protocols, CIP Tracking, Time Analysis
Active Changeover — Line 2
8 oz Cheddar Shred → 2 oz Snack Pack Cheddar
CO-2026-0192  |  Operator: T. Kowalski  |  Started: 12:45  |  Est. Duration: 35 min
In Progress
Step
Duration
✓
Stop line & clear remaining product from hopper
2 min
✓
Remove 8 oz forming collar & install 2 oz collar
8 min
✓
Thread new film roll (PET/PE 8.0 in width)
6 min
✓
Adjust vertical & horizontal seal temperatures
3 min
Calibrate checkweigher to 2.02 oz target
4 min
Load new label roll (LBL-SP-2OZ-01)
3 min
Run 10 test packs, verify seal + weight + code
5 min
QC sign-off & resume production
4 min
Allergen Matrix — VFFS Products
ProductMilkSoyWheatChangeover Protocol
Shredded MozzarellaYESNoNoStandard
Shredded CheddarYESNoNoStandard
Snack Pack CheddarYESNoNoStandard
Sauce Packet (Nacho)YESYESNoAllergen CO
All VFFS products are dairy (milk). Soy-containing products require full CIP allergen changeover per SOP-AC-003. Dedicated line preferred when scheduling soy-containing runs.
Changeover Time — Estimated vs. Actual (Last 10)
CO #DateLineFrom → ToEst.ActualVariance
CO-019205/19L28oz Ched → 2oz Snack35mIn Progress—
CO-019105/18L116oz Mozz → 4oz Shred40m38m-2m
CO-019005/17L3Sauce → 2lb Shred50m55m+5m
CO-018905/16L2Snack → Cup30m28m-2m
■ Changeover target: <40 min standard, <60 min allergen. CIP cycle tracked via PLC with automated logging.
V10 Regulatory & Compliance Label Compliance, Nutrition, Allergen Statements, Net Weight, Lot Traceability
Label Compliance Status — All VFFS Products
ProductNutrition PanelAllergen StatementNet WeightLot CodeLabel Approved
4 oz Shredded Mozz Current CONTAINS: MILK 4 oz (113g) L260519-H1 Approved 03/2026
8 oz Shredded Cheddar Current CONTAINS: MILK 8 oz (227g) L260519-H2 Approved 03/2026
2 oz Snack Pack Current CONTAINS: MILK 2 oz (57g) L260519-H3 Approved 04/2026
1 oz Sauce Packet Pending Update CONTAINS: MILK, SOY 1 oz (28g) L260519-H4 Revision Pending
Lot Traceability — Bulk to Retail Pack
Bulk Cheese
BLK-260518-B4
Bongards Mozz 640 lb
→
Shredding
SHR-260519-01
Line 4 Hermitage
→
VFFS Packing
L260519-H1
Line 1 — 4oz bags
→
Case Pack
CS-260519-0042
24ct case / Pallet #18
→
Ship / Customer
SO-2026-2104
NYC DOE Dist 12
Net Weight Compliance — NIST Handbook 133
ProductLabeled WtMAVSample AvgSample MinStatus
4 oz Shred Mozz4.00 oz3.89 oz4.03 oz3.94 ozCompliant
8 oz Shred Cheddar8.00 oz7.82 oz8.05 oz7.96 ozCompliant
2 oz Snack Pack2.00 oz1.92 oz2.02 oz1.96 ozCompliant
1 oz Sauce Packet1.00 oz0.94 oz1.01 oz0.97 ozCompliant
■ Labels reviewed per 21 CFR 101. Net weight verification per NIST Handbook 133. MAV = Maximum Allowable Variation. Traceability per FSMA 204.
V11 Reporting & Analytics Daily Production, Weekly Efficiency, Monthly Cost, Film Optimization
Daily
Weekly
Monthly
Film Optimization
Daily Production Report — May 19, 2026
Total Units Packed
18,640
Target: 17,200 (+8.4%)
Avg OEE (Running Lines)
88.0%
Target: 85% (+3.0%)
Total Waste (all categories)
0.42%
Target: <0.50%
Production by Line
LineProduct(s)UnitsCasesOEEDowntimeRejects
Line 14oz Shred Mozz / 8oz Ched10,24056892%18 min14
Line 22oz Snack Pack8,40017584%24 min8
Line 3— (Maintenance)000%Full Day0
Weekly Efficiency — 4-Week Trend
WeekTotal UnitsAvg OEEFilm Waste %Reject RateChangeover TimeCustomer Fill Rate
Apr 28 – May 282,40087.2%0.44%0.21%38 min avg95.8%
May 5 – May 986,10088.5%0.41%0.19%36 min avg96.4%
May 12 – May 1684,80089.1%0.39%0.18%35 min avg96.8%
May 19 (Partial)18,64088.0%0.38%0.18%——
Monthly Cost Analysis — April 2026
Material Cost
$184,200
78.2% of total
Labor Cost
$38,400
16.3% of total
Overhead
$12,960
5.5% of total
Total VFFS Cost
$235,560
331,200 units produced
■ Reports auto-generated at end-of-shift and aggregated daily. Monthly cost analysis tied to NetSuite WO completions and inventory transactions.
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