Ingredient cost creep
Ingredient prices change weekly. Most SMEs reprice their recipes quarterly at best. The gap between what you planned to spend and what you actually paid compounds silently across every batch you run.
Most manufacturing margin problems are information problems. The data to solve them already exists — in your ERP exports, your supplier invoices, your team's institutional knowledge. Talos connects it, quantifies what it costs you in £, and delivers findings in 7 days. No integration. No IT involvement.
Most manufacturers think they know their batch margin. They're estimating. The Talos Audit tells you the exact number — and precisely where it's going.
Ingredient prices change weekly. Most SMEs reprice their recipes quarterly at best. The gap between what you planned to spend and what you actually paid compounds silently across every batch you run.
Every batch that produces less than planned is a loss nobody measures. Most manufacturers track planned yield. They rarely compare it to actual yield per run — and never quantify the cumulative £ impact.
Capital tied up in ingredients with no active job allocation. Expiring batches. Over-ordered lines that never move. Most MDs know it's there — nobody has quantified it in £ and matched it back to the production schedule.
Roughly a third of production runs in a typical batch manufacturer have a material deviation from plan — over-portioning, line inefficiency, substituted ingredients. Almost none of these are costed and reported to the MD.
Ingredient cost creep and yield variance ranges are consistent with recent UK food & drink cost inflation and manufacturing yield benchmark data.
You export a file. We do the analysis. You receive a board-ready report that tells you exactly where the money is going — in £.
Export your last 30–60 days of batch production and purchase data from your ERP — Sage 50, Sage 200, Access, or Excel. Three clicks. Send via our secure ProtonDrive link. No software installation. No IT team required. We also accept structured PDF reports. If you can't export at all, we provide a simple intake template.
We process your export off-site against your own batch and recipe data, applying standard cost variance methodology to calculate price, yield, and usage deviation per batch. Every £ of loss is found, quantified, and traceable to a specific row in your own source data. You do nothing while this happens.
A board-ready PDF report delivered in a 45-minute video call. Executive summary, batch-by-batch variance table, top loss drivers with exact £ values, specific and costed recommendations. Every number traces back to your own data — not industry averages, not estimates. You can act on it the same week, and verify every figure with your own accountant if you want to.
Our commitment. Every finding we surface is quantified in £ and arithmetically traceable from your own production data — your accountant can verify every figure independently. We commit in writing: if the audit cannot identify findings that quantify to at least the cost of the engagement in addressable variance, we refund the full fee. Results depend on your batch volume, your data history, and what your production records contain — which is why the Margin Clarity call comes first. If we don't believe your data will produce meaningful findings, we tell you before you commit a penny.
The audit solves the immediate problem. The platform solves the structural one. Most manufacturing businesses are sitting on years of data that has never been asked the right question — structured ERP data, supplier documents, institutional knowledge, and operational patterns, reconciled into one coherent picture of where margin goes and why.
Send us your ERP export. We calculate price, yield, and usage variance per batch and deliver a board-ready report within 7 days. Every finding quantified in £ and traceable to your source data. The start of a margin intelligence relationship — not a one-time report.
Monthly data refresh using your latest ERP export. Delta comparison against your audit baseline. Threshold-based monitoring for ingredient price spikes, yield drift, and ghost stock build-up. A 3-page monthly update delivered to your inbox. The audit, kept current.
Margin loss doesn't only live in your ERP. It hides in supplier invoices that were never reconciled against quoted prices, in quoting decisions made without visibility of real job cost, and in institutional expertise held in people's heads — knowledge that walks out the door when they do. Talos will ingest all of it.
A dedicated AI system trained on your ERP history, supplier relationships, operational knowledge base, and production patterns. Answers questions in plain language: why did margin drop in March, which ingredient is the biggest risk this quarter, what would switching suppliers cost you. Built from the data we've been processing since day one.
"Most manufacturing margin problems are information problems. The data to solve them already exists — scattered across ERP systems, supplier emails, delivery notes, and the heads of experienced operators. Talos is built to connect all of it."
— Talos Intelligent SystemsThe 7-Day Batch Margin Audit is not a consultancy report. It is the first data instrument in an ongoing strategic relationship — one that tells you exactly where margin is going today, then helps you systematically recover it over time. Every finding is in £. Every recommendation is specific and costed. And unlike a management consultant's assessment, every number is traceable to your own production data.
Three clicks from Sage 50, Sage 200, or equivalent ERP. CSV or Excel. Send via our ProtonDrive secure link. No site visit. No questionnaire. No preparation that consumes your team's day.
Your export is normalised, matched to canonical cost fields, and run through three variance calculations per batch: price variance, usage variance, and yield variance. I personally run every pipeline and review each finding before it reaches you. All off-site. Zero client involvement.
The top loss drivers are ranked by £ impact. Not percentages. Not industry benchmarks. The actual £ figure your business lost across the audit period — per ingredient, per product line, per batch run.
Executive summary, batch variance table, top loss drivers in £, specific and costed recommendations. Delivered in a 45-minute video call. Written for an MD, not a consultant. Every number is traceable to your source data — you can act on it the same week and verify it independently.
Every scenario below is an illustrative composite — not a named client — built from real UK SME batch and process manufacturing patterns across food, drink, and adjacent sectors. Every number is grounded in industry data and Talos audit methodology.
Supplier prices had risen three times in 18 months. The bill of materials hadn't been updated. Every batch was being costed against a recipe that no longer reflected actual ingredient costs — the MD had no idea how much this was worth until the numbers were run.
Yield running 6.2% below plan on the signature line. A supplier price increase never updated in the bill of materials. A spice blend being over-dosed by 18% against recipe standard on one production line. Three unrelated causes, each invisible on its own — reconciling every batch against its own standard surfaced all three in the same audit window.
Ghost stock — ingredients purchased for jobs that had been delayed, cancelled, or reformulated. Capital sitting in a cold store, invisible to the accounts team. Matched back to production history in the audit: 14 ingredient lines, £52k, some approaching expiry.
Grain-to-extract yield was tracked brew-by-brew but never compared against target systematically. When batch actuals were run against recipe standards, an 8% yield shortfall appeared consistently across 70% of brews — driven by two malt suppliers shipping inconsistent moisture content. The variance engine traced it to supplier and grain variety within 48 hours of data ingestion.
If something you need isn't answered here, book a discovery call and ask directly.
Three clicks from your ERP. We need your batch production records and purchase data for the last 30–60 days — exported as CSV or Excel from Sage 50, Sage 200, Access, or equivalent. If your system can't export in a structured format, we provide a simple four-tab intake template. We specify exactly what we need in advance. The average client spends 30 minutes gathering and sending data.
No. The Talos data pipeline is built for real-world manufacturing data — messy column headers, inconsistent units, merged cells, multiple file sources. We've processed exports from Sage 50 spreadsheets, manually maintained Excel job books, and Access databases. If your data is genuinely too fragmented to work with, we'll tell you before we charge you anything.
You send your data via a ProtonDrive secure link — end-to-end encrypted. We process it entirely off-site on our own infrastructure. No third-party cloud processing. No data residency on client premises. For audit-only engagements, your data is deleted from our systems within 30 days of engagement close. If you take the monthly monitoring service, your audit baseline is retained for the duration of the active monitoring relationship (up to 12 months), so we can compare each month against it. The engagement agreement you sign before we start includes explicit data handling provisions.
We commit to two things in writing. First: every finding we surface is quantified in £ and arithmetically traceable from your own production data — your accountant can verify every figure independently using the same source file. Second: if the audit cannot identify at least £2,500 in addressable variance findings — the equivalent of the engagement cost — we refund the fee in full. Results depend on your batch volume, your data history, and what your production records contain, which is why the Margin Clarity call comes first. If we don't believe the data will produce meaningful findings, we tell you before you commit a penny.
The report length scales with your dataset — a client with 60 days of data across 80 batches will receive a longer report than one with 30 days across 20 batches. Every report contains: a cover page with a data integrity hash so you can verify the file we analysed matches what you sent; an executive summary with total margin exposure in £; a full batch variance table covering every batch in the audit window; the top 3 loss drivers ranked by £ impact with the specific calculation behind each; and specific, costed recommendations — not general improvement advice. Delivered in a 45-minute video call. You can act on the findings the same week.
Your ERP records transactions. Talos calculates what those transactions cost you relative to what you planned. Most SME systems — Sage 50/200, Access, Excel — weren't built to run batch variance analysis against recipe standards. They store the data; they don't surface the gap. We work with your existing ERP exports as a data source. No replacement, no migration, no IT project.
Talos combines proprietary automated data intelligence with fully transparent, CIMA-standard variance calculations. The data preparation methodology — how your export is read, matched, and structured for analysis — is proprietary and not disclosed. What is fully disclosed: every calculation. We use CIMA standard cost variance formulas — the same methodology any management accountant would recognise. Price variance: (actual price − standard price) × actual quantity. Usage variance: (actual quantity used − standard quantity) × standard price. Yield variance: (actual output − planned output) × standard cost per unit. All calculations are shown in the report and are fully traceable back to your source data.
No. The audit applies to any batch or process manufacturer where production is planned against a recipe or bill of materials and margin is lost in the gap between planned and actual. Beyond food and drink, this includes breweries and distilleries, cosmetics and personal care, nutraceuticals and supplements, specialty and fine chemicals, paints and coatings, pet food and animal feed, flavours and fragrances, and contract or private-label manufacturers across any of those sectors. If your operation runs a recipe, plans a batch, and exports production data from an ERP or similar system, the methodology applies. Food & beverage is our launch vertical because it has the highest batch complexity — but the variance engine is not sector-specific. Book a discovery call and we'll tell you directly whether it's a fit.
We send the report PDF and invoice the balance within 24 hours of the delivery call. Within 48 hours of payment, you'll receive a one-page monthly monitoring proposal — typically £500–800/month depending on volume. The monitoring service runs the same analysis monthly on your latest ERP export, generates a 3-page delta report, and flags anything that's moved materially from your audit baseline. There's no obligation to continue. Most clients do.
The sweet spot is manufacturers running at least 20 batches per month with 12+ months of ERP or production history. Below that, the variance signal is harder to isolate from noise. If you're running fewer batches, book a call anyway — sometimes the data density is higher than the batch count suggests, and we'd rather tell you it's a fit than turn you away based on a number alone.
We're taking on founding clients now — at the lowest price this audit will ever be. A 20-minute Margin Clarity call is the first step. We ask about your production data, your ERP system, and what your biggest margin frustration is. No pitch. We listen first. If we're not the right fit, we tell you.
Free 20-minute call · Remote nationwide · Founding price: £2,500 · Rises after first three clients
A real anonymised Talos Health Report — three findings, full variance calculations, standard cost variance methodology, and specific recommendations. Every number traceable to source data.
Click below to download the sample Talos Health Report. We'll be in touch if you have questions — no obligation, no pitch sequence.
Download Sample Report (PDF)Founder & Systems Architect · Talos Intelligent Systems Ltd
MSc Information Technology (Merit · UWE 2024) · BSc Project Management · Microsoft AI Fundamentals · Microsoft Cloud · AWS Cloud Essentials · Oracle Cloud Associate (training completed, certification exams in progress)
Manufacturing businesses run on data they can't fully see. ERP systems record what happened — quantities, costs, batches. They don't surface the gap between what production actually cost and what it should have. That gap is where margin goes, quietly, batch by batch. I built Talos to find it.
Emmanuel holds an MSc in Information Technology (Merit, UWE 2024) and has spent a decade building the analytical layer between complex operational data and decisions that actually get made — starting in freelance web and e-commerce delivery for US clients since 2016, through Azure-backed commercial platforms at Bayside Consult, to NHS operational and digital delivery today. Talos's analysis approach was designed and built entirely in-house: applying standard cost variance calculations per batch and producing a board-ready PDF with every finding traceable to its source row. No third-party black box. No methodology you cannot verify.
Secure data handling is built into the engagement design, not bolted on. His MSc research covered cybersecurity in operational environments, grounded in NIST CSF and ISO/IEC 27001 principles. The analytical system is designed with awareness of ISO/IEC 42001 — the AI Management Systems standard — covering transparency, traceability, and responsible automated inference. Client data travels via ProtonDrive, is processed off-site on encrypted hardware, and deleted within 30 days of report delivery for audit-only engagements (retained only for the duration of an active monitoring relationship where that service is engaged).
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