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Approach towards Food Safety Management
in Coca Cola (India)
Navneet Mehta Director-‐ Eurasia Analytical Service Centre
Coca Cola India Pvt. Ltd
22 March 2012
4
Being a Leader has its own
Taking Risks with our Corporate Reputation is not an Option
5
Quality & Food Safety is critically linked to Corporate Reputation
6
Base: Total Respondents (N=420)
0% 10% 20% 30% 40% 50% 60% 70%
Advertising
Variety and Availability
Price
Brand Reputation
Quality of products and services
Influences on Opinion about a company (Unaided)
% respondents
Quality & Safety of Products which is a top most influence on the opinion about a company, followed by Reputation
Aided Repsonses Top Box Score
Its products / services are of highest quality 87%
Good image 67%
Concern about the health and safety of its consumers 66%
Positive opinion from other people 60%
Takes care not to harm the environment 50%
Clean, spill proof packaging of products 47%
Wide range of products 44%
It is innovative 40%
Good advertising 39%
Strong financial performance 32%
Involved in taking a lead on social causes 28%
Q
Q
R
R
R
R
Only Quality, Food Safety and Reputation related factors get > 50% top box score
A food problem in one area soon becomes a concern across the globe
Globalization & Awareness
Food Safety - Domino Effect
Classified -‐ Internal use Every link may trigger a chain reaction
TCCC is known for its consistently high quality products around the world.
While taste & appearance is important, safety of the products is critical for consumers.
The best way to ensure safety of our products is to put in place a strong Food Safety Management Systems across supply chain
Raw Materials Production Distribution Customer/
Consumer
Waste
Capture
Ensure Food Safety & Security Across Entire Supply Chain While:
Maintaining Quality in a Rapidly Evolving Business Environment
Producing Products Compliant to Increasing Regulatory
Requirements & Consumer Expectations
Food Safety Imperative
11
Establish
Standards
Enable
Execution
Measure
Performance
Initiate
Corrective Action
Perfect Product
Trusted Everywhere
Risk Mitigation Process Driven Approach
12
Food Safety Management
World Class Standards The Coca Cola Operating Requirements
Inbound Supplier Audits/
Authorization Monitoring for unintended compounds
Manufacturing Line Approval Basic GMP/ HACCP Audits Water Scan Certification
Outbound Food Safety in Distribution ( Audits) Marketplace Quality Monitoring
(includes Fountain & Commercial Beverages)
Consumer/ Customer Concern (Toll Free No. 1800-‐180-‐ 2653)
Support New Product Commercialization with Food Safety
Capability Building
FSSAI Imperatives for Food Business
General Requirements on Hygienic and Sanitary Practices to be followed by all Food Business Operators Schedule 4 of the FSSAI regulation Defines Good Manufacturing Practices, Good Hygienic Practices, Hazard Analysis and Critical Control Points and such other practices to be complied by the food business.
align all the Food Safety Systems with the new regulation
14
Coca-Cola in India: Manufacturing
Sales Volume Approx 600 million cases Largest Portfolio of Non Alcoholic Beverages -‐Carbonated Soft Drinks (CSD), packaged drinking water, juice based drinks, ready-‐to-‐drink hot tea and coffee Manufacturing & Distributing the
Brands Coca-‐Cola, Diet Coke, Fanta, Sprite, Georgia Nationally We have 4 of the 5 top soft drink brands: Coke, Thums Up, Sprite, Limca Over 55 locations for Soft Drinks, Juice & Water manufacturing
Ccca Cola brands available in 1.3 MM outlets, 20% of FMCG universe
Creating Food Safety culture to deliver value to the customers by Using right technology / infrastructure People Capability & Empowerment Building appropriate management systems o Using Appropriate external partners / agencies to roll out implementation o Reward & Recognition o Governance Model
Food Safety Culture : Where people are aware and follow Food Safety Practices when no one is looking
Manufacturing Food Safety
17
All aspects of Food Safety Standard ( FSSAI ), PAS-‐220 and ISO-‐22000 covers Some examples
Layout and Building Design
Incoming Materials Supplier Authorization Supplier Assessment Incoming Quality Tests
Processing Hygienic Design of manufacturing equipments Food safe process flow Cleaning and Sanitizing
Storage, Transport, and Distribution
Personal Hygiene & Pest Control
FOOD SAFETY IN MANUFACTURING
18
Coca-‐Cola Bottling unit
Location of a plant in a non-‐contaminating area Paved roads inside and outside the plant to prevent dust
Source water is protected by encasing the Bore well and keeping casing 1 feet above ground level to ensure prevention of chemical or microbiological contamination of source water
LAYOUT & BUILDING DESIGN
19
Ceiling & walls painted with approved anti-‐fungal paint.
Controlled access to identified personnel -‐ manned gates, swipe card system in process areas.
LAYOUT & BUILDING DESIGN
20
Suppliers for all materials have to pass through a supplier approval process. The suppliers have to undergo a rigorous supplier assessment process Ingredients, processing aids & packaging materials are always procured from approved suppliers. Robust standards and specifications In plant analysis of the materials before accepting any consignment. Vendor Rating System
INCOMING MATERIALS
21
Well designed divert panels to ensure cleaning and sanitizing of all the tanks and respective pipelines, no dead-‐spaces Seams are smoothened to prevent product/ ingredient residues buildup
PROCESSING Equipment Design
Food grade gaskets to be used wherever applicable.
Spray balls are provided in each tanks to facilitate cleaning of the tanks during Hot CIP
22
Only potable drinking water sources are used for manufacturing IS 10500 : 1991-‐ Potable Water IS 14543 : 2004-‐ Packaged Drinking Water WHO ed3 -‐ International Standard for Drinking Water
PROCESSING Food Safe Process Flow
All water source(s) are tested for compliance to potability standards by approved External Test Labs.
23
Proper Hot Caustic Sanitization of glass bottles
No manual handling between bottle washing and filling
Three bottle inspection stations to remove bottles with any traces of dirt or foreign materials
PROCESSING Food Safe Process Flow
Use of Electronic Bottle Inspectors for effective inspection of washed bottles
25
PROCESSING Cleaning and Sanitizing
Auto CIP performed at regular intervals to facilitate cleaning of all the food contact surfaces
External cleaning of equipment is done manually with water jets
26
Insecticide sprays & Glue traps are provided in yellow zone patches. Non residual insecticides are used only during non production hours and are applied in the yellow zones . Physical rodent traps like Glue traps, ultrasonic repellants are used. Birds are prevented from entry by providing bird meshes, clappers, orintho-‐repellent paint.
PEST CONTROL
27
STORAGE, TRANSPORTATION & DISTRIBUTION
Raw materials and processing aids are stored in well segregated, covered & ventilated areas with proper labeling
Finished products are kept under well ventilated covered areas to avoid direct sunlight (for light sensitive products)
The stacks are at a distance of about 1.5 feet from the walls to facilitate cleaning
First Expire First Out is always maintained for ingredients, intermediate and final product.
28
Instant Hand sanitizer dispenser at all entrances or hand washing stations are provided
Plant personnel wear clean and sanitized (approved sanitizer) attire with caps and gloves.
Training is provided to all the employees for upkeep & hygiene
All Personnel periodically undergo Health Check up for any contagious disease
PERSONAL HYGIENE
Display of Hygiene policy at entry to all processing area and main gate.
Work instruction of processing area (in Hindi)
Points
Pictorial and local language display of GMP Practices in production area.
Use of Electronic Access control at the entry points of all processing areas .
Maturity
As a unit progresses in Quality & Food Safety Management systems implementation, the characteristics are classified from risk to excellence and improvement Plans Incorporated into Business Plans
Excellence Improvement
Process Compliance
Risk
Quality Maturity Continuum
People
Work Processes
Environment
Structure
Measurement Mat
urit
y C
hara
cter
isti
cs
Maturity of the End results
Classified -‐ Internal use
AaUuDdIiTtOoRr
BbUu TtEeCcHhNnIiCcAaLl
Congratulation ! My 1000th
Audit ! celebrate
Classified -‐ Internal use
Supported by Expertise help
EeXxPpEeRrTt
CcRr
IiTtIiCc
AaLl Rr
IiSsKk
GAPs
Classified -‐ Internal use
I see you have all required documents & evidence! What
are you trying to Hide?
Practical demonstration of compliance
FSMS Implementation
H ACCP 100%
ISO 9001 > 90%
FSSC-22000 > 60%
Ensure Supply Concentrates & Beverage Bases Sugar Carbondioxide Juices / Pulp
Tea & Coffee Ingredients Processing Aids Packaging Material
Goal: Input Quality
Strategy: Robust Supplier Audit, Approval and Authorisation Program
40
Supplier Quality Management Define Requirements - Brochure
Quality Systems Quality Programs Supplier Guiding Principles Purchased Materials -‐ Services Process Monitoring and Control Finished Product Management Food Safety (HACCP) Chemical Residue and Contamination Control Traceability Scientific & Regulatory Affairs Notification of Regulatory Actions Notification of Process Change Auditor Access Security Confidentiality Code of Business Conduct
Clearly communicate Company Requirements Consolidates into one reference
Ensures consistency
Engagement & Capability building
41
Sugar Suppliers Quality /Technology Meet
Carbon Dioxide Suppliers meet
Examples :
We have to chose
Classified -‐ Internal use
Key Messaging to all Suppliers: Ingredients & Primary Packaging
Self Regulation through GFSI
Our Imperative -‐ Act proactively Implement one of the food safety management systems approved under GFSI
BRC Global Standard Version 5 Dutch HACCP (Option B) FSSC 22000
Align with FSSAI requirement In 2011, over 50% of ingredient suppliers already certified to FSMS In 2012 we target all suppliers including Packaging Invite other Food Manufacturers to join in
Classified -‐ Internal use 43
Classified -‐ Internal use
We have had remarkable growth during past 5 years. Volume doubled (260 mm unit cases to 600 million unit cases) The manufacturing Quality also improved and became more reliable
Such growth needed the Distribution system to match up on Quality, Food Safety & Upkeep
The Challenges increase due to : Poor infrastructure across the country Hot & Humid climate poses challenge to our products Low awareness and appreciation for Quality in Distribution
The Distribution Complexity : Multiple Bottlers : 18 Large number of Sales Territories : 40 Bottler Owned Warehouses : 125 3rd Party Distributors : 6300
Classified -‐ Internal use
What was done in 2010 ??
Needed to build attention and buy-‐in of the Franchise Bottlers
Converted KORE (in Distribution) into simple , easy to understand Communication Package rolled out :
Visual Dossiers / Poster in Local dialect (with Humour) Audit Checklist
Catchy acronyms : WUN / RUN
WUN = Warehouse Upkeep Norms RUN = Route Vehicle Upkeep Norms
Warehouse & Fleet Upkeep Norms Posters At a glance
Warehouse
Fleet
Classified -‐ Internal use
National foot print Consumers from across the country can call
national toll free number get their queries and concerns addressed seek information provide feedback educate to empower customers to place request for
a guided plant tour
( For lodging grievances Consumers)
Inbound calls
1800-‐180-‐2653
CONSUMER INTERACTION CENTRE KEY FEATURES
Laboratory Analytical Services
Total investment of $US 5 MM ( Rs. 20 Cr) Highly advanced purpose built laboratory ~ 2000 square meters (20,000 square feet) 9000sqft available for expansion
Eurasia Analytical Service Center, Pune (EASC) Set up in 2010 start
Major Analytical Instruments
ICP-‐MS Intended Use Heavy Metal Analysis Arsenic, Cadmium, Lead, Chromium, Nickel, Copper (approx 76 elements) Range of Detection ppt to ppm Manufacturer Agilent
GC-‐MS Intended Use Residues and Volatile organic compound Analysis Range of Detection ppb to ppm Manufacturer Agilent
LC-‐MSMS Intended Use Residues Analysis Manufacturer Waters Range of Detection ppb to ppm
UPL C Intended Use Sweeteners, Colorants, preservatives and Ingredients Analysis Manufacturer Waters India Range of Detection ppb to ppm
DI O N E X I C Intended Use Cation and Anion Analysis Manufacturer Dionex Range of Detection ppb to ppm
Methrohm I C Intended Use Cation and Anion Analysis Manufacturer Metrohm Range of Detection ppb to ppm
Major Analytical Instruments
Autotitrator Intended Use For Acidity and water analysis. Manufacturer Metrohm Range of Detection ppm
Auto SPE Intended Use Sample Preparation for Residue Analysis Manufacturer Dionex
Microwave Digestor Intended Use Sample Preparation for Metal Analysis Manufacturer CEM Corporation
Soft Drink Analyzer Intended Use Brix Analysis Manufacturer AntonPar
Role of EASC
Food Safety & Quality Assurance
Product Integrity testing Regulatory compliance Supplier authorization Risk based monitoring of key
ingredients and materials Adv. Troubleshooting Consumer quality monitoring
Consumer Quality Monitoring Program (TSP)
Product Integrity Program
Monitoring Programs
Microbiological Capability
Independent from the Business
Classified -‐ Internal use
Food Safety Management
World Class Standards The Coca Cola Operating Requirements
Inbound Supplier Audits/
Authorization Monitoring for unintended compounds
Manufacturing Line Approval Basic GMP/ HACCP Audits Water Scan Certification
Outbound Food Safety in Distribution ( Audits) Marketplace Quality Monitoring
(includes Fountain & Commercial Beverages)
Consumer/ Customer Concern (Toll Free No. 1800-‐180-‐ 2653)
Support New Product Commercialization with Food Safety
Capability Building
Classified -‐ Internal use
Food Safety Management
World Class Standards The Coca Cola Operating Requirements
Inbound Supplier Audits/
Authorization Monitoring for unintended compounds
Manufacturing Line Approval Basic GMP/ HACCP Audits Water Scan Certification
Outbound Food Safety in Distribution ( Audits) Marketplace Quality Monitoring
(includes Fountain & Commercial Beverages)
Consumer/ Customer Concern (Toll Free No. 1800-‐180-‐ 2653)
Support New Product Commercialization with Food Safety
Capability Building
-‐Manmohan Singh
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