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Approach towards Food Safety       Management            in     Coca Cola (India)                     Navneet  Mehta      ...
Being a Leader has its own                             4  
Taking Risks with our CorporateReputation is not an Option                                  5  
Quality & Food Safety is critically linkedto Corporate Reputation                                             6  
Quality  &  Safety  of  Products  which  is  a  top  most  influence  on  the  opinion  about  a  company,  followed  by  ...
Globalization & Awareness                  A  food  problem  in  one  area  soon  becomes                              a  ...
Food Safety -­ Domino Effect             Every  link  may  trigger  a  chain  reaction                             Classif...
TCCC  is  known  for  its  consistently  high                                                        quality  products  ar...
Food Safety ImperativeRaw Materials    Production    Distribution   Customer/         Waste                               ...
Risk Mitigation Process Driven Approach        Establish               Enable        Standards              Execution     ...
Food  Safety  Management         World  Class  Standards                                                                 T...
FSSAI      Imperatives for Food Business General  Requirements  on  Hygienic  and  Sanitary  Practices   to  be  followed ...
Coca-­Cola in India: Manufacturing                                                                        Sales  Volume   ...
Manufacturing  Food  Safety      Creating  Food  Safety  culture  to  deliver  value  to  the  customers  by         Using...
FOOD  SAFETY  IN  MANUFACTURING  All  aspects  of  Food  Safety  Standard  (  FSSAI  ),  PAS-­‐220  and  ISO-­‐22000  cove...
LAYOUT  &  BUILDING  DESIGN  Location  of  a  plant  in  a  non-­‐contaminating  area    Paved  roads  inside  and  outsid...
LAYOUT  &  BUILDING  DESIGN  Ceiling  &  walls  painted  with  approved  anti-­‐fungal  paint.                            ...
INCOMING  MATERIALS  Suppliers  for  all  materials  have  to  pass  through  a  supplier  approval  process.    The  supp...
PROCESSING     Equipment  Design  Well  designed  divert  panels  to  ensure  cleaning  and  sanitizing  of  all  the  tan...
PROCESSING     Food  Safe  Process  Flow  Only  potable  drinking  water  sources  are  used  for  manufacturing  IS  1050...
PROCESSING     Food  Safe  Process  Flow      Proper  Hot  Caustic  Sanitization  of  glass      bottles                  ...
Use  of  Electronic  Bottle  Inspectors  for  effective  inspection  of  washed  bottles  
PROCESSING     Cleaning  and  Sanitizing  Auto   CIP   performed   at   regular   intervals   to  facilitate   cleaning   ...
PEST  CONTROL    Insecticide  sprays  &  Glue  traps  are  provided  in  yellow  zone  patches.      Non  residual  insect...
STORAGE,  TRANSPORTATION  &  DISTRIBUTION  Raw   materials   and   processing   aids   are   stored   in  well   segregate...
PERSONAL  HYGIENE  Instant  Hand  sanitizer  dispenser  at  all  entrances  or  hand  washing  stations  are  provided    ...
 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 GMPPractices 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                      ...
Congratulation !      My 1000th  Audit !                                                AaUuDdIiTtOoRr     celebrate      ...
              Supported  by  Expertise  help                                                                CcRrIiTtIiCcAa...
I  see  you  have  all  required        documents  &  evidence!  What             are  you  trying  to  Hide?             ...
FSMS Implementation                      H A C CP 100%                      ISO 9001 > 90%                      F SSC-2200...
Ensure Supply                                                                                                             ...
Supplier Quality ManagementDefine Requirements -­ Brochure                           Quality  Systems                     ...
Engagement & Capability building Examples  :    Sugar  Suppliers  Quality  /Technology  Meet                              ...
Key  Messaging  to  all  Suppliers:  Ingredients  &  Primary  Packaging        We have to chose                           ...
Self Regulation through GFSI     Our  Imperative    -­‐  Act  proactively       Implement  one  of  the  food  safety  man...
We  have  had  remarkable  growth  during  past  5  years.          Volume  doubled  (260  mm  unit  cases  to  600  milli...
What  was  done            Needed  to  build  attention  and  buy-­‐in  of  the   in  2010  ??              Franchise  Bot...
Warehouse & Fleet Upkeep Norms        Posters At a glance                                                                 ...
CONSUMER  INTERACTION  CENTRE     KEY  FEATURES                                          1800-­‐180-­‐2653                ...
Laboratory Analytical Services                                    Eurasia  Analytical                                     ...
Major Analytical Instruments                                                         UP L CICP-­‐MS                       ...
Major Analytical Instruments    A utotitrator                       Soft D rink A nalyzer    Intended Use For Acidity and ...
Role of            EASC                                Product  Integrity  Program                                    Moni...
Food  Safety  Management         World  Class  Standards                                                                 T...
Food  Safety  Management         World  Class  Standards                                                                 T...
                                                -­‐Manmohan  Singh                                                        
 
Food Safety Management in Coca Cola (India)_2012
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Food Safety Management in Coca Cola (India)_2012

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Food Safety Management in Coca Cola (India)_2012

  1. 1. Approach towards Food Safety Management in Coca Cola (India) Navneet  Mehta   Director-­‐  Eurasia  Analytical  Service  Centre   Coca  Cola  India  Pvt.  Ltd     22  March  2012    
  2. 2. Being a Leader has its own 4  
  3. 3. Taking Risks with our CorporateReputation is not an Option 5  
  4. 4. Quality & Food Safety is critically linkedto Corporate Reputation 6  
  5. 5. Quality  &  Safety  of  Products  which  is  a  top  most  influence  on  the  opinion  about  a  company,  followed  by  Reputation   Influences  on  Opinion  about  a  company  (Unaided)  Quality  of  products  and  services Brand  Reputation Price Variety  and  Availability %  respondents Advertising Aided  Repsonses   Top  Box  Score   Q   0% 10% 20% 30% 40% 50% 60% 70% Its  products  /  services  are  of  highest  quality   87%   R   Good  image   67%   Q   Concern  about  the  health  and  safety  of  its   66%   consumers   Only  Quality,  Food   R   Positive  opinion  from  other  people   60%   Safety  and  Reputation   R   Takes  care  not  to  harm  the  environment   50%   related  factors  get  >   50%  top  box  score   R   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%   Base:  Total  Respondents  (N=420)  
  6. 6. Globalization & Awareness A  food  problem  in  one  area  soon  becomes   a  concern  across  the  globe  
  7. 7. Food Safety -­ Domino Effect Every  link  may  trigger  a  chain  reaction   Classified  -­‐  Internal  use  
  8. 8. 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  
  9. 9. Food Safety ImperativeRaw Materials Production Distribution Customer/ Waste Consumer 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 11  
  10. 10. Risk Mitigation Process Driven Approach Establish Enable Standards Execution Perfect Product Trusted Everywhere Measure Initiate Performance Corrective Action 12  
  11. 11. Food  Safety  Management   World  Class  Standards                                                        The  Coca  Cola  Operating  Requirements     Inbound        Manufacturing     Outbound            Supplier  Audits/        Line  Approval    Food  Safety  in  Distribution  (  Audits)   Authorization   Basic  GMP/  HACCP   Marketplace  Quality  Monitoring   (includes  Fountain  &  Commercial  Beverages)            Monitoring  for  unintended      Audits   Consumer/  Customer  Concern              compounds                    (Toll  Free  No.  1800-­‐180-­‐   2653)        Water  Scan      Certification                          Support  New  Product  Commercialization  with  Food  Safety   Capability  Building  
  12. 12. 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  
  13. 13. 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    
  14. 14. Manufacturing  Food  Safety      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    
  15. 15. FOOD  SAFETY  IN  MANUFACTURING  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   17  
  16. 16. LAYOUT  &  BUILDING  DESIGN  Location  of  a  plant  in  a  non-­‐contaminating  area    Paved  roads  inside  and  outside  the  plant  to  prevent  dust   Coca-­‐Cola  Bottling  unit   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   18  
  17. 17. LAYOUT  &  BUILDING  DESIGN  Ceiling  &  walls  painted  with  approved  anti-­‐fungal  paint.     Controlled  access  to  identified  personnel  -­‐   manned   gates,   swipe   card   system   in   process  areas.   19  
  18. 18. INCOMING  MATERIALS  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     20  
  19. 19. PROCESSING    Equipment  Design  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  Food  grade  gaskets  to  be  used  wherever  applicable.   Spray  balls  are  provided  in  each  tanks  to   facilitate  cleaning  of  the  tanks  during  Hot  CIP   21  
  20. 20. PROCESSING    Food  Safe  Process  Flow  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       All   water   source(s)   are   tested   for   compliance   to   potability  standards  by  approved  External  Test  Labs.   22  
  21. 21. PROCESSING    Food  Safe  Process  Flow   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   23  
  22. 22. Use  of  Electronic  Bottle  Inspectors  for  effective  inspection  of  washed  bottles  
  23. 23. 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     25  
  24. 24. PEST  CONTROL    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.   26  
  25. 25. 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.   27  
  26. 26. PERSONAL  HYGIENE  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   28  
  27. 27.  Display  of  Hygiene  policy  at  entry  to  all  processing  area  and  main  gate.  
  28. 28. Work  instruction  of  processing  area  (in  Hindi)    
  29. 29.    Points  
  30. 30. Pictorial and local language display of GMPPractices in production area.
  31. 31. Use  of  Electronic  Access  control    at  the  entry  points  of  all  processing  areas  .
  32. 32. 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 PeopleMaturity Characteristics Excellence Work Processes Improvement Process Compliance Risk Environment Q uality M aturity Continuum Structure Measurement Maturity of the End results
  33. 33. Congratulation ! My 1000th Audit !  AaUuDdIiTtOoRr   celebrate BbUu   TtEeCcHhNnIiCcAaLl     Classified  -­‐  Internal  use  
  34. 34.         Supported  by  Expertise  help     CcRrIiTtIiCcAaLl            RrIiSsKk  EeXxPpEeRrTt   GAPs Classified  -­‐  Internal  use  
  35. 35. I  see  you  have  all  required   documents  &  evidence!  What   are  you  trying  to  Hide?         Practical  demonstration  of  compliance       Classified  -­‐  Internal  use  
  36. 36. FSMS Implementation H A C CP 100% ISO 9001 > 90% F SSC-22000 > 60%
  37. 37. Ensure Supply   Concentrates  &   Beverage  Bases     Sugar     Carbondioxide     Juices  /  Pulp     Tea  &  Coffee   Ingredients  Goal:  Input  Quality       Processing  Aids     Packaging  Material       Strategy:  Robust  Supplier  Audit,  Approval  and  Authorisation  Program    
  38. 38. Supplier Quality ManagementDefine 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   C learly communicate Company Requirements Consolidates into one reference E nsures consistency 40  
  39. 39. Engagement & Capability building Examples  :    Sugar  Suppliers  Quality  /Technology  Meet   Carbon  Dioxide  Suppliers  meet   41  
  40. 40. Key  Messaging  to  all  Suppliers:  Ingredients  &  Primary  Packaging       We have to chose   Classified  -­‐  Internal  use  
  41. 41. 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  
  42. 42. 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  Distribution  Complexity  :    Multiple  Bottlers       :        18    Large  number  of  Sales  Territories   :        40    Bottler  Owned  Warehouses     :    125    3rd  Party  Distributors     :   6300   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   Classified  -­‐  Internal  use  
  43. 43. What  was  done   Needed  to  build  attention  and  buy-­‐in  of  the   in  2010  ??   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     Classified  -­‐  Internal  use  
  44. 44. Warehouse & Fleet Upkeep Norms Posters At a glance                               Warehouse               Fleet Classified  -­‐  Internal  use  
  45. 45. CONSUMER  INTERACTION  CENTRE    KEY  FEATURES   1800-­‐180-­‐2653   National foot print Consumers from across the country can call Inbound  calls     national toll free number (  For  lodging  grievances     get their queries and concerns addressed Consumers)   seek information provide feedback educate to empower customers to place request for a guided plant tour
  46. 46. Laboratory Analytical Services Eurasia  Analytical   Service  Center,    Pune   (EASC)       Set  up  in  2010  start  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
  47. 47. Major Analytical Instruments UP L CICP-­‐MS   Intended Use Sweeteners,Intended  Use    Heavy  Metal  Analysis  Arsenic,   Colorants, preservatives andCadmium,  Lead,  Chromium,  Nickel,  Copper  (approx   Ingredients Analysis76  elements)   Manufacturer Waters IndiaRange  of  Detection  ppt  to  ppm   Range of Detection ppb to ppmManufacturer    Agilent       GC-­‐MS   Intended  Use    Residues  and  Volatile  organic   DIONE X IC compound  Analysis   Intended Use Cation and Anion Range  of  Detection  ppb  to  ppm   Analysis Manufacturer    Agilent     Manufacturer Dionex   Range of Detection ppb to ppm LC-­‐MSMS   M ethrohm I C Intended  Use    Residues  Analysis   Intended Use Cation and Anion Manufacturer    Waters     Analysis Range  of  Detection ppb  to  ppm   Manufacturer Metrohm   Range of Detection ppb to ppm
  48. 48. Major Analytical Instruments A utotitrator Soft D rink A nalyzer Intended Use For Acidity and Intended Use Brix Analysis water analysis. Manufacturer AntonPar Manufacturer Metrohm Range of Detection ppm A uto SP E Intended Use Sample Preparation for Residue Analysis Manufacturer Dionex M icrowave Digestor Intended Use Sample Preparation for Metal Analysis Manufacturer CEM Corporation
  49. 49. Role of EASC Product  Integrity  Program     Monitoring  Programs   Consumer  Quality  Monitoring  Program  (TSP)   Microbiological  Capability  Food Safety & Quality AssuranceProduct Integrity testingRegulatory complianceSupplier authorizationRisk based monitoring of keyingredients and materialsAdv. TroubleshootingConsumer quality monitoring Independent  from  the  Business  
  50. 50. Food  Safety  Management   World  Class  Standards                                                        The  Coca  Cola  Operating  Requirements     Inbound        Manufacturing     Outbound            Supplier  Audits/        Line  Approval    Food  Safety  in  Distribution  (  Audits)   Authorization   Basic  GMP/  HACCP   Marketplace  Quality  Monitoring   (includes  Fountain  &  Commercial  Beverages)            Monitoring  for  unintended      Audits   Consumer/  Customer  Concern              compounds                    (Toll  Free  No.  1800-­‐180-­‐   2653)        Water  Scan      Certification                          Support  New  Product  Commercialization  with  Food  Safety   Capability  Building   Classified  -­‐  Internal  use  
  51. 51. Food  Safety  Management   World  Class  Standards                                                        The  Coca  Cola  Operating  Requirements     Inbound        Manufacturing     Outbound            Supplier  Audits/        Line  Approval    Food  Safety  in  Distribution  (  Audits)   Authorization   Basic  GMP/  HACCP   Marketplace  Quality  Monitoring   (includes  Fountain  &  Commercial  Beverages)            Monitoring  for  unintended      Audits   Consumer/  Customer  Concern              compounds                    (Toll  Free  No.  1800-­‐180-­‐   2653)        Water  Scan      Certification                          Support  New  Product  Commercialization  with  Food  Safety   Capability  Building   Classified  -­‐  Internal  use  
  52. 52.     -­‐Manmohan  Singh                
  53. 53.  

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