This document discusses Coca Cola India's approach to food safety management. It outlines the importance of quality, food safety, and reputation to the company's corporate reputation. It emphasizes ensuring food safety across the entire supply chain from raw materials to production to distribution to customers. The company has world-class food safety management standards and systems in place to meet all regulatory requirements and consumer expectations. Food safety is a top priority in manufacturing, where the culture emphasizes awareness and compliance with practices even when unobserved.

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. Being a Leader has its own
4

3. Taking Risks with our Corporate
Reputation is not an Option
5

4. Quality & Food Safety is critically linked
to Corporate Reputation
6

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. Globalization & Awareness
A food problem in one area soon becomes
a concern across the globe

7. Food Safety -­ Domino Effect
Every link may trigger a chain reaction
Classified -­‐ Internal use

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. Food Safety Imperative
Raw 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. Risk Mitigation Process Driven Approach
Establish Enable
Standards Execution
Perfect Product
Trusted Everywhere
Measure Initiate
Performance Corrective Action
12

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Use of Electronic Bottle Inspectors for effective inspection of washed
bottles

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. 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. 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. 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. Display of Hygiene policy at entry to all processing area
and main gate.

28. Work instruction of processing area
(in Hindi)

29.
Points

30. Pictorial and local language display of GMP
Practices in production area.

31. Use of Electronic Access control at the entry
points of all processing areas .

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
People
Maturity Characteristics
Excellence
Work Processes Improvement
Process
Compliance
Risk
Environment
Q uality M aturity Continuum
Structure
Measurement
Maturity of the End
results

33. Congratulation !
My 1000th
Audit ! AaUuDdIiTtOoRr
celebrate
BbUu
TtEeCcHhNnIiCcAaLl
Classified -­‐ Internal use

34.
Supported by Expertise help
CcRrIiTtIiCcAaLl RrIiSsKk
EeXxPpEeRrTt
GAPs
Classified -­‐ Internal use

35. I see you have all required
documents & evidence! What
are you trying to Hide?
Practical demonstration of compliance
Classified -­‐ Internal use

36. FSMS Implementation
H A C CP 100%
ISO 9001 > 90%
F SSC-22000 > 60%

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. 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
C learly communicate Company Requirements
Consolidates into one reference
E nsures consistency 40

39. Engagement & Capability building
Examples :
Sugar Suppliers Quality /Technology Meet
Carbon Dioxide Suppliers meet
41

40. Key Messaging to all Suppliers: Ingredients & Primary Packaging
We have to chose
Classified -­‐ Internal use

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. 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. 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. Warehouse & Fleet Upkeep Norms
Posters At a glance
Warehouse
Fleet
Classified -­‐ Internal use

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. 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. Major Analytical Instruments
UP L C
ICP-­‐MS
Intended Use Sweeteners,
Intended Use Heavy Metal Analysis Arsenic,
Colorants, preservatives and
Cadmium, Lead, Chromium, Nickel, Copper (approx
Ingredients Analysis
76 elements)
Manufacturer Waters India
Range of Detection ppt to ppm
Range of Detection ppb to ppm
Manufacturer 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. 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. Role of EASC
Product Integrity Program
Monitoring Programs
Consumer Quality Monitoring Program (TSP)
Microbiological Capability
Food Safety & Quality
Assurance
Product Integrity testing
Regulatory compliance
Supplier authorization
Risk based monitoring of key
ingredients and materials
Adv. Troubleshooting
Consumer quality monitoring
Independent from the Business

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. 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.
-­‐Manmohan Singh