Food Safety Management in Coca Cola (India)_2012

Approach towards Food Safety Management

in Coca Cola (India)

Navneet Mehta Director-‐ Eurasia Analytical Service Centre

Coca Cola India Pvt. Ltd

22 March 2012

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Being a Leader has its own

Taking Risks with our Corporate Reputation is not an Option

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Quality & Food Safety is critically linked to Corporate Reputation

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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

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Establish

Standards

Enable

Execution

Measure

Performance

Initiate

Corrective Action

Perfect Product

Trusted Everywhere

Risk Mitigation Process Driven Approach

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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

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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

http://images.google.com/imgres?imgurl=http://www.mercola.com/images/blog/2004.05.25.coca-cola.jpg&imgrefurl=http://www.mercola.com/2004/jun/9/mid_calorie_sodas.htm&h=215&w=215&sz=42&tbnid=9pHwMiG4njYJ:&tbnh=101&tbnw=101&hl=en&start=2&prev=/images?q=coca-cola&hl=en&lr=&sa=G

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

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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

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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

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Ceiling & walls painted with approved anti-‐fungal paint.

Controlled access to identified personnel -‐ manned gates, swipe card system in process areas.

LAYOUT & BUILDING DESIGN

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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

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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

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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.

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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

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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

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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

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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.

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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

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Supported by Expertise help

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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

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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

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Sugar Suppliers Quality /Technology Meet

Carbon Dioxide Suppliers meet

Examples :

We have to chose


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


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


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


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


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

Food Safety Management in Coca Cola (India)_2012

Education

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