Capacity Building to meet Quality Requirements

Transcription

1 Capacity Building to meet Quality Requirements CONFERENCE ON INDIAN DAIRY INDUSTRY NDRI Karnal On Oct 22,2009 Kuldeep Sharma Director Entrepreneurship and Technology Development Center Noida

2 What Comes to your mind while thinking of the following word Quality Value Chain Is Quality limited to Bacteria only? Is middleman the real culprit?

3 Food Quality Issues Quality non-conformity Physical Other Microbiological Legal non-conformity Labelling Foreign bodies Chemical Allergy

4 Quality Issues Except Microbiological No. of Incidents Product Design/Change Management Hygienic Design Cleaning and Disinfection Water Treatment Cleaning Disinfection Raw Material Storage (Soap Packaging) Housekeeping Rework Not Identified Not Yet Reported Incorrect equipment design directly contributes to a significant number of hygiene incidents ( and probably a key influence in many other cases )

5 Quality in Food Industry For me quality of raw material in agri-food sector is something which can not be improved further but maintained only. There is no technology in the world which could convert a low quality raw material into a high quality finished food.

6 SKILLS KNOWLEDGE MARKET RESEARCH CONSULTANCY / TRAINING AUDITING MARKET ACCESS COMPETITIVE STRATEGY TRAINING / ACTION EXPOSURE QUALITY MANAGEMENT CAPACITY BUILDING FRAMEWORK METHODOLOGY

7 Capacity Building : The Solution Broadly, it can be defined as a process by which skills, institutions and knowledge are built, utilized, retained and nurtured with a view to providing an entity with the means of responding to a development challenge. Say Clean Milk Production

8 The old Theory Practice makes a man Permanent

9 Capacity Building : The Solution Two components that are vital in any plausible definition of the concept are human skills (the ability to perform a task) and institutions (effectiveness and efficiency of organizations, systems, processes and procedures).

10 Role of Knowledge Knowledge enters the definition as a distinct component because it allows for the combination of skills, experiences, insights, expert intuition, actionable recommendations from research, among others, to enable an entity to continuously innovate and apply best-practice solutions to emerging and evolving challenges.

11 Application of Knowledge The application of knowledge makes skills and institutions dynamic and responsive. Thus, a definition of the concept of Capacity Building that is limited to skills and institutions in exclusion of the knowledge component is incomplete. Consultant V/s Auditor HACCP

12 The simplicity factor The most difficult part of capacity building is to simplify the applied knowledge. Let us learn HACCP in the simplest possible way.

13 90 % OF THE TIMES HEART BURNS HAVE NOTHING TO DO WITH THE HEART

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24 What are the battery limits for designing capacity building programs in Quality

25 The Site selection

26 Sources of infection during processing & distribution Raw materials Processing Packaging Storage and distribution ENVIRONMENT

27 Concentration of microorganisms Acceptable concentration at time of: consumption production Cleaning & sanitation required Ultimate time of consumption P Raw materials Processing Heat treatment Processing and packaging Storage distribution and shelf life

28 Few Cases How much sensitized are we towards this issue of Quality? Let us feel it by looking at some mixed cases of Food and Non Food

29 P&G (1980 s) In Japan about 1 million bottles of a liquid soap which had been found to contain bacteria was recalled. A company spokesman said product had been found to contain two types of sundry germs at 3-5 times higher than the companies self imposed limit. After discovering the problem the company stopped producing the soap for a few months with lost production totalling about 500 million Yen.

30 Thousands of bottles of a hair conditioner have been taken off the store shelves in Australia (Reported in a Newspaper) after it was found to contain a disease producing organism. Health Department tests found the organism was a opportunistic human pathogen (Burkholderia cepacia). A shipment of product to New Zealand was also recalled. A spokesman said the exercise had cost the firm a considerable amount of money.

31 Mouth Wash - August 2005 FDA News FOR IMMEDIATE RELEASE P05-55 August 29, 2005 Media Inquiries: Michael Herndon, Consumer Inquiries: 888-INFO-FDA FDA Announces Nationwide Recall of Medline Brand of Alcohol-Free Mouthwash and Hygiene Kits Containing Mouthwash Because of Possible Health Risk The U.S. Food and Drug Administration (FDA) is notifying the public of a nationwide voluntary recall of alcohol-free mouthwash and hygiene kits containing mouthwash distributed by Medline Industries, Inc., Mundelein, Ill because of the potential contamination with Burkholderia cepacia. Consumers and health care providers who have Medline brand alcohol free mouthwash should stop using the product immediately and check to see if it is being recalled. FDA is committed to informing the public about products that may be contaminated and can potentially cause illness, said Dr. Lester M. Crawford, FDA Commissioner. Consumers are encouraged to pay close attention to the identifying information for product information associated with this recall.

32 Get election results here, including a Bay Area county-by-county breakdown. Nationwide Meat Recall Is Largest In US History Oct. 14 (AP) Poultry processor Pilgrim's Pride is recalling 27.4 million pounds of cooked sandwich meat after warnings of possible contamination from listeria the largest meat recall in U.S. history. The company pulled 295,000 pounds of turkey and chicken products Wednesday but expanded the recall over the weekend after tests came back positive for a strain of the potentially fatal bacteria, the company said Sunday. 12,500 tonnes! The nationwide recall covers meat processed at the company's plant in suburban Franconia from May 1 through Oct months production! The recall covers deli meat primarily sold under the company's Wampler Foods brand, though it is also sold under brands including Block & Barrel, Bonos, Golden Acre, Reliance and a variety of private labels. The products include turkey and poultry sold freshly sliced or made into sandwiches at deli counters and in individually sold packages of sliced deli meats. Because consumers might not have access to the meat's original packaging, the best way to know if a product falls under the recall is to ask if it comes from a package that bears the plant number P-1351 inside the U.S. Department of Agriculture mark of inspection, said company spokesman Ray Atkinson. Production dates also can be found on that part of the label. The deli products were sold in retail groceries, in delicatessens and by food service distributors. Pilgrim's Pride, based in Pittsburg, Texas, is the nation's second-largest poultry company behind Tyson Foods. Its stock price plunged more than 30 percent, down $2.31 to $4.70, in morning trading Monday on the New York Stock Exchange. Consumers were urged by the company to return any affected meat to the store or deli where it was purchased for a full refund.

33 The poisoning was caused by a valve connecting a supply pipe with a tank used to recycle leftover milk. So rarely had the valve been washed that a solid block of dried milk, as wide as a 2p coin, had formed inside it, breeding a bacterium called Staphylococcus aureus. Health inspectors failed to detect the problem, and workers at the plant reported the equipment was seldom cleaned properly. "We have ignored the regulation for several years now, and have never been instructed to follow it,"one of them told the Yomiuri newspaper.

34 Microbes can hide in small areas of a manufacturing plant Because micro-organisms are so small they can gather in large numbers in a very small area 4 million bacteria could fit on the head of a pin!

35 Snow Brand Japan, summer 2000 Approximately 15,000 people ill and one death due to Staphylococcus aureus toxin in low fat milk products Valve was said to be used infrequently, but was used every day and had not been cleaned for 3 weeks

36 Snow Brand Japan, summer 2000 Affects: Product recall President and 7 executives resigned Plant closed and lost of millions yen per day 45% market share reduced to <10% - market share recovered slowly

37 Failure: Who will trace it to me? Food Laws Public health authorities with computer network Traceability Setup The number of food poisoning outbreaks, which are traced to their origin is increasing rapidly

38 So What is the solution? How much have you invested back in the system for capacity building of your organization in the following area(s) Extension Services ( Milk production, Feed Production, Animal Breeding) Plant Designing and Redesigning (Hygienic) Equipment designing, material of construction Process design flow and controls Quality Management Systems Material Handling in and out of Factory Training of Sales and Marketing team on Quality Preparing yourself on Market Access issues for Developed Markets

39 Thanks Where there is a will ; there is a way.