October 2018 Issue

FOODANDBEVERAGE MATRIX RNI No: MAHENG/2018/75095

MONTHLY NEWSPAPER FOR F&B INDUSTRY Volume 1 / Issue 8 / Mumbai / October 2018 / Pages 20 / INR Rs 50/-

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October 2018 |Food And Beverage Matrix

FOODANDBEVERAGE MATRIX

MONTHLY NEWSPAPER FOR F&B INDUSTRY Dear Readers,

Editor’s Note

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here are a variety of opportunities for growing food and beverage businesses in the coming years, but staying on top of changing customer needs, understanding preferences, leveraging new packaging and employing key technology and will all be essential in this competitive marketplace. Following are the key factors to be addressed depending upon the nature of business. Ensuring production of safe food, understanding customer needs and following trends would be the key driver.

Changing customer PreferencesBold and exotic flavours, snacking and health and wellness are all at the forefront for consumer food preferences and are frequently driving those choice options with their adventurous palates. Food home delivery is also evolving, keeping in mind consumers’ wishes to be part of the mealmaking process with easy-tofollow recipes and healthy, fresh

ingredients. Staying on top of these shifting lifestyles and preferences is essential for relevant and profitable food and beverage companies. As we witnessed in past years, large packaged food companies that haven’t been on-trend with healthy snacking resulted in declining sales

Food safety- Consumer confidence in the safety of the food supply need to enhanced. Food manufacturers are expected to mitigate risks and improve in the area. For all, food safety and preventive efforts shall continue to be top of mind now and understanding the need, an article on FSMA PCHF is included in this edition.

Digital transformation- Sales on direct-to-consumer sites and third-party e-commerce platforms account for 36 percent of specialty food and beverage sales. The demand for online delivery and subscription food services is growing as busy consumers show their preference for doorstep delivery. As the fierce competition for shelf space continues, home

delivery in growing in demand as well. Customers order their choices from their devices, and delivery is provided within hours or available for pickup at neighbouring locations. Look for this service to continue to grow regionally, too, as local grocery outlets, dairies and farmers develop operations to meet their customers’ needs.

Technology Consumers started researches before they buy more than ever, and that includes food and beverages. With a quick search on their smartphones, consumers can make informed and speedy choices about the products they consume. What foods provide the protein and energy boost needed for a workout? Which drinks promote healthier skin? Where is this food grown? What are the core values and history of the company manufacturing the product?

Successful food and beverage businesses would use digital and social platforms to connect with consumers, providing robust

product research avenues, tips, stories, forums and more for the information hungry consumer. Harnessing the internet of things and big data are important parts of that overall strategy as well.

Best of Luck!

Please keep sending us your valuable suggestions with your expectations & feedback to manan@tresbonconsulting. com. For more articles you may also log on to our website and enjoy reading any time.

Thank you Manan Bajaj

e t Issu nth x e N Our r 2018 Mo ai

mbe ess Mumb Nove usin bad ry B eda Bake Ahm d l o c f e and R

GEA BUILDS ONE OF THE LARGEST AUTOMATED MOZZARELLA CHEESE PRODUCTION PLANTS IN INDIA

GEA stream stretching machine for the production of 1.000 to 6.000 kg/h of pasta filata cheese. (Image: GEA)

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echnology group GEA, pioneer in dairy and food processing technology, has recently concluded an order for one of the largest automated cheese plants in India. The customer, Milky Mist Dairy Foods Private Limited, is one of the leading private dairies in Southern India. Headquartered in Erode, Tamil Nadu, Milky Mist has a diverse portfolio of value-added milk products including cheese, paneer, yoghurt, flavored yoghurt and ghee.

This is the second order in a row from Milky Mist to GEA in India; the first one being a complete greenfield

project for processing 0.6 million liter of milk and 40 tons of whey powder per day was successfully completed

by GEA in April 2018.

GEA supplied a fully automatic, complete mozzarella/pizza cheese line along with CIP (cleaning in place) system to produce cheese at two metric tons per hour (2mt/hr). The stateof-the-art equipment and innovative technologies from cheese vats, maturation system, stretching molding machine to brining vats enhance product quality, yield and energy efficiency in the Milky Mist plant.

Unlike conventional hot water stretching systems, with GEA’s patented continuous steam stretching of curd, the milk does not lose any fat and proteins in whey – resulting in enhanced yield, better fibrous structure for longer stretchabilty and reduced energy consumption by up to 30%. The plant features another patented technology by GEA: The whey drainage and maturation tunnel system for continuous maturation of curd in controlled acidity development, which is first of its kind in India. GEA’s patented anti-sticking surface treatment on machine parts, “Vulcan”, ensures that there are no Teflon particles in the final product – a very important feature in the safe production of highquality cheese. Furthermore, the plant uses micro filtration for continuous decontamination of the brine bath.

“GEA has already executed another project for us. We appreciate their innovative approach to a specialized product like mozzarella cheese.

As we wish to take our products international, we are convinced that we need to adopt technologies which will not only ensure high quality and hygiene standards but also maintain

environmental sustainability”, said Mr T. Sathish Kumar, Managing Director of Milky Mist.

“We are offering an environmentally friendly technology for very high quality mozzarella cheese. It is a pleasure to work with clients who want to introduce such high standards which will enable the industry to grow sustainably”, added Suket Gohil, Managing Director of GEA India.

GEA molding machine (carousel pre-hardening unit), Model HG, for the production of 500 to 2.000 kg/h of cheese. (Image: GEA) Contined to page no 4

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October 2018 |Food And Beverage Matrix

MB SUGARS SWEETEN WORLD’S LARGEST CHOCOLATE MUD PIE IN GOA

B group had partnered with ‘The Prince of Chocolates’, celebrity chef Varun Inamdar to create Guinness record history on August 3, at Dr Shyam a Prasad Mukherjee Stadium, Taleigaon, Goa. The group together with celebrity chef Varun Inamdar had attempted the Guinness World Record for creating the largest chocolate mud pie weighing one tonne with a diameter of over 6 feet. The challenge which was led by Inamdar included many chefs from Goa and culinary professionals and was done on August 3 at Trinity’s flagship showcase – the 15th Annual India Hospitality + F&B Pro International Expo 2019.

We are in the business of specialty Sugar since 1997 and catering to Food, Bakery and Hospitality Industry. Thus

it comes naturally to us that we should aim at a record related to food.

The reason we chose a chocolate mud pie this time around is because Goan's love sweets and desserts,” says Marketing Director Mr. Samyak Lodha.

The current record for the largest chocolate mud pie was set at 500 kilograms. “We decided that instead of just barely breaching the benchmark, we should breach it well and thus decided to attempt double the weight. In this way, the record will hopefully stay for a long time,” says Mr. Lodha.

Over 2200 pounds (1000 Kgs) of ingredients were used into

making the mud pie, which included Castor Sugar & Icing Sugar sponsored

by MB Sugars.

A specially fabricated vessel and oven of 8 feet was designed by Mr. Pradeep Panchal of Kitchen Mall over the last 18 months. This has been electrically coiled.

Mr. Nitin Deore (Consumer Product Division Head) and Mr. Hidayat (Mumbai & Goa Bakery Business Head) from MB were present for the event. “There is a lot of mixing, cutting involved and there were plenty of chefs joining in. We also had people from Goa University, Agnel Institute Of Food Crafts & Culinary Sciences among others and getting all these stake holders together was a challenge” says Mr. Deore.

MARKETING DIRECTOR SAMAYAK LODHA, MB SUGARS

After serving the mud pie to the audience, the rest of it was then distributed to various charities around Goa through the Food Bank for the Poor.n

Contined from page no 2

Demand for cheese in India is likely to grow by more than 20% (2015-2020, CAGR – Compound Annual Growth Rate). With changes in food habits and increased demands for fast food and takeaways, India is witnessing more and more inclusion of cheese in daily meals. Given this, the demand for different varieties of cheeses especially pizza and mozzarella cheese is expected to grow.

The plant equipment has been supplied by GEA in Italy.

The local GEA experts have more than 40 years of experience in mozzarella cheese production technology.

With its expertise to meet every production target, GEA can supply, install and commission complete production plants for soft/fresh, semi-hard and hard cheeses, as well as pasta filata cheese like mozzarella, pizza cheese and ricotta etc.

The Milky Mist plant is one of the largest operational and fully automated pizza cheese lines in India.

GEA is showcasing the mozzarella cheese processing technology and equipment at ANUTEC FOODTEC, September 27- 29, 2018, Bombay Exhibition Centre in Mumbai (India), Hall 1, booth E15.

About GEA GEA is one of the largest suppliers for the food processing industry and a wide range of other industries that generated consolidated revenues of approximately EUR 4.6 billion in 2017. The international technology group focuses on process technology, components and sustainable energy solutions for sophisticated production processes in various end-user markets. The group generates around 70 percent of its revenue in the food and beverages sector that enjoys long-term sustainable growth. As of December 31, 2017, the company employed almost 18,000 people worldwide. GEA is a market and technology leader in its business areas.

The company is listed on the German MDAX (G1A, WKN 660 200). In addition, GEA’s stock is included in the MSCI Global Sustainability Indexes. Further information is available on the Internet at gea.com.n

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October 2018 |Food And Beverage Matrix

THE INDIAN BEVERAGE AND LIQUID FOOD MARKET DYNAMIC DEVELOPMENT IS REFLECTED AT DRINK TECHNOLOGY INDIA Whether it is soft drinks, alcoholic beverages, dairy products or edible oils: the demand for beverages and liquid food products in India has been on the rise for years. Significant growth is also expected in the future. With more than 300 exhibitors and an extensive supporting program, drink technology India (dti) showcases the trends of the industry and provides impetus for the industry in India. dti will take place from October 24 to 26 at the Bombay Exhibition Centre in Mumbai.

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1. The Indian beverage and liquid food market continues to grow in all areas

he Indian beverage market is continuing to grow. The reasons for this include the rising population, a growing and consumption-oriented middle class and the continuing urbanization. The continuing spread of modern trade structures, such as supermarkets, also favors the growth in the beverage and liquid food sector.

In the process, demand from Indian consumers is increasing in all beverage and liquid food segments. According to the VDMA Food Processing and Packaging Machinery Association, the total demand for beverages is expected to increase by around 89 percent by 2022: from more than 27 billion liters in 2017 to over 50 billion liters.

Richard Clemens, Managing Director

2. Drink technology India cements its position as a driving force for the industry 3. Rapid rise in demand for alcoholic beverages and edible oils

of the VDMA Food Processing and Packaging Machinery Association, explains: “Local beverage production grew by 63 percent over the period from 2012 to 2017 and reached a

value of approximately 13.8 billion euros in 2017. Further growth of nine percent per year is expected over the next few years.” In order to meet demand and continue to grow, Indian companies need appropriate machinery for the production, processing and packaging of beverages and liquid food. According to the VDMA, India is one of the most important sales markets in Asia for companies manufacturing such equipment. For Clemens, dti plays a key role for the Indian beverage and liquid food industry: “dti will provide numerous stimuli for investments into the growth industries.”

India currently ranks ninth among the ten largest buying countries for alcoholic beverages. Here, beer and spirits rank first and second. Beer is becoming increasingly popular, especially among the younger Indian population. According to the VDMA, sales are expected to increase by 22 percent by 2022.

India is already the world’s second largest market for spirits behind China. Here, the VDMA is expecting growth of just under 14 percent over the same period.

The supporting program of dti provides important stimuli with regard to the subject of alcoholic beverages. The place2beer, which takes place Alcoholic beverages are becoming at dti for the first time, provides a comprehensive overview of increasingly popular the latest developments. It is an indispensable program item for microbreweries, medium-sized and industrial breweries as well as suppliers to catch up on the trends relating to beer brewing.

The second day of the Round Table Talks will be dedicated to trends and developments with regard to alcoholic beverages. Numerous speakers have already announced their presentations on the subject of “Trends and Developments in Alcoholic Beverages in India”.

Representatives of companies and experts from research institutions will be among the participants. One of them will be Yogesh R. Bhandane, CEO of Boroton Research Centre Pvt. Ltd., with a presentation on the trends and needs of the Indian wine industry. A comprehensive overview of the Indian wine market will be presented by Gorakh Gaikwad, Associate Vice President at Sula Vineyards Pvt. Ltd. K. N. Gopalakrishnan, Contined to page no 7

Food And Beverage Matrix | October 2018 Contined from page no 6

7 milk producer. According to the VDMA, an average annual increase in the demand for dairy products of 4.4 percent is expected for the period from 2017 to 2022.

The dynamic growth of the Indian beverage and liquid food market is reflected at the trade fair. The most important topics and trends of the industry will be highlighted in the supporting program. Visitors can find solutions and innovations to meet the developments of the Indian market from the approximately 300 exhibitors representing the entire process chain of the beverage and liquid food industry. A first overview of participating exhibitors is available to visitors here soon.

Head of Brewery & Processing at Carlsberg India Pvt. Ltd., will present the current trends in the Indian beer industry.

Continuing demand for edible oils In India, the topic of fats and oils is on the rise. The demand for edible oils in India is currently growing rapidly.

According to the VDMA, demand is growing faster than the country’s own production. Sales more than doubled

research will provide insights into the world of oils and fats.

Growth in all segments of the beverage and liquid food industry In addition to alcoholic beverages and edible oils, there are also indications of increased demand for other product categories. According

About drink technology India drink technology India (dti) is the most important event for the Indian beverage, dairy and liquid food industry. It takes place in conjunction with the pacprocess India, indiapack and food pex India trade fairs of Messe Düsseldorf. The event location alternates between Mumbai (Bombay Exhibition Centre), New

between 2012 and 2017. The VDMA anticipates further growth in demand over the next five years: from just under 13 million tonnes (2017) to more than 19 million tonnes (2022).

This corresponds to an increase of 58 percent. dti is responding to this trend with the oiltech Forum. It will take place for the first time during the trade fair as part of the Oiltech Pavilions, powered by oils+fats. The Oil Technologists’ Association of India (OTAI) is supporting the organization and design of the program. A half-day seminar will take place on the first day of the trade fair. Under its central theme ‘Challenges in Packaging of Edible Oils and Other Related Products‘, the seminar is subdivided into the topics ‘Regulatory Requirements, Current and Tomorrow’, ‘Latest Technology and Advancements’ and ‘Consumer and Brand Owner’s Perspective’.

Leading experts from industry and

and food pex India. The next drink technology India will take place in Mumbai from October 24 to 26, 2018.

About the drinktec worldwide network drinktec worldwide represents a strong global network that unites drinktec – the world’s leading trade fair for the beverage and liquid food industry in Munich – with the drink technology India (dti), CHINA BREW CHINA BEVERAGE (CBB) and food & drink technology Africa (fdt) trade fairs. drink technology India, CHINA BREW CHINA BEVERAGE and the food & drink technology Africa are the leading platforms in their respective countries for the industry. The trade fairs in China (Shanghai) and Africa (Johannesburg) take place every two years. In India the event takes place in Mumbai in even-numbered years. In odd-numbered years the event takes place twice a year: in Bangalore in the spring, in New Delhi in autumn.

With a total of 2,847 exhibitors and more than 140,000 visitors in Munich, India, China and Africa, Messe München is the world’s leading event organizer for the beverage, food, packaging, milk and liquid food industry.

About Messe München

to the VDMA the total sales of soft drinks, for example, are expected to more than double to 43 billion liters by 2022. For bottled water, the VDMA even forecasts an increase in sales by 156 percent. India is the third largest market for dairy products behind the USA and China—and at the same time the world’s largest

Delhi (Pragati Maidan grounds) and Bangalore: in even-numbered years it takes place in Mumbai, in oddnumbered years in Bangalore and New Delhi.

212 exhibitors and 9,699 trade visitors presented their developments and solutions at drink technology India 2017, pacprocess India, indiapack

Messe München is one of the leading exhibition organizers worldwide with more than 50 of its own trade shows for capital goods, consumer goods and new technologies. Every year, a total of over 50,000 exhibitors and around three million visitors take part in more than 200 events at the exhibition center in Munich, at the ICM – Internationales Congress Center München and the MOC Veranstaltungscenter München as well as abroad. Together with its subsidiary companies, Messe München organizes trade shows in China, India, Brazil, Russia, Turkey, South Africa, Nigeria, Vietnam and Iran. With a network of associated companies in Europe, Asia, Africa and South America as well as around 70 representations abroad for over 100 countries, Messe München has a global presence. n

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October 2018 |Food And Beverage Matrix

WORLD ANIMAL PROTECTION URGES DAIRY SECTOR TO END CRUELTY

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orld Animal Protection has urged the dairy firms to bring an end to the cruelty meted out towards dairy ruminants.

The team of World Animal Protection on a visit to urban as well as rural dairies in Delhi found that the animals were being kept in dreadful conditions. Most of these dairies fell back in providing basic necessity and hygiene welfare to the cattle.

At the start of the mission, dairy companies must adhere to the commitment not to source milk or milk products from urban and semiurban dairies who keep cattle and other ruminants in the conditions that are not congenial.

Around 50 million dairy animals are suffering every day and a significant number of them suffer the worst cruelty and live in unacceptable conditions.

Animals are leashed and confined to small sheds for long period thus hampering their mobility and are forced to lie in their own urine and faeces. With poor ventilation and dirty drinking water, all this causes a great suffering to the cattle with fever, infections and wounds. Cattles left in open loiter around finding food and forage in the garbage resulting in

hunger-struck and poor health.

The recent visits to the dairy farms focused the light that while all dairies in India are governed by the Registration of Cattle Premises Rules (RCPR) under the Prevention of Cruelty to Animals Act, many urban and semi-urban dairies are operating outside the law as well as side lining rules and policies to protect animals and the environment.

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Food And Beverage Matrix | October 2018 Contined from page no 8

In an investigation, World Animal Protection found rather disturbing evidence of absence of proper management of dairy animals across six major cities in India.

“It was shocking to see this cruelty. We are extremely concerned about the welfare of these dairy animals and want people to understand where the milk they consume may come from. Dairy companies have a responsibility towards these dairy animals as well as their consumers and they must end this cruelty,” said Campaign Manager, Animals in Farming, India Dairy at World Animal Protection, Sonia Bindra.

World Animal Protection also wishes to bring to the knowledge of the citizen and manufacturers about the irresponsible disposal of waste by these dairies which could result as breeding ground for disease, potential human health hazards and environmental pollution.

“These urban and peri-urban dairies are openly flouting rules.

Some even operate illegally without proper registration.

This should not be allowed.

These animals give us milk, they serve our needs and deserve a better life. These dairy companies need to commit to not sourcing milk from urban and peri-urban dairies and also influence and invest to ensure basic welfare is provided to dairy animals in their final supply chains,” said India Country Director at World Animal Protection, Gajender K Sharma.n

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TRADITIONAL BEVERAGE INDUSTRY IN SHOCK WITH SYNTHETIC SYRUP, SHARBAT STDS PROTECTION

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he apex food regulator, with its recent decision to review the standards of synthetic syrup and sharbat, has sent shockwaves in the traditional Indian beverage industry. The industry claims that the proposed amendment is not only scientifically flawed but it appears to have been brought in to make it impossible to manufacture any commercial product in the variety.

Major players of traditional Indian beverages like Dabur, Hamdard and Guruji Thandaiwala, have objected to the proposed move wherein two new parameters of ‘specific gravity’ and ‘ph value’ have been added and the category of fruit syrup and sharbat is not mentioned.

The industry is of the view that the parameters are made in such a way that it would be difficult for the players to make synthetic syrups and Contined to page no 11

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October 2018 |Food And Beverage Matrix

FSMA-PREVENTIVE CONTROLS FOR HUMAN FOOD

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his article is definitely going to be of interest for industry fellow dealing in exports to USA as this gives you an overview of “The Current Go¬od Manufacturing Practice, Hazard Analysis, and Risk‐ based Preventive Controls for Human Food regulation intended to ensure safe manufacturing/processing, packing and holding of food products for human consumption in the United States and further to this even other GFSI Approved Standards also getting aligned to FSMA requirements. BRC Food Version 8 is also aligned to it and now no need to wait for USFDA Inspection to happen, how can voluntary Certification by choosing additional module along with BRC Food audit or selecting later at any point of time, when your business need it.

adopted throughout the world because it helps to focus attention on the most important areas to prevent food safety issues rather than reacting to problems as they arise. Preventive control programs are structured to work in conjunction with and be supported by other relevant programs such as Good Manufacturing Practices (GMPs), good agricultural practices and good transportation practices as the basis for food safety management system.

Successful application of preventive controls approaches not only helps to ensure regulatory compliance, but also minimizes the risk of producing products that can harm consumers!

Traditional HACCP was developed for U.S. space program in the 1960s.

One of the main advantages of the HACCP concept is that it enables food operations of all sizes to move away from a philosophy of control based primarily on the end product testing (i.e testing of product failure), to a preventive approach whereby potential hazards are identified and controlled in the food processing environmental (i.e of prevention of product failure). Because of the limitation of end‐product testing necessary to provide assurance that the food was safe, the focus shifted to preventing hazards through product formulation and process control in a risk‐based manner. The concept was called Hazard Analysis and Critical Control Point (HACCP). Since then,

Preventive Controls more than HACCP The FDA Food Safety Modernization Act (FSMA) Preventive Controls for Human Food rule is launched from September 2016 and regulation requires that certain activities must be completed by a “preventive controls qualified individual (PCQI)”.A proactive and systematic approach to food safety emphasizing the preventive controls approach has been universally accepted and

HACCP implementation expanded voluntarily in the food industry with the understanding that food safety is best assured if each producer & processor understands the significant hazards in their product and operation, and uses scientifically sound preventive controls to significantly minimize, prevent or eliminate the hazards. CCP was the major focus area. HACCP technique was developed initially to

deal with microbiological hazards that affect product safety and also those leading to microbiological spoilage, eventually it was applied to all issues of product safety associated to biological, chemical or physical hazards. It has been observed that there is an increasing interest in application of HACCP technique to identify product quality defects (e.g. particle size, color, taste, texture) and

level the occurrence of a food‐ safety hazard” may not be required for some preventive controls. The broader term, parameters and values, supports identification of a frequency or other metric to assess compliance, rather than setting a precise minimum or maximum value to which a parameter must be controlled.

Further, immediate corrections (like re‐cleaning a line before start up) may be more appropriate than formal

Preventive Food Safety System to determine appropriate “control measures”. It is recommended that where both food safety and quality are included, there should be clear distinction between safety and quality and it should be understood by food operation. It has been observed that in most of the sector, industry choose to hide or under rate the risk related to suppliers to avoid putting up controls on suppliers, really a challenging one but with Supply Chain Preventive Control as one of key preventive control, industry need to change the approach and really spread out their expectation and need within the supply chain be spreading knowledge through trainings, interactions and continuously monitoring compliance at supplier level.

However, the preventive controls process incorporates controls beyond those managed as process‐related CCPs in the HACCP framework.

These preventive controls address not only CCPs, but also controls for hazards related to food allergens, sanitation, suppliers and others requiring a preventive control considering biological, physical, chemical (including radiological) or economically motivated food safety hazards. The preventive controls approach also recognizes that critical limits- “A maximum and/or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable

corrective action involving product risk evaluations for some preventive controls. Finally, the extent of validation activities (or demonstrating the controls actually work) may be less rigorous for some preventive controls than others.

The Food Safety Plan is a dynamic document, which must be kept current if changes are made to the system or to equipment when new products are added, or new hazards are identified.

Food Safety Plan includes hazard analysis, which is used to identify required preventive controls for the process, for sanitation, for food allergens and supply‐chain programs, where these are needed to address the hazards requiring a preventive control.

These elements, along with a recall plan make up the Food Safety Plan.

Many GMPs and other prerequisite programs are managed outside of the Food Safety Plan. While these are separate programs and may not require the same level of documentation as the elements of the Food Safety Plan, they are important. They are generally managed using standard operating procedures with documents and records kept as appropriate. Keep in mind that elements of GMPs that are not covered in the Food Safety Plan are still required.

Under the Preventive Controls for Human Food regulation, the Contined to page no 11

Food And Beverage Matrix | October 2018 Contined from page no 10

responsibilities of a “preventive controls qualified individual” include to do or supervise: 1. Preparation of the Food Safety Plan, 2. Validation of the preventive controls, 3. Records review and d) reanalysis of the Food Safety Plan.

A written hazard analysis is the first required element in a Food Safety Plan. When the hazard analysis process identifies hazards requiring a preventive control, the written preventive controls portion of the plan must address relevant process preventive controls, food allergen preventive controls, sanitation preventive controls, supply‐chain or other preventive controls.

These are the preventive controls needed to control the hazards identified in the hazard analysis as requiring a preventive control.

Monitoring, corrective action and verification procedures for each of the preventive controls identified must also be included in your plan as appropriate to ensure the effectiveness of the controls. A recall plan is also a required element of a Food Safety Plan when a hazard requiring a preventive control is identified. You are also required to maintain implementation records to document that you have implemented your Food Safety Plan.

First step to understand and comply with Preventive Controls for Human Food for any facility would be to have at least one Preventive Control Qualified Individual (PCQI). Attending FSPCA Preventive Controls for Human Food Course as per USFDA approved course curriculum is one way to become PCQI and the course are conducted by FSPCA Lead Instructors for Preventive Controls for Human Food Course,

Manan Bajaj Director Tresbon Consulting Solutions and Services Pvt. Ltd. Mumbain

Contined from page no 9

sharbats. It asserts that the existing norms/standards for the category did not require any changes and the proposed changes were unnecessary.

Hence, several representations have been sent to the FSSAI on the proposed draft of Food Safety and Standards (Food Products Standards and Food Additives) Amendment Regulations, 2018, relating to revision of standards of synthetic syrup and sharbat.

In the Food Safety and Standards (Food Products Standards and Food Additives) Regulations, 2011, in Regulation 2.3 relating to “Fruit & Vegetable Products,”

11 the sub-regulation 2.3.21 relating to “Squashes, Crushes, Fruit Syrups/ Fruit Sharbats and Barley Water” is proposed to be substituted by - 2.3.21 for Squashes, Crushes, Cordial and Barley Water, without mentioning fruit syrups and fruit sharbats.

Further the sub-regulation 2.3.24 relating to “Synthetic Syrup or Sharbat” is proposed to be substituted by- 2.3.24 Sharbat and Synthetic Syrup, wherein the ‘or’ has been changed to ‘and,’ which has serious implications on such products’ manufacturing.

While earlier under 2.3.24 there was no mention of any parameter except of Total Contined to page no 18

Food And Beverage Matrix | October 2018

13

THE ORIGIN OF OPERATIONAL EXCELLENCE : STATISTICAL PROCESS

CONTROL

How it feels?

Terrible?

This was a common scenario during early 20th century.

LS Kannan Associate Partner Paradigm Services Pvt Ltd

I

n our journey to understand Operational Excellence, we have seen early days of quality, craftsmanship, auditing

by Guilds in Western Europe, Pearl Harbor incident, institution of Deming prize in Japan, interchangeable parts, Taylor’s time study and motion study, Ford and mass production.

In this article, we will see the first application of scientific methodology (statistics) into the field of quality.

Productivity Vs Quality As we discussed earlier, Taylor’s Time and Motion approach and Ford’s Thinkers and Doers approach were getting popular and widely accepted.

With Ford's task fragmentation, work departments came into existence -

each department taking care of its own tasks. Unskilled labourers doing assigned tasks under supervision of skilled foremen. Skilled and experienced labourers were assigned the task of inspecting products at every stage.This process was later called as in-line inspection or Maker – Checker method as it was contrary to craftsmen’s method of checking as part of making (craftsmanship).

The Quality Control (QC) Department Imagine that you were heading a group of 15 army personnel and were planning to attack around 50 of approaching opponents. As they approach your bunker, you come out and order your men to fire. Alas! Your gun’s lever has struck…. You could not fire!

To tackle this condition, US Army has appointed special officers for inspecting the received armaments.

At one point in time, there were equal numbers of people deployed in inspecting as compared to people fighting on war field. Later, as more men required for fighting, the task of inspection was shifted to suppliers.

This led to formation of Pre-shipment Inspection at supplier premises. Inline inspection of products (not the process) along with pre-shipment inspection resulted in formation of Quality Control Department. The senior management of manufacturing companies started focusing only on improving productivity of their factories, leaving the quality control department to bear the onus of product quality. There was no focus on the quality of the production operations.

The Statistical Magician - Dr. Shewhart But things started to change at Bell Laboratories – the engineering arm Contined to page no 14

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October 2018 |Food And Beverage Matrix

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Western Electric which manufactured telephones and communication devices. On May 16th 1924, Dr. Walter Andrew Shewhart delivered a short presentation to his management.

The high points of presentation were 1. Every process has variations 2. Operators were reacting to every variation from the target measurement by adjusting the process (say machine setting).

3. Those adjustments cause more deterioration - making processes worse instead of improving them.

4. Continuous measurement of such parameters will help operators to understand the process variations.

5. Once process' inherent variations were understood, operators can decide when to adjust a process and when to leave it untouched.

In order to help monitoring these measurements and making decisions, he used the common statistical tools.

The control charts we use today are his contribution to the field. As these

methodologies evolved over time, Shewhart’s methods came to known as Statistical Quality Control (SQC) and later improvised as Statistical Process Control (SPC). From then on, things changed quickly in Western Electric, whose supplies gained reputation for quality among US Army. In 1939, Shewhart published his book Statistical Method from the Viewpoint of Quality Control (Get it from Amazon or Flipkart).

During this period, Dr Deming got impressed by the work of Shewhart and contacted him. Deming supported Shewhart by editing his works to publish the book. They began a long association between them working on improving quality and productivity of armory manufacturers during World War II, propagating SPC across American industries and quality revolution in Japan by Deming from 1950 onwards.

What is Statistical Process Control?

Let us understand what is SPC.

There are various processes in manufacturing system. We can say that manufacturing system consist of components like machine, material, man, method of processing and some measurements. At each stage of manufacturing, certain parameters of those components are measured. Say your target measurement is 10 mm.

After each measurement, operators tend to adjust the machine to correct the process. If you got 10.2 mm, then he will adjust to reduce the length.

Next piece might meet 10 mm or it might go on the other side to 9.6 mm.

This induced variation causes the process deviate more and resulting in more defects.

measures. If the measurement is within the boundaries of control chart, he does not need to react and if the measurement goes out of the boundaries, he needs to react. The measurements within boundaries are called chance cause variation or common cause variation.

Those measurements falling out of boundaries are called assignable cause variation or special cause variation.

As per SPC, there are only two tasks for a foremen, react when to react (adjust the machine) and do not react when not to react (do not adjust the machine). Thus the production process is controlled. Then what is the role of statistics here? Yes, statistics helps an operator to distinguish these two – when to react and when not to. Operator has to plot a chart called control chart with the measurement values, as he

Operational Excellence : ISO

These upper and lower boundaries are calculated using statistics and called as Upper Control Limit or UCL (average + 3 Standard deviation) and Lower Control Limit or LCL (average - 3 standard deviation).

The Origin of WHAT IS ISO? ISO stands for International Organization for Standardization. It is an independent, nongovernmental organization which sets standards for every business across the world. According to its english name, it should be known as IOS but the ISO turned out to be the initialization of the organization’s French name and it stuck. ISO has a representation of over 162 countries and has released more than 19000 standards till date. ISO is headquartered in Geneva, Switzerland.

History of ISO The ISA

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ISO’s roots could be traced to International Electrotechnical Commission that was formed in 1906, in London. The then director of IEC, Charles Le Maistre could be called as the father of ISO. Owing to his efforts, in 1926 The International Federation of National Standardizing Associations was formed in Newyork.

Even though it was formed in New York, it head quartered in Switzerland.

It was comprised mostly of the Central European nations. Countries with their standard measurement in Inches did not participate in this association. The ISA Contined to page no 15

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Contined from page no 14

was run by a Swiss engineer by the name Huber Ruf. During the Second World War, with the European Union in shambles, the ISA was dissolved.

The methods followed by today’s ISA closely resemble that of ISO. America, Britain and Canada slowly recognized the rising importance of standards and came together to form the United Nations Standards Coordinating Committee (UNSCC) in 1944. The aim of UNSCC was to spread the importance of standardization to its member nations and to the world at large. Especially for war based coordination, supply and maintenance of armaments, etc. The requirements of interchangeability was also emphasized. This organization was then run by Charles Le Maistre of IEC. The member nations included America, Canada and Britain and was extended to allied nations like France, Belgium, and British Colonies etc.

The other nations were ignored.

After the WW2 At the end of the war, UNSCC realized the shortcomings of the organization- mainly that of the missing nations and strive to form a worldwide association comprising of all nations. During this time the ISA was gaining strength. Both UNSCC and ISA came together in 1945 and decided to form a new association.

In a meeting held in London during 14th to 26th October, it was decided that ISA would be dissolved and a new association would be formed. It was also decided that once the new association is operational, UNSCC would be merged into it.

The new association and naming The resulting association so formed was designed to operate in such a manner that neither victories nor losses in war could affect its functioning and served to be an open organization for the member nations. While America and British wanted to name this organization as

International Standards Coordinating Association, the European nations had suggested ISO. In the voting that followed, the name ISO was made the choice of name. Thus on 26th October 1946, ISO was born and started its functioning. In another voting, Geneva was chosen as its head quarters.

Note : In 1951, the first ISO standard ISO/R 1:1951Standard reference temperature for industrial length measurements was released. Thanks to www.iso.org

ISO Structure and Auditing We have seen in an earlier article that auditing is in practice from early 13th century in Europe, thanks to Guilds.

During the World War 2, British Military issued standard requirements to its suppliers - which were profoundly thought over and designed to avoid accidents at suppliers premises; and it was the role of British Military to ensure that their suppliers are following the prescribed standards, to avoid loss of human lives and materials due to accidents.

Later, these British standards were adapted by ISO. With these roots, auditing for compliance has become an indispensable part of ISO system.

Most of ISO standards recommend internal auditing as well. Recall the display of Guild emblem at shops in Europe as a symbol of their stature and prestige. The same continues with ISO in the form of certifications and displaying certificates.

First Party Audits First party audits are conducted by the organisation upon itself to declare their compliance, we call internal audits.

Second Party Audits When a client audits your premises, or as a buyer you audit your suppliers, those audits are termed as second party audits, i.e, audits done by someone associated with our business.

Third Party Audits The Audits done by third parties who are not a part of our business - or independent person or organisation.

Certification and Surveillance Audits When an organisation applies for certification for a specific standard

year). This audit determines whether the organisation is still complying to requirements and if it was found to be negative, the certificate will be withheld.

Who issues ISO Certificates to companies?

ISO as an organisation lays out guidelines for businesses and publish them in the form of standards (books).

ISO neither conducts audits nor issues certificates. Then who gives the certificates? The certification bodies - independent private organisations who are capable of conducting audits as per the guidelines, registered with and accredited by Accreditation Bodies of countries.

So, these are the organisations who

Types of Auditing Whenever you contact and auditing agency for your ISO 9001, they will mention those audits as third party audits, right? Then what are first party and second party audits? The ISO standard for Quality Management System Vocabulary, ISO 9000 : 2005 defines as below. first time, comprehensive audits will be conducted by the third party certification agency. This audit is called certification audits. Once the organisation is found to conform to all the requirements of standard, then ISO certification will be issues to it.

Note : Photograph - In London, in 1946, 65 delegates from 25 countries meet to discuss the future of International Standardization. Thanks to www.iso.org

These certificates have limited validity (say, normally 3 years).

But, it is the responsibility of certification agency to review continuous compliance of certified company to subscribed standard.

Hence, it conducts periodic audits (in a interval of 6 months or 1

audits us and issues certificates of conformance, if our organisation meets the requirements as per ISO guidelines. These organisations are in turn, regularly monitored and audited by accreditation bodies.

Accreditation Bodies ISO is constituted with National Standard bodies of each of its member countries. Those National Standard bodies function as a Accreditation Body for their country. These accreditation bodies in turn registers and controls the certification bodies.n

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October 2018 |Food And Beverage Matrix

Contined from page no 11

will make the product tasteless and unsaleable.

Acidity and pH are inter related and with low acidity the pH value prescribed is not achievable. Further with TSS at 30%, the specific gravity of 1.3 is also not achievable.

It has also drawn the attention of FSSAI to 2.3.21 sub regulation 1.4 wherein the regulation says that any syrup/ sharbats containing a minimum of 10% of dry fruits shall also qualify to be called as fruits syrups while in new regulations it has been proposed that 25% fruit juice is required.

Soluble Solids not less than 65 per cent by weight. Now the FSSAI has proposed certain parameters.

For sharbats, Acidity as citric acid is set between 0.05 to 0.15%, Specific Gravity between 1.3 to 1.5%, Total Soluble Solids-TSS - (Per cent by mass) is More than 30.0% and pH is Less than 4.5.

For synthetic syrup, Acidity as citric acid is set at 0.1 to 0.3, Specific Gravity at 1.0 to 1.5, Total Soluble Solids (Percent by mass) More than 30.0 while pH should be Less than 4.5.

According to industry sources, with these parameters it would be difficult to make products.

It adds that the TSS for both sharbat and synthetic syrup is proposed to be reduced to 30% against the current limit of 65%. This is unviable as a product of 30% TSS can only be preserved chemically while under current parameters it is self-

preserving. Also there is mention of prohibiting use of any flavour.

An industry insider questions, can a khus syrup be prepared without use of flavouring agents?

Further, acidity for sharbat with mini 25% fruit juice is being fixed at 0.050.15% and for synthetic syrup with no fruit juice is being fixed at 0.10.3% against the 3.5% under current regulation. It would be impossible to make juice conforming to these parameters, stated another industry insider.

The company said, “The proposed draft for sharbat seems unscientific as it will completely change the sensorial characteristics of the current established sharbat formulations and

He questions, what is the technical necessity to do so? Adding to this question of pH value of less than 4.5, he says, how this level will be achieved with low acidic content. They are self contradictory, he quipped.

In its presentation, Guruji Thandaiwala Pvt. Ltd stated that the classification of sharbat and syrup was impractical and confusing. The prohibition of using any flavour

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Hamdard also in its representation mentioned that for 100 years they are making sharbats in India and they are known for their scientific preservation techniques wherein they also use natural identical flavours along with natural flavours, fruit juices and herbal distillates.

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Advisory Board Saheb Bajaj CEO Punjab Sind Foods (India) Pvt. Ltd Arun Varangavkar Chairman Garkul Industries Shiv Prakash Bajaj Chairman Tresbon Consulting Solutions Rajiv Mitra MD Govid Milk and Milk Products Prakash Waghmare Waghmare Food Products Harvinder Bhatia Country Head Bitzer India Pvt Ltd Prassana Deshpande Director Chaitanya Group of Industries Ram Kumar MD Spectra Plast India Pvt Ltd Samayak Lodha MD MB Sugars

also destabilise the delicate balance of ingredients, rendering the product unsuitable and unsaleable for desired use.”

Dabur in its representation observed that under Regulation 2.3.24 it should be allowed that the product might contain food additive permitted in these regulations while for sharbat the proposed regulation be modified to Sharbat shall contain 10% fruit juice, distillate of fruit, herb, vegetable or flower or spice alone or in combination.

Dabur explains in its presentation that the current recipes of sharbat are in compliance of existing standards.

Herbal distillates are also added to sharbat to avoid process losses and distillates cannot be added to concentrate of 25% as mentioned in the proposed draft standards since volatile content will be lost during the cooking process of sharbat to achieve the desired result.n

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