BBC's 70th Anniversary Feature

24-PAGE SPECIAL FRIDAY, NOVEMBER 14, 2014.

Friday/November 14, 2014/WEEKEND NATION EXTRA 2

Message from Richard Cozier – Managing Director and CEO –The BHL Group IT IS with immense pride that I congratulate the Barbados Bottling Co. Limited (BBC) on its 70th anniversary. As a business and more specifically, as manufacturers, 70 years is indeed noteworthy and deserving of acclaim.

There are several entities, which like us, began in production, but unfortunately, have since vacated the commercial landscape. Challenges notwithstanding, BBC has stood the test of time and this is a tribute to the individuals who put processes in place to ensure that 70 years on, the plant’s operations are still going strong. It is the mandate of our present staff to carry on the mantle.

BBC has a strong position within the BHL Group, which is bolstered by its ability to consistently produce world class beverages in adherence to the strictest quality standards, both at the local and international level.

Innovation has become the hallmark of this entity and the astute business acumen of its leadership and steadfast support of its staff have cemented BBC’s position as the leading producer in the sparkling soft drink category.

The accolades are a testament to this and almost

from its inception and up to present day, BBC remains one of the most accredited operations within CARICOM. Our partnership with Coca-Cola has also allowed us to demonstrate our prowess in beverage production and placed us in the forefront, as one of the top performing systems in our category.

My relationship and affiliation with BBC is dear to me. I had the privilege of leading this entity when it was first adopted by Banks in 1991 and though off to a rough start, my tenure was memorable and I was able to forge many strong bonds and friendships, which to this day remain. Even then, the organisation’s potential for substantial growth was evident and the future now looks brighter still.

Over the years, BBC has had much to celebrate – the evolution of our packaging from glass to PET, the move from Roebuck Street to Newton which allowed us to physically expand our operations as well as our various product offerings – would not have been possible without our consumers and for your unwavering support of our business over the years – we extend a heartfelt thanks. We look forward to continuing to bring you the best our sector has to offer.

Sincerest gratitude must also be extended to the BBC Team - congratulations on this achievement and I look forward to our years ahead.

RICHARD COZIER: Managing Director and CEO –The BHL Group

Friday/November 14, 2014/WEEKEND NATION SPECIAL 3

to your beautiful island nation.

Message from Muhtar Kent, As you know, an ice-cold Coca-Cola Chairman and Chief Executive Officer, The Coca-Cola Company, is very special. So, too, are the men and women who make Coke and all our Atlanta, Georgia. brands available to refresh and uplift consumers across every community CONGRATULATIONS TO YOU and everyone at the Barbados Bottling we serve.

In fact, I would say that, just Company on your 70th anniversary as the secret formula of Coca-Cola of refreshing residents and visitors

has been essential to our success over the years, another critical part of our story is the sparkle and fizz our people bring to this business every single day.

Thanks and best wishes to all our colleagues at the Barbados Bottling Company on this achievement marking your 70th anniversary.

MUHTAR KENT Chairman and Chief Executive Officer, The Coca-Cola Company, Atlanta, Georgia (GP)

Message from Alfredo Rivera, President, Coca-Cola Latin Center Business Unit.

OUR SINCERE CONGRATULATIONS to you and to all associates of the Barbados Bottling Company on its 70th anniversary.

We appreciate your dedication and contribution to the Coca-Cola system for over seven decades, inspiring our consumers to enjoy our beverages every day.

We are very glad to be part of the anniversary celebration in Barbados.

This anniversary marks a milestone in our system.

Best wishes to all members of the Barbados Bottling family.

The Barbados Bottling Company plant a Newton, Christ Church.

(RC)

ALFREDO RIVERA President, CocaCola Latin Center Business Unit (GP)

Congratulations

to the Barbados Bottling Company on their 70th Anniversary. caribsupply A leader in industrial gas, merchandise, equipment and service!

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Friday/November 14, 2014/WEEKEND NATION SPECIAL 4

Message from Lorenzo Roach, Beverage Plant Manager (2012-2014) THE SAYING GOES that “a chain is only as strong as its weakest link.”

That defines the strength of an organisation, signifying that its success relies on each team member doing well and everyone sharing in the success.

Having said this, it has been a distinct privilege and honour to lead the Barbados Bottling Company (BBC) team from 2012 to 2014.

During this time, I have witnessed a coalition of effort and synergy that is unique.

The BBC team deserves this success and in congratulating my peers on having reached this landmark, I also wish to thank them for their dedication and commitment to providing Barbadians with the best in refreshment.

In this trying economy, the beverage industry has been fraught with challenges. This has forced the team at BBC to draw on its resources, go back to the drawing board, so to speak, and, in several instances, emerge stronger than ever to maintain its place as Barbados’ No. 1 beverage producing plant.

My vision for BBC is that it will remain on the cutting edge and continue to invest in the relevant technology that will enable us to employ an even higher level of efficiency while continuing to emphasise quality and taste.

A solid investment in people has always been our primary focus and has led us to recruit and retain the best in our industry, with a focus on the specialised functions.

Our management systems and the implementation of these is also top priority and we will continue to spend time ensuring that we pursue world-class certifications.

This enables us to manage our business with confidence and allows consumers to be secure in the knowledge that we are governed by, and observe, international benchmarks. This has always been the case from our humble beginnings and continues to this day. We would have it no other way.

As I move on to a new chapter in my professional career as dairy operations manager of Barbados Dairy Industries Limited, I am assured that BBC is on a firm foundation, rooted in excellence, innovation and quality. BBC’s standards are second to none and 70 years from now, our hope is that we will continue to stand as a monument of distinction and a distinguished symbol of manufacturing pride in Barbados.

To Team BBC, continue to exude the strength, camaraderie and togetherness for which you have become known and to all of Barbados, thank you for supporting our efforts for the past 70 years.

Here’s to many more!

LORENZO ROACH

Beverage Plant Manager (2012-2014) (GP)

Friday/November 14, 2014/WEEKEND NATION SPECIAL 5

TWO MEN WERE RESPONSIBLE for establishing BBC and starting the trail of success that remains today.

Bob King and Noel Hunte were a formidable force and together used their expertise to solidify BBC’s place as a leading beverage producer.

King was BBC’s first managing director, a title he held for 47 years until the company was sold to Banks Holdings Limited in 1991.

King had the ‘Midas touch’ when it came to business management and was involved in a number of entrepreneurial ventures. In addition to starting BBC, he was also managing director of the West India Biscuit Company for many years as well as the Caribbee Hotel.

He also owned and operated several plantations, including Vaucluse.

His colleague Noel Hunte, who was originally involved in the automobile repair business, was asked to oversee the production plant. He was promoted from plant manager to general manager soon after the company’s launch and remained with BBC for 20 years before venturing into private consulting, travelling to Coca-Cola plants in Nassau, Bermuda and New Zealand, where he assisted in helping companies to streamline and improve their operations. As a result, Hunte became known throughout the region and beyond as “the man who started Coca-Cola in Barbados,” and various franchises called on him to assist with their plants.

Under their leadership, BBC made its first production run in 1945.

BOB KING (GP)

NOEL HUNTE (GP)

Friday/November 14, 2014/WEEKEND NATION EXTRA 6

THE CLOSURE of the United States Naval Base in St Lucia proved a blessing for Barbados and a turning point in the beverage industry in Barbados.

Unlike its Caribbean counterparts where United States armed forces were based and Coca-Cola was readily available, this was not the case in Barbados.

This presented a prime opportunity for the entry of Coca-Cola into the island.

Close friends Joe Deveaux and Dick Stokes of Stokes and Bynoe, grasped the opportunity. The two approached Bob King with the possibility of introducing the Coca-Cola franchise to Barbados and the rest, as they say, is history.

At the time, production lines generated a mere 32 bottles per minute with seven employees on each shift.

It took a year before the plant became fully operational and King along with two office employees and one delivery person achieved their first production run.

As fate would have it, a representative from Coca-Cola came to Barbados conducting market research. It was projected that the company would sell approximately 2500 cases per year and the partnership with Coca-Cola agreed upon.

Simplicity, efficiency and quality set Barbados Bottling Company Limited apart in those formative years. This, coupled with a state-of-theart plant set the tone for the success which would soon be evident.

FROM LEFT : Sales Manager,Trevor Ashby with Lance Johnson, Jeff's Restaurant installing a Post Mix Machine at Jeff s Restaurant. This was one of the early installations. (GP)

BOARD OF DIRECTORS 1984 - 1985 (Sitting from left): David McKenzie, Peter Marshall, manager and director; Bob King, chairman and managing director; Jack Yearwood, company secretary, Dick Stokes and Martyn King.

Inset left Cyril Sisnett and Sir Kenneth Hunte. (GP)

Friday/November 14, 2014/WEEKEND NATION SPECIAL 7

BOB KING Founder

NOEL HUNTE Founder

The Barbados Bottling Company Limited THE Barbados has benefitted fromBottling exemplaryCompany Limited has benefitted from management over the years which has exemplary management over the years paved the way for various milestones: which has paved the way for various milestones:Bob King – Founder and 1944-1991 Managing Director (with Noel Hunte and 1944-1991 Bob serving King – Founder and Robert Gordon in Management Managing Director (with Noel Hunte positions under his leadership prior to andtenure RobertofGordon serving inin 1975) the Peter Marshall Management positions under his 1975-1985 – Peter Marshall leadership –prior to the 1985-1991 Martin Kingtenure of Peter Marshall in–1975) 1991-1999 Richard Cozier 1975-1985––Dan Peter Marshall 1999-2004 Stoute 1985-1991 – Martin King 2004-2012 – William Haslett 1991-1999––Lorenzo Richard Roach Cozier 2012-2014 1999-2004 – Dan Stoute 2004-2012 – William Haslett 2012-2014 – Lorenzo Roach

PETER MARSHALL 1975

RICHARD COZIER 1991

Notable achievements over the years include: The acquisition of additional land in Roebuck Street to expand the plant’s operations Introduction of post mix units Installation of new bottling equipment.

Launch Coke, Sprite and Frutee in a 500ml returnable glass bottle Moving the factory from Roebuck Street to Newton – BBC was the first BHL Subsidiary to operate from the Newton property, they were joined later

by B&B (now Banks Distribution) and more recently Banks Barbados Breweries Limited The launch of the 16oz PET package to replace the 12oz PET

DAN STOUTE 1999

The launch of Diet Red Frutee – the first fruity flavoured drink with zero calories. The product was later discontinued Winner of “Most Improved Bottler Award” and second place in the CocaCola Regional Quality Ranking in 2001.

First place in the Coca-Cola Regional Quality Ranking and Winner of the CocaCola Pemberton Award for Quality in 2002, 2003 and 2006 Winner of the BIDC National Industry Awards Exceptional Quality Achievement Award for 2003, 2004, 2005, 2006 and 2007 The winner of the Coca-Cola Sustainability Cup from a field of 16 bottlers in 2010.

Best Caribbean Supplier winner in 2012

WILLIAM HASLETT 2004

LORENZO ROACH 2012

In 2010 BBC achieved certification to the following international standards: Quality ISO 9001, Food Safety FSSC 22000, Environmental ISO 140001 and British Standard, BS OHSAS 18001.

Introduction of 355ml Coke, Sprite and Frutee packaging Successful introduction of light weighting both in the bottle and closure of BBC’s products Successful introduction of the new 500ml Frutee bottle Launch of BBC’s Water including BBC Water, Cranberry Flavoured Water and Pomegranate Flavoured Water Successful passing of a Coca-Cola surprise audit that was recently concluded

Friday/November 14, 2014/WEEKEND NATION SPECIAL 8

EVERYBODY IN BARBADOS knows Frutee.

Available in ten different flavours, Frutee is a giant in the Barbados market because of the range of flavours and the excellent marketing that backs up a powerful product.

That ten-flavour range is currently comprised of Xtreme Red, Banana Blast, Grapefruit Edge, Sorrel Rush, Pineapple Pulse, Ginger Beer, Ginger Ale, Pear Splash, Mango Tango, and Cherry Apple.

Going even further, Frutee launched its Clear line of beverages as a low-calorie alternative to the popular soft drink with flavours of Apple, Pomegranate, Strawberry Kiwi, and Tropical Vibes.

Jeremy Foster, Category Manager for Sparkling soft drinks at Banks Holdings Limited, said: “The really exciting thing about a brand like Frutee is that we have no limitations – flavour innovations are always on

our mind and we often times launch two or three new flavours each year – usually spread among the different packaging sizes.”

Frutee has been a Barbadian staple since its creation by the Barbados Bottling Company. In 2008, Frutee rebranded the package and revamped its flavour names.

In 2010, Frutee Clear was launched and two years later the product saw yet another rebrand. Continuing its innovation, Foster said: “2015 is going to be a big year for Frutee.

We have some really exciting things planned, Barbados better get ready.”

BBC has been around for 70 years and has established itself as a top-notch beverage company that produces internationally acclaimed brands.

Foster added: “Our brands are certainly on par with international brands in terms of quality, ingredients, flavours, packaging, and innovation.” That notion is exemplified by the

awards that BBC has received over the years.

In respect to the level of quality for which BBC is known, here are some of the awards it has recieved: • 2001 – Winner of Most Improved Bottler Award and second place in the Coca-Cola Regional Quality Ranking.

• 2002, 2003, 2006 – Winner of the Coca-Cola Regional Quality Ranking and winner of the Coca-Cola Pemberton Award For Quality.

• 2003, 2004, 2005, 2006 & 2007 – Wnner of the BIDC National Industrial Awards Exceptional Quality Achievement Award.

• 2010 – Winner of the Coca-Cola Sustainability Cup from a field of 16 bottlers.

• 2012 – Winner of Best Caribbean Supplier from Trade KO. Coca-Cola was first manufactured in

JEREMY FOSTER, category manager for sparkling soft drinks. (GP) Barbados in 1945. The BBC franchised product is of the highest quality, three times (2002 to 2004) being named the best of the Caribbean Coca-Cola plants.

Coca-Cola boasts nearly 400 beverages in its portfolio and has topped the charts for every country in which it is sold. Up until 2013, Coca-Cola had the recurring title of most valuable brand in the world until being unseated by Apple and Google.

Originally founded in 1892, Coca-Cola has penetrated the globe with its high-quality and innovative products and unparalleled marketing. BBC has obviously made the name proud by accruing title after title and continuing to produce excellence.

Friday/November 14, 2014/WEEKEND NATION SPECIAL 9

A FUNCTIONAL BEVERAGE, is exactly what it sounds like. A drink with a purpose, designed to a specific goal. Examples of functional beverages include sports and performance drinks, energy drinks, ready to drink teas, enhanced fruit drinks, soy beverages and enhanced water. The market of functional beverages isn’t exclusive to atheletes, but is open to everyone.

Water is a functional beverage, its purpose to hydrate and nourish. BBC boasts the distinction of being the first company to produce locally bottled water and has continued to innovate in this realm. Aside from the BBC Water, BBC launched its Flavoured Water line in 2013.

Cranberry flavoured water was the first in line and has been joined

by Pomegranate flavoured water. Both contain real juices.

“We try to keep abreast of what’s new in the market.

What consumers are trending towards in terms of flavour profile and super fruits is one them.

“For the Pomegranate Flavoured Water, there weren’t any options out there and we wanted to make a mark. Because of this consumers have truly taken to the product which we are very happy

SHELLEY PHILLIPS (GP) to see,” said Shelly Philips, Category Manager at BHL. Another functional beverage coming out of BBC is Powerade, another Coca-Cola product.

Powerade is a rehydration drink which caters for athletes. As they train hard, Powerade is there to replace lost electrolytes.

Over the years, the brand has had a variety of flavour innovations and vitamin infusions to fulfill its purpose.

Philips asserted that, “It’s a product known for innovation and good value for money. The product

replaces electrolytes lost when you sweat.

“Powerade rehydrates you with four of the main minerals and vitamins lost during physical activity.”

Powerade in Barbados, aligns itself with events that promote fitness including the Powerade Run Barbados series, ICBL walk/run, BSSAC, and Step It Up series.

As time progresses, it is expected that the functional beverage line coming out of BBC will continue to improve and impress as it has consistently done.

Friday/November 14, 2014/WEEKEND NATION SPECIAL 10

PAULA ROSE, manager of the Research and Development Department, BHL. (GP) QUALITY IS EVIDENT in every aspect of the Barbados Bottling Company Limited’s (BBC’s) operation.

That is part of the reason the plane has consistently maintined its quadruple ISO Certification status.

Paula Rose, manager of the Research and Development Department of BHL, works closely with BBC in the pursuit of creative improvement.

“We look at innovation in terms of new products, and we also look at how we can improve our existing products. We always try to improve on what we are currently doing.

Recently, we launched our flavoured beverage line and our purified water line,” said Rose.

Many people don’t know exactly what goes into the creation of new products. For a company like BBC, that process involves a lot of consumer communication and then testing to create something that is desired and adheres to all relevant standards.

“We follow a commercialisation process flow. We work closely with marketing and sales and the whole team comes together for the research.

“The Commercial Department guides us with their surveys and data acquirement. Commercial gives us a concept brief, which tells us exactly what they would like developed.

That becomes our guideline for research and innovation that starts the ball rolling.

“Then we go into the lab and do work, talking with suppliers and doing a lot of testing. Then comes the production trials of products.

There are a lot of steps because we need to make sure that the product that we put on the market is of the highest quality.

“We have to make sure that we meet all of the international and our own internal standards. We work hand in hand with the Quality Department.”

As a company that provides

beverages, there are many standards that must be strictly followed.

BBC holds certification in four international standards: 1. ISO 9001:2008-Quality Management Systems A compilation of quality management principles which provides the framework for ensuring customer satisfaction and quality assurance.

2. ISO 14001-Environment Management Systems Environmental management principles which offer guidelines on the implementation, management and advancement of an environmental programme which enables the company to reduce negative impacts to the environment and meet local regulatory requirements.

3. FSSC 22000-Food Safety Management Systems Food safety management principles which ensure that the establishment provides the public

with products that are safe for consumption.

4. OHSAS 18001Occupational Health & Safety Management Systems Occupational health and safety management principles that enable the company to eliminate or control occupational health and safety risks by means of implementing sound occupational health and safety practices. It also provides the company with the ability to meet its legislative obligations.

Ruthlyn Small, quality assurance manager at BBC, said: “Adopting high quality standards can be viewed as a strategy employed by the company which enables us to meet and/or exceed our consumers’ expectations. It allows for consistent quality through measurement, analysis, and continuous improvement.”

Small continued: “The entire value chain must be considered in the achievement and maintenance

RUTHLYN SMALL, Quality Assurance Manager at BBC. (FP) of high-quality standards.

“Management commitment is of paramount importance, the investment of highly capable process equipment, well trained employees, good document management systems, and a robust corrective action programme, are just some of the ways in which the quality standards are maintained within the company.”

Being certified by an international body such as the International Organization for Standardization (ISO) gives the public a high level of confidence when consuming products. Secondly, it opens up huge opportunities for the penetration of the local brand into global markets.

Small added: “We here at BBC understand the importance of consistently providing our customers and consumers with beverages of the highest quality. We define quality as a culture, it’s embodied in everything that we do. It’s the way we do business.”

Friday/November 14, 2014/WEEKEND NATION SPECIAL 11

ST. JOHN'S AMBULANCE sampling Coca-Cola. (GP)

COCA-COLA IN THE cane fields promotion. (GP)

www.erichassellandson.com info@erichassellandson.com

SUPERMAN PROMOTING Coca-Cola. (GP)

Friday/November 14, 2014/WEEKEND NATION SPECIAL 12&13

1

2

3

THE BARBADOS BOTTLING COMPANY LIMITED (BBC) operates a 24-hour per day, five days per week production facility in which the fully automated manufacturing plant is run by three shifts to supply market needs.

Over the decades the company has refined its production methods, modernising its plant, adopting process improvements, and securing accreditation for attaining internationally benchmarked production standards.

Today, the 70-year-old company’s production team 1. THEY START the runs a well-oiled machine, process and preforms moving product from start to (above) are finish in a process that’s energy transformed into bottles. efficient, environmentally friendly and safety conscious.

2. MOULDS SUCH as The journey that bottle these at left are used to of Frutee in your refrigerator create the signature makes to get to you begins patterns on the bottles. in a climate-controlled room at the BBC’s Newton, Christ Church, manufacturing plant.

3. Finished bottles on the It starts when the machine is activated to send little way to filling. preforms (bottles yet to be shaped) to the blow (Pictures by Rawle Culbard) moulding machine.

5

4

Champions of the process Step 1: Bottle manufacture Bottles used in the BBC’s manufacturing process are supplied in two preformed sizes, and are selected according to the capacity required during the production run. For example, bottles used in the manufacture of the 355 and 500 ml drinks are made using the same preforms. For the two-litre drinks a larger size of perform is required.

During the bottle manufacturing process the preforms are heated and stretched in a process called blow moulding, and textured in moulds according to product requirements in precision computer-controlled machines.

Each unit (bottle) manufactured during this process is subject to such scrutiny that the highly sensitive machines dispatch any preform or finished bottle presenting the slightest abnormality to the rejection bin.

As would be expected, routine quality control checks are performed during the process. Random bottles are taken, examined, and tested to ensure their quality and consistency.

The machines are equipped with monitors that track temperature and other indicators which need to be kept within prescribed ranges to minimise spoilage and

runs at about 400 bottles a minute and the blow moulder outputs 350 [bottles per minute], so we blow some bottles maybe two hours before, just enough to give a buffer, and we run both directly to the machine and from the silo. So the line always has a supply of 400 bottles per minute coming out. So when we produce, we produce exactly what we need and then we close off. We don’t leave any waste or anything lying around.”

With the blowing process set to ensure smooth flow the team sets the rest of the wheels rolling as follows:

MELICIA SOBERS of the Quality Assurance Department, adjusting settings. ensure that the highest quality products roll off the line.

Because of the speed of operating system, to ensure a smooth production flow the team will start the process by

blowing a number of bottles beforehand.

Process support specialist Ricardo Gilkes explained it this way: “Because we have a high-speed machine – the filler

6

CASES of Frutee Ginger Ale being shrink wrapped.

PROCESS SUPPORT SPECIALIST RICARDO GILKES attending to a block in the flow to the shrink wrapping machine.

using nano filtration to purify it, of 400 per minute. Inside the then it is sterilized by exposure filling machine, containers are rinsed, filled with the beverage, to ultraviolet light). capped and are stamped with a date code.

Step 3: Blending During the blending process Step 5: Labelling the syrup and treated water Once out of the filler as well as carbon dioxide bottles enter the labeller are blended together to where brand signage is affixed make the final beverage.

Step 2: Syrup on them, after which they are manufacturing sent for packaging.

First, the team makes simple Step 4: Filling Bottles proceeding along syrup and then final syrup. The Step 6: Packaging the production line enter final syrup is then mixed with Packaging involves three and exit the filler at a rate treated water (water treated

7

CASES STACKED and awaiting palletisation.

8

processes: i. Hiconing formation: Bottles are first grouped into six-packs during a process called hiconing. ii. Case construction: The six-packs then are grouped to form 24 packs and shrink wrapped to create cases. iii. Palletising: During this part of the process the cases are packed onto pallets in numbers of 48.

Pallets are then moved by forklift to the warehouse and

THE PRODUCTION PROCESS at the Barbados Bottling Company is facilitated by two process support specialists whose roles support the production manager, quality manager, asset care manager, and warehouse manager.

Process support specialist Ricardo Gilkes can be said to focus on the manufacturing side, having oversight for the areas of blow moulding, blending, filling the bottles, and packaging.

Among many other functions, Gilkes monitors the system to ensure everything is going the way it should, and supports the shift leader if there is an issue.

The other process support specialist Rhonda Ward focuses on the byproducts of the process – waste – and is responsible for the BBC’s one-of-a-kind wastewater treatment plant.

9

PALLETISED and ready for shipment.

OVER TO the warehouse.

4. ONCE at the filling machine bottles are rinsed, and filled bottles.

5. FILLED, CAPPED, date coded and en route to be labelled.

t h e o ffi c e @ b c a . o r g . b b

w w w. b c a c r i c k e t . o rg

Friday/November 14, 2014/WEEKEND NATION SPECIAL 12&13

1

2

3

THE BARBADOS BOTTLING COMPANY LIMITED (BBC) operates a 24-hour per day, five days per week production facility in which the fully automated manufacturing plant is run by three shifts to supply market needs.

Over the decades the company has refined its production methods, modernising its plant, adopting process improvements, and securing accreditation for attaining internationally benchmarked production standards.

Today, the 70-year-old company’s production team 1. THEY START the runs a well-oiled machine, process and preforms moving product from start to (above) are finish in a process that’s energy transformed into bottles. efficient, environmentally friendly and safety conscious.

2. MOULDS SUCH as The journey that bottle these at left are used to of Frutee in your refrigerator create the signature makes to get to you begins patterns on the bottles. in a climate-controlled room at the BBC’s Newton, Christ Church, manufacturing plant.

3. Finished bottles on the It starts when the machine is activated to send little way to filling. preforms (bottles yet to be shaped) to the blow (Pictures by Rawle Culbard) moulding machine.

5

4

Champions of the process Step 1: Bottle manufacture Bottles used in the BBC’s manufacturing process are supplied in two preformed sizes, and are selected according to the capacity required during the production run. For example, bottles used in the manufacture of the 355 and 500 ml drinks are made using the same preforms. For the two-litre drinks a larger size of perform is required.

During the bottle manufacturing process the preforms are heated and stretched in a process called blow moulding, and textured in moulds according to product requirements in precision computer-controlled machines.

Each unit (bottle) manufactured during this process is subject to such scrutiny that the highly sensitive machines dispatch any preform or finished bottle presenting the slightest abnormality to the rejection bin.

As would be expected, routine quality control checks are performed during the process. Random bottles are taken, examined, and tested to ensure their quality and consistency.

The machines are equipped with monitors that track temperature and other indicators which need to be kept within prescribed ranges to minimise spoilage and

runs at about 400 bottles a minute and the blow moulder outputs 350 [bottles per minute], so we blow some bottles maybe two hours before, just enough to give a buffer, and we run both directly to the machine and from the silo. So the line always has a supply of 400 bottles per minute coming out. So when we produce, we produce exactly what we need and then we close off. We don’t leave any waste or anything lying around.”

With the blowing process set to ensure smooth flow the team sets the rest of the wheels rolling as follows:

MELICIA SOBERS of the Quality Assurance Department, adjusting settings. ensure that the highest quality products roll off the line.

Because of the speed of operating system, to ensure a smooth production flow the team will start the process by

blowing a number of bottles beforehand.

Process support specialist Ricardo Gilkes explained it this way: “Because we have a high-speed machine – the filler

6

CASES of Frutee Ginger Ale being shrink wrapped.

PROCESS SUPPORT SPECIALIST RICARDO GILKES attending to a block in the flow to the shrink wrapping machine.

using nano filtration to purify it, of 400 per minute. Inside the then it is sterilized by exposure filling machine, containers are rinsed, filled with the beverage, to ultraviolet light). capped and are stamped with a date code.

Step 3: Blending During the blending process Step 5: Labelling the syrup and treated water Once out of the filler as well as carbon dioxide bottles enter the labeller are blended together to where brand signage is affixed make the final beverage.

Step 2: Syrup on them, after which they are manufacturing sent for packaging.

First, the team makes simple Step 4: Filling Bottles proceeding along syrup and then final syrup. The Step 6: Packaging the production line enter final syrup is then mixed with Packaging involves three and exit the filler at a rate treated water (water treated

7

CASES STACKED and awaiting palletisation.

8

processes: i. Hiconing formation: Bottles are first grouped into six-packs during a process called hiconing. ii. Case construction: The six-packs then are grouped to form 24 packs and shrink wrapped to create cases. iii. Palletising: During this part of the process the cases are packed onto pallets in numbers of 48.

Pallets are then moved by forklift to the warehouse and

THE PRODUCTION PROCESS at the Barbados Bottling Company is facilitated by two process support specialists whose roles support the production manager, quality manager, asset care manager, and warehouse manager.

Process support specialist Ricardo Gilkes can be said to focus on the manufacturing side, having oversight for the areas of blow moulding, blending, filling the bottles, and packaging.

Among many other functions, Gilkes monitors the system to ensure everything is going the way it should, and supports the shift leader if there is an issue.

The other process support specialist Rhonda Ward focuses on the byproducts of the process – waste – and is responsible for the BBC’s one-of-a-kind wastewater treatment plant.

9

PALLETISED and ready for shipment.

OVER TO the warehouse.

4. ONCE at the filling machine bottles are rinsed, and filled bottles.

5. FILLED, CAPPED, date coded and en route to be labelled.

t h e o ffi c e @ b c a . o r g . b b

w w w. b c a c r i c k e t . o rg

Friday/November 14, 2014/WEEKEND NATION SPECIAL 14

FROM LEFT: Peter Bell, Kevin Holder and Isaiah White. (RC)

FROM LEFT: Corey Yearwood, Duane Cambell, Peter Belgrave, Vertis Sealy, Don Riley, Shane Ifill and Brian Morris. (RC) MARY BRYAN , Administration Department.

FROM LEFT: Jeremy Whittaker, Janelle Belgrave, Shannie Harrison, Ruthlyn Small, Melicia Sobers, Liam Pounder and Shakira Grannum. (RC)

Congratulations to

The Barbados Bottling Company Limited on their

Anniversary

Warrens, St. Michael. Tel: 417-7777 www.simpson-motors.com

Friday/November 14, 2014/WEEKEND NATION SPECIAL 15

THE AQUARIUM (above) at BBC which is used to monitor the quality of the treated water. At right, Rhonda Ward, one of BBC’s support specialists.

(RC)

THE Barbados Bottling Company (BBC), in league with the rest of the BHL Group to make greener movements and progress to community contribution, has adopted another of the requirements that Coca-Cola international stipulates – a wastewater treatment plant.

The goal of this pursuit is to return to the environment – at a level that supports aquatic life – the equivalent of the amount of water used in the system operations through comprehensive wastewater treatment.

The Coca-Cola website indicates: “We are maturing our governance and technical support programmes for wastewater toward a performance-based model that focuses on further optimising efficiency and improving the quality of water we discharge to the environment.

“Some areas of the world are stressed with conflict and other national challenges that are currently preventing our local operations from investing in the needed resources to meet this goal.

While a very limited number, we are working with these facilities to support them and to help ensure they are aligned in the future as conditions allow.”

As a licensed and award-winning Coca-Cola facility, BBC has made grand efforts to fall in line with procedures that strive to improve the environment. Rather than discarding all wastewater from the washdowns of equipment it is treated it with the use of microbes. The microbes break down the constituents to carbon dioxide and useable water.

The facilities at BBC in Newton, Christ Church, take the run-off water from their operations and it goes through a dual system of treatment.

First, the wastewater is treated mechanically and then biologically.

The first step removes suspended solids of up to 60 per cent, then the water is further filtered with the use of microbes to attain a purity suitable for aquatic life.

The facility at BBC maintains an aquarium to monitor the quality of the treated water which is tested rigorously.

At the end of the process, the water is almost of a drinkable quality. It only needs a final purification stage. The water is good enough for washing and drip irrigation, though irrigation is the only use legally allowed in Barbados for wastewater.

“We would like to be able to use the water for more purposes than we have been given permission to use it for. We are permitted by EPD to use it for irrigation. Though we are working toward being able to use the water for other purposes such as washing trucks and pallets,” said Rhonda Ward, one of two process support specialist at BBC. BBC recycles 80 per cent of its waste, an admirable and unique quality among large operations.

In the future, it is hoped that the Government will allow for companies with the magnanimous goals of BBC to use the treated wastewater for more functional purposes to help improve the environment and community contribution.

Friday/November 14, 2014/WEEKEND NATION SPECIAL 16

PETER MARSHALL IN 1985 (GP) PETER MARSHALL has many fond memories of the Barbados Bottling Company Limited (BBC).

The retiree’s contribution is etched on the pages of the manufacturing plant’s history as he deftly managed the plant from 1975 to 1985, and assisted in cementing the legacy of the organisation that proudly stands today.

Marshall describes the turning point in the plant’s history, as the expansion of its Roebuck Street location.

This was the foresight of the late Sir Kenneth Hunte – a Board Director at the time and one who Marshall describes as “an extremely forward thinking gentleman”. A.R.E. Bob King was also instrumental in this business decision which saw the company acquiring the land on which the current Insurance Corporation of Barbados now stands.

Marshall vividly recalls that there were several initial

reservations surrounding the purchase but the move proved supremely successful and eased the congestion of their previous location, easily accommodating 21 trucks and additional warehouse space.

While the plant physically made the move to greener pastures, what remained was the staff’s unwavering commitment and dedication to its customers. This was heightened at Christmastime and Marshall fondly remembered having to place restrictions on the enthusiastic sales team who would stop at nothing to service their customers and close those all-important sales.

“We had one employee whose route was in the north of the island and he would think nothing of returning to the plant at 10 p.m. to reload and go back out to customers. On the whole, the salesmen were that passionate. We had to put certain restrictions in place or they would just keep working well into the night.”

Marshall himself also lived that passion and of the numerous stories

which abound in his memory of personal sacrifice, one in particular always comes to the fore, painting a true picture of those early days.

“We had just installed what are referred to as post-mix units for fountain drinks in what is now Harbour Lights and the owner called me at 11:30 p.m. to say that he was experiencing a problem with them.

I went down to Roebuck Street myself and with the help of security personnel loaded up a truck with drinks and took them down to him.You just did what you had to do.”

Marshall’s tenure not only saw an unmatched level of tenacity, but a level of innovation that was unparalleled in the industry. A partnership with Plastic Containers gave way to the introduction of the PET bottle. More than just packaging, the PET bottle meant that the sales team would now have a lighter package to transport and storage burdens of bottles would be a thing of the past. Barbadians responded favourably to the introduction.

Next came the introduction of the

post-mix units and this particular innovation helped to cement BBC as a market leader in the beverage industry.

“The beverage industry was changing and we embraced the changes. When I introduced post-mix, the competition downplayed it. We were the first to introduce post-mix on the island and from there schools and other establishments requested them and they just took off.”

The saying goes that the true test of leadership is how one manages challenges and Marshall’s management of BBC certainly had its fair share. As with any business, a strategic and sensible pricing mechanism can signal success or spark failure and the former manager further said that BBC was forced to increase its prices, which prompted a personal call from the late Prime Minister of Barbados, the Right Excellent J. M. G. M. Tom Adams himself.

As the story goes, Prime Minister Adams had not long before delivered a budget speech which would see

• Continued on next page.

Friday/November 14, 2014/WEEKEND NATION SPECIAL 17

COCA-COLA Steel Band. (GP) an increase in consumption tax by three cents for every beverage. Management took that as the signal to increase their prices, which warranted the now infamous phone call to do no such thing. Prime Minister Adams feared that the average Barbadian would be unable to afford a soft drink which by now had become a staple, especially at lunch time.

Needless to say, the prices of the beverages remained in spite of the consumption tax which resulted in a loss of three cents per bottle for the company. But BBC bounced back and the price would stabilise in the years ahead.

Pricing mechanisms were important but equally or even more important was customer engagement and BBC’s strategy for this was clear. They would engage in sampling and strategic promotions and sponsorships which would help keep the brands top of mind. There was the entertaining and majestic Coca-Cola Carnival, the Coca-Cola Steel Band that would accompany trucks brimming with ice-cold Coca-Cola to hardworking field workers and the partnership with FIFA to

promote football.

“We were a part of all of the main events and even had the foresight to sponsor Crop Over in its infancy. Sponsorship was key in reaching a wide cross section of people. In the business of beverage production, it is important to be in touch with people at all levels.You have to know everyone from the Governor General to the janitor. That connection with people is important, especially in a small country such as ours.”

This led to many accolades from international and global brand Coca-Cola especially in the areas of quality assurance.

As successful as the plant was, it never lost its connection to its team of staff. The organisation maintained weekly meetings and was one of the few companies which had a formal Christmas party at that time.

“Our staff always knew what was going on.

We also had committed team in sales who also tried to keep their colleagues involved and informed. Trevor Ashby, who was sales manager at the time was also well informed and well connected. We were a force to be reckoned with.”

enviroklene@caribsurf.com

joseyjosewaste@hotmail.com

Friday/November 14, 2014/WEEKEND NATION SPECIAL 18

SISNETT BOYCE, retired former customer service manager of Barbados Bottling Company Limited.

(GP)

UPON HEARING HIS STORY, the average person would describe Sisnett Boyce as a “jack of all trades”.

He prefers to simply be called dedicated.

Now retired, the former customer service manager spent his entire professional career in the soft drinks industry, beginning in 1962 as a mere boy of 16 and finally retiring as customer service manager, some 48 years later.

Fresh out of school, Boyce’s first encounter with the beverage manufacturer would see him being hired as a casual worker. This meant that the role was temporary and he was assigned to performing odd jobs about the plant.

At first the job represented independence and the financial freedom which all 16 year olds crave.

However, as time progressed Boyce had become fond of the plant on Roebuck Street and began to see it as more than just a Christmas job. Fortunately, a permanent position would follow the following year and he officially became a part of the staff complement working in the Warehouse Department.

Never one to settle, he quickly moved up the ranks and would be promoted to assistant stock manager soon after. Then, the position of assistant sales manager was advertised internally and sights set even higher, he would apply and be awarded the post.

After the sale to Banks Holdings Limited (BHL) in 1991 he would be promoted yet again but this time to customer service manager – a post he described as challenging but one which he loved best.

The early days at BBC were cited as some of the best and Boyce recalled a close-knit staff.

“BBC was a good company. It was a joy to work there and there was a pride in working with an international brand such as Coca-Cola.

“Football was very popular in Barbados and the staff who worked in production were very active players and in an effort to play a few matches in the evenings and still be paid, they would fill in for each other. One guy would go and play the match and the other would hold on so that the one playing would still get his overtime pay.”

This camaraderie would be tested with the sale to BHL in 1991. Assistant sales manager at the time, Boyce remembered the period well.

“Everybody was unsure. Rumours were rampant about who would be going home, so to speak.

I began to weigh my options and kept an open mind about it.”

His future was not only secure in the company as assistant sales manager but he was presented with

• Continued on next page.

THE EARLY DAYS of the bottling plant at Newton, Christ Church. (GP)

Friday/November 14, 2014/WEEKEND NATION SPECIAL 19

• From Page 18.

address customers’ needs, it was he who also recommended that they move to Newton. another professional opportunity “When the Customer Service as the group grew.

Department was in Wildey, I found that it “DaCosta and Musson were the distributors for the company’s products but was at times difficult to manage customer issues from that distance. So to be in sync then chairman and CEO, Mr Allan Fields, with B&B, I recommended to Mr. Fields that now Sir Allan Fields, had hopes for the we move to Newton and that was where we Group’s own distribution arm. Two years really started to resolve customers’ issues.” after BBC moved to Newton, B&B Boyce’s approach to customer service Distribution was established with the was simple: deal with each issue separately implementation of computer technology. and distinctly.

“All of the trucks from BBC as well “Every customer’s problem is different. as the trucks from DaCosta and Musson that If customers came to me with an issue, were stationed in Wildey had to be moved my approach was to always listen and allow to the site that was identified in Newton. them to talk. I also always ensured that “The company was to be fully I visited them regularly. There was not computerised but that didn’t work out and a rum shop that I had not been both B&B and DaCosta and Musson were forced to resort to the former way of using in to visit my customers.”

At BBC’s 70th anniversary juncture, billing books that day. That day the trucks Boyce still sees BBC’s customers went out late. I was chosen to head what as loyal and true to the brand. would be the customer service arm “I wish BBC everything that is good. of this new distribution entity.”

The company has world-class products and It was in customer service that he truly found his niche and was charged with setting I see no reason why it cannot remain the No. 1 bottling company in Barbados and up the entire department. When the initial by extension, the Caribbean.”

Wildey location proved too distant to

Friday/November 14, 2014/WEEKEND NATION SPECIAL 20

THE Barbados Bottling Company Limited (BBC) continues to prove that it is one of the region’s est manufacturing plants.

As is sometimes done, auditors from Coca-Cola last week performed an unannounced audit on the company and were again impressed with BBC’s operations.

“Auditors Darla Burge and Claudia Landazabal were impressed with our facility and with the incoming materials reception for our packaging and highlighted these as achievements which they would take back to their Atlanta offices.

“Additionally they indicated no findings against our corrective actions program and pointed out that this was very TRICIA BARTLETT, INTEGRATED MANAGEMENT unusual in the Coca-Cola SYSTEMS COORDINATOR, BBC. system,” said Tricia Bartlett, IMS coordinator, BBC. again demonstrated compliance with the The audit took place over a period of four Coca-Cola operating requirements in the and a half days from November 7 under areas of Quality, Safety and Environmental intense scrutiny and during that time BBC Management Systems.

tbl1000@yahoo.com

Friday/November 14, 2014/WEEKEND NATION SPECIAL 21

THE FORMER ROEBUCK STREET plant. (GP)

LLEWELLYN BULLEN

LLEWELLYN BULLEN currently works as a logistics coordinator in the BHL Supply Chain Department that has a strong hand in the operations of the Barbados Bottling Company. Earlier this year, Bullen was honoured with nomination at the BHL CEO Awards for his dedication, ethic, and many years of service to the company.

“I have been with BBC over 40 years. My 40th anniversary was last year at the BHL Group. Prior to that, I worked with BBC as a BBC employee for 38 years. But at BHL, I am still physically at BBC and still doing work for BBC as well as other BHL entities, but I am primarily with BBC,” said Bullen.

“Over those years, changes have been gradual. When you look back and you see where you were and where you come from, it just seems like yesterday morning. I started as a bottle sorter. In those days, BBC produced its products in glass.

Those were the days of the seven-and ten-ounce bottles, then we moved to 12 ounce. “I was in bottle sorting for two years before they moved me into the warehouse doing general work. While there, I became a forklift driver and then I became a supervisor sometime in the ’80s. After the move to Newton, I took on a role as senior supervisor. So I used to deal with both warehouse matters and logistics matters.

Then I became wholly and soley a logistics coordinator,” Bullen recalled.

Bullen says he prefers this role because “Every day is different and there are new challenges. It involves shipping, whether imports or exports.

It involves dealing with accounts, invoices, the suppliers.

It involves getting the product, the cargo, out of the port in a timely manner. It’s very varied.”

“It has been great. We came from an environment in Roebuck Street where we would have outgrown the location.

In fact, when Banks took over the BBC operation, we were using a 12 ounce Coca-Cola and Sprite, as well as BBC in terms of the Frutee products. Soon after their arrival, they went into the half-litre bottle and with that our sales skyrocketed. What we were doing back then was producing the drinks at Roebuck Street and sending them to this location in Newton to be stored. In the early days, it was a logistics nightmare but we got it done,” said Bullen.

From long-time managers to new recruits, Bullen can only beam about the excellence that everyone brings to the company. He admitted: “I love what I’m doing. I’m not a limelight person, I don’t seek it or glamour in it. I work with a very wonderful team, both workwise and we even socialise.

There are some really amazing people in this team.

I work in a wonderful department. It funtions and works well for all the BHL companies.”

In thinking about the future, Bullen said: “For me personally, I would like to see the BHL products in all of the Caribbean countries. In terms of BBC, I would like to see BBC continue to move from strength to strength. It is a very good company to work for. It gives you a lot of opportunities and I’m glad to be here.”

We thank the Barbados Bottling Company for keeping us all refreshed with their beverages for the past 70 years.

“Working to Build a Stronger Nation” visit our website at www.williamsind.com

Friday/November 14, 2014/WEEKEND NATION SPECIAL 22

WENDELL BROWN loves his job and enjoys the people he works with. So it should come as no surprise that he has spent the last 34 years of his working life as an employee of the Barbados Bottling Company Limited (BBC).

A machining and fabrication specialist in the Asset Care Department, Brown manages the company’s workshop and works with the mechanics and technicians to ensure the machines run as required on a day-to-day basis.

If there’s a breakdown due to a broken shaft, for example, Brown is mobilised to repair the shaft so it can be reinstalled to get the machine going until a replacement is sourced.

In some cases where such repairs are performed, he said: “They are only

WENDELL BROWN (GP) geared to offer a temporary solution, as the modern machinery used in the plant requires precision parts which are ordered and/or kept in stock as spares in the event of a failure.”

During the early years the situation was quite different, Brown said. The older machines were

primarily manual and presented fewer challenges when it came to fabricating replacement solutions.

A creative person, Brown said what he enjoyed most about his job was “fixing things and making things”.

“If I am given a project and it’s something that I start from scratch, for instance if I have to make a part, I get a regular piece of steel and I put it into the lathe, [and] machine it to what it should be . . . to the various sizes and so on . . . ,” he said.

“To see the finished product come out and work the way it should work . . . that is what makes me feel real good,” said the veteran machinist who started his career at the Barbados Foundry, before joining the BBC as a maintenance mechanic.

Brown was elevated to his current post six years ago.

sales@barbadosindustriesltd.com

Friday/November 14, 2014/WEEKEND NATION SPECIAL 23

BEING THE LONE female forklift operator at the Barbados Bottling Company (BBC) might cause Danielle Worrell to stand out in the crowd, but what’s even more compelling about her story is the journey to the point at which she stands today.

Worrell joined the Banks Holdings Limited family as an operations assistant in May 2011, and at the time was stationed at Pine Hill Dairy.

Ensuing years, however, would see her moving within the group, serving on secondment between Pine Hill and BBC as operations assistant.

One day in 2013 an opportunity presented itself that Worrell could not overlook. A vacancy was advertised at BBC for an inventory clerk and she went for it.

“I saw many opportunities within BBC to advance oneself and to broaden my scope of skills,” she said. “I wanted to join the Warehouse Department, and the vacancy was for an inventory clerk and part of the role of a clerk was to drive the forklift.”

Success in her bid, however, presented its own challenges. Worrell had neither a licence nor driving experience but refused to let the apparent hiccup stand in her way.

She said within the BBC, the environment was such that employees were generally encouraged to learn and gather new skills.

So she got a permit and was allowed to practise on the forklift.

Worrell was full of praise for her colleagues, saying the guys in the department were very helpful in showing her the ropes.

In the four months after her first driving lesson Worrell made significant progress.

She started off with moving raw materials

DANIELLE WORRELL (GP) and worked her way towards the ultimate goal, developing expert proficiency in working with finished goods.

The ride was pretty smooth, Worrell said, adding at no time was she forced to perform any task she was uncomfortable with. Rather, she was coached by her supervisors and other workmates.

Now with a year of experience under her belt, Worrell does “most of the things the guys do, except going on the container ramp and taking things out of the container”. That is the last challenge to overcome, she said, and she’s chosen to pace herself for it because it involves heights – a concept she readily admits she finds daunting. With the unfailing support and tutoring from colleagues, however, she will prevail.

A very positive person, Worrell relishes the dynamic environment in the Warehouse Department. “That is what keeps me interested in the job,” she said, “because curve balls come your way, you’re thrown into new environments. That’s what I like about BBC and the Warehouse Department.”

CHILDREN enjoying Banana Frutee.

COCA-COLA Christmas promotion.

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SPRITE SPONSORED big shot weekend.