Capacity Building to meetQuality Requirements

CONFERENCE ON INDIAN DAIRY INDUSTRY

NDRI KarnalOn Oct 22,2009

Kuldeep Sharma Director Entrepreneurship and Technology Development Center Noida

What Comes to your mindwhile thinking of the following word

• Quality

• Value Chain

• Is Quality limited to Bacteria only ?• Is middleman the real culprit ?

Food Quality Issues

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

2002 2003 2004 2005 2006

Quality non-conformity

Physical

Other

Microbiological

Legal non-conformity

Labelling

Foreign bodies

Chemical

Allergy

Quality Issues Except Microbiological

No. ofIncidents

Incorrect equipment design directly contributes to a significant

number of hygiene incidents

( and probably a key influence in many other cases )

0

1

2

3

4

5

6

7

8

9

Product Design/Change Management

Hygienic Design

Cleaning and Disinfection

Water Treatment

Cleaning

Disinfection

Raw Material

Storage (Soap Packaging)

Housekeeping

Rework

Not Identified

Not Yet Reported

Quality in Food Industry

• For me quality of raw material in agri-food sector is something which can not be improved further but maintained only.

• There is no technology in the world which could convert a low quality raw material into a high quality finished food.

MARKET

RESEARCH

MARKET

ACCESS

COMPETITIVE

STRATEGY

QUALITY

MANAGEMENT

CONSULTANCY / TRAINING

AUDITING

TRAINING / ACTION

EXPOSURE

KNOWLEDGE

SKILLS

METHODOLOGY

CAPACITY BUILDING FRAMEWORK

Capacity Building : The Solution

• Broadly, it can be defined as a process

by which skills, institutions and

knowledge are built, utilized, retained

and nurtured with a view to providing

an entity with the means of responding

to a development challenge.

Say Clean Milk Production

The old Theory

Practice makes a man

Permanent

• Two components that are vital in any

plausible definition of the concept are

human skills (the ability to perform a

task) and institutions (effectiveness

and efficiency of organizations,

systems, processes and procedures).

Capacity Building : The Solution

Role of Knowledge• Knowledge enters the definition as a distinct

component because it allows for the

• combination of skills,

• experiences,

• insights,

• expert intuition,

• actionable recommendations from research,

among others, to enable an entity to continuously

innovate and apply best-practice solutions to emerging and evolving challenges.

Application of Knowledge

• The application of knowledge makes

skills and institutions dynamic and

responsive. Thus, a definition of the

concept of Capacity Building that is

limited to skills and institutions in exclusion of the knowledge component

is incomplete.

Consultant V/s Auditor HACCP

The simplicity factor

• The most difficult part of capacity building is to simplify the applied knowledge.

• Let us learn HACCP in the simplest possible way.

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

What are the battery limits for designing capacity building programs in

Quality

The Site selection

Sources of infection

during processing & distribution

ENVIRONMENT

ProcessingRaw materials Packaging

Storage and distribution

Co

nc

en

trati

on

of

mic

roo

rgan

ism

s

Acceptable concentration

at time of:

consumption

production

Raw

materials

Cleaning & sanitation required

Ultimate time of

consumption

P

Processing Heat

treatment

Processing

and packaging

Storage distribution and shelf life

Few Cases

• How much sensitized are we towards this issue of Quality ?

• Let us feel it by looking at some mixed cases of Food and Non Food

P&G (1980’s)

In Japan about 1 million bottles of a liquid soap which had been found to contain

bacteria was recalled. A company spokesman said product had been found to

contain two types of sundry germs at 3-5 times higher than the companies self

imposed limit. After discovering the problem the company stopped producing the soap

for a few months with lost production

totalling about 500 million Yen .

Thousands of bottles of a hair conditioner have been taken off the store shelves in

Australia (Reported in a Newspaper) after it was found to contain a disease producing organism. Health Department tests found

the organism was a opportunistic humanpathogen (Burkholderia cepacia). A

shipment of product to New Zealand was also recalled. A spokesman said the

exercise had cost the firm a considerable amount of money.

FDA News

FOR IMMEDIATE RELEASEP05-55

August 29, 2005 Media Inquiries:

Michael Herndon, 301-827-6242Consumer Inquiries:888-INFO-FDA

FDA Announces Nationwide Recall of Medline Brand of Alcohol-Free Mouthwash and Hygiene

Kits Containing Mouthwash Because of Possible Health Risk

The U.S. Food and Drug Administration (FDA) is notifying the public of a nationwide voluntary recall of alcohol-free mouthwash and hygiene kits containing mouthwash

distributed by Medline Industries, Inc., Mundelein, Ill because of the potential contamination with Burkholderia cepacia.

Consumers and health care providers who have Medline brand alcohol free mouthwash should stop using the product immediately and check to see if it is being recalled.

“FDA is committed to informing the public about products that may be contaminated and can potentially cause illness”,

said Dr. Lester M. Crawford, FDA Commissioner. “Consumers are encouraged to pay close attention to the identifying information for product information associated with this

recall.

Mouth Wash - August 2005

http://abclocal.go.com/kgo/news/7oys/101402_nw_meat_recall.html

Get election results here, including a Bay Area county-by-county breakdown.

Nationwide Meat Recall Is Largest InUS HistoryOct. 14 (AP) — Poultry processor Pilgrim's Pride is recalling 27.4 million pounds of cooked sandwichmeat after warnings of possible contamination from listeria — the largest meat recall in U.S. history.

The company pulled 295,000 pounds of turkey and chicken products Wednesday but expanded therecall over the weekend after tests came back positive for a strain of the potentially fatal bacteria, thecompany said Sunday.

The nationwide recall covers meat processed at the company's plant in suburban Franconia from May1 through Oct. 11.

The recall covers deli meat primarily sold under the company's Wampler Foods brand, though it is alsosold under brands including Block & Barrel, Bonos, Golden Acre, Reliance and a variety of privatelabels. The products include turkey and poultry sold freshly sliced or made into sandwiches at delicounters and in individually sold packages of sliced deli meats.

Because consumers might not have access to the meat's original packaging, the best way to know if aproduct falls under the recall is to ask if it comes from a package that bears the plant number P-1351inside the U.S. Department of Agriculture mark of inspection, said company spokesman Ray Atkinson.Production dates also can be found on that part of the label.

The deli products were sold in retail groceries, in delicatessens and by food service distributors.

Pilgrim's Pride, based in Pittsburg, Texas, is the nation's second-largest poultry company behindTyson Foods. Its stock price plunged more than 30 percent, down $2.31 to $4.70, in morning tradingMonday on the New York Stock Exchange.

Consumers were urged by the company to return any affected meat to the store or deli where it waspurchased for a full refund.

12,500 tonnes !

6 months production !

The poisoning was caused

by a valve connecting a supply

pipe with a tank used to recycle

leftover milk. So rarely had the

valve been washed that a solid

block of dried milk, as wide

as a 2p coin, had formed inside

it, breeding a bacterium

called Staphylococcus aureus.

Health inspectors failed to

detect the problem, and workers

at the plant reported the

equipment was seldom cleaned

properly. "We have ignored

the regulation for several

years now, and have never

been instructed to follow it,"one

of them told the Yomiuri

newspaper.

Microbes can hide in small areas of a manufacturing plant

Because micro-organisms are so small they can gather in large numbers in a very small area

4 million bacteria couldfit on the head of a pin!

• Snow Brand Japan, summer 2000

• Approximately 15,000 people ill and one death due to Staphylococcus aureus toxin in low fat milk products

• Valve was said to be used infrequently, but was used every day and had not been cleaned for 3 weeks

Snow Brand Japan, summer 2000

Affects:

• Product recall

• President and 7 executives resigned

• Plant closed and lost of millions yen per day

• 45% market share reduced to <10%- market share recovered slowly

Failure: Who will trace it to me?

• Food Laws

• Public health authorities with computer network

• Traceability Setup

• The number of food poisoning outbreaks, which are traced to their origin is increasing rapidly

So What is the solution ?

• How much have you invested back in the system for capacity building of your organization in the following area(s)

– Extension Services ( Milk production, Feed Production, Animal Breeding)

– Plant Designing and Redesigning (Hygienic)– Equipment designing, material of construction – Process design flow and controls– Quality Management Systems– Material Handling in and out of Factory– Training of Sales and Marketing team on Quality– Preparing yourself on Market Access issues for Developed

Markets

Thanks

Where there is a will ; there is a way.