Dy. Manager- Product Development & Quality Assurance
Tierra Food
Total years of experience :21 years, 4 Months
Identification and Propagation of local cassava varieties suitable for chips production based on bite feel, taste profile etc.
Propagation and commercialization of new cassava verities suitable for chips production in collaboration with Central tuber crops research institute Trivandrum kerala, India.
Participation in project meetings to provide expertise on ingredients, product build-up, equipment specifications etc.
Conduction of taste panels to check consumer acceptability of new seasoning blends submitted by suppliers.
Development of new seasoning blends and prototype, and also industrialisation of their production with potential seasoning developers like Givaudan, VKL in order to develop new flavour configurations.
Recommendation of best product packaging and equipment options based on operational feasibility, consumer research, sensory panel results and supplier capabilities.
Documentation and maintenance of product specifications and ingredient formulations up to date.
Ensure that suppliers are given clear directions and feedback about their performance related to compliance with companies quality programs.
Review products and programs submitted by potential suppliers.
Monitoring of competitor product development activities and food industry technology developments.
Achievements:
Developed a Quality Control system for the Quality Control of less industrialised bases like cassava and Banana.
Complete setting up of Quality Control system, includes designing of lab, equipment selection and purchase of equipment’s.
Developed a quality assurance manual based on the principles of ISO 9001:2000 and food safety manual based on FSMS 22000.
Successfully started and scaled up production.
• Provide expert opinion on ingredient, product build and equipment aspects to the team.
• Update and maintain specifications of raw materials, finished product standards, master formula files and other documents.
• Prepare monthly personal hygiene report and supervise sanitary operations of the plant including maintenance activities.
• Ensure that suppliers are given clear direction and feedback about their performance related to compliance with company’s food quality programs.
• Review products and programs submitted by potential suppliers.
• Conduct training, HACCP, hygiene and SAFE audits for locations,
• Performed tests on new formulas to evaluate actual results compared to predicted results.
• Performed tests on current production materials as required by customer requests or complaints.
• Supervision and work scheduling of hygiene crew and Q.A Staff.
• Preparation of production flow charts and standard operation procedures, operator’s reports and quality inspection reports for new products.
• Review, improve and evaluate exiting production with regards to quality and efficiency.
• Analyze results and experimental data.
• Develop products from initial concept to production including scale up, ingredient selection, shelf life testing, cost savings, process improvement and troubleshooting.
• Develop Quality Assurance procedures and documentation system for the manufacture of new products, and also periodic evaluation, assessment and update of the system using for existing products.
• Work with outside consultants and new suppliers to develop new applications and new technologies.
• Implementation of new formulations.(Test batch preparation for new products and also for new raw materials, machine-ability testing of new formulations and packaging materials, Trail run of new machines, etc)
• Periodic check up of parameters like Line efficiency, scrape recycling, yield etc.
• Examination of sensory aspects and shelf life.
• Monitoring housekeeping and sanitary activities &associated inspection.
• Inspection and approval of releasing products.
• Man power scheduling and assessment.
• I.S.O Implementation and documentation.
• Motivation and staff training.
• Preparation, update and modification of records like standard manufacturing procedure, Material usage report, packing and labeling standards, master formula file, Production flow charts etc.
• Preparation of documents like Monthly sanitation report, Weight and dimension control report, Packaging inspection report, Process water quality report etc.
• Inspection of process control parameters. (Cooking temperature, pressure etc . )
• Preparation and establishment of standard procedures for the storage of raw materials, finished products and periodic check up of storage conditions (parameters like storage temperature, room humidity, expired items etc.)
• Liaise and co-operate with technical and commercial colleagues in procurement, sales and technical service, marketing and distribution, and also with official food inspection and hygiene agencies.
• Audits formula particularly for newly implemented formulation but also include periodic audit for long running formulation.
• Audits ingredients and process, compares with standard and detects variation.
• Documents all evaluation/audit results using established formats such as process inspection report, quality advice notes, weight control chart and defects, inspection report.
• Verbally call the attention of all those concerned regarding a problem situation/variation outside standard tolerance and require those concerned to take immediate actions.
• Qualifies finished product prior to release. Sampling and evaluation of finished products in accordance with established procedures and guidelines.
• Audits GMP and sanitation at every shift and highlights production lead man for corrective action.
• Assist production and / or operating units in solving problem situation based on observed data, deviation/changes noted during audit
• Quality control of raw materials and finished goods. (Physical, chemical and microbiological Analysis).
• Supervision and maintenances of quality assurance lab and equipments
• Process inspection. (Inspection and documentation of process control parameters like Retorting time, Boiling temperature, Blanching time and temperature, Filling temperature etc.)
• Inspection of sanitary and housekeeping activities.
• Check up and supervision of production of products like Tomato Sauce, Jam and Pickles.
• Inspection of Packaging and Labeling operations.
• Conduction of training programs for employees in GMP.
• Assessment of packaging materials.
• Participated in scheduled meetings.
Syllabus Covered Food chemistry, Food microbiology, Sanitation and Hygiene, Basic nutrition, Food packaging, Food preservation, Post harvest technology and unit operations, Food adulteration testing, Analytical instrumentation, Food commodities, Food toxicology, Food analysis, Introduction to food manufacture and entrepreneurship development.
