R&D and Production Manager (Dairy, Ice Cream and Juices)
Gourmet Foods Ltd.
Total years of experience :15 years, 11 Months
Main Responsibilities
• Responsible for planning, organizing and managing the day to day allocation of resources (equipment, people, material & systems) in order to efficiently, safely and cost effectively achieve performance targets as agreed with production management.
• Coordinate with project and maintenance in installation / modification of equipment’s to improve the production processes and products.
• Create a team culture driven by objective, goals and KPI’s.
• Encourages team discussion to help produce collective solutions through acting as positive role model and leading from the front despite obstacles/barriers.
• Optimize and initiate continuous improvement of processes and machines by studying thoroughly their designs, working principles, mechanisms and their efficiency enhancement through modifications in coordination with mentor.
• Developed implemented and 100% compliance of Standard Operating Procedure (SOP) related to manufacturing activities for both dairy and ice cream plants.
• Reduce the process material losses (Primary and secondary) and overhead costs (labor, utilities and CIP chemical costs).
• Arranging and managing workshops to develop the sense of hygiene; personal, equipment and environmental safety and ensure their compliance through audits on monthly basis.
• Allocate and maintain stock levels for all raw, packaging and technical supplies according to minimum, maximum and reorder quantities by raising LPR.
Major Achievements:
• Updated all Specification in Interspaces system.
• Develop all new sauces at Innovation center.
• Updated all finished product specification in all concern departments.
• Improve the existing recipes and decrease Product coast and increase profit margin in existing product.
• Lead new project of installation to production of ice cream plant.
• Lead the team for ISO certification and get 3 certificates HALAL, ISO 9001, ISO 22000.
• Develop 12 new Flavors Premium Ice Cream like MOVENPICK for our new Project Parlor Ice Cream in 3 Months.
• Develop 6 New Premium Products Ice Cream Sandwich
• Develop new Recipes Liquid Tea Whitener and Tea Whitener Powder for Gourmet Foods.
• Develop 6 Flavors in Nectar’s and 3 flavors in Drinks for Gourmet Foods.
• Responsible for Quality, Production, R&D and packaging material all 5 Plants Dairy, Ice Cream and Juices (Lahore, Faisalabad, Multan, Islamabad).
• Working on ERP
Main Responsibilities
• Monitoring of dairy trials according to specifications.
• Monitoring the shelf life study of different trials.
• Comparative analysis of trials with normal product.
• Documentation of stock balance in excel and SAP.
• Operation of R&D lab equipment like pH meter, Viscometer, Mini Ice Cream Machine, Incubator, etc… etc…
• Operation of R&D pilot plant (UHT plant, Mixing plant, Homogenizer, Ice Cream Freezer, Blast Freezer, Stick Molded Machine, Ripple Machine, Fruit Feeder, Cup Filling Machine, Juice Pasteurizer, Wrapper Machine, Chiller, etc... etc…)
• Batch making trials of different products Juice, UHT milk, Flavored Milk, Liq. Tea Whitener, Tea Whitener Powder, Ice cream and Frozen Dessert, Yogurt, and Yogurt Ice Cream, & Drinking Yogurt, Flavored Yogurt, Flavored Drinking Yogurt,
• Comparative Tasting of trials regularly with normal product as well as competitor product
• Coordinate to conduct all new product development trials to observe quality parameters and machine capability.
• Develop all R&D Sop’s
• Develop raw and packaging material supplier for ice cream.
• Develop hygiene system R&D and R&D Production hall.
• Develop raw, packaging and finished product specification.
• Responsible for Record Keeping of all development trials.
• Meltdown test of new products.
• Coordinate to conduct new products development, transit trial and trade test at factory and market level.
• Coordinate to conduct new products development, MR samples, transit trial and trade test at factory and market level.
• Worked on SAP system (An internal system for inventory and product and material Clearance.)
• A comprehensive experience of using equipment’s likes Moisture tester, Gerber machine, Ph meter, Autoclave units, Viscometer, and other lab equipments.
Major Achievements:
• Success fully starts fresh Dairy plant in Karachi Responsible for Plant installation to Production (Installation, Maintains, Recipe Development, and Production).
• Updated all Raw material Specification in Interspaces system.
• Coordinate to develop all new sauces at Innovation center.
• Updated all finished product specification in all concern departments.
• Shelf life study.
• Meltdown test of new Ice Cream Trials
• Develop 1st time in Pakistan Yoghurt Ice Cream.
• Lead the R&D Department in BRC Traceability audit Sahiwal, Sukkur and Karachi Plants.
• Develop Ice Cream, UHT Milk, Yoghurt, Flavored Yoghurt, Flavored Drinking Yoghurt, & Cream and Juices.
• Develop hygiene system.
• Working on ISO certification & Halal Certification.
• Working on SAP (PP Module) all Dry Mixing Activities. Like Proses Order, Reservation, Reconciliation month end and year end cycle count Etc. Etc.
• Fully operate pilot plant Mix plant & Geel Mark Freezer, Chiller, Homogenizer, Pasteurizer, Ripple Machine, Fruit Feeder, Cup Filling Machine, Juice Pasteurizer, Molded & Extruded product Machine and Wrapper machine especially UHT plant for all new product trial samples like ice cream, juice and Milk as per requirement.
• Fully Operate Machine Rollo 35 - 2 and All Ice cream Freezer in ice cream production
• Machine cleaning, maintenance and parameter adjustment.
• Completed all the tasks of production volume as per plan.
• Wrapper printing and printing setting.
• Minimum downtime during production.
• Supervised a team of almost 20 employees. (Staff management).
• Troubleshooting during production and available on call as well.
• Training of new staff both ethically and technically.
• Improved hygiene plan of the area.
• Fully Operate Packer ( A ) M/C
• Improved hygiene plan of the area
• Training of new staff both ethically and technically.
FOOD HANDLER CERTIFICATION ELGIN ST. THOMAS PUBLIC HEALTH ONTARIO (CANADA) Food Handler certification from Elgin St. Thomas Public Health (ONTARIO) CANADA.
Mechanical Engineering (Fitter General) M, T, P, V, D 2005-2007 Technical Board of Education Punjab Lahore.