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Food Retail Logistics & Packaging Summit & Awards
Vivek Sarbhai
Vice President : Logistics & Customer Operations
Cadbury India Ltd
2
End to End Cold Chain is required to drive consumer satisfaction through reduced Heat Damage complaints
Mode Location From Location To Target Temperatures Target Temperatures Summit Bournville
Primary Transportation Plant Depot 21 C +/- 1 C 21 C +/- 1 C
Depot storage Depot Depot 21 C +/- 1 C 21 C +/- 1 C
Secondary Transportation Depot RD 23 C +/- 1 C 23 C +/- 1 C
RD storage RD RD 23 C +/- 1 C 23 C +/- 1 C
RD to retail RD Retail 25C +/- 1 C 27C +/- 1 C
Retail storage Retail Retail 25 C +/- 1 C 27 C +/- 1 C
B. Project Summit : Temperature Norms from Plant to RetailA. 69% of consumer complaints are Heat Damage
C. Complaints on Temptations, Celebrations and CDM increase in summer
Capability : End to End Cold chain
3
End to end Cold chain Landscape
External suppliers
External Suppliers
Cadbury Plants and
CMO
Wholesalers
RM/PM W/H
3PL Distribution
Centres
Distributors
MT DC & MT Distributors
Stores
Retail Outlets
SH
OP
PE
RS
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Cold chain
Temperature
controlled
warehousesCold Chain
Ref vehicles
in Summers
& Insulated
in Winters
Storage in
AC Rooms
Delivery
in cold
chain
vehicles
Delivery
units with
Shippers
Visicooler/
AC
Storage
4
Implementation Plan: We have identified 8 Work tracks & developed a 4 year implementation roadmap
Retail Outlet
Re-distributor
Warehouses
1. Cold chain at RD godowns in TG Towns
2. Visi Coolers at all Wholesalers
Mfg. Plants
1. Refrigerated Trucks usage for Premium chocolates and also all along in summer months
1. Visi Coolers in all HEG/FS/SAS in TGS Towns
2. Cold chain from RD to Retail
3. Visi Coolers in sub stockists (small towns / rural)
1. Cold chain from depot to RD (T,G,S,SST)
2. Depot cold room infrastructure
Requirement Unit 2010 2011 2012 2013 Total
Visi coolers No.
Visi coolers No.
`Visi coolers No.
Requirement Unit 2010 2011 2012 2013 Total
Freezers/ ACs No.
Delivery Units No.
Requirement Unit 2010 2011 2012 2013 Total
Refer Vehicles No.
Cold Room Space
Sq ft
Requirement Unit 2010 2011 2012 2013 Total
Increase in Refer Vehicles
No.
Hardware Quantities
5
End to End Cold Chain – Infrastructure plans
Retail Outlet
Re-distributor
Warehouses
1. % of TITANIUM RDs compliant on all elements
Mfg. Plants
1. Refrigerated Trucks usage for Premium chocolates and also all along in summer months
1. Visi Coolers in all HEG/FS/SAS in TGS Towns
1. Cold chain from depot to RD (T,G,S,SST)
2. Depot cold room infrastructure
Requirement Unit Exit 2010 2011
Visi coolers No.
Requirement Unit YTD Aug ‘10 Exit 2010 2011
Warehousing:A/C Temperature GaugeDelivery:Freezers, Shippers & Chill pads
%
%
Requirement Unit 2010 2011
Refer Vehicles No.
Cold Room Space
Sq ft
Requirement Unit 2010 2011
Refer Vehicles / Total Cold Chain fleet (incl. insulated)
%
2. % of GOLD RDs compliant on all elements
6
End to End Cold Chain – 75% Volume Delivery thru cold chain
Fleet Size 32
%age compliance 69%
Fleet Size 30
%age Compliance 75%
Fleet Size 41
%age compliance 77%
Fleet Size 40
%age compliance 76%
West Branch
East Branch
South Branch
North Branch
68%75%
143130
0%
20%
40%
60%
80%
2010 2011
%age C
old
Chain
Com
pliance
0
40
80
120
160
Fle
et
siz
e (
No)
Increase in Cold Chain Compliance
Fleet Size of 143 across regions
7
End-to-End Cold Chain Depot Space (Sq. Ft.)
114000
135907
2009 2010
37%
2010: Quantum leap in cold chain
Cold Chain Fleet & Distance
63
114
5.14
2.5
0
20
40
60
80
100
120
2009 2010
Cold
Ch
ain
Fle
et
Siz
e
0.0
1.0
2.0
3.0
4.0
5.0
6.0
Cold
Ch
ain
Mn K
Ms
8
Monitoring & managing the temperature throughout the cold chain
Where Preliminary / Earlier Current Advanced / Future
In Temperature controlled factory warehouses & depots
Temperature data logger
Temperature data logger with SMS / email in case of violation
1. Compressor monitoring & alert in case of breakdown.2. Door open alarm
Primary transportation Temperature noted at the beginning & end of trip
Temperature data logger set at periodic intervals. Print out at the end of trip
Temperature data logger with SMS / email in case of violation
Secondary transportation ( depots to redistributors)
Temperature noted at the beginning
Temperature data logger set at periodic intervals.
Temperature data logger with SMS / email in case of violation
Redistributors (RDs) warehouse
Air conditioner temperatures
Temperature data logger
Temperature data logger with SMS / email in case of violation
Tertiary distribution (RDs to retailers)
- - Shipper temperature log
9
A/C Warehouse – temperature log report for year
10
Reefer vehicle - temperature log report for a trip
11
Live Temperature Monitoring of a Multi-chamber warehouse
12
Online Vehicle Tracking & Temperature Monitoring System
• GPRS based solution
• Tracking possible for – temperature setting of reefer unit– Temperature of return air– Door status– Hourmeters– Fuel level– Vehicle location & kms travelled– No of stops & halting time
• Review data for any period starting every 30 min,1 hr, 3 hrs, 6 hrs, daily etc
• Email or SMS Alert for temperature range violation
13
Online Vehicle Tracking & Temperature Monitoring System
14
Designing Energy Efficient cold rooms
• Usage of PIR / Rockwool insulation to achieve low thermal conductivity as against traditional RCC & brick wall structures
• Designing refrigeration / air conditioning system for optimum cooling & RH
• Air conditioning capacity (tons) reduced to less than half.
RCC roof & Brick Wall structure 80 mm PIR panels for roof & walls
15
Thank you