Food Retail Logistics & Packaging

Summit & Awards

Vivek Sarbhai
Vice President : Logistics & Customer Operations
Cadbury India Ltd
Capability : End to End Cold chain

End to End Cold Chain is required to drive consumer satisfaction through reduced Heat
Damage complaints
A. 69% of consumer complaints are Heat Damage B. Project Summit : Temperature Norms from Plant to Retail
M ode Location From Location To Target Temperatures
Target Te
Summit Bour
Primary Transportation Plant Depot 21 C +/ - 1 C 21 C +

Depot storage Depot Depot 21 C +/ - 1 C 21 C +

Secondary Transportation Depot RD 23 C +/ - 1 C 23 C +

RD storage RD RD 23 C +/ - 1 C 23 C +

RD to retail RD Retail 25C +/ - 1 C 27C +

Retail storage Retail Retail 25 C +/ - 1 C 27 C +

C. Complaints on Temptations, Celebrations and CDM increase in summer

2
End to end Cold chain Landscape

Ref vehicles Delivery

Temperature Delivery Visicooler
in Summers in cold Storage in
Cold Chain controlled units with / AC
& Insulated chain AC Rooms
warehouses Shippers Storage
in Winters vehicles

Distributors Wholesalers

Cold chain Cold chain

Cold chain

Cold chain

SHOPPERS
External Retail Outlets
suppliers Cold chain

RM/PM Cadbury 3PL

W/H Plants and Distribution
CMO Centres Cold chain
Cold chain
MT DC & MT Stores
External Suppliers Distributors

Cold chain Cold chain

Cold chain

3
Implementation Plan: We have identified 8 Work
tracks & developed a 4 year implementation roadmap

Hardware Quantities
Retail Outlet Requirement Unit 2010 2011 2012 2013 Total

Visi coolers No.

1. Visi Coolers in all HEG/FS/SAS in TGS Towns

Visi coolers No.

2. Visi Coolers at all Wholesalers

3. Visi Coolers in sub stockists (small towns / `Visi coolers No.

rural)

Re-distributor Requirement Unit 2010 2011 2012 2013 Total

1. Cold chain at RD godowns in TG Towns Freezers/ ACs No.

2. Cold chain from RD to Retail Delivery Units No.

Warehouses Requirement Unit 2010 2011 2012 2013 Total

Refer Vehicles No.

1. Cold chain from depot to RD (T,G,S,SST)

Cold Room Sq ft
2. Depot cold room infrastructure Space

Mfg. Plants Requirement Unit 2010 2011 2012 2013 Total

Increase in Refer No.

1. Refrigerated Trucks usage for Premium Vehicles
chocolates and also all along in summer months

4
End to End Cold Chain – Infrastructure plans

Requirement Unit Exit 2010 2011

Retail Outlet
Visi coolers No.
1. Visi Coolers in all HEG/FS/SAS in TGS Towns

Requirement Unit YTD Aug ‘10 Exit 2010 2011

Re-distributor
Warehousing: %
A/C
1. % of TITANIUM RDs compliant on all Temperature Gauge
elements Delivery:
Freezers, Shippers & %
Chill pads
2. % of GOLD RDs compliant on all elements

Warehouses Requirement Unit 2010 2011

Refer Vehicles No.

1. Cold chain from depot to RD (T,G,S,SST)
Cold Room Space Sq ft
2. Depot cold room infrastructure

Requirement Unit 2010 2011

Mfg. Plants
Refer Vehicles / %
1. Refrigerated Trucks usage for Premium Total Cold Chain
chocolates and also all along in summer months fleet (incl.
insulated)

5
 End to End Cold Chain – 75% Volume Delivery thru
cold chain
Fleet Size of 143
North across regions
Branch
Fleet Size 32
%age compliance 69%

East
Branch
Fleet Size 30
%age Compliance 75%

West
Branch
Fleet Size 41
%age compliance 77%

Increase in Cold Chain Compliance

80% 75% 160
South
%age Cold Chain Compliance

68%

60% 130
143
120 Fleet Size Branch 40
Fleet size (No)

%age compliance 76%

40% 80

20% 40

0% 0
6 2010 2011
2010: Quantum leap in cold chain

End-to-End Cold Chain Depot Space (Sq. Ft.)

Cold Chain Fleet & Distance

120 6.0
114 135907

100 5.0
5.14 37%
Cold Chain Fleet Size

Cold Chain Mn KMs

114000
80 4.0
63
60 3.0
2.5
40 2.0

20 1.0

0 0.0

2009 2010 2009 2010

7
Monitoring & managing the temperature throughout
the cold chain
Where Preliminary / Earlier Current Advanced / Future

In Temperature Temperature data loggerTemperature data 1. Compressor monitoring

controlled factory logger with SMS / & alert in case of
warehouses & depots email in case of breakdown.
violation 2. Door open alarm

Primary transportation Temperature noted at Temperature data Temperature data logger

the beginning & end of logger set at periodic with SMS / email in case
trip intervals. Print out at of violation
the end of trip

Secondary Temperature noted at Temperature data Temperature data logger

transportation ( depots the beginning logger set at periodic with SMS / email in case
to redistributors) intervals. of violation

Redistributors (RDs) Air conditioner Temperature data Temperature data logger

warehouse temperatures logger with SMS / email in case
of violation

Tertiary distribution - - Shipper temperature log

(RDs to retailers)

8
A/C Warehouse – temperature log report for year

9
Reefer vehicle - temperature log report for a trip

10
Live Temperature Monitoring of a Multi-chamber
warehouse

11
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

12
Online Vehicle Tracking & Temperature Monitoring
System

13
Designing Energy Efficient cold rooms

RCC roof & Brick Wall structure 80 mm PIR panels for roof & walls

• 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.

14
 Thank you

15