The Duality Between Quality Control And Traceability James Kosalos President Cafes Sustentables de Mexico, S.A. de C.V. Jamesk@cafesumex.com Pagina 1
Agenda The Importance Of Traceability In The Coffee Quality Control Chain Quality Control Doesn t Exist Without Traceability Control of quality means that there is control of process Control of process means that there is knowledge of the inputs and the outputs of every process step.thus traceability! The Reverse, Traceability Without Control Of Process Is A Waste Of Time. Traceability As A Marketing Strategy Certified Micro-lots Pagina 2
The Mantenence Of Quality, 1 of 2 After perfect and fully ripe fruit is selectively picked, it is not possible to improve quality; the best we can do is to maintain quality through proper handling in all of the steps that occur between the harvest and the cup in your hand. Packaging Growing Harvesting Roasting Transporting Wet Mill Processes Key: Transporting CRITICAL ESSENTIAL VERY IMPORTANT IMPORTANT Dry Mill Processes Transporting Storage Brewing Storage Transporting Storage Pagina 3
The Mantenence Of Quality, 1 of 2 After perfect and fully ripe fruit is selectively picked, it is not possible to improve quality; the best we can do is to maintain quality through proper need handling in Producers all of the steps that occur between the to focus their harvest and the cup in your hand. efforts on these Packaging steps Growing Harvesting Roasting Transporting Wet Mill Processes Key: Transporting CRITICAL ESSENTIAL VERY IMPORTANT IMPORTANT Dry Mill Processes Transporting Storage Brewing Storage Transporting Storage Pagina 4
The Mantenence Of Quality, 2 of 2 It Is Easiest To Use A Maxwell Daemon Maxwell s Daemon** & his door There Are Problems With This Approach: No traceability No understanding of the coffee No opportunity to improve the resulting percentages And the Daemons are poor employees they can be very capricious Inferior Regular Excellent ** http://es.wikipedia.org/wiki/demonio_de_maxwell Pagina 5
Consistent Quality Requires Controls PRODUCT SELECTION ( & documentation) PRODUCT EVALUATION ( & documentation) CONTINUOUS IMPROVEMENT ( & documentation) Process Controls, Quality, And Sustainability Are All Based On: DOCUMENTATION & TRACEABILITY Pagina 6
Contemplating The Path Of The Coffee Multiple Coffee Farms Wet Mill Reception of fruit Processing until dry. Storage Multiple Coffee Farms Dry Mill Storage Processing for export Storage Wet Mill Fruit Reception of fruit Processing until dry. Storage Parchment Green Coffee Pagina 7
Process Control In Production Of Coffee 1. Evaluation Of The Fruit That Arrives Daily At The Wet Mill 2. Each Patio Lot, Once Dried, must Be Formally Evaluated Before It Can Be Safely Mixed With Any Other 3. All Processes Must Be Supervised To Assure Compliance With Contract Specifications El Cafetal 1 Crítical Evaluation Feedback 1 AND NATURALS JUMP OVER EVERYTHING. Wet Mill Evaluation Tells the producers what must be improved and the wet mill operator how to process/ separate the coffee Feedback 2 Crítical Data Tells the wet mill operator what needs to be improved and provides blending instructions to the dry mill operator Crítical Data Tells the dry mill operator how to adjust processes to to guarentee quality and provides coffee quality data for the buyer. 2 Crítical Crítical Data 3 Dry Mill 3 Crítical Evaluation Feedback Termination: Exportable Coffee Pagina 8
Process Control 1 1. Each Day It Is Necessary To Evaluate The Fruit That Arrives At The Wet Mill Logged Data: Names of producers, their parcelas and their certifications 1 Crítical Data Quantities and qualities of fruit brought to the mill each day Prices paid for fruit Tells the producer how to improve his coffee and tells the operator of the wet mill how to separate and process the fruit Pagina 9
Fruit Quality Confirmed When Received Payment And Premiums Based On Quality Fruit Not Meeting Basic Quality Standards Is Separated The amount of insect damage is measured by counting the number of damaged beans that float after being pulped Basic Quality Standard: Clean fruit, free of foreign material Fruit harvested the same day and free of any sign of fermentation Ripe fruit (< 1% immature) Healthy fruit (< 20% damaged by insects) Additional Standard For Higher quality: < 5% insect damaged fruit Pagina 10
Process Control 2 1. After Drying Each Patio Lot Must Be Evaluated Formally Before It Is Safe To Blend It With Any Other Lot Logged Data: Date, time, and length of each process Lot evaluation data for feedback to control processes and for design of blends 2 Critical Data Tells the wet mill operator what needs to be improved and provides blending instructions to the dry mill operator Yields obtained Inventory Pagina 11
Formal Evaluation After The Wet Mill Appearance & Moisture Content Bean Size Distribution Yield & Number Of Defects All Data Logged In The QA System s Digital Data Base Pagina 12
Confirmation Of Cup Quality All Patio Lot Quality Data Including Cup Characteristics Are Stored In The PortaCafe Digital Data Base Storred Quality Data Are Used To Design Blends The system s precision sample roaster assures consistently roasted coffee and reliable cupping results Pagina 13
Process Control 3 1. All Dry Mill Processes Must Be Supervised To Assure Contract Compliance Logged Data: Quantities of materia prima that are used in each blend Quality by aspect of the coffee at each process step 3 Critical Data Precise inventory of process components Tells the dry mill operator what to adjust to improve or to assure quality and consistency and provides export quality data for the buyer Pagina 14
Quality In The Dry Mill Blends Are Designed To Comply With Contract Specifications Coffee Being Processed For Export Is Evaluated Continously All Bags Of Coffee Are Labeled With A Swiftach Pistol Pagina 15
End Of Process: Bagged & Labeled Coffee Logged Data: Detailed information associated with each sale Inventory Agreement and contract with customer Seller & Buyer Quality Assuror Design blend to meet contract specifications Issue dry mill work order Assure compliance with customer instructions Dry Mill Operator Locate blend components Process to specifications Label all the bags Assign sequential lot number Print bar code labels Log all data: SINAPRO, export customs, ISF-10, etc Fasten bar code labels to bags Load / seal shipping container Update inventory Time Sequence Pagina 16
Truth In Labeling!! Bar Code Labels Contain All Tracking Data Labels Sewn Into The Bags Also Bear The Quality Control Certification Pagina 17
At The End: 100% Traceable Coffee Consistent Quality, Coffee Farm To Consumer: PortaCafe Sistema de Control de Calidad Consumers Roasters www.trackyourcoffee.com Cafetales and producers COOPS Exporters Importers JGK Pagina 18
And So.. What Is The Difference Between Quality Control And Process Control? NOTHING, They Are One And The Same!! And The Difference Between Quality And Traceability? NOTHING, They Are A Duality That Depend Only On The Point Of View!! And How Do Certifications Fit Into This Picture?.. Pagina 19
Quality And Certification Certification Without Quality Control Some Producers Invest In A Certification Without Realizing That The Chain Of Documentation They Need Is Also The Basis Of A Process Control System Pagina 20
Maintaining Perspective What Does A Certification Say To The Buyer? The producer is following some specific and well documented metrics The Field Of Possibilities Pagina 21
Maintaining Perspective What Does A Certification Say To The Buyer? The producer is following some specific and well documented metrics Organic Certification The Field Of Possibilities Pagina 22
Maintaining Perspective What Does A Certification Say To The Buyer? The producer is following some specific and well documented metrics Organic Certification The Field Of Possibilities ly d n rie ion F at rd Bi rtific Ce Pagina 23
Maintaining Perspective What Does A Certification Say To The Buyer? The producer is following some specific and well documented metrics Rainforest Certification Organic Certification The Field Of Possibilities ly d n rie ion F at rd Bi rtific Ce Pagina 24
Maintaining Perspective What Does A Certification Say To The Buyer? The producer is following some specific and well documented metrics Rainforest Certification Organic Certification The Field Of Possibilities UTZ Certification ly d n rie ion F at rd Bi rtific Ce Pagina 25
And How About Consistent Quality? The producer is producing quality coffee with documented procedures that allow him to improve his product. The Field Of Possibilities Pagina 26
And How About Consistent Quality? The producer is producing quality coffee with documented procedures that allow him to improve his product. Quality Assurance Practices The Field Of Possibilities Pagina 27
And How About Consistent Quality? The producer is producing quality coffee with documented procedures that allow him to improve his product. Rainforest Certification Quality Assurance Practices Certificacion UTZ Organic Certification The Field Of Possibilities ly d n rie ion F d icat r i B ertif C Pagina 28
And How About Consistent Quality? The producer is producing quality coffee with documented procedures that allow him to improve his product. The Field Of Possibilities Rainforest Certification Quality Assurance Practices Certificacion UTZ Organic Certification The Majority Of The Requirements For A Certification Are Covered By Those Of A Quality Assurance ly System d ien Fr ation d r Bi ertific C Pagina 29
Summary The Duality: Quality & Traceability In Coffee Production Documentation And Traceability Are The Cornerstones For Quality.And The Basis Of Most Certifications Maintaining Quality Requires Attention To Detail, Critical Evaluation And The Application Of Feedback Pagina 30