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It's all coming up right now on Alabama STEM Explorers.

Hey, welcome to Alabama STEM Explorers.

Today we're at the Coca-Cola Bottling company with my friend Brenda My name is Brenda Dillard.

I am the manufacturing trainer manager.

I will be giving you a brief overview of the Dasani process.

I'm going to begin with our preform actually that starts the process of production.

So this preform is actually dumped into a hopper, that hub of this it and makes it so it's ready to go into the other is of stretches These are the bottles and get it ready to go into a below loading section.

Once this ball preform is heated, it travels to the heated section to arrive is and it goes into our Once it's loaded, the bottle comes out of it and is formed and then it filled Once its filled I see the product inside, it is filled and then it's kept.

Would you like to try?

It's a really easy process.

So once the bottle has been capped and filled, it travels through the line If there's an count, it defects a missing cap or low fill that occurred.

We have what we call rejects any kind of defect.

So it ensures that everything that's going down is a steady once its capped.

It's actually coded.

If you take a look here, you have about a.

You see the injected bottle code.

It has a 52 week shelf life and it actually coated red here.

And then it goes into our label machine.

So the actually runs really fast.

And we have the labor of actually run a little slow.

So we have some conveyors there called Accumulation Table, which single file is the bottles waiting to be labeled.

So once it's actually coded, it goes into our level issues and we actually have two for each line so that we can keep up with our filling process.

The bottle is once is labeled, it is conveyed down to ready to be packaged.

It goes into our which is where we do the over wrapping.

All the cases.

If it wasn't that goes there, it goes to a spiral turnstile and then it goes into Why do I have to wear these head nets?

Good question.

You know, we are all about food safety, right?

So this is one where we ensure that we are protecting our product for the consumer.

Good safe product.

We always have to keep that in mind.

It's crazy how this container.

It is a very, very detailed process and it's even more that we just don't blow it and just send it out the door.

We actually have to do quality checks to ensure that the quality of the product is really good.

So our operators have to do and they actually have to cut the bottles into sections like this.

So they have to actually check the thickness of the body to ensure that the is properly throughout the bottle So you have the bottom finish, you have the bales in the panels of the bottles, and then you have the feet.

Now we have to meet these specifications, its rejected So we have talked about how we process the bottle right but what about the product?

Right.

So we begin our number one resource here is our water, right?

We have one of the largest water treatment systems within our company, and we actually receive our water from the, which is the city of Montgomery So that water comes in and good quality, right?

It meets all the regulator standards.

However, for our Dasani process, we go a little bit, but we use reverse osmosis process, all the minerals and things that the city allows, but we take it out so we can help make up for our water.

It was this the we have to do a little more right So the quantity here does our quality checks on our water to ensure that the water is a good for production.

It was, it was that occurs.

They can begin to the process.

So if you look at our labeling said we add minerals to the water, to enhance the flavor That's what we do that a part of blending.

If you look there, you can see a blended station for our Dasani water.

So we the water and then we do our test and we also add a little ozone for protection as well.

Now, you can't just take the water directly off the line because ozone is in it, it but it dissipates in about 24 hours.

So we are continually testing our product.

We are continually doing we are on the product, we are doing contents test.

We have to make sure that all our packaging integrity checks are there.

We have to actually make sure if our label says it's 12 ounces, we have to assure that we're in compliance with that length of stay the way.

And also if we're the capping if we have to make sure that the cap is on tight we want to feel one.

So we can make sure there's no leakage or damage to it so that we don't want to cause any leakers or anything.

Also, just to make sure that the bottle is is right is helps us like where we are is traveling stability at all palette integrity because we have the form basis.

If this is not the plastic that distribute it properly, it can cause the wobbly bottles to be transferred.

Then they can also cause problems in our and in our cases, it could potentially cause us to have bad during our transition.

That's crazy how many bottles you make in hour well This this line currently runs about 1350 bottles a minute, which on average we could reduce in an out of about 81,000 per hour, which is equivalent to about 2500 cases an hour.

So that is how it is very fast.

So and then it's also it's very good that we just don't house the products here.

We actually ship to so we produce it.

We we manufacture, fill and package, but we ship it to So, Brenda, tell me a little bit more about quality control.

Well, we actually have a quality assurance team here.

Each line has its own dedicated quality technician who is trained to do quality checks, integrity checks and packaging to show the product is actually tested on a daily basis as well to ensure that the quality is the uphold.

And also we have we have different test.

We test anything from the ph, all we do turbidity, test and a lot of analytical test that goes in there and it just don't go.

They stop there.

We do additional tests.

We do have an in-house micro lab that does minimal micro testing on our finished product as well.

And we have a sensory evaluation board that does we on our products It is conducted 24 hours.

So we have a trained panel to do the test to ensure that we're consistently producing the safe part up to the standard.

Tell me about the minerals in the water.

Where are the Dasani minerals actually supplied by the Coca-Cola Company?

And it's a brand name.

So we have to make sure that when we are mixing these minerals, that we are following their standards.

So everything that has to be tested, whatever attribute is called for we have to make sure with is that we cannot deviate from any of our specifications.

Wow.

What makes Dasani different from Other water is purified because like earlier, I explained the reverse osmosis process and the minerals Okay, What is reverse osmosis?

So the water comes here from the manner.

So we have what we call it dual pass reverse osmosis.

It's a sphere built of a lot of membranes that takes out all the smallest things that you can't see.

So we are making the water more clear that it is clear for our It is a better quality water its pure.

How long does it take from this to go to this?

it actually takes approximately 10 minutes for the entire process to be complete.

That's from entering the preform.

Stand with the filling process and and then warehouse and how many people work here?

We have approximately 198 associates that include multi departments, quality production, maintenance, warehouse and blending as well in identifying people.

Well, we are always looking for more.

So, Brenda, are your bottles recyclable?

Yes.

Well, all our packages are recyclable.

But if you see these two bottles here, it says 100% recycled here.

But these two bottles are recycled, but they are very good.

So we also recycle our caps and our labels and we also recycled cardboard as well.

So everything we have in the plant is recyclable.

What happens when a bottle is a recycled?

Its sent to back to the supplier to be recycled.

It introduces back and action is going to come back in the same form.

And how does recycling the bottles help the planet?

Well, there's multiple benefits to having a recycling program.

It actually reduces waste and it also brings back of bring back resources into the plant that can help for things like new releases we're giving back to our associates and helping the environment as well.

You said something about sanitation earlier.

What is sanitation?

Well, sanitation we actually have a sanitation crew are trained to help to make sure actually before anything can actually happen, even before producing a product or introducing anything on to our line we have to have activities in place.

We have sanitation to do internal sanitation, which involves clean in place.

It cleans the interior like equipment But we also have to make sure that everything is clean and in place on external side.

So we have the sanitary system and most of the partners actually take part in there to ensure that our facilities are full context so that even our raw materials will help in maintaining it all the time.

So, Brenda, how did you end up working here?

Well, actually, I came on as a partner manager.

I went all to the company's website and was just looking for opportunities and I came on board and I came to was.

And so that's why quality is really a big deal to me.

And then I just I've been here with the company about six years and everything is constantly changing and there's innovation coming.

New department is coming.

So in the last year, I actually six months.

I transitioned into the management.

So now I have more concept of all the aspects of the business from coming in with now a new associate.

I love the opportunity of going out to all the colleges participating with them, encouraging young people to come on board and become a part of our team as well.

So if I were to work here, what would I have to do?

Well, again, you have to be of age of course, but the only thing you have to do is meet the minimum requirements and come a board or at some point we have internship reach out to our onboarding and look to what do we have to offer before the internship and become aboard.

We got multiple, multiple positions to be able to actually support the STEM program we have.

Things are quality for technology too.

We are blending things.

We have size, micro laboratory and we also have a lot of because you look good with your hand.

I want to be on the This is the place.

So what happens once the water is done being made?

Okay, we don't ship directly to our customers.

We have an outside port that we actually ship our water to.

But we, we have made sure that the transition from this location to that location is really, really good.

So we we do an extra quality step there.

We have ensured that the trailer there.

We are actually placing our product so it's in good We have to make sure that it like did have any kind of foul odor or or any kind of damage to the trailer like holes and things just to make sure we keep our products safe.

So before loaded, we inspect the trailer, even though they belong to our company.

We still in big inspect those, as well.

Okay.

And I would like to actually go see my friend and see how that sounds Great.

We're back at the Montgomery Coca-Cola plant with my friend Mr. Tucker.

How much water is there actually behind us?

Currently, we have about a million cases of water, but we have the capacity for 2 million cases.

But as we move closer towards the summer, the volume increases, but currently it's roughly about a million cases.

Why do you need more water in the summer?

So this warehouse was designed specifically to deal with disasters.

Initially, we kept all this water over at the production center, but we designed this warehouse for local disasters within the southeast.

So we build up more water as we get closer to hurricane season.

And so we'd be prepared for whatever may happen.

We have enough water to supply to the public, wherever it's needed.

And how much water do you ship out yearly on average each day?

We move 70 to 80 truck loads of water out and we receive about the same.

We ship directly to Sam's Club.

They probably get a load of water a day for a month, but annually we move somewhere between 2 to 3 million cases per day.

What other sizes of water do you make?

So we carry the one liter that you currently have, but we also have the half liter.

We have the 20 ounce we have the 12 ounce and we carry it 32 pack, half liter.

That is mainly for your Sam's Club and and the larger retailers.

So we carry this water, because it is so important during natural disasters.

The demand for water is immediate and we are so structured, if you will, that the moment we get a call that there's a disaster, there's a demand anywhere in the south east for water, we have the carriers in place that can quickly come together and move as many loads as we need to move out of this facility to wherever the disaster is.

So in in essence, the the sole purpose of this is, of course, to keep water out there for the public.

But mainly we are prepared to be a source during disasters.

Does the water ever go bad?

Yes, it does.

But what we do is the system that we use back here, it's first in first out system.

And what does that mean?

What comes in first goes out first.

Meaning, it's a constant rotation.

So, for example, if we have a date, this is January 1st comes then and after that we get a date that says February 1st.

The January 1st would go out first so that we keep that rotation to prevent product from going out of date.

And at the same time, making sure the product that we put in the market are within date good product.

And why is it so important for the water to be in date?

So that is just the general standard across the board as it relates to retail and products.

Right.

So water has that.

You go to the supermarket and you buy canned goods, different type, even a bag of chips that has a life or a shelf life.

It's all and all, all retail is got to make sure that whatever product they're selling to the public, the public is using is we didn't date because no one really want to go buy something that's expired because it could make you sick or you could have side effects from it.

So that's a that's a problem, wouldn't it?

So how do you know the amount of water that store needs?

Okay.

The system that we use is here at the at the warehouse on the other side of the wall.

If you look that way, we have what we call material handlers or some other companies called Order Selectors.

So we have a system in place.

It's called a voice pick system.

So when a customer places an order, let's say a customer buys 20 cases of water.

The voice pick system consists of a phone and a headset.

So the material handler also like the logs into the system, and a voice is going to tell him her how many cases to pull from the pick slot and which pallet to put it on.

So if the customer buys 20 cases of one liter Dasani, the voice is going to tell that selector.

When he gets that a slot for the one liter that pick 20.

And when one he picks that 20, he has to confirm that, Yes, I picked 20 cases.

So it's a conversation that the selector has with the system, the voice pick system that seems extremely efficient.

What happens after they pick the cases up?

Okay.

So the select to pull the cases puts them on a pallet and the voice is going to tell the select the win.

That order is complete.

Now, each order is specific for a store, so the voice is going to tell the select your order is complete and the selector is going to say printer.

And when the selector says printer, a pallet ticket is going to come out of the printer with his name on it and the name of the store is going to be on the palate, take it as well.

The select pair is then going to attach that pallet, take it to that specific pallet.

And when you look at the pallet ticket, it's going to tell the selector where to place that pallet on the loading dock and the loader will know which trailer that load that pallet.

And based on the route that's being built and each route may consist of five or six different stores as well, but it's put together based on the territory where that where that driver is going to go deliver for that day.

So, Mr. Tucker, where do you sell all this water?

So this water is mostly shipped here in the south east.

So, for example, the warehouse that we run on the other side of the wall that I spoke about services, the Montgomery area, Dothan Area, Evergreen area, and Auburn as well.

We also move water to Columbus.

Columbus Warehouse is also in our division.

And this water is shipped some to parts of Florida, but mainly any area within the south is we ship water to that is a lot of places that you ship water to.

But are there just humans working here?

Mainly.

But we also have a robotic system that works on the packaging of different types of product as well.

Currently in this warehouse, we don't have any robotic system that does packaging of water.

All that is done and process at our production center.

Just on the other side of the wall, the warehouse that we spoke about, we have that what I referred to as the voice pick system, which is very, very interesting system in the sense it's designed for accuracy.

So the way it works is back to the water.

The select is supposed to pull ten cases of water, and that water is in a specific pick slot.

When they select the guest on a pick slot, the selected must tell the voice where he is by giving the the the voice a specific number.

And once he gives the voice that number, then the voice will tell the selector how many cases to pull.

So it's really designed for accuracy to minimize errors and make sure that whatever we're moving to the stores, we're filling the orders at as accurate as we can.

So, Mr. Tucker, you said that you help with disasters.

What kind of disasters you help with.

So most recently, we had the tornadoes in Selma, in the Selma area, and we were able to move water very quickly to that area.

Also, I believe a few years back when the hurricane hit Panama, we were able to again move water into the area and met with the men in the area and also in Mississippi.

When they had the water crisis, water was going on.

We had enough on hand to meet the demand.

The requests for whatever they needed.

We had it in-house to supply them with that, with that water supply.

But again, it speaks to the purpose of this facility.

The purpose of this warehouse is building up water to serve the serve the community, wherever that may be.

When a disaster strikes.

And that's apart from, of course, every day service to our customers.

But that was the big picture when this warehouse was created just as a footprint to serve, be of service, be a source of good source during disasters in addition to helping with natural disasters.

What other things in the community you help with?

So we are very involved in the community.

We would provide water and parades.

We would provide water at school events, ground breaking events, sometimes military events.

Any major event that's happening within the community and we we're called upon to donate water or provide beverage to that event, we would show up and we would have whatever the the demand is.

We would definitely have enough on hand to supply them with their demand.

So part of the purpose, the company exists.

We're very much involved in community and that's part of our mission statement as well, that we're very involved in the community.

And once we're called upon, we make it a priority to service, to provide service within the community.

Well, thank you, Mr. Tucker, for having me today.

And come back for another episode of Alabama STEM Explorers.

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Alabama STEM Explorers.

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Alabama STEM explorers is made possible by the generous support of the Holle Family Foundation established to honor the legacy of Brigadier General Everett Holle and his parents, Evelyn and Fred Holle, champions of servant leadership.