MAHESH BALKRISHNA SHIVALKAR
Associate Vice President
New Panvel
Summary
28 years Experienced in Production, Quality & Operation functions, Manufacturing processes, New Green Field projects, NPD, Plant Maintenance, Legal & statutory requirements for FMCG, Plant setup & Machinery Installation. Also, working experience as a Consultant for System & Food safety Standard applications seeks a new career path where I can put my experience to use for the benefit of the company. Manage, lead, and Execution in short-, medium- and long-term projects on entire plant operation & documentation, Selections of Equipment’s / BOQ preparation as per specs, Negotiations & Purchase, system setup, quality control, and quality assurance by preparations, reviews, auditing, method and process validations, calibrations, and workflow analysis. Achieve success through the development and implementation of Regulatory requirements in the field of Manufacturing and to bring-in value to the Organization’s Quality System with my overall knowledge, commitment, and dedication with focused hard work. Expertise in NPD from the proposal of new products/categories to final product development including a selection of best packaging material and labeling & back panel development. Overall developed more than 13 variants of food products in my career. Well versed in the Planning & Execution, Maintenance, Generation and review of SOPs, Procedures, training, Continuous Improvement, and other documentation systems.
Resourceful plant management leader with expertise in cost controls, lean manufacturing principles and employee training. 28-year track record of success in Food production.
Overview
28
28
years of professional experience
1
1
Certification
Work History
Vice President
Pittitte Group Of Companies
Navi Mumbai
02.2026 - Current
- Handling four plants in the category of Sweets, Home Care, and Puja Samugri with a team size of 1,500 people. Reporting to the MD.
- Led cross-functional teams for the successful completion of major projects, resulting in increased efficiency and client satisfaction.
- Collaborated with senior management to develop strategic initiatives and long term goals.
- Identified opportunities to improve business process flows and productivity.
- Established a culture of continuous improvement, fostering innovation and driving sustainable growth across the organization.
- Optimized resource allocation by analyzing operational needs, reallocating resources as needed to maximize efficiency across all functions.
- Established a high-performance culture within the team by setting clear expectations and providing regular feedback on individual performance contributions.
- Increased efficiency by streamlining processes and implementing new software tools for the team.
- Leveraged technology to automate workflows and streamline processes, resulting in increased productivity and cost savings across the organization.
- Spearheaded organizational restructuring initiatives, streamlining operations and reducing overhead costs.
- Increased company growth through collaboration with sales and marketing departments.
- Built high-performance teams through effective recruitment practices focused on competency alignment coupled with ongoing performance management processes.
Plant Head
Balaji Wafers
Valsad, Gujarat
09.2024 - Current
- To Set up a new 8 lacs sqft Wafers/Namkeen/Snacks/Mix product manufacturing plant as per FSSC 22000 & BRC standard
- Preparation of CAPEX & OPEX, Plant Layouts / Man Material Movement flow. Project schedule & Gantt Chart.
- Selections of - Process Equipment’s, Plant Machineries like Automatic process lines with color sorters, seasoning machines, FFS machines, Robot machines & automatic Case packing machines, Stadeue pouch MAMATA machine, Automatic multiple Extruder machine lines, Extruder Frying machines, HVAC, ETP/WTP, BOILER, FIRE SYSTEM, CCTV/LAN/IT etc. BOQ preparation as per specs, Negotiations & Purchase.
- Installation & Erection with Team & Vendors
- System setup, quality control, and quality assurance
- Manufacturers of Wafers, Namkeen, Extruded products, Mix, Fryums, Chivada
- Reporting to – Director
- Team – Manager & Executive total 75 nos & Associates approx. 2000 nos
- Green Field Project
Plant Head
Agrostarc Pvt. Ltd.
Vasai, Mumbai
04.2022 - 09.2024
- Set up a new 44000sqft RTE & RTC product manufacturing plant as per FSSC 22000 & BRC standard
- Preparation of CAPEX & OPEX, Plant Layouts / Man Material Movement flow. Project schedule & Gantt Chart.
- Selections of - Process Equipment’s, Plant Machineries like HVAC, ETP/WTP, BOILER, FIRE SYSTEM, CCTV/LAN/IT etc. BOQ preparation as per specs, Negotiations & Purchase, Installation & Erection with Team & Vendors. System setup, quality control, and quality assurance by preparations, reviews, auditing, method and process validations, calibrations, and workflow analysis.
- Operations Product operation & conversion costing.
- Planning & Execution of daily production activities to meet targets set by organization. Scouting new contract manufacturers, vendors and clients considering the budget and marginal profit gains for the company.
- Facility setups for GMP as per product categories & requirements, preparing the budget.
- Coordination & Handling of B2B customers, Operators, Audits
- Reviewing operational budgets and recommending changes to management
- Developing strategies to improve operations efficiency and effectiveness.
- Manufacturers of RTE & RTC products like Gravies, Chatnies, Sauces, Marinates & Frozen products.
- Reporting to – COO
- Team - Total 70 people [Manager -4, Executive, Supervisors, Operators & others]
General Manager GM Operations
Evergreen Foods
Dombivli, Mumbai
12.2018 - 04.2022
- Creating, setting up Systems and Overseeing Production/Manufacturing of all existing and any new products of Evergreen Snacks and Implementing Best Practices
- Develop and implement a Plan for optimizing output and reducing Costs whereby increasing Profitability
- Work on reviewing/re-aligning existing product range based on Sales, Cost, and Profit and propose corrective actions.
- Set up of totally new plant with all requirements of ISO & BRC within stipulated plan & timeline Including machinery setup of the Extrusion line, Fryum, Bakery, Namkeen/Farsan, NutriBar, Packaging machines, ETP&RO plant, Fire system, DG, Entire Electrical layout & set up Production Planning and Quality Control
- Creating and implementing production process (Forecasting) and Schedules for optimized usage of resources. Maintaining quality of raw material, intermediate products, finished products by identifying steps for quality control.
- Develop strategies to improve overall quality and productivity.
- Creating, setting up Systems, developing SOPs / Specs and Overseeing Quality Checks for our Products. Maintained Human safety, product quality & hygiene standards as per ISO, FSSAI. Generate business, Cost and employee reports to management. Provide direction and guidance to employees in their assigned job duties. Help the organization in Reducing Costs Analyze the current product production process and streamline the same.
- Work on quality of existing products, and development of the laminate structure to improve the shelf life of products as well as cost effectiveness.
- Formulating new products by doing trials, doing the sensory evaluation, finalizing recipes and variants for selection and approval, and incorporating feedback.
- Develop and propose new products/categories for increasing overall Sales and Building Brand Value. Suggesting packaging material, labeling, and back panel development as well as improvement of existing products.
- Analyze assessment of product for better material, process, and new production techniques for cost reduction as well as better sensory profile.
- Conducting in-depth consumer sampling exercises for testing new products/variants.
- Handling and Managing Machinery: Helping in identifying, procuring, setting up, and maintaining required production machines for existing and New products from time to time. Implementation of preventive & autonomous maintenance in the plant.
- Execution of Minor & Major plant projects. Vendor Management
- Evaluating existing vendors and identifying and replacing vendors as per requirements for new and existing products. Periodic vendor audits
- Development of new vendor as per standard requirements.
- Statutory compliance: Co-ordination & handling experience with agencies like Maharashtra Pollution Control Board, Boiler Inspection, Factory & Labor Inspector, State Electricity Board, Factory Food license, Factory act, Food Safety, Fire NOC, Mahanagar Gas Ltd.
- Adherence to Environment laws, Weights & Measurements, Human safety, Food Safety, HACCP, etc. Adherence & amendment of Legal, FSSAI/FDA requirements.
- Meeting or compliance with all local legal regularity’s requirements. Maintaining relevant records. Setting up and Monitoring Good Practices, Statutory and non statutory practices such as ISO, HACCP, BRC, etc. for the unit. Maintain Apply and Comply with all/any of the required licenses for the unit.
- Product / Brand TM registration & renewal work
- Carry out the requisite quality and operational audits to ensure complete compliance.
- Training the skilled/unskilled persons involved in production on all aspects of SOP / Quality etc.
- Find out training needs identification for Team & execute.
- Laboratory
- Setting up and monitoring a Lab for the unit
- Manufacturers of Extruded Products, Roasted Makhana, Potato Wafers, Ruffles, Chikki Bar, Fryum, Namkeen & Rasan
- Manpower Handled- Total 100 people [Manager -5, Executive, Supervisors & others – 95]
Sr Manager Production, Quality & R & D
The Green Snacks Foods Pvt. Ltd.
Mumbai
11.2016 - 11.2018
- Manage all activities end to end related to the production and delivery of all the brand’s products in the most cost efficient, productive, and quality-conscious manner as per the desired standards and protocol.
- Analyze the current product production process and streamline the same.
- Monthly reporting of Unit Economics to MD, monitoring & achieving defined targets of COGS (Cost for a good sale), Prepare SOPs for production setup. Manpower planning.
- Maintaining the quality of raw materials, intermediate products, and finished products by identifying steps for quality control. Formulating new products by doing trials, doing a sensory evaluation, finalizing recipes and variants for selection and approval, and incorporating feedback. Training the skilled/unskilled persons involved in production on all aspects of SOP / Quality etc.
- Continue assessment of product for better raw material, process, and new production techniques for cost reduction as well as better sensory profile.
- Conducting in-depth consumer sampling exercises for testing new products/variants.
- Licensing with the concerned authorities for procuring relevant licenses / documentation / approvals required for the products to comply with all regulations and mandates as required by FSSAI / FDA/Exports Any other regulatory body as may arise the case.
- Monthly reporting with PPT to Higher Management with detailed Production, Quality, NPD, Wastage & overall saving & RM/PM procurement & development.
- Carry out the requisite quality and operational audits to ensure complete compliance.
- Carry out annual performance appraisals of subordinates.
- Find out training needs identification for Team & execute.
- Interview & selection for resources requirements.
- Manufacturers of Extruded Products, Dehydrated Products, Multigrain roasted products, Crackers & dips.
- Reporting to – Directors
- Manpower Handled - Total 65 people [R&D Manager -2, Production Manager -2, Quality Manager – 1, AF CMU - 60]
Food Safety Consultant Manager
Paradigm Service Private Limited.
Mumbai
04.2015 - 10.2016
- Worked with Various clients like Godrej Oil, Parle, Vadilal, ADF, Royal Foods, Dohler, Nutrifre Foods, Qualitas Foods, Clique Exports, Fazlani Exports, Supreme Packaging, Positive packaging, & Jindal Poly etc.
- Worked with Godrej Oil for certification of FSSC 22000:2013
- Worked with Jindal Poly for certification of BRC 2015 in various phases (Successfully got AA rating for the year 2015 –2016)
- Worked with Vadilal& ADF for certification of ISO 22000.
- Worked with Parle for certification of ISO 22000.
- Worked with Value Bavery for certification of ISO 22000.
- Worked with The Supreme Packaging Industry for BRC 5 standard.
- Worked with four unit of Royal Food Stuff Karadi(IQF Vegetable/Fruits, Frozen Pulp, Dehydrated Fruits) on
- Implementation of HACCP to BRC 7 Standard implementation & continuous improvement.
- Worked with Value Bavery(Tea, Coffey, Sabaraf, Flavors) for certification of FSSC 22000:2013 & continual improvement project.
- Worked with Clique spices (Processing Pods, Dry & Wet Seasonings, Jam & Jelly, Tea) for USDA inspection standard year 2016.
- Worked with Dohler(Concentrated Flavors)Ind for FSSC22000 & AIB.
- Worked with Mikky Foods Gujarat (Flours & Grain product) on BRC 7 & KSQR requirements.
- Worked with Nutritrite Foods Pune (Frozen Snacks/ RTE curries) for implementation of ISO 22000
- Managing Quality
Operator to Plant Sanitarian (Food Safety Manager)
Kelloggs India Pvt. Ltd.
Mumbai
01.1998 - 01.2015
- Involved in Application & implementation of ISO 9001, ISO 22000:2005, BRC 6 (Food), BRC 5(Packaging), and FSSC 22000:2013 standards in Manufacturing functions.
- Involved in continuous improvement & training for Industrial staff, Core team.
- HACCP Management, Monitoring & Communication with Cross functional Team.
- Responsible for developing & implementation of Production strategy.
- Involved in planning & organizing the production activities to achieve the targets.
- Conducting daily meetings & Coordinate with cross functional team regarding equipment’s issues for continuous
- Improvement (ex. west control, m/c OEE)
- Equipment’s & Facility Sanitary design as compare to 12 principles.
- Implementation of Quality management system including FSRA – Food Safety Risk Assessment for each new equipment.
- BRC Issue 6, MQFS Standard for Kellogg’s Internal Quality System, Administration of Global Audit and third party
- Audit Programs(BRC/ HALAL/FSSC 150 22000/ISO 22000) , Specialization in GEMBA audit, 5S system
- FAT of lines – Factory Acceptance Trial for all new lines & equipment’s.
- Administered food safety measures and incidence & prepare RCA (Route Cause Analysis) & CPAR (Corrective and Preventive Action) Closure reports.
- Manufacturers of Cereal Products like Corn flakes & their variants, Extruded Baked products & their coated variants, Muesli products, Masala Oats etc.
- Teams – QC Executives – 10, Production Executives – 8, HK – 50, Pest Control – 3, Chemical control – 4, Food Safety – 4
- Growth Path
- Sr Quality Executive & Plant Sanitarian with M/s Kellogg’s India Pvt. Ltd. (From 2010 to Apr 2015).
- Quality Inspector from 2008 to 2010
- Production Supervisor from 1998 to 2008
Education
B.Sc. - Biology
First Class
MMCP - Maintenance Mechanic in Chemical Plant
First Class
NTCTVT - National Council training for Vocational Trade
from Mumbai board
Skills
Head/GM/ Production Operations
Production Planning and QA/QC
Manufacturing Operations
Quality Management System (QMS)
Green Field Project
Preventive & Autonomous Maintenance
New Product Development
Budgeting & Cost Control
Techno Commercial Operations
RM/PM Procurement & Sourcing
Supply Chain Management
EHS Program & Utility Operations
HACCP, ISO, FSSC, BRC & GMP
Fulfillment of Legal & Statutory requirements
Vendor Development / Vendor Audit
Strategic Operations Management
Lean Manufacturing System
Green Field Projects, NPD, BRC, FSSC 22000, ISO 22000, FSMS, HACCP, US-FDA, QA/QC, GMP, SOP, GMP, GHK, 5S, FSMS/Quality/EHS/FSSC control/Due Diligence auditing, Vendor and Supplier audits, evaluation, validations & development, EHS vision and strategy, Legal & statutory requirements related to Food Manufacturing
MIS/RRM, CAPEX/OPEX, AOP, COGS, SOP, Standard Operating Procedures, Quality System Manual, HACCP Plan & HACCP Manual, BRC, GMP, Documentation procedures for ISO 22000:2005/ FSSC 22000 / BRC Audits, MQFS (Manufacturing Quality & Food Safety), Plant Visits, Audits, GMS, FSSAI 22000
Waste minimization
Operations management
Health and safety compliance
Production scheduling
ISO standards
Cost reduction
Environmental regulations
Energy efficiency
Safety management
Team building and development
Production planning
Cost controls
Project management
Performance improvements
Training programs
Facility management
Regulatory compliance
Operational auditing
Equipment upgrading
Quality control management
Manufacturing operations
Certification
Lead Auditor FSSC 22000
Timeline
Vice President - Pittitte Group Of Companies
02.2026 - Current
Plant Head - Balaji Wafers
09.2024 - Current
Plant Head - Agrostarc Pvt. Ltd.
04.2022 - 09.2024
General Manager GM Operations - Evergreen Foods
12.2018 - 04.2022
Sr Manager Production, Quality & R & D - The Green Snacks Foods Pvt. Ltd.
11.2016 - 11.2018
Food Safety Consultant Manager - Paradigm Service Private Limited.
04.2015 - 10.2016
Operator to Plant Sanitarian (Food Safety Manager) - Kelloggs India Pvt. Ltd.
01.1998 - 01.2015
University (Mumbai) - MMCP, Maintenance Mechanic in Chemical Plant
Sandoz India Limited - NTCTVT, National Council training for Vocational Trade
Institute of Technology & Management Studies - B.Sc., Biology
DECLARATION
I hereby declare that the information furnished above is true to the best of my knowledge and belief.