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KELVIN MUKUBWA
Lusaka
Summary
Results-driven Food Process and Beverage Development Professional with expertise in beverage manufacturing and pilot plant operations. Specializes in process optimization, quality control analysis, and translating laboratory formulations into commercial-scale production. Experienced in SOP development, HACCP/ISO 22000 compliance, and cross-functional collaboration, with a strong focus on safe work practices and continuous improvement in manufacturing operations.
Overview
1
1
Certification
4
4
years of professional experience
Work History
Research and Development Scientist
Big-tree Beverages Ltd
Lusaka, Zambia
01.2025 - Current
- Lead pilot plant trials and beverage formulation activities for new product development and commercialisation projects.
- Supported process scale-up by translating laboratory formulations into commercial manufacturing processes, ensuring product consistency and optimizing plant performance.
- Collaborate closely with production and operations teams to optimise manufacturing processes, troubleshoot processing deviations, and improve operational efficiency.
- Conducted beverage stability studies, shelf-life testing, sensory evaluations, and routine quality analyses to ensure product quality and enhance process reliability.
- Monitored mixing, processing, filtration, and production parameters in beverage processing operations to ensure compliance with quality standards.
Quality Assurance Unit Lead
Big-tree beverages Ltd
Lusaka, Zambia
01.2024 - 12.2024
- Supervised daily quality assurance activities within beverage manufacturing operations to ensure compliance with HACCP, ISO 22000, GMP, and company quality standards.
- Supervised daily Quality Assurance operations in a high-volume manufacturing environment.
- Conducted internal audits, hygiene inspections, and CCP verifications, identifying and addressing potential risks to ensure compliance.
- Designed and delivered training programs for QA staff on compliance, food safety, and documentation practices.
- Investigated product deviations and implemented corrective actions, enhancing manufacturing consistency and reducing non-conformities.
- Supported production teams in identifying process deviations, implementing corrective actions, and improving manufacturing consistency.
- Investigated customer complaints, product deviations, and process non-conformities using root cause analysis and CAPA methodologies.
- Facilitated cross-functional communication between QA, Production, Operations, and R&D teams, strengthening collaboration to enhance plant and process performance.
- Developed and maintained SOPs, quality records, inspection procedures, and audit-ready documentation systems.
- Supported continuous improvement projects focused on reducing downtime, improving process efficiency, and strengthening quality compliance.
- Conducted supplier evaluations and vendor quality assessments to ensure raw material compliance with manufacturing requirements.
Quality Assurance Analyst
Big-tree beverages Ltd
Lusaka, Zambia
10.2022 - 12.2023
- Monitored operational prerequisite programmes (OPRPs), Critical Control Points (CCPs), and production quality parameters to ensure compliance and enhance beverage manufacturing operations.
- Performed routine quality inspections and analytical testing of incoming raw materials, in-process production samples, and finished beverage products to ensure compliance with company and regulatory standards.
- Conducted laboratory quality analyses, including moisture testing and stability assessments, to ensure product integrity under varying environmental and storage conditions.
- Verified calibration, sanitation, and operational readiness of laboratory and production equipment to ensure accurate, reliable, and repeatable quality results.
- Monitored controlled storage conditions, cold chain systems, reefer temperatures, and product handling processes, escalating deviations and supporting corrective actions where necessary.
- Supported process optimisation initiatives by providing production and quality data to QA, R&D, and Operations teams to improve manufacturing consistency and reduce process deviations.
- Participated in pilot-scale product evaluations and supported process verification activities for new beverage formulations and production trials.
- Applied HACCP, TACCP, VACCP, GMP, and risk-based quality principles to identify contamination risks, product integrity issues, and process non-conformities.
- Participated in internal and external audits by preparing documentation, verifying traceability systems, and supporting corrective and preventive action (CAPA) activities.
- Collaborated with Production, QA, and R&D teams to drive process improvement initiatives and enhance manufacturing quality through pilot plant evaluations.
Education
Diploma - Science Laboratory Technology
Evelyn Hone College
Lusaka, Zambia01-2022
Grade 12 Certificate - High School
Libala Secodary School
Lusaka , Zambia 11-2014
FSSC 22000 Version 6 - Awareness & Internal Auditor Training
Intertek International Ltd
Sheik Zayed Road, Dubai, United Arab Emirates 01-2024
Skills
- Food Product Development
- Fermentation Process Development
- Product formulation
- Lab Scale Testing
- Quality assurance
- Food safety systems
- Process optimisation
- SOP development
- Root cause analysis
- Sensory Analysis Techniques
- Production support
- HSE awareness
Certification
- Microsoft word and excel certificate
- FSSC 22000 Certificate version 6
- Lean six sigma white belt
- Lean six sigma yellow belt
Timeline
Research and Development Scientist
Big-tree Beverages Ltd
01.2025 - Current
Quality Assurance Unit Lead
Big-tree beverages Ltd
01.2024 - 12.2024
Quality Assurance Analyst
Big-tree beverages Ltd
10.2022 - 12.2023
Diploma - Science Laboratory Technology
Evelyn Hone College
Grade 12 Certificate - High School
Libala Secodary School
FSSC 22000 Version 6 - Awareness & Internal Auditor Training
Intertek International Ltd