La nostra esperienza con la FSMA - Convegno L'Export di Alimenti verso i Paesi Terzi, consolidamento - Alimenti e salute
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Bologna, 4 giugno 2018
Convegno
L’Export di Alimenti verso i Paesi Terzi, consolidamento
di flussi tradizionali e apertura di nuovi mercati
La nostra esperienza con la FSMA
Page 1
Company overview
Il business
Il Gruppo La Doria è leader nella produzione di derivati del pomodoro, frutta, legumi
conservati e sughi pronti ambient.
Il Gruppo è fortemente vocato all’export e produce prevalentemente a marchio private
labels, i marchi commerciali della Grande Distribuzione e della Distribuzione Organizzata, sia
italiani che esteri.
La Doria è un'azienda familiare alla 2^ generazione. Fondata nel 1954 dalla Famiglia Ferraioli, è
presente sul mercato da oltre 60 anni.
Page 2
Company overview
La posizione competitiva
• 1° produttore italiano di pelati e polpa di pomodoro
• 1° produttore italiano di legumi conservati
• 2° produttore italiano di succhi di frutta e 1° nello specifico segmento delle private labels
• 1° produttore italiano di sughi pronti nel segmento delle private label
• Primi sul mercato britannico delle conserve di pomodoro e dei legumi conservati a
marchio private labels
• Primi nelle conserve di pomodoro in Giappone ed Australia
Page 3
Company overview
Le leve competitive
Alta qualità del prodotto
Prezzo concorrenziale
Forte efficienza industriale che consente di essere altamente competitivi nei costi, grazie a
elevata tecnologia di processo, economie di scala, utilizzo ottimale della capacità produttiva e
integrazione verticale della produzione con la produzione interna di scatole.
Volumi elevati in grado di soddisfare le esigenze dei colossi della Distribuzione Moderna
Ampiezza e profondità della gamma
Segmentazione dell’offerta private labels a presidio di tutte e tre le linee pl (primi prezzi, marchio
insegna e premium price).
Innovazione di processo e di prodotto a servizio delle private labels in linea con i nuovi trend di
consumo e le innovazioni dell’industria di marca.
Elevata flessibilità nella personalizzazione delle ricette, packaging e servizio
Relazioni consolidate di lungo termine con i maggiori players della Grande Distribuzione
Rapporti di partnership con clienti e fornitori strategici
Corporate Governance in linea con le best practice e cultura della Sostenibilità
Page 4
Company overview
La struttura del Gruppo La Doria
La Doria è una società quotata alla Borsa valori di Milano, segmento Star (segmento titoli alti
requisiti).
Famiglia Ferraioli (63%)
Flottante (37%)
DOR
(58%) (98.67%)
LDH (La Doria) Ltd- società di trading, leader sul mercato britannico nei derivati del pomodoro e legumi conservati prodotti
dal Gruppo, oltre che in altri articoli complementari (pasta secca, tonno e salmone in scatola,
Eugea Mediterranea S.p.A. - società italiana produttrice di derivati del pomodoro e puree di frutta.
Page 5
Company overview
Il trend del fatturato consolidato
+2,4%
(in milioni di Euro)
800 748,3
669,1
700 631,4 653,1
604,4
578,9
600
500
400
300
200
100
0
1999 2001 2003 2005 2007 2009 2011 2013 2015 2017
Italia Estero
Page 6
Company overview
Un’ampia gamma di prodotti
POMODORO VEGETALI FRUTTA/TE’ SUGHI PRONTI ALTRE LINEE
(LDH trading)
Pelati Legumi lessati Nettari Sughi rossi
Polpa Baked beans Succhi 100% Pesto Pasta secca
Passata Red kidney beans Bevande Sughi bianchi Tonno e salmone
Pasta in scatola Sughi con carne in scatola
Pomodorini Tè freddo
Frutta sciroppata
Sughi pronti Carote Sughi con pesce
in scatola
Zuppe legumi e Condimenti per Mais in scatola
vegetali insalate Pet food
Page 7
Company overview
I siti produttivi
7 siti produttivi
Superficie totale
812.000 m2 La Doria
(Parma)
La Doria
(Faenza)
di cui coperta
304.000 m2
Eugea Mediterranea
La Doria (Lavello)
(Acerra)
746 dipendenti fissi La Doria
circa 1.000 stagionali (Angri)
Headquarter
La Doria La Doria
(Sarno) (Fisciano)
Page 8
Company overview Le certificazioni ACERRA ANGRI EUGEA FAENZA FISCIANO PARMA SARNO Page 9
Iter per FSMA
Come previsto dal 21CFR117.126 (2)
La Doria ha identificato degli individui qualificati addestrati per l’FSPCA
Page 10Formazione PCQI
E’ stato quindi creato un team PCQI multidisciplinare con componenti di sito e
componenti fissi
Page 11Redazione Food Safety Plan
La Doria ha quindi sviluppato differenti Food Safety Plan per coprire
tutte le produzioni per il mercato US così come previsto da:
PART 117 -- CURRENT GOOD MANUFACTURING PRACTICE,
HAZARD ANALYSIS, AND RISK-BASED PREVENTIVE CONTROLS
FOR HUMAN FOOD
Subpart C--Hazard Analysis and Risk-Based Preventive Controls Sec.
117.126 Food safety plan
Page 12Come abbiamo strutturato il food safety plan
A grandi linee abbiamo previsto:
Descrizione del prodotto
Product Name Romano Pasta Sauce Sam’s
Product Description, including Important Food Tomato based products with ricotta cheese and pecorino Romano
Safety Characteristics - PART 114—ACIDIFIED FOODS
pH < 4,5
Ingredients tomato pulp (tomato, tomato juice, citric acid), tomato paste (tomato, tomato
juice, citric acid), Ricotta Cheese (Pasteurized Whey, Salt, Citric Acid), olive
oil, water, onion, Pecorino Romano Cheese made with Sheep's Milk (sheep's
milk, salt, rennet), basil, salt, sugar, garlic, lactic acid.
CONTAINS: MILK
Packaging Used Glass Jar 680g net weight, metal cap, paper label.
2 jars are shrink wrapped and put in a x12 carton
Intended Use The product is ready-to-eat
Intended Consumers General public not suitable for infant
Shelf Life 36 months ambient, unopened;
3-4 days in refrigerator after opening
Labeling Instructions Empty contents into a saucepan. Heat gently, stirring occasionally until piping
hot throughout. Do not allow to boil. Pour into the drained pasta and serve.
Storage and Distribution Ambient Page 13Come abbiamo strutturato il food safety plan
Schema a blocchi semplice
Receiving shelf stable
ingredients Receiving frozen ingredients Receiving chilled ingredients Receiving packaging material
shelf stable ingredients
storage chilled ingredients storage packaging material storage
frozen ingredients storage (onion, pecorino romano,
(olive oil, chopped tomatoes, (garlic and basil) (jars, lids, label, carton)
tomato paste, lactic acid, ricotta cheese)
sugar and salt)
mix all ingredients water
pastorization tube in tube
hot filling and sealing cleaning jars
(invert and flush with
filtered air)
coding
Heat treatment and cooling in tunnel of closed jar
vacuum test
x ray detection
labelling
secondary pack
positive release
Page 14
shippingProcess Narrative
Process Narrative
Receiving packaging material
Withe glass jars are received on pallet shrink wrapped
Metal caps are received in plastic blue bags inside carton that are put on pallet.
Vendors provide a certificate of conformance that packaging materials is suitable for food
contact.
Labels are received on pallet shrink wrapped and put on pallet.
Receiving shelf stable ingredients
Olive oil: is received in1000 kg tanks or bulk in cisterns. In this case supplier provide certificate of
washing of the cistern.
Chopped tomatoes and tomato paste: are aseptic and are supplied in drums of 200 kg around on
pallet (4 drums / pallet) or in big bag of 800/1000 kg.
Lactic acid: is supplied in 1000 kg tanks
Sugar and salt: are received in 25 kg. bags.
Receiving frozen ingredients
Garlic and basil are received both in blue plastic bags inside a carton on pallets. Product is delivered on
refrigerated trucks (-18°C) with the obligation to provide truck temperature registration during all stages of
loading and transport until the unloading to the farm
Receiving chilled ingredients
Onion: are received in plastic bins in truck.
Pecorino romano and ricotta cheese are received in blue plastic in carton bins in refrigerated truck (0/4°C)
Packaging storage
glass jars are stored in the square outside
Metal caps , label and other pack material are stored in the package warehouse
Shelf stable ingredients storage
Olive oil: is stocked in refrigerated tanks
Chopped tomatoes and tomato paste: are stored in the square outside
Lactic acid, sugar and salt: are stored in raw material, room temperature, warehouse
Page 15
Frozen ingredients storage
Garlic and basil are stored in refrigerated warehouse (-18°C)Come abbiamo strutturato il food safety plan
Schema seguito per Hazard Analysis:
Hazard Analysis
Hazard identification (column 2) considers those that may be present in the food because
the hazard occurs naturally, the hazard may be unintentionally introduced, or the hazard
may be intentionally introduced for economic gain.
B = Biological hazards including bacteria, viruses, parasites, and environmental pathogens
C = Chemical (including radiological) hazards, food allergens, substances such as pesticides and drug
residues, natural toxins, decomposition, and unapproved food or color additives
P = Physical hazards include potentially harmful extraneous matter that may cause choking, injury or other
adverse health effects
(1) (2) (3) (4) (5) (6)
Ingredient/ Identify potential food safety Do any potential Justify your decision What preventive control Is the
Processing Step hazards introduced, controlled food safety for column 3 measure(s) can be applied to preventive
or hazards require a significantly minimize or control
preventive
enhanced at this step prevent the food safety applied at
control?
hazard? this step?
Process including CCPs, Allergen,
Sanitation, Supply‐chain,
YES NO other preventive control YES NO
Receiving B None
packaging C Undeclared X Labels must Allergen Control X
material allergens declare Label are preventively
(jars, lids, label, allergens present approval by QA and
carton) in the product controlled at the incoming
(milk) for presence of allergen
by QC
P None
Receiving shelf B None
stable C Peroxides, IPA, X Ingredient come
ingredients pesticides, heavy from evaluated
(olive oil) metals, dioxin and supplier audited
micotoxin PCBs and monitored.
Furthermore,
where deemed
necessary,
certificates and /
or statements
accompanying the
goods are
required on the
basis of a risk
assessment and
or internal
analysis are
conducted on the
product
P None
EMA Presence of different X Olive oil is a raw Supply chain control X
oil material at fraud Raw material comes from
risk evaluated supplier Page 16
Receiving shelf B None Low pH, shelf-
stable stable product is
ingredients not likely to have
(tomatoes biological hazardsQuali Pericoli sono stati considerati?
1 Hazard Analysis:
As per CFR 117.130(a)(2) La Doria has considered known or reasonably foreseeable hazards
that include:
• Biological hazards, including microbiological hazards such as parasites, environmental
pathogens, and other pathogens;
• Chemical hazards, including radiological hazards, substances such as pesticide and
drug residues, natural toxins, decomposition, unapproved food or color additives, and
food allergens; and
• Physical hazards (such as stones, glass, and metal fragments); and
Known or reasonably foreseeable hazards that may be present in the food for any of the
following reasons:
• The hazard occurs naturally;
• The hazard may be unintentionally introduced; or
• The hazard may be intentionally introduced for purposes of economic gain. (ema)
Page 17Quali Preventive control
1 Preventive controls:
As per CFR 117.135(b) La Doria implements preventive controls to provide assurances that any
hazards requiring a preventive control will be significantly minimized or prevented and the
food manufactured, processed, packed, or held will not be adulterated under section 402 of the
Federal Food, Drug, and Cosmetic Act or misbranded under section 403(w) of the Federal Food,
Drug, and Cosmetic Act.
Preventive controls are written and include controls at critical control points (CCPs), if there
are any CCPs; and Controls, other than those at CCPs, that are also appropriate for food safety.
Preventive controls include:
• Process controls: procedures, practices, and processes to ensure the control of
parameters during operations such as heat processing, acidifying, including maximum
or minimum value, or combination of values, to which any biological, chemical, or
physical parameter to be controlled to significantly minimize or prevent a hazard
requiring a process control.
• Food allergen controls. include procedures, practices, and processes to control food
allergens for ensuring protection of food from allergen cross-contact, including during
storage, handling, and use; and labelling the finished food, including ensuring that the
finished food is not misbranded under section 403(w) of the Federal Food, Drug, and
Cosmetic Act.
• Sanitation controls. include procedures, practices, and processes to ensure that the
facility is maintained in a sanitary condition adequate to significantly minimize or
prevent hazards such as environmental pathogens, biological hazards due to employee
handling, and food allergen hazards. Sanitation controls must include, as appropriate
to the facility and the food, procedures, practices, and processes for the: Cleanliness of
food-contact surfaces, including food-contact surfaces of utensils and equipment;
Prevention of allergen cross-contact and cross-contamination from insanitary objects
and from personnel to food, food packaging material, and other food-contact surfaces
and from raw product to processed product.
• Supply-chain controls. include the supply-chain program as required by subpart CFR
117 Subpart G--Supply-Chain Program
• Recall plan. Recall plan as required by CFR 117.139. Page 18
• Other controls. Preventive controls include any other procedures, practices, and processes necessary
(for example hygiene training and other current good manufacturing practices)Come abbiamo strutturato il food safety plan
Esempio di matrice per la valutazione dei Process Preventive Controls
Process Hazard(s) Critical Corrective Verification Records
Monitoring Action
Control(s) Limits What How Frequency Who Operative instruction
Mix all Finished Product pH not pH of sauces Measure of the Each batch QC Process IL01 QP-L: Correct the pH Verification of SAP
over 4,30 after mixing all pH on samples before the control sampling for pH adding lactic acid, registration from control
ingredients product discharge
(production the ingredients from the batch control re control the the QC plan
microbic
std: as per sap kitchen IL02 QP-L pH batch supervisor
alteration control operative
control plan)
(Clostridium instruction
and Bacillus
species, other
pathogenic
microorganisms
) activation if pH
is over 4.60
pasteurization Alteration due Safety limit Control of the on line Start up for Process IL02 QP-02 ste Suspend the Verification of SAP
to under F100≥ 6.5 couple T and t as registration and flow rate and operator point tube in tube product as registration from control
tube in tube (equivalent to per SAP control automatic control start up and 1 IL03 QP-02 set provided by the the QC plan
processing
100 ° C for 6.5 plan with device h for T point control tube Non conformity supervisor
minutes). system in case of in tube procedure ,
lower IL16 QP-02 alarm quarantine of the
temperature control tube in product and
tube involvement of
QA
cleaning jars Foreign bodies Pressured Control of the on line Start up / Process IL17 QP-02 jar Suspend the Verification of SAP
contamination air pressure of registration and shift operator inverter and product as registration from control
pressured air automatic control treatment with provided by the the QC plan
due to handling as per SAP
with stop of the pressured air Non conformity supervisor
or packaging control plan
line in case of control procedure ,
lower pressure involvement of
QA
Hot filling and Microbic min T as per Control of the Measurement of Start up / Process IL18 QP-02 control Suspend the Verification of SAP
alteration due to SAP control filling the temperature each hour operator at filling station product as registration from control
sealing plan with calibrated provided by the the QC plan
low filling temperature
thermometer Non conformity supervisor
temperature procedure ,
involvement of
QA
Glass Absence of Control of the Visual control Start up / Process IL01 QP-D 01: Suspend the Verification of SAP
contamination glass fragment line from the each hour operator / QC Glass product as registration from control
cleaning of the management provided by the the QC plan
due to operator
Non conformity supervisor
breakage jar up to
procedure ,
during filling of capper involvement of
glass jars QA
Net weight not Net weight Weight control Control on Start up / Process IL05 QP-L USA Suspend the Verification of SAP
conform to US 680g balance end/ each operator Check weight product as registration from control
control USA provided by the the QC plan
market 1/2 hour
Non conformity supervisor
procedure ,
involvement of Page 19
QACertificazione volontaria
FSMA PREVENTIVE CONTROLS MODULE
Page 20Ulteriori corsi e consulenti
CORSI:
Corso su etichettatura USA Export USA: Food defence
Corso food fraud
AGENTE USA E CONSULENTE:
EAS Consulting Group LLC,1700 Diagonal Road, Suite 750,Alexandria VA, 22314
Page 21Difficoltà e proposte per il futuro
DIFFICOLTA’:
Trattandosi di un nuovo mercato fortemente in crescita la nostra maggiore
difficoltà attualmente sta nel dover creare nuovi SID che possano coprire
sia produzioni industriali che campioni destinate alle fiere.
ASPETTATIVE:
Cosa auspichiamo? La creazione di un network con altre aziende ed enti
locali nazionali per condividere per esempio aspetti operativi e/o per
avvalersi degli stessi consulenti anche in un’ottica di cost saving
Page 22Grazie per l’attenzione
Page 23Puoi anche leggere
