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TRIPOSHA PRODUCTION PROPOSAL FOR AN INTEGRATE PROJECT FOR THE IMPROVEMENT OF THE PRODUCTION OF THE ROW MATERIAL AND THE FINAL PRODUCT

TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

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Page 1: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

TRIPOSHA

PRODUCTION

PROPOSAL FOR AN INTEGRATE

PROJECT FOR THE IMPROVEMENT OF

THE PRODUCTION OF THE ROW

MATERIAL AND THE FINAL PRODUCT

Page 2: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

FOOD SECURITY

AVAILABILITY

ACCESSUTILIZATION

Page 3: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

PROBLEMS

Local Capacities-Lack or insufficient Organization of the

small farmers

-Transport difficulties

-Low storage capacities

-Marketing problems

Small Producers of soya and maize-Lack of tools

-Poor seeds

-Lack or insufficient storage

-Limited technical capacities

-Excess utilization of the

natural resources

Triposha factory-Insufficient storage capacities

-Limited production capacities (50%)

-Obsolete machineries

-Lack of spare parts

-Dependent from the row materials

Page 4: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

PROJECT METHODOLOGY AND BENEFITS

New

machines

Spare parts

Laboratory

Warehouse

Improvements

Local storages

Farmers associations facilities

Transport facilities

Agricultural Tools

Technical Assistance

Certified seeds

Training

FINANCIAL SUPPORT FOR

Triposha Factory

District Level

Farmers

Page 5: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Transport

capacities

Organizaton of

Collection centers

Biological

Products

Environmental

techniques

Warehouse

Improvement

At principal

factory

Improvement

Of the production

capacities

Farmers of Soya and Maize

Technical assistance

Triposha

Distribution

To MHC

Centers

Page 6: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

PROJECT METHODOLOGY AND BENEFITS

� For FARMERS

� Increase of production

� Improvement of the quality

�Environment protection

�Proper storages

�Collection and transport on time

�Price equity

�Better incomes

� Improvement of food intake

NUTRITION IMPROVEMENT

Page 7: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

PROJECT METHODOLOGY AND BENEFITS

� For the LOCAL ECONOMY

�Standardization of production

� Improvement of the quality

�Better community storages

�Organization of the local networks

�Price stabilization

�Cash movement

�Market opening (ex. Triposha factory, WFP p4p)

Page 8: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

PROJECT METHODOLOGY AND BENEFITS

� For the TRIPOSHA FACTORY

�Warehouse facilities

�Regular delivery of the row material

�Quality standards

�Proper storage

�Adequate buffer stock

� Improvement of the quantity and quality of the

Triposha production

Page 9: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

OTHER OPPORTUNITIES

� Mobilization of technical resources

� Regional funds and capacity building

� EU funds

� ?

Page 10: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

CAPACITY

IMPROVEMENT PLAN

Page 11: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Little bit of history…..THE PROJECT

� In 1976 manufacture of ‘Thriposha’ commenced in Sri Lanka by CARE Canada in collaboration with the Ministry of Health (MoH)

� In 1979 CTC was successful in bidding for the management of the production facility and was a signatory to a tripartite agreement involving the MoH and CARE Sri Lanka

� Care withdrew from the Programme in 1987 and CTC Services Ltd. continued to manage the Programme on the request of the MoH.

PROCUREMENT AND DISTRIBUTION

� Procurement of raw and packing materials is handled by MoH together with the distribution of the finished product. CTC Services Ltd. handles procurement of services and other items needed

BUDGETS AND PROCESS OF REIMBURSEMENT TO CTC Services Ltd.

� Detailed budget for capital and revenue expenditure is submitted by CTC Services Ltd. to MoH in September each year in respect of expenditure for the following year.

� Expenditure incurred by CTC Services Ltd. is reimbursed by the MoH against documents submitted together with a monthly management fee

KEY FEATURES

� Annual Budget - Rs. 750Mln. (Funding – MoH)

� Raw & Packaging Materials (85% of total expenditure)

Page 12: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Objective of the Thriposha Programme

� To provide a supplement which contains energy, proteins and all required

micronutrients to the most nutritionally vulnerable segments of the

population � Pregnant and lactating women

� Infants and children from 12-59 months .

1. To maintain satisfactory weight gain during pregnancy.

2. To reduce incidence of low birth weight (LBW).

3. To reduce maternal mortality.

4. To reduce nutritional anemia among pregnant women.

5. To reduce third degree protein energy malnutrition (PEM) by 90% and second

degree PEM by 50% in infants and pre-school children and reduce infant

mortality.

6. To reduce underweight among children under 5 years.

Page 13: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

The nature of the programme

� The Programme provides a take-home dry food supplement.

� Beneficiaries are entitled to a packet (750 g) of Thriposha once every two weeks,

which translates into a daily food supplement of 50 g.

� Thriposha is one component of the MCH package of the public health sector.

Ingredients Percentage (%)Maize 66

Soya 30

Full cream milk powder 3

Vitamin premix 0.1

Mineral premix 0.9

Source: Government Assisted Thriposha Programme: The Nutrition Coordination

Division, Ministry of Healthcare & Nutrition.

Page 14: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

General Manager

Secretary

Operations/Tech

Manager

Executive (01)

(Accounts)

Quality

Control Manager

Executive (02)

(Technical)

Executive (01)e

(Stores)

Executive (03)

(Production)

Executive

(Purchasing)

Executive

(Quality)

Supervisor (01)

Accounts

Supervisor (01)

Distribution

Supervisor (01)

Technical

Supervisor (01)

Stores

Supervisor (02)

Packing

Supervisor (01)

Medical Centre

Supervisor (01)

Purchasing

Programme

Assistants(04)

(Distribution)

Assistants (02)

Accounts

Assistants (02)

Stores

Assistant

QC

Non Staff

Employees

(02)

Non Staff

Employees

(10)

Non Staff

Employees

(50)

Non Staff

Employees

(05)

LEONARD

Accountant

SHERWOOD VACANT

AJITH GAMAGE

NEON

Assistant

Manager

NIMAL

MINISTRY OF

HEALTH

Dr.Shanthi

Gunawardena

PROJECT

SUPERVISOR

Berty

Albreta Chaminda Mahesh Maali Shanthi

Jasintha

AthulaNuwan

Abeythilake* Chandimal

Padmachandra

Noel*

Marlon

DassanayakeChandrakanthi* Nelum

ThiliniCrishantha

Amila

Asanka

JayasingheMenaka

Samantha

Driver

Non Staff

Employees

(50)

Non Staff

Employees

(03)

Confidential

Steno (01)

(Distribution)

Jayanthi

Nelum

Lal

Priyadharshani

EMPLOYEES

� TOTAL PERMANENT CADRE – 154

� Executives/Supervisors/Clerical – 29

� Operators/Drivers/Skilled/Unskilled – 125

Page 15: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Thriposha Distribution

� Thriposha is issued to: � MOH clinics;

� Estates;

� Probation and childcare centres;

� Mahaweli authority;

� Ward patients in some hospitals.

Centres Beneficiaries

Districts 25 708 709438

Mahaweli Authority 2 7176

Estates 449 43468

Probation & Child Care 8 23949

784031

No. of

TOTAL

Distribution

Page 16: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

1.1 mn Beneficiaries

Annual Thriposha Requirement – 19,800 MTs

Current capacity (80% plant efficiency) – 10,440 MTs (53% )

0.58 mn Beneficiaries receive Thriposha (53%)

Long TermShort Term

Cater to 1.1 mn Beneficiaries (100%)Reach .72 mn Beneficiaries (65%)

54% Capacity improvement23% Capacity improvement

Page 17: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

CLEANINGDEHULLING

BRADY LINE ANDERSON LINE

BLENDING

PACKING

STORAGE

DISTRIBUTION

SOYAMAIZE

PRODUCTION PROCESS

MILK POWDER

VITAMINS

MINERALS

STORAGE TANK STORAGE TANKSTORAGE TANK STORAGE TANK

CLEANING

Production Process

STORAGE STORAGE STORAGE

Page 18: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product
Page 19: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Anderson Line

Page 20: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Brady Line

Page 21: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Packing and Storage

Page 22: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Supply Chain

Maize

Soya

Milk

Powder

Vitamins

Minerals

Packing

Material

Imported

Mainly

Local

Local

Government

Tender Process

Maize Farmers

Soya Farmers

Collection &

Cleaning

Local Farmer

Associations

ThriposhaProduction

Quality Check

In houseRaw MaterialQuality Check

& Storage

FinishedProductStorage

PLAN

SOURCE DELIVERMAKE

Inconsistency in Maize & Soya

Supply

Average 3 -6 Months

For the process

Annual capacity

10440 MTs

580,000 Beneficiaries

880 centres

Livelihood of over 30000

Rural Families

Page 23: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Capacity Improvement Plan

Thriposha Production

Blend Size

Anderson

Brady

Avg. Blends per hr.

Avg. Production per hr.

Production per Day (Kgs)

No of Master Bags Per Day

Production per Month (MTs)

No of Master Bags Per Month

Annual Production (MTs)

No of Beneficiaries

Beneficiary %

Capacity Increase (MTs)

%

Current

450

3.05

1

4.05

1822.5

43740

1944

875

38880

10498

583200

53%

Short Term

450

3.5

1.5

5

2250

54000

2400

1080

48000

12960

720000

65%

2462.4

23%

Page 24: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Capacity Improvement Plan

Thriposha Production

Blend Size

Anderson

Brady

Avg. Blends per hr.

Avg. Production per hr.

Production per Day (Kgs)

No of Master Bags Per Day

Production per Month (MTs)

No of Master Bags Per Month

Annual Production (MTs)

No of Beneficiaries

Beneficiary %

Capacity Increase (MTs)

%

Current

450

3.05

1

4.05

1822.5

43740

1944

875

38880

10498

583200

53%

Short Term

450

3.5

1.5

5

2250

54000

2400

1080

48000

12960

720000

65%

2462.4

23%

Long Term

450

3.85

3.85

7.7

3465

83160

3696

1663.2

73920

19958.4

1108800

101%

6998.4

54%

Anderson

Page 25: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

130000 USD

330000 USD

From Austria

March 2009

Funded by

UN

World Food

Programme

2008

300,000 USD

Our Needs….

Long TermShort Term

New Proportionate Mill

Blender – 5 MTs p/h

Auto Feeder for Milk

Vitamins/ Minerals

01Miracle Tank

02 Storage Tanks (100 MTs)

Boiler

1000 KVA Generator

• Replace Brady line with new Anderson line

• Increase the Capacity to 20000 MTs.

• Approximate cost USD 2.5 mn

Extruder

Proportionate Mill

Hammer Mill

Dryer

Mega Mill

Gravity Separator

Auto Packing line

02 Storage Tanks

Blowers

Tubing

Conveyers

Bucket Elevators

Construction of a new Store 60’x270’x30’

Approximate cost USD 500,000

Training & Development for Employees

Improvement to the facilities

• Canteen

• Changing & Locker Rooms

• Wash Rooms

• Laundry

• Medical Centre

Upgrading the Workshop&

Engineering Stores

New Vehicle Fleet

2 Double Cabs

01 Passenger Van

Upgrading the Lab&

Production Floor

TO ACHIEVE

ALL THIS…..

WE MUST HAVE

MOTIVATED PEOPLE

2 nos. Auto Packing Line

Page 26: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Proposed Factory Layout

WFP Report – August 2008

Page 27: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Summary of the Short Term Requirement

USD Euro

01 Miracle Tank 20,000 15,714

Boiler 110,000 86,429

2 Automated Packing Lines 330,000 259,286

New Store 500,000 392,857

1000 KVA Generator 410,000 322,143

Replacement of 3 Vehicles 275,000 216,071

Total 1,645,000 1,292,500

CostITEM

Thank You

Page 28: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Annex

Project synthesis

Editorial on The Lion(italian version)

Estimated Budget For The Items Required For The

Capacity Improvement Of Thriposha Factory

Thriposha Product Specifications

Page 29: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

LIONS AGAINST THE HUNGER :SRI LANKA PROJET

A delegation of LIONS Italy (Carlo Federico Bonini district 108IB4 and Pierluigi Tarenghi

district 108IB2) together with Mrs. Catherine Dickehage, national coordinator of Italian

Committee for WFP have visited Sri Lanka from November 24 to 30.

The field visit was coordinated and organized by WFP Country office Sri Lanka based in

Colombo.

Main aim of the delegation was to get first hand information on the Triposha factory needs

and have a clear picture of the project cycle from production to delivery to the beneficiaries.

The field trip has been extremely interesting: Sri Lanka is a beautiful country with he artful

people. We have been very glad to discover a community that was so keen to cooperate

with us. We had the chance to meet many people: the management of the factory,

representatives of different ministries, doctors, women and child who benefit from the project.

We got even more involved in the project and our committeemen to the service we chose

grew even bigger.

Page 30: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

2 - LIONS AGAINST THE HUNGER :SRI LANKA PROJET

Dr Y.D. Nihal Jalathilaka Ministry of Health

Dr Shanthi Gunawardana Ministry of Health

Mrs.A.A.R Ratnayake Ministry of Agricolture

S.E Ambassador Pio Mariani Embassy of Italy

Luca Fraticelli Head of mission Embassy of Italy

Ajith Gamage General Manager Triposha factory

K.S.T Perera General Manager KST Evergreen LTD

S.E Mario Zenari Apostolical Nuncio

Ranjith Fernando President Lions club Homagama (district 306C2 )

We spent some time with Mr Fernando and we visit the eye clinic/laboratory in a local health centre (Sight first

programme )

Adnan Khan Country director World food Programme

Azeb Asrat Deputy country director World Food Programme

Giancarlo Stopponi Head of programme unit World Food Programme

Kithsiri Mullegamgoda Project Manager World Food Programme

Page 31: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

3 - LIONS AGAINST THE HUNGER :SRI LANKA PROJET

We also met a couple of Italian Businessmen who ilve and working Sri Lanka

The meeting we attended, all at top level,gave us the chance to improve and widen the

project's objective. Italian Lions will no more limit their support to a service that aims at

doubling the production capacity of the factory but also will work closely with the ministry of

Health and Ministry of Agriculture in order to widen the projet and support the production

cycle.

In particular the support to the Ministry of Agricultures will include exchange and vovational

training with the university of Piacenza-Faculty of Agricultures, capacity building and

training in cooperation with FAO witch will include improvement of the quality of seeds and

improvementof local agricolture productivity.

On the other hand the support to the Ministry of Health will include an improvement to the

distribution cycle, an increase of the participation level of local farmers, the print out of a

workbooks on production techniques to be delivered to local farmers, the print out of a

numbers of notebooks for mothers for the growth monitoring of infants and pre-school kids.

We are now preparing a work plan which include timing and specific costs for all phases of

the project. We will be pleased to send you a copy as soon as we will complete it.

In the meantime I wish you all the best.

Page 32: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product
Page 33: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

Priority list

No. ITEM MODEL Estimated cost USD Supplier Details Remarks

ANDERSON INTERNATIONAL CORPORATION

6200 Havard Avenue

Cleveland, OHIO 44105-4896

Tel: 216-641-1112

Facsimile 216-641-0709

2 Mega Mill MM-18 60000 PARTICLE MANAGEMENT SOLUTIONS

3 TEFC Motor 100HP 10000 2 Sammons Court, Bolingbrook, IL 60440

B.N.W. Industries

7930 N. 700 E.

Tippecanoe, IN.

46570 USA

Office 574-353-7855

Fax 574-353-8152

Email [email protected]

713 W LAFEVER, OSSIAN, IN 46777 USA (260) 622-7831 1(800) 537-6260 FAX

(260) 622-4798

www.atferrel l.com info@atferrel l .com

15 Blower 2000016 Bucket Elivators

17 Tubing

18 Convayers

8Miracle Tank for Thriposha Powder

Storage – Capacity 10 Metric Tons 1700010 Boiler (4 Tone) CBLE100-250-200ST 110000 Cleaverbrookes, USA 2nd stage

4 Mega Mill MM-9 40000 Ph: 630-759-9595 Fx: 630-759-6099

5 TEFC Motor 40 HP 4000 www.prater-sterling.com

14 Gravity Separator 90 - V 40000 Forsberg Company, UK, www.forsbergs.com

2002 nos Battery Operated FolkLifts (5

Tone) RX60-50 160000

902 Nos. Fully Automatic Form Fill &

Seal Machines for Thriposha Packing LX-52314000 5th stage

19 Centralised Vacume Cleaner Unit EF125i 154545 Cardwele Company, UK

21 02 nos. 25kg Washing Machines Fully Auto 500022 02 Double Cabs 180000 Including Duty

23 01 Car Including Duty

11 02 nos Storage Tanks (100 MTs each) 180000 Sukup, USA, www.sukup.com WFP

12 Nutri Blender 70000 WFP

13Auto feeder for Milk, Vitamins and

Minerals 42000 WFP

Total Estimated cost of the Items 1.701.545,00

RIEPILOGO PRIORITA' USD € (al cambio $1,30)

1st stage $402.000 309.231 €

2nd stage $110.000 84.615 €

3 &4th stage $244.000 187.692 €

5th stage $314.000 241.538 €

6th stage $159.545 122.727 €

7th stage $180.000 138.462 €

WFP $292.000 224.615 €

TOTALE $1.701.545 1.308.881 €

6th stage

7th stage

70000

700007 02 nos. Mix-Mill Hammer Mills

3 &4th stage

6 Belt-o-matic model 320B dryer/cooler

ESTIMATED BUDGET FOR THE ITEMS REQUIRED FOR THE CAPACITY IMPROVEMENT OF THRIPOSHA FACTORY - JA-ELA, SRI LANKA.

1 Anderson Extruder 125000

1st stage

30000

Page 34: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

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Page 35: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

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Page 36: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

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Page 37: TRIPOSHA PRODUCTION · triposha production proposal for an integrate project for the improvement of the production of the row material and the final product

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