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Date: 01 – July - 2013 www.iita.org A member of CGIAR consortium
Feasibility, Design and Implementation of
Aflasafe Demonstration-Scale Manufacturing
Plant
Lawrence K. Kaptoge
Peter Cotty
Joseph Atehnkeng
Joao Augusto
Ranajit Bandyopadhyay
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013
Out line
• What is aflasafe and aflatoxins
• Prevalence of aflatoxins in crops
• Aflasafe development
• manufacturing
- Lab scale
- Pilot plant
• Design considerations for Lab and Plant
• Status/Progress of the plant
• Future of aflasafe
Date: 01 – July - 2013
• Highly toxic metabolite produced by the ubiquitous Aspergillus flavus fungus
• The fungus infects crops and produces the toxin in the field and in stores
• Fungus carried from field to store
• Contamination possible without visible signs of the fungus
• Some predisposing factors: – pre-harvest high temp and
drought stress
– wet conditions at harvest and
post-harvest periods
– insect damage
Aflatoxin Facts
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013
Prevalence of Aflatoxins in Food & Feed
• Several African staple commodities affected
• High human exposure in Africa – mother to baby
• Levels and frequency of occurrence high
– >30% maize in stores with >20 ppb aflatoxin
– ~90% stores are contaminated with Afla fungi
– Up to 40% grain in households with aflatoxin
• Concern for food and feed processors, government and
emergency food reserve agencies, school-feeding
• Aflatoxins disproportionately impact the poor
• Highly toxic strains, conducive environmental
conditions, traditional farming methods and improper
grain drying and storage practices, unregulated markets
www.iita.org A member of CGIAR consortium Date: 01-July-2013
Human and Animal Health Effects
acute
acute hepatic necrosis, cirrhosis,
carcinoma
Death; 200 people in Kenya; 74 in
India
chronic
carcinogenic
stunting in under-fives
anti-nutritional
immune-suppressive
gut integrity?
underreported
unknown
500 ppb AF diet AF-free diet
~40% reduction in live weight (8 weeks)
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Trade Losses due to Aflatoxins
• Nigeria and Senegal major groundnut exporters in 1960s. Compliance has economic incentives
Senegal:
• If aflatoxin levels are reduced, then national income would increase by
– $281 million through oil cake export
– $45 million through confectionary groundnut export.
• Best quality exported; poorer quality consumed domestically.
Peanut
Maize
Coffee
Cocoa
Groundnut Pyramids in
Nigeria during 1960s
Pyramids in Egypt?
World Bank; Mbaye (2004)
AF36
Aflaguard
Biocontrol WORKS
In 100’S of thousands of acres in
the US!
IT WORKS In Africa
TOO!
Aflasafe
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Atoxigenic Strain Identification
Collection/characterization Toxin assay
Field
efficacy
test
Lab
competition
assay
VCG/DNA characterization
cnx nia-D
Unknown 2
+
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Available carriers Cost effective
Adequate stability for transportation
Stored
Compatible application
Viability
• Rice kernels
• Wheat seeds
• Alginate pellet
• Conidial suspensions
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Carrier / Substrates Evaluation
A = Sorghum B = Cassava slice
C = Maize kernel D = Corn cob
E = Stalk tissue
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013
Why Sorghum
• Readily available
• Easy to handle
• Can support for a about three weeks
• Does not require additional nutrient supplement
• Cheap
Alginate pellets = US$2.53 – 5.76 /kg
Wheat seeds = US$1.8 – 0.26 /kg
Sorghum = < US$0.5 /kg
• Good delivery system
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Lab production of aflasafe
Soak in water
for 2 hours
Autoclave grains for
45 minutes at 121oC
Soak grains in
spore suspension
(1x106) for 5 min Incubate at 31oC
for 18 hours
Dry in cloth bags at 50 oC
for 4 days in an oven
Quality control in
moist chamber
Inoculum on sorghum
grain for storage White sorghum grains
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
How aflasafe Works
Broadcast
@ 10 kg/ha 2-3 weeks
before flowering
Sporulation on moist soil
Spores
Insects
Aflasafe in 5 kg boxes
3-20 days
Wind
Soil
colonization
30-33 grains m-2
Fungal network in killed grain
Farmers treating maize and groundnut fields with AflaSafe
MAIZE: Aflatoxin reduction (%)
Stage 2009 2010 2011
Harvest 82 94 83
Storage 92 93 x
PEANUT: Aflatoxin reduction (%)
Stage 2009 2010 2011
Harvest - 95 82
Storage 100 80 x
71% and 52% carry-over of
inoculum 1 & 2 years after
application
Results from 382
on-farm trials
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Lab & Manufacturing Plant Production Process
LATEST PRODUCTION PROCESS
www.iita.org A member of CGIAR consortium
Aflasafe Pilot Plant Objectives
Demonstration-scale plant to be used as a model to:
• Optimize and adapt the manufacturing process
• Reduce aflasafe manufacturing cost
• Turn-key facility for replication in other countries
• Demonstrate commercial viability for mass production
of Aflasafe.
Date: 01 – July - 2013
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Production Process
Lab & manf. Plant core processes:
Production of the inoculum
Production of the substrate
Mixing of the inoculum and substrate at the right rate
Packaging (weighing, sealing and labelling)
Current (Lab) production process 1.2 t/wk (300kg/day)
Manufacturing Plant:
• Mechanise Lab Production
• Scaled up to 5t/hr
• Simplify production – Cleaning, Pasteurisation, Packaging
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013
Final Plan
Partition: Labs, Substrate Processing and Packaging/storage of finished product.
Packaging & Finished Product Storage
Wash Rooms
Lab
Grain Intake, Cleaning, Pasteurisation and Storage
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
3 Partitions:
o Inoculum
Production Lab
o Quality Control
o Resting Room
Ante Chamber 1 & 2
Aflasafe Laboratory
www.iita.org A member of CGIAR consortium
Laboratory Design Steps and Considerations
Steps
• Feasibility/Programming.
• Basic/Schematic Design.
• Design Development – Prdn of floor plans, mvt analysis, equipment
details, drawers, doors, shelves etc .
• Production of Construction Documents – designs detailed and
materials specified.
• Bidding and Negotiation.
• Construction.
Key Design considerations
• Capacity to produce inoculum for 5t/hr (40 ton/day)
• Away from the grain processes/contaminants.
• Ante-chambers – 2 before inoculum lab.
• Seamless floor with cove installation, Bench tops impervious to water,
resistant to acids, alkalis and solvents.
• Recessed lighting, No open windows etc.
• Supervisor office with glass windows overlooking the 2 labs
• NAFDAC requirements
Date: 01 – July - 2013
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Design considerations
• Capacity.
• Combines loading, transferring, filling, and unloading of grain all into
one low maintenance, economical and easy to use system.
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Major works
• Provision of utilities - Complete Water and mains power supply
• Building renovation - Complete Two labs
Workers’ resting room
Rest Room
Packing and storage
• Factory construction – Ongoing
Equipment installations
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Lab
Inoculum Prod. Lab QC Lab
Ante Chambers Spore Susp. Rm Packaging/Storage
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Grain Roaster and Cooler
Aflasafe Equipments
www.iita.org A member of CGIAR consortium Date: 01 – July - 2013
Weighers
Weigher Controller and
management on PC Process Weigher
37
atoxigenic strain manufacturing facility Arizona Cotton Research & Protection Council, USA
AF36 production in USA
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013
06-Dec.-12 IITA - Pathology (Aflasafe)
www.iita.org A member of CGIAR consortium Date: 01-July -2013
Plant equipment cost
S/N Supplier Item Total 1 Chore Time Brock Silos, Elevators, Grain Loop 178,401.48 2 Roast-A-Matic Roaster 60,270.00 3 Roast-A-Matic Cooler 36,494.00 4 Roast-A-Matic Panel and Tools 13,150.00 5 Roast-A-Matic Cyclone 7,850.00 6 Roast-A-Matic HEPA Filter 8,500.00 7 Carter Day Debearder 10,351.00
8 Carter Day Scalperator 13,914.00
9 Carter Day Fine Cleaner 48,425.00
10 Carter Day Exhaust Fan 4,698.00
11 Wintersteiger Hege 11 Seed Treater 7,815.00 12 USC AT500EXT Seed Treater 7,189.00
13 AccuTech Process Weigher 12,846/33
14 AccuTech 2-5kg Smalls Packer 15,129/62
15 AccuTech 5-20 kg packer 14,542/85
16 AccuTech Saxon Heat Sealer 16,597/61
17 AccuTech Hanato Ex-720 Sealer 7,501/15
18 AccuTech Compressor 3,366.23
19 AccuTech Inkjet 7,060.00
20 AccuTech Commissioning and Training 4,796/13
21 Sub Total 407,483.71
22 Siemens Plant Control Panel 52,530.00
Grand Total 460,013.71
www.iita.org A member of CGIAR consortium Date: 01-July -2013
Lab Equipment
Item
Inoculum
Production
Lab
Quality
Control Lab Remarks
Laminar Flow Hood 2 0 Delivery Expected
Laminar Flow Hood 0 2 Delivery Expected
Autoclaves SX-700 2 1 Delivered
Incubator (Air) 5 1 Delivery Expected
Water jacket
incubators. 0 2 Delivered
Fridge. 2 1 Delivery Expected
Turbidimeter 1 1 Delivered
Water distiller 1 Delivered
Ph meter 0 1 Delivery Expected
Balance 1 1 Delivery Expected
Magnetic Stirrer 2 1 Delivered
Vortex mixer 1 2 Delivery Expected
Microscope 1 Delivered
Shaker 1 Delivered
www.iita.org A member of CGIAR consortium
Installation
• Appointed contractor – Jalzak Ltd.
• Scope – installation the following equipments;
Intake/Dump pit together with the augers.
Elevator EL1
Process/Bulk Weigher for determining grain weight .
Debearder that sits below the Process weigher.
Elevator EL2
Scalperator and Fine Cleaner. They are combined as one machine i.e. Scalperator
sits on top of Fine Cleaner.
Elevator EL3 for elevation to 100 ton Clean Grain Storage Silo
Auger TS2 to convey the grain to Pasteuriser/Grain Roaster.
Position the Roaster and cooler.
Grain Loop system with all inlets and outlets.
1 x 100 ton and 3 x 50 ton Roasted grain storage silos.
Towers: 1 x 1828mm high EL3 and 2 x 1219mm high Grain Loop.
Auger TS3 at Point B for conveyance to the Treater.
AT500 EXT Treater.
Auger TS4 for conveying from the Treater to packer.
Packers: 2-5 kg and 5-20 kg.
Heat Sealer.
Electrical connections from the electrical panel to all the above equipments. Panel,
cables and conduits provided by IITA
Date: 01-July -2013
www.iita.org A member of CGIAR consortium
Installation
• Siemens – to install the PLC panel and all process monitors; temperature, RH.
• AccuTech – Packaging equipment and management system.
Special requirements – Internet connection.
Date: 01-July -2013
www.iita.org A member of CGIAR consortium
Installation Program/Schedule
Date: 01-July -2013
ITEM
NO DSCRIPTION WK1 WK2 WK3 WK4 WK5 WK6
1 MARKING OUT THE FLOOR
2 INTAKE PIT/ AUGER
3 BULK WEGHER
4 DEBEADER
5 SCALPERATOR/GRAINS CLEANER
6 AUGER TS2
7 ROASTER AND COOLER
8 AUGER TS3
9 AT500 EXT TREATER
10 THE FOUR SILOS
11 THREE ELEVATOR TOWERS
12 ELEVATOR EL1
13 ELEVATOR EL2
14 ELEVATOR EL 3
15 GRAIN LOOP SYSTEM
16 PACKERS
17 AUGER TS4
18 HEAT SEALER
19 ELECTRICAL CONNECTIONS
20 SITE CLEANING
21 SITE HANDOVER
www.iita.org A member of CGIAR consortium Date: 01-July -2013
Packaging
Old and new aflasafe packaging
Country Funding strains partners commercialization capacity
ongoing
Nigeria BMZ, MycoRED, AATF, USAID, World
Bank, Bill & Melinda Gates Foundation
Senegal AATF
Burkina Faso Austrian Development Agency
Kenya Bill & Melinda Gates Foundation, AATF,
USDA
starting
Mozambique Government of Mozambique, USDA-
FAS, USAID
Zambia USAID-Zambia
The Gambia AATF
Peru CGIAR
interested
Ghana Bill & Melinda Gates Foundation
Mali Bill & Melinda Gates Foundation
Tanzania Bill & Melinda Gates Foundation
Rwanda USAID-Rwanda
Ethiopia USAID East Africa Regional Office
Uganda USAID East Africa Regional Office
Ivory Coast Nestle
India ??
Aflasafe expansion -- The current national approach
ww
w.iita
.org
yet to start
partially started
completed
www.iita.org A member of CGIAR consortium Date: 01-July -2013
Aflasafe Development in Africa
www.iita.org
Products ready for registration
Products under testing in farmers’ fields
Strain development in progress
Aflasafe-NigeriaTM
Aflasafe-SenegalTM
Aflasafe-KenyaTM etc…
Senegal Mali
Burkina
Ghana
Nigeria
Kenya
Tanzania
Mozambique
Zambia
www.iita.org A member of CGIAR consortium Date: 02 – July - 2013
National vs. Regional Approach
strains: regional strains
manufacturing: regional hubs
registration: regional protocols
www.iita.org
Aflasafe-NigeriaTM
Aflasafe-SenegalTM
Aflasafe-KenyaTM
Aflasafe-ZambiaTM
Aflasafe-MozambiqueTM
etc…
Aflasafe-WestTM
Aflasafe-EastTM
Aflasafe-SouthTM
PACA – Meridien Institute
www.iita.org A member of CGIAR consortium Date: 02 – May - 2013