feasibility, design and implementation of aflasafe demonstration-scale manufacturing plant

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


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


Atoxigenic Strain Identification

Collection/characterization Toxin assay

Field

efficacy

test

Lab

competition

assay

VCG/DNA characterization

cnx nia-D

Unknown 2

+


Available carriers Cost effective

Adequate stability for transportation

Stored

Compatible application

Viability

• Rice kernels

• Wheat seeds

• Alginate pellet

• Conidial suspensions


Carrier / Substrates Evaluation

A = Sorghum B = Cassava slice

C = Maize kernel D = Corn cob

E = Stalk tissue


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


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

Product: Aflasafe

Mixture of 4 native atoxigenic strains

Nigeria


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

16

14

14 tons inoculum produced in 2011 for deployment


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


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


Feasibility Study and Design


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


3 Partitions:

o Inoculum

Production Lab

o Quality Control

o Resting Room

Ante Chamber 1 & 2

Aflasafe Laboratory


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


Aflasafe Plant


Aflasafe Plant Plan


Grain Processing Plant


Design considerations

• Capacity.

• Combines loading, transferring, filling, and unloading of grain all into

one low maintenance, economical and easy to use system.


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


Aflasafe Plant


Aflasafe Lab

Inoculum Prod. Lab QC Lab

Ante Chambers Spore Susp. Rm Packaging/Storage


Aflasafe Grain Roaster and Cooler

Aflasafe Equipments


Weighers

Weigher Controller and

management on PC Process Weigher

www.iita.org A member of CGIAR consortium Date: 01-July -2013

Heat sealers


2-5 and 5-20 Kg packers


Ink jet printer


Seed coaters

37

atoxigenic strain manufacturing facility Arizona Cotton Research & Protection Council, USA

AF36 production in USA


06-Dec.-12 IITA - Pathology (Aflasafe)


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


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


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


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


Installation

Date: 01-July -2013


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


Packaging

Old and new aflasafe packaging


Packing And Transportation

46 46

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


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


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

http://www.entwicklung.at/en/


http://www.aflasafe.com/

http://www.iita.org/

feasibility, design and implementation of aflasafe demonstration-scale manufacturing plant

Science

plant future of aflasafe

aflatoxins nigeria

stores fungus

aflatoxin levels

ppb aflatoxin

plant statusprogress

food feed

aflatoxin concern