Aflasafe TM manufacture Ibadan & Machakos modular plant - presentation at KALRO Machakos

Date: 21-08-2014 www.iita.org A member of CGIAR consortium

aflasafeTM

Manufacture (Ibadan & Machakos Modular Plant)

Lawrence K. Kaptoge

Charity Mutegi

Ranajit Bandyopadhyay

Peter Cotty

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Objectives – aflasafe Pilot Plant Ibadan Nigeria

Overview

o Objectives of the Ibadan Plant

o aflasafe Production Process

o Common Plans and Pictures of Ibadan Plant

o Modular Draft Plans for the Machakos Plant

o Site considerations.

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Objectives – aflasafe Pilot Plant Ibadan Nigeria

Demonstration-scale manufacturing plant to be used as a model to:

• Optimize and adapt the manufacturing process

• Reduce production cost

• Develop a turn-key facility for replication in other countries

• Demonstrate commercial viability for mass production of

Aflasafe and recruit commercial partners.

• Build awareness, demand, and aggregation channels for low-

aflatoxin crops.

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Aflasafe Production

Involves 2 main processes:

1. Production of inoculum.

2. Production/Preparation of Carrier/substrate

Inoculation/Coating – (Mixing at right rate)

Packaging (weighing, sealing and labelling)

Initial Lab production process 1.2 t/wk (300kg/day)

Manufacturing Plant:

• Mechanise Lab Production

• Scaled up to 5t/hr

• Simplify production

o Cleaning

o Sterilisation – dry process and cost reduction

o Inoculation - coating

o Packaging – simple and cheap

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Production Block Diagram

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Ibadan Plans

Packaging & Finished Product Storage

Wash Rooms

Lab

Grain Intake, Cleaning, Pasteurisation and Storage

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Progress

Workers’ Resting Room

Inoculum Production Lab

Quality Control Lab

Quality Control Lab & Lab office

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Progress

Cooler

Roaster

Plant Before & after completion

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Progress

Weighing & Heat Sealing

Inoculation & Weighing

Finished Product Storage

Final Package – Front & Back

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Production 2014

• Production of aflasafe for: • Nigeria – 120 tons (Scaled down from 250 tons)

• Senegal – 12 tons

• Zambia – 3 tons

• Mozambique – 1 ton

• Ghana – 1 ton

• Burkina Faso – ?

• Kenya – ?

Inoculum Production

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

Building: Approximately 10 m tall; 20

m wide; 30 m long.

Silos hold about 20 tons each.

Hoppers also in coater and packing

lines.

Raw Grain

Spore Culture

Room

End P

rodu

ct S

tora

ge

Packing Room

Toilet

End Product

Silos

Roasted Grain

Final Cleaners

Roasters

Bagger

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

HEPA filter

Motor

Internal Aerator

Cut away view of perforated

tube in silo.

This is the type of design we plan to use

for the Roasted Grain Silos – the grain

enters the silo hot. This worked will in

initial trials.

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

Auger from Roaster to Silo

Remains hot to keep clean

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

This is the current aeration

tube. The larger silos will

have a 36” diameter tube

and only travel about half

way up the silo.

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Modular Plant

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Line Diagram of the Modular Plant

www.iita.org A member of CGIAR consortium Date: 21-08-2014

Site Visit’s Considerations

Location of the facility:

o availability of a good, well-drained and accessible site that is protected from

wind, rain/floods and high water table.

o Room for large vehicles to move through the facility without having to back

up. (Semi-trailers need about 20m turning radius).

o Room for future expansion

o Land for waste disposal.

o Environmental assessment report?

o Possibility of similar existing facilities e.g. seed plant?

o Proximity of the facility to homestead/residential estate, offices etc - in line

with problems associated to vehicle traffic, noise, dust, chaff etc.

Total storage capacity and Bin size requirements

o Small bin size - delays during unloading.

o current and future likely annual storage capacity

Facilities:

o existing power and water supply to the site?

o Upgrade of existing facilities?

o Technical Personnel

www.iita.org A member of CGIAR consortium Date: 02 – May - 2013