Aflasafe manufacturing, scaling up and commercialisation

Date: 23-11- 2013 www.iita.org A member of CGIAR consortium

Aflasafe Manufacturing - Scaling Up and

Commercialization

Lawrence K. Kaptoge

Peter Cotty

Joseph Atehnkeng

Joao Augusto

Nick Garber

Ranajit Bandyopadhyay

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

• Produce axenic Bio pesticide

• Model turn-key facility for replication in other countries

• Demonstrate commercial viability for mass production

of Aflasafe and recruit commercial partners.

Date: 23-Nov-2013

www.iita.org A member of CGIAR consortium Date: 23-Nov-2013

Scaling Up

Lab & manufacturing Plant core processes:

Production of the inoculum

Production of the substrate/carrier

Inoculation/Coating

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

o Cleaning

o Sterilisation – dry process and cost reduction

o Inoculation - coating

o Packaging – simple and cheap


Scaling Up

Date: 23-Nov-2013

LAB PRODUCTION PROCESS PILOT PLANT PRODUCTION PROCESS


Beginning and Progress So far

STARTING POINT


Final Plan

3. Inoculation, Packaging & Temporary Storage

Wash Rooms

Lab: Production

of Inoculum

1. Substrate/carrier (Sorghum) production comprising:

Grain Intake, Cleaning, Pasteurisation and Storage


Final Plan

Date: 23-Nov-2013


Progress So Far

Laboratory:

Complete and operational: Inoculum production Lab (Laminar Flow hoods, New heating incubators)

Quality control lab

Spore suspension room

Manufacturing Plant: • Purchase and Installation of:

• Intake Pit – Lowry (USA)

• Debearder, Scalperator, Fine Cleaner – Carter Day (USA)

• Silos and Grain Handling Equipments – Brock (USA)

• Grain Roaster and Cooler – Roast-A-Matic (USA)

• Weighers and Sealers – Accutech (SA) - Air & Sea Freight


Progress So Far: Building Renovation

Despatch of aflasafe


Progress So Far: Lab & Equip. Installation

Workers’ Resting Room

Inoculum Production Lab

Quality Control Lab

Quality Control Lab & Lab office


Progress So Far: Substrate Preparation


Production and Pending works

• Production of aflasafe for: • Nigeria – 9.6 tons

• Senegal – 6 tons

• Burkina Faso – 1.5 tons

• Zambia – 11 tons

• Kenya – 1.8 tons

• Installation of PLC Panel by Siemens to: • Monitor critical processes: temperature, RH.

• Control Critical Process

• Display real time operation of the entire plant and processes

• Packaging system by AccuTech • For packaging of small packs (2-10kg) and big packs (10-20 kg)

• Sealing of weighed product.

• Weighing management system (AMIC)

Date: 23-Nov-2013


Quality Control

Date: 23-Nov-2013

0%

10%

20%

30%

40%

50%

60%

Silo Roaster

Exit

Cooler

Exit

Treater

Exit

Germinating

Contaminated

0.00%

0.20%

0.40%

0.60%

0.80%

1.00%

1.20%

1 2 3 4 5

% o

f se

ed

s to

ge

rmin

ate

or

reve

al fu

ng

al c

on

tam

ina

tio

n

aflasafeTM plant location from which sorghum was sampled

aflasafeTM ZM02 batch number

Pe

rce

nt o

f se

ed

s c

on

tam

ina

ted

by f

un

gi o

the

r th

an

A. fla

vu

s

Fig. 1 – Sorghum samples taken at different locations during

processing without inoculating to determine effectiveness of

roasting to kill and sterilize the substrate/carrier.

Fig. 2 – Final aflasafe product sampled in batches and incubated at 100% humidity for 7 days.

Fungal contamination reported within acceptable levels.


Challenges & Conclusion

• Challenges

• NAFDAC registration

• Training and retaining good operators

• Sterilisation of equipment esp. Conveyors and augers

• Synchronization of some processes

• Obtaining international certification like ISO

• Measures against product counterfeit

• Maintaining grain for long under prevailing ambient conditions

• Waste disposal – Dry and wet

• Commercialization: 2 investors ready

• Conclusion

• Roasting has proven viable to kill and sterilize aflasafe TM substrate.

• The production facility can be cleaned to a microbiological standard

using hot, roasted grains.

• aflasafe TM produced in this facility meets rigorous standards, at a lower

cost, and using commercially available equipment.

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

http://www.aflasafe.com/

http://www.iita.org/

Aflasafe manufacturing, scaling up and commercialisation

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