(p 1) iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2 nd 97 Very low cost extruders (VLEC) for small scale production of food and

(p 1)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97

Very low cost extruders (VLEC)for small scale production of food and feeds

D. Bounie, E. Van HeckeUSTL (Université des Sciences et Technologies de Lille)

IAAL (Institut Agricole et Alimentaire)Bâtiment C6

59655 Villeneuve d’Ascq Cedex - FranceTel : +33 (0)3 20.43.49.21, Fax : +33 (0)3 20.43.44.86E-Mail : [email protected], [email protected]

Smart Extrusion Workshop, Sydney2 december 1997


PLAN

Very Low Cost Extrusion Cooking (VLEC) vs. Low Cost Extrusion Cooking (LEC) and classical Extrusion Cooking

Possible applications of VLEC• feeds at farm-level

integrated traceability from feeds to livestock• locally processed nutritious weaning foods (development projects)

on going project in Viet Namdestruction of antinutritional factors and optimisation of energy density through improvment of formula and control of thermomechanical treatment

• precooked blended flours for relief aid present situation in Africa

small scale production at « camp level » vs. centralized production in remote countries : from emergency to rehabilitation and development

Pilot equipment developped at the University of Lille


PLAN









ENERGY DENSITY OF BABY FOODS

Energy requirementsfor a 65 months child

765 kcal / day

Breast feeding520 ml milk /day, at 65 kcal / 100 ml

(540 ml in Africa, 500 ml in Viet Nam)

340 kcal / day

Baby-food

765 - 340 =425 kcal / day

+

one meal = 170 ml max.if two meals / day : 340 ml / day

Energy density of gruels

425 / 340 = 125 kcal / 100 ml

calorie content of blended flours~ 4 kcal / g d.b.

(4 for carbohydrate and protein, 9 for fat)

Dry content of baby food

> 30 g. d.b. / 100 ml

Max. viscosity of gruel to be ingested is 1.6 Pa.s! !


ENERGY DENSITY OF BABY FOODSInfluence of dry matter content on viscosity

Viscosity(Pa.s)

15 20 25 30 35

dry matter (g) / 100 ml

10

Feeding of infants and preschool children with gruels- either instant or boiled - is limited by :

volume (170 ml max.) and consistency of gruels (1.6 Pa.s max.)

1.6

traditionalhome treatment

30

Ways to increase energy density by decreasing gruel viscosity :• addition of fat• hydrolysis of starch :

synthesis of endogeneous amylases (germination) addition of exogeneous amylases drastic thermomechanical treatments : extrusion cooking


PROCESSING OF PRECOOKED BLENDED FLOURwith alternatives for supplementation with vitamin/mineral mix

Grinding

Drumdrying

Mixing+ cooking

VMS

Precooked flour

Grinding

Roasting

Mixing

VMS

Extrusion cooking

Mixing

VMS

VMS

Milling

(Vitamin/mineralsupplement)


Full fat soya seedsWhole corn

seedsRice Mung beans Sesame Salt

VIETNAMESE BABY FOOD : FLOWSHEETVIETNAMESE BABY FOOD : FLOWSHEET

2 - Dehulling

3 - Winnowing

Dehulled soya seeds

1 - Drying

Hulls

Wheighing

Dehulling

Dehulled mung beans

Hulls

Winnowing

4 - Mixing

5 - Extrusion cooking

6 - Cooling / drying

7 - Milling

8 - Mixing

9 - Bagging

Other ingredients :dried meat powder, mushrooms, carrots, yeast, malt


TRADITIONAL VIETNAMESE FOOD

Cereals and legums,eggs,mushrooms and spices ...

fruits ...

dried fishes ...


WEANING FOOD :Raw materials

Soya

Rice

Corn

Sesame

Salt


WEANING FOOD :Process

1 - Preconditioning of soya :moisturizing + drying

2 - Dehulling of soya



3 - Winnowing of soya

4 - Mixing of ingredients

Coarse premix



Extrusion-cooker

5 - Extrusion cooking

Barrel and screw Starved and choked screw

Die outlet



6 - Cooling / drying

7 - Milling


8 - Post mixing withmineral/vitamins premix


9 - Bagging


WEANING FOOD :End product


PLAN









REFUGEE CAMPSIN GREAT LAKES REGION

South Kivu (ex-Zaïre)

Rwanda


SEVERE MALNUTRITIONIN REFUGEE CAMPS

Marasmus Kwashiorkor


STORAGE AND GENERAL DISTRIBUTION

OF RELIEF FOOD


GENERAL DISTRIBUTION


INDIVIDUAL RATION& FAMILY COOKING

Individual weekly ration (1200 kcal/day)

Corn250 g

Beans50 g

Oil15 g

Salt15 g


Area ofmanual mixing

Cleaner

Dustremoval

Stocks of raw materials

Dustremoval

Hammer mills

Belt conveyor

Fan

Screwconveyor

Extrusion cooker

Cutter

Hammer millBatchmixer(500 Kg)

Continuousmixer

Conveyor

Bagging and sewing

Stocks ofend-products

Screw orpneumaticelevator

Scewconveyor

Workshop

Batchmixer(500 Kg)

CENTRALIZED PRODUCTIONOF RELIEF BLENDED FLOURS ( > 20 MT/day - Kenya)


MillScrew conveyor

Mixer

Screwelevator

Feedingbin

Screw extractor

Extrusioncooker

Cutter

Screw conveyor

Fan

Fan

Mill

Pneumatic conveyor

Deliverybin

Horizontalbatchmixer

Cleaning

Wheighing

Wastes

Stocks(raw materials)


Stocks(end products)

Water

Warehouse(CMV, sugar,salt

spare parts)

Packaging+ sewing

Office

OfficeTrucks unloading

Electricalcabinet

Wheighing


Stocks(end products)

Electricalstation

Toilets +bathroom

CENTRALIZED PRODUCTIONOF RELIEF BLENDED FLOURS ( > 5 MT/day - Kenya)


PLAN









CAPITAL COST REQUIREMENTFOR A 0.5 MT/HR LEC WEANING FOOD FACTORY

(Harper, 1995)

Land (2 ha)

Site preparationelectricalwater/sewerroadsbuilding (450 m2)bulk grain storage handling

Machinerycleaning/dehulling moduleprocessing moduleblending modulepackaging module (manual)ancillary machineryspare parts @ 10%crate, insurance, freight @ 20%contingency @ 10%

Engineering, installation,management training

Cost subtotal(machinery & installation)

VAT (14%) on investmentexpense

Cost total

252015

60112

634957346834

51

60

354102

341

136

156

168

Item sub-total

Cost (US$x103)

1,200

1,368

Total

Expected costfor VLEC :11,000 US$


TYPICAL MANUFACTURING COSTSFOR A PACKAGED FORTIFIED BLENDED FOOD

(Harper, 1995)

(500 kg/hr or 12 MT/day; 3 8-hr shifts/day, 5 days/week; formula : 70% cereal, 30% oilseed; packaging 250g poly bags)

Cost Category

Materials

Salaries/wages

Depreciation

ElectricityOther utilitiesMaintenanceSpare partsTranportMisc.

Subtotal

VAT @ 14%

Total

Categorycomponent

White maizeSoya beansVitaminsMineralsPoly bagsMaster bags

ManagerQC technicianSupervisorMech./Elec.OperatorsLabourersClericalAccountantPackers

Equipm. (10 yr)Building (40 yr)

Dailyrequirement(A)

2.651.1412.0 kg31.2 kg48,000480

123212124160

7,200 kW-hr

1,200 MT/km

Unit costUS$(B)

136.2/MT282/MT75/kg50/kg22/1,000480/1,000

49/shift31.3/shift43.6/shift21.8/shift4.1/shift1.4/shift2.7/shift19.1/shift1.4/shift

179.8/day49/day

0.05/kW-hr21.8/day13.6/day65.4/day0.3/MT-km409/day

Totaldailycosts (US$)(C= AxB)

1327117924542528863

4963131444917111982

18049

334221427332409

Specificcost(US$/MT)(D=C/12)

110.598.220.435.424.05.2

4.15.210.93.64.11.40.91.66.8

15.04.1

27.81.81.15.427.334.1

449or US$ 0.45

62.9

512or US$ 0.51


LOW COST EXTRUDERS FOR DRY EXTRUSION

• Almex (Netherlands)• Anderson (USA)• Brady Corp. (USA)• Croix (France)• France Extrusion (France)• Insta-Pro (U.K.)• Millbank (New Zealand)• Setrem Inotec (France)

Main manufacturers

Equipment

Anderson 4,5Anderson 8Anderson 12

Brady 206

Croix T 95

Insta-Pro 500Insta-Pro 2000RInsta-Pro 2500

Millbank 500Millbank 1000

Setrem S50Setrem X125

Power

(kW)

1956-93186-373

74.5

22

375590

3555

3790

Heating

Autogenous (+steam)Autogenous (+steam)Autogenous (+steam)

Autogenous

Autogenous

AutogenousAutogenousAutogenous

AutogenousAutogenous

Autogenous (+steam)Autogenous (+steam)

Output

(kg/hr)

2501,00010,000

340-450

200-300

200-300590-910900-1,350

350750

200-500500-1,500

Screwdiameter

(mm)

114203305

95

95138

L/Dratio

121212

88

Screwspeed

(RPM)

280360360

900-1000

550550550

550550

Moisturecontentduringextrusion(%)

< 18 %(> 20 % with steam)

20 % max

> 14 %> 14 %> 14 %

Temperaturecontentduringextrusion(°C)

205 ° max205° max205° max

140 (soja)170 (cereals)

130-170

150-170 (cereals)135-145 (soya)

150150

Principal technical specifications


V.L.E.C. AT UNIVERSITY OF LILLE


TECHNICAL SPECIFICATIONS

• drive motor : electric motor (power rating : 7.5 kW) ; motor speed : 1500 RPM• transmission : single ribbed, no-split belt + set of pulleys (reduction =1/3)• screw speed : 0 to 500 rpm ; continuous variation of speed using electronic speed variator working at controlled torque• cast iron frame• capacity : 30 to 60 kg/hr• pototype’s price: < 20,000 US$ (price of serial machine is expected to be less than 10,000 $)

BARREL AND SCREW (L/D = 3.25)

Barrel with helicoidalor longitudinal grooves Screw Clamping ring

A B C

D = 24 mm

D = 40 mm

L = 130 mm

Die plate

D

Head space(adjustable die clearance)


BIBLIOGRAPHY

• Bounie D., Briend A. and Greletty Y., 1994. Précuisson des aliments de l’aide d’urgence : comportement rhéologique de bouillies énergétiques préparées à partir de divers mélanges obtenus par cuisson-extrusion. In Proc. Conf. Agoral 94 : La Cuisson des Aliments, Nantes, 5-6 octobre 1994, pp 427-439.• Bressani R., Harper J.M., Wickstrom B., 1984. Processed and packaged weaning foods : development, manufacturing and marketing. In : Improving the nutritional status of children during the weaning period, Mitzner K. and al. Eds., Intl Food and Nutrition Program, MIT, Cambridge, MA, pp 117-148.• Coll., 1979. Low cost extrusion cookers. Second International Workshop Proceedings, Dar Es Salaam, Tanzania, Wilson D.E. and Triebelhorn R.E. Eds., Fort Collins, Colorado State University• Coll., 1989. Pour améliorer l’alimentation des jeunes enfants en Afrique Orintale et Australe : une technologie à la portée des ménages. Proceedings of International Symposium, Nairobi, 12-16 Oct. 1989, Alnwick D. and al. Eds., CRDI, Ottawa• Harper J.M., 1995. Low-cost extrusion : possibilities for Africa. The SA J. of Food Sci. and Nutrition, 7(4), pp 142-147.• Harper J.M. and Jansen G.R., 1985. Production of nutritious precooked foods in developing countries by low-cost extrusion technology. Food Review Intl., 1(1), pp 27-97• Jansen G.R., O’Deen L., Triebelhorn R.E. and Harper J.M., 1981. The caloric densities of gruels made from extruded corn-soy blends. UNU Food Nutr Bull, 3(1), pp 39-44• Jansen G.R., 1992. Centrally processed weaning foods for use in developing countries. Food Reviews Intl, 8(3), 307-345• Walker A.F., 1990. The contribution of weaning-food to protein-energy malnutrition. Nutrition Research reviews, 3, pp 25-47

Documents

(p 1) iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2 nd 97 Very low cost extruders (VLEC) for small scale production of food and