Manufacture and distribution of aflasafe tm

Date: 04-03-2014 www.iita.org A member of CGIAR consortium

Manufacture and Distribution of aflasafe TM

Lawrence K. Kaptoge

Peter Cotty

Joseph Atehnkeng

Joao Augusto

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: 04-03-2014

www.iita.org A member of CGIAR consortium Date: 04-03-2014

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: 04-03-2014

LAB PRODUCTION PROCESS PILOT PLANT PRODUCTION PROCESS


Beginning and Progress So far

STARTING POINT


Final Plan

Packaging & Finished Product Storage

Wash Rooms

Lab

Grain Intake, Cleaning, Pasteurisation and Storage


Final Plan

Date: 04-03-2014


Progress So Far

Laboratory:

Complete and operational:

Inoculum production Lab (Laminar Flow hoods, New heating incubators)

Quality control lab

Spore suspension room

Manufacturing Plant: • Purchased and Installed equipment for :

• Grain intake – Lowry Dump Pit (USA)

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

• Storage - Silos and Grain Handling Equipment – Brock (USA)

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

• Packaging - Weighers and Sealers – Accutech (SA)


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: Packaging


Plant Progress


Plant Progress


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: 04-03-2014


Quality Control

Date: 04-03-2014

0%

10%

20%

30%

40%

50%

60%

Silo Roaster

Exit

Cooler

Exit

Treater

Exit

Germinating

Contaminated

0.00%1.00%2.00%3.00%4.00%5.00%6.00%7.00%8.00%9.00%

10.00%

0 2 4 6

%

of

see

ds

to g

erm

ina

te o

r re

ve

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

of

see

ds c

onta

min

ate

d b

y 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.

10%

9%

8%

7%

6%

5%

4%

3%

2%

1%

0%


Quality Control

Date: 04-03-2014

0%

10%

20%

30%

40%

50%

Silo Roaster Exit Cooler Exit Treater Exit

Germinating

%

of

see

ds

to g

erm

ina

te o

r re

ve

al fu

ng

al c

on

tam

ina

tio

n

aflasafeTM plant location from which sorghum was sampled

Fig. 1 – Sorghum samples taken at different locations during processing without inoculating to determine effectiveness of

roasting to kill and sterilize the substrate/carrier.



Quality Control

Date: 04-03-2014

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

8.00%

9.00%

10.00%

0 1 2 3 4 5 6

aflasafeTM ZM02 batch number

Perc

ent of seeds c

onta

min

ate

d b

y fun

gi o

ther

than A

. flavus

Fig.1. Final aflasafe product sampled in batches and incubated at 100% humidity for 7 days.


10%

9%

8%

7%

6%

5%

4%

3%

2%

1%

0%


Conclusion

• 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/

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Manufacture and distribution of aflasafe tm