CREATING THE CASSAVA REVOLUTION. Cassava Processors

Transcription

1 CREATING THE CASSAVA REVOLUTION Cassava Processors

2 DADTCO General DADTCO established in Shareholders; people with Africa experience who share the belief that economic development comes from private businesses with the aim to improve income standards of African Farmers. MISSION OPERATIONS APPROACH HOW Create the cassava revolution In Africa and then to the rest of the World Reach as many smallholder farmers as possible Provide a guaranteed market to farmers Create new processing technologies Make quality products, matching buyer s needs Substitute expensive imports Export grade A starch to Europe and the USA.

3 Why cassava? An edible root crop with about 23% starch content (82% on dry matter basis). Root is stable in the ground for up to 2-3 years. Roots start to degrade as soon as harvested. Approximately 9 12 months cycle with high yields (10 to 60 MT per HA) Can be planted and harvested throughout the year. Easy to grow, drought tolerant, low fertilizers, pesticides and maintenance demand. Cassava has many advantages for starch production: High level of purity. Excellent thickening characteristics. A neutral bland taste. Desirable textural characteristics. *A cheap crop containing a high concentration of starch that can surpass the properties of other starches (maize, wheat, sweet potato, and rice).

4 Global distribution of cassava Cassava prefers ambient temperatures > 30 C and grows particularly well in the agro-climatic conditions found in most parts of Sub-Saharan Africa.

5 Composition starch crops 100% 90% 80% 70% 60% 13% 3% 14% 72% 79% Water 50% 40% 70% 2% Protein+Minerals 30% 20% 10% 0% 5% 22% 2% 15% Maize Cassava Potatoes 4% Fibers Starch *Cassava lowest in protein content, protein major impediment for the production of starch,

6 Failed cassava processing projects Africa Nigeria, 178 IITA/C:AVA locally built small flash dryers. Capacity: 8Mt roots/day. 90% is standing idle Nigerian Starch Mills, Anambra State. Capacity 250 Mt roots/day. Little or no production. Nigeria, Matna Foods Company Limited, Ondo State. Capacity 150 Mt roots/day Out of production Nigeria, Psaltry processing plant. In the process of construction No cassava in the surrounding Nigeria, Ekha Agro (ISI) Syrup glucose plant. Capacity 400 Mt roots/day Out of production and for sale at the moment. Nigeria; TFI cassava flour plant, Capacity 200 Mt of roots/day. Sporadic Lack of roots

7 Failed cassava processing projects Africa Nigeria, Uzere starch factory Capacity 120 Mt/day Never been in operation. Brazilian design. Swaziland, Casquip ISI built starch factory. Capacity 120 Mt roots/day Has never been in operation is for sale Ghana, Ayensu ISI built starch factory. Capacity 180 Mt roots/day Unviable and out of operations. Cameroon, Sotramas starch factory. Capacity 120 Mt roots/day. Never been operational. Rwanda, Kinazi Cassava Processing Plant. Capacity: 120 Mt/day Out of operation and for Sale Tanzania, Scheer foundation Capacity 80Mt roots/day. Has not yet been operational. Land grabbing

8 Failed cassava processing projects Africa Ivory Coast, ISI built starch/flake plant for Nestle Yopougon. Capacity 30 Mt roots/day. Standing idle at the moment. Mozambique Cleanstar, Bioethanol Capacity 60 Mt roots/day Has never has been in operation. Uganda, Lira, Starch factory Capacity 30 Mt roots/day. Defunct. Malawi. Universal Industries Capacity 60 Mt roots/day Erratic production, lack of roots, high fuel consumption. And Many others

9 Why cassava projects fail in Africa Perishability Roots degenerate the moment they are harvested Transportation time too long Smallholder crop Lack of regular root supplies Farmers widely scattered, small volumes and bad feeder roads Transport costs 65-75% fruit water adds to transport costs Transport costs too high

10 Why cassava projects fail in Africa No Suitable processing technology Either centralized, large economy of scale or Cottage type industries Both resulting in starch losses Quality issues Cyanide in the roots, lack of validation methods Non food grade processing Plantation farming not feasible Crop too labour intensive at replanting time High yielding crop only when personal care is provided. Over-invoicing by importers Import monopolies and price cartels Coastal bound, makes local souring unattractive

11 DADTCO Solution; 5 essential technologies Demand driven cassava farmers management Full release of all starch from plant cells Removal of fibres and non starch substances Removal of all cyanide containing contents Reducing moisture content (drying) Roots Supply AMPU, same day processing ASPU (Mobile Refinery Unit) DADTCO enzymatic process Mobile Drying/ Flash Drying Production of cyanide free Starch Grade B with 1,8% fibres

12 DADTCO Solution; same day processing 1. Wet processing part Decentralized Releases starch Removes non starch Extends shelf life 2. Dry processing part Centralized Close to cheap energy sources Urban area, markets

13 Why Decentralized Processing Same day processing No post harvest losses Better quality starch Transport costs To transport cake instead of roots is three times more efficient Pollution Centralized fruit water causes pollution. Close to farmers fields Management regular supply workable

14 Demand driven cassava farmers management Root supply management is a core skill: Alliances with local governments, farmers, research institutes and agricultural organisations. Use of advanced information technology systems, media, barcoding and GPS/GIS systems. Communication and information sharing with farmers. Team of mobilizers in the field organizing farmers Cash payments DADTCO ID cards Track & Trace of all root supplies *Farmers have a guaranteed market and direct payment upon delivery

15 Building trust Processing on farmer s door step; Awareness campaigns involving radio messages, chiefs, farm leaders and local administrators Organize farmers sessions and identify farmers Registration of cassava farmers and issuing of ID cards Introduce improved agricultural practices and follow-up Issuing of a purchase guarantee for next year Organize a cassava platform with research, farmers and extension services. Guaranteed market; farmers know the price at planting date

16 DADTCO supports farmers with know-how Use clean tools Select healthy plants Mobilizers spread know-how on 4 most limiting factors in cassava farming: 1. Access to disease free high yielding varieties 2. Production, stocking, treatment and planting of stems. 3. Replanting dead stems. 4. Increase plant density Store under shade for 10 days Make 30 cm long cuttings Cut off the top and basal parts of the stems Make sure the cuttings have 5 to 8 nodes

17 Socio-economic IMPACT one AMPU Local economy $1,200,000 per year in the villages amongst 4000 farmer families. $300 per family additional money on a cash income of not more than $100 -$300. Foreign exchange savings per AMPU $3,800,000 foreign exchange savings per year, replacing imported wheat and/or malted barley. Building alliances Creating market attracts other investments Building bridges between multinationals and local farmers

18 Autonomous Mobile Processing Unit (AMPU) AMPU processing The AMPU is assembled in a 45 foot high cube container The AMPU moves around a cassava growing region, stays 3 to 4 months at one platform(site) and moves in rotation to 4 or 3 sites per year. Roots are processed into cake with 98% released starch 50% reduction of water. Cassava cake properly packaged and stored, can be kept for at least 6 months under ambient conditions. Washing & peeling Chopping Rasping Dewatering by decanter Cassava cake 52% moisture *If the farmer cannot come to the factory lets bring the factory to the farmers

19 AMPU Capacity An AMPU has a capacity of 5 MT cassava roots per hour On a 2 shift basis one AMPU will process 80 MT roots per day or MT per annum. This in turn is equivalent to: o MT Cassava Cake o MT Cassava Starch Cake o MT Cassava Flour (HQCF) o MT Starch Grade B. o MT Starch Grade A o MT Mixed syrups AMPU Cassava Cake quality standards Dry matter 47-50% Starch Min 92% (dry matter basis) Fibers 2.5-5% (depending on enzyme addition) Ash <0.6% Protein <0.5% HCN <2 ppm ph Starch granule Excellent integrity for modification process One AMPU creates a market for 4500 smallholder farmers. Shelf life Storage Density Load >6 months Shade, ventilated, ambient temperature 1m3 equals 1,000 kg 33 ton in standard 40ft container *A single AMPU can supply sufficient starch adjunct for over 1 million hl beer per annum

20 DADTCO CASSAVA PRODUCT FLOW SMALLHOLDER FARMER SMALLHOLDER FARMER SMALLHOLDER FARMER SMALLHOLDER FARMER SMALLHOLDER FARMER AMPU AMPU AMPU AMPU AMPU CASSAVA CAKE *ASPU CENTRAL FLASH DRYER ASPU ASPU REFINERY CASSAVA STARCH CAKE DADTCO FLOUR MOBILE/ FLASH DRYER CENTRAL FLASH DRYER STARCH GRADE B STARCH GRADE A *The ASPU; a newly developed mobile first step refinery unit, reducing 70% of the fibre content in the cake

21 Match products with clients real needs, create new markets 100% 90% 80% Ash&Fibres 70% 60% 50% Starch 40% 72 30% % 10% Moisture 0% Cassava Roots DADTCO Cake DADTCO Starch Cake DADTCO Flour DADTCO Starch (Grade B) DADTCO Starch (Grade A) Thai Tapioca Removal of moisture and fibres equals starch

22 Water Absorption capacity fibres 9% fibres 91% Starch *Drying of fibres costs fuel

23 DADTCO Starch Grade B DADTCO Cassava Cake: 9% fibres on dry matter basis Removal of 6% fibres DADTCO Starch Grade B with 3% fibres on dry matter basis 9% fibres 7,2% fibres = 2,8% fibres 91% Starch 97% Starch * Two-third removal of fibres gives large impact

24 Average roots requirement per DADTCO product Product Intermediate product Roots 1 Mt cake, requires 1.8 Mt roots* 1 Mt cassava starch cake requires 1.1 Mt Cassava cake, requires 2.0 Mt roots 1 Mt DADTCO flour, requires 1.9 Mt Cassava cake, requires 3.4 Mt roots 1 Mt Starch grade B, requires 1.8 Mt Cassava starch cake, requires 3.6 Mt roots 1 Mt Starch grade A, requires 1.8 Mt cassava starch cake, requires 3.6 Mt roots *For rough calculation purposes only

25 Types of flour made from cassava Four types of cassava flour can be distinguished: 1. High Quality Cassava Flour(HQCF), obtained by industrial wet processing 2. High Quality Cassava Flour(HQCF), obtained by Small Medium Enterprises (SME) wet processing. HQCF Washing and Peeling Grating Pressing Drying and Cooling 3. High Quality Cassava Flour(HQCF), obtained by cottage industry manual wet processing. Milling Sifting 4. Cassava flour obtained by grinding of dried cassava chips Low quality, high in cyanide content, unhygienic Quality.

26 The art of making cassava flour High Quality Cassava Flour, its quality is determined by: 1. The Rasper (to rasp the roots into a mash); the more powerful the rasper the more released starch and the lower the cyanide content. 2. The Dryer; the quicker the drying and cooling down process the less moulds and microorganisms in the end-product 3. Hygiene and water quality. DADTCO Industrial wet processing HQCF Small industrial wet processing HQCF Cottage industry Manual wet processing HQCF Cottage industry Grinding of dried chips Cassava flour

27 Major quality issues HQCF DADTCO HQCF DADTCO Starch grade B SME HQCF Cottage Industry HQCF 0 Cyanide content (ppm) 20 Cottage Industry cassava flour DADTCO Starch grade B DADTCO HQCF SME HQCF Cottage Industry HQCF Cottage Industry cassava flour 0 Total bacterial counts > DADTCO HQCF DADTCO Starch grade B SME HQCF Cottage Industry HQCF Cottage Industry cassava flour 100% Released starch 10%

28 Elimination of cyanide: a Prerequisite Cassava roots contain cyanogenic glucosides which breakdown to form hydrocyanic acid (HCN), a toxic compound. Processing is necessary to reduce the HCN potential. Traditional processing methods ineffective to reduce HCN potential to safe levels. To reduce cyanide levels you need to mechanical break down the cell walls with industrial raspers. Insufficiently processed cassava roots cause high levels of cyanide causing neurological disorders.

29 New developments 1. DADTCO s R&D team In collaboration with RIKILT, University of Wageningen and the Mondlane University Maputo Mz, has validated the fluctuating and high presence of Linamarin, a cyanogenic component present in cassava. On the basis of this validation the team has developed and patented an enzyme to produce 100% cyanide free cassava products (the research was financed by the Kutemann fund). 2. DADTCO s technology department has developed an ASPU (Autonomous Starch Processing Unit). The ASPU is built in a 20ft container and is designed to remove 70% of the fibres in the cassava slurry. The Starch Cake produced by a combination of AMPU and ASPU is: Cyanide free Contains very few fibres (can be compared to native starch in its behaviour) and contains 20% less water than the original Cassava Cake Is odourless and white in colour *DADTCO excited about development new technologies ASPU and Cyanide free cassava products

30 DADTCO s activities in Africa NIGERIA MOZAMBIQUE Flash Dryers Taraba State + 3 AMPUS Drying 2 AMPUS Milling Sieving Osun state +3 AMPUS Cooling Flour/Starch grade B Bagging Rivers State + 3 AMPUS GHANA 1 AMPU

31 Bread with 20% of DADTCO s Starch grade B Baking trials with 20% DADTCO s starch grade B in collaboration with the Research and Technology department of AB MAURI, the Netherlands. AB Mauri, part of Associated British Foods (ABF), 2 nd largest globally in yeast and bakery ingredients, operates in 26 countries. Inclusion of 20% DADTCO s starch grade B showed perfect results in: bread volume, colour, crumb structure, crumb resilience, taste and shelf life: Volume Colour Testing Crumb structure *Results exceeded expectations, 20% of DADTCO s starch grade B gave excellent bread

32 The SABMiller Partnership The launch of the world s first commercially produced cassava lager in Mozambique. In 2011 DADTCO and SABMiller Africa entered into a partnering arrangement whereby DADTCO s cassava know- how and AMPU technology would be made available to the brewer to complement its own cassava beer brewing technology. DADTCO Mandioca Mozambique (DMM): Steep increase in cake sales volumes making good profits SABMiller has invested 10 million US$ in a cassava starch refinery based on cassava cake. Cassava content Impala 70% cassava cake and 30% malted barley Increase in cassava cake sales DMM 2,000 1,800 1,600 1,400 1,200 1, Sep Dec 2013 Jan April 2014 May Aug 2014 Sep Dec 2014 Jan April 2015 * Beer with cassava from our own farms..

33 DADTCO Prices (in Euro) AMPU 700,000 ASPU 300,000 Mobile Dryer 850,000 Working Capital 400,000 Logistics/Sites 600,000 Refinery 1,500,000 Central Flash Dryer 2,300,000 Cyanide removal 5 Euro/MT

34 What is in it for the smallholder cassava farmers? A BRIGHT FUTURE