IITA board room 1 during a4nh meeting - Ibadan-23-Nov 2013

1. Date: 23-11- 2013 www.iita.orgA member of CGIAR consortium
Aflasafe Manufacturing - Scaling Up and
Commercialization
Lawrence K. Kaptoge
Peter Cotty
Joseph Atehnkeng
Joao Augusto
Nick Garber
Ranajit Bandyopadhyay

2. www.iita.orgA 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

3. www.iita.orgA 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

4. www.iita.orgA member of CGIAR consortium
Scaling Up
Date: 23-Nov-2013
LAB PRODUCTION PROCESS
PILOT PLANT PRODUCTION PROCESS

5. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
Beginning and Progress So far
STARTING POINT

6. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
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

7. www.iita.orgA member of CGIAR consortium
Final Plan
Date: 23-Nov-2013

8. www.iita.orgA member of CGIAR consortium 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

9. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
Progress So Far: Building Renovation
Despatch of aflasafe

10. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
Progress So Far: Lab & Equip. Installation
Workers’ Resting Room
Inoculum Production Lab
Quality Control Lab
Quality Control Lab & Lab office

11. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
Progress So Far: Substrate Preparation

12. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
Progress So Far: Substrate Preparation

13. www.iita.orgA member of CGIAR consortium
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

14. www.iita.orgA member of CGIAR consortium
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
%ofseedstogerminateorrevealfungalcontamination
aflasafeTM plant location from which sorghum was sampled
aflasafeTM ZM02 batch number
PercentofseedscontaminatedbyfungiotherthanA.flavus
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.

15. www.iita.orgA member of CGIAR consortium Date: 23-Nov-2013
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 aflasafeTM substrate.
• The production facility can be cleaned to a microbiological standard
using hot, roasted grains.
• aflasafeTM produced in this facility meets rigorous standards, at a lower
cost, and using commercially available equipment.

16. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013