Kenya - 21 August 2014

1. Date: 21-08-2014 www.iita.orgA member of CGIAR consortium
aflasafe
TM
Manufacture (Ibadan & Machakos Modular Plant)
Lawrence K. Kaptoge
Charity Mutegi
Ranajit Bandyopadhyay
Peter Cotty

2. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Objectives – aflasafe Pilot Plant Ibadan Nigeria
Overview
o Objectives of the Ibadan Plant
o aflasafe Production Process
o Common Plans and Pictures of Ibadan Plant
o Modular Draft Plans for the Machakos Plant
o Site considerations.

3. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Objectives – aflasafe Pilot Plant Ibadan Nigeria
Demonstration-scale manufacturing plant to be used as a model to:
• Optimize and adapt the manufacturing process
• Reduce production cost
• Develop a turn-key facility for replication in other countries
• Demonstrate commercial viability for mass production of
Aflasafe and recruit commercial partners.
• Build awareness, demand, and aggregation channels for low-
aflatoxin crops.

4. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Aflasafe Production
Involves 2 main processes:
1. Production of inoculum.
2. Production/Preparation of Carrier/substrate
 Inoculation/Coating – (Mixing at right rate)
 Packaging (weighing, sealing and labelling)
Initial 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

5. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Production Block Diagram

6. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Ibadan Plans
Packaging & Finished Product Storage
Wash Rooms
Lab
Grain Intake, Cleaning, Pasteurisation and Storage

7. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Progress
Workers’ Resting Room Inoculum Production Lab
Quality Control Lab
Quality Control Lab & Lab office

8. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Progress
Cooler
Roaster Plant Before & after completion

9. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Progress
Weighing & Heat Sealing Inoculation & Weighing
Finished Product Storage Final Package – Front & Back

10. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Production 2014
• Production of aflasafe for:
• Nigeria – 120 tons (Scaled down from 250 tons)
• Senegal – 12 tons
• Zambia – 3 tons
• Mozambique – 1 ton
• Ghana – 1 ton
• Burkina Faso – ?
• Kenya – ?
Inoculum Production

11. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant
Building: Approximately 10 m tall; 20
m wide; 30 m long.
Silos hold about 20 tons each.
Hoppers also in coater and packing
lines.
Raw Grain
Spore Culture
Room
EndProductStorage
Packing Room
Toilet
End Product
Silos
Roasted Grain
Final Cleaners
Roasters
Bagger

12. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant
HEPA filter
Motor
Internal Aerator
Cut away view of perforated
tube in silo.
This is the type of design we plan to use
for the Roasted Grain Silos – the grain
enters the silo hot. This worked will in
initial trials.

13. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant
Auger from Roaster to Silo
Remains hot to keep clean

14. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant
This is the current aeration
tube. The larger silos will
have a 36” diameter tube
and only travel about half
way up the silo.

15. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant

16. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant

17. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Modular Plant

18. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Line Diagram of the Modular Plant

19. www.iita.orgA member of CGIAR consortium Date: 21-08-2014
Site Visit’s Considerations
Location of the facility:
o availability of a good, well-drained and accessible site that is protected from
wind, rain/floods and high water table.
o Room for large vehicles to move through the facility without having to back
up. (Semi-trailers need about 20m turning radius).
o Room for future expansion
o Land for waste disposal.
o Environmental assessment report?
o Possibility of similar existing facilities e.g. seed plant?
o Proximity of the facility to homestead/residential estate, offices etc - in line
with problems associated to vehicle traffic, noise, dust, chaff etc.
Total storage capacity and Bin size requirements
o Small bin size - delays during unloading.
o current and future likely annual storage capacity
Facilities:
o existing power and water supply to the site?
o Upgrade of existing facilities?
o Technical Personnel

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