Ibadan during the BMGF - N2Africa visit- 01 - July 2013

1. Date: 01 – July - 2013 www.iita.orgA member of CGIAR consortium
Feasibility, Design and Implementation of
Aflasafe Demonstration-Scale Manufacturing
Plant
Lawrence K. Kaptoge
Peter Cotty
Joseph Atehnkeng
Joao Augusto
Ranajit Bandyopadhyay

2. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013
Out line
• What is aflasafe and aflatoxins
• Prevalence of aflatoxins in crops
• Aflasafe development
• manufacturing
- Lab scale
- Pilot plant
• Design considerations for Lab and Plant
• Status/Progress of the plant
• Future of aflasafe
Date: 01 – July - 2013

3. • Highly toxic metabolite produced
by the ubiquitous Aspergillus
flavus fungus
• The fungus infects crops and
produces the toxin in the field and
in stores
• Fungus carried from field to store
• Contamination possible without
visible signs of the fungus
• Some predisposing factors:
– pre-harvest high temp and
drought stress
– wet conditions at harvest and
post-harvest periods
– insect damage
Aflatoxin Facts

4. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013
Prevalence of Aflatoxins in Food & Feed
• Several African staple commodities affected
• High human exposure in Africa – mother to baby
• Levels and frequency of occurrence high
– >30% maize in stores with >20 ppb aflatoxin
– ~90% stores are contaminated with Afla fungi
– Up to 40% grain in households with aflatoxin
• Concern for food and feed processors, government and
emergency food reserve agencies, school-feeding
• Aflatoxins disproportionately impact the poor
• Highly toxic strains, conducive environmental
conditions, traditional farming methods and improper
grain drying and storage practices, unregulated markets

5. www.iita.orgA member of CGIAR consortium Date: 01-July-2013
Human and Animal Health Effects
acute
acute hepatic necrosis, cirrhosis,
carcinoma
Death; 200 people in Kenya; 74 in
India
chronic
carcinogenic
stunting in under-fives
anti-nutritional
immune-suppressive
gut integrity?
underreported
unknown 500 ppb AF dietAF-free diet
~40% reduction in live weight (8 weeks)

6. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Trade Losses due to Aflatoxins
• Nigeria and Senegal major groundnut
exporters in 1960s. Compliance has
economic incentives
Senegal:
• If aflatoxin levels are reduced, then national
income would increase by
– $281 million through oil cake export
– $45 million through confectionary
groundnut export.
• Best quality exported; poorer quality
consumed domestically.
Peanut
Maize
Coffee
Cocoa
Groundnut Pyramids in
Nigeria during 1960s
Pyramids in Egypt?
World Bank; Mbaye (2004)

7. AF36
Aflaguard
Biocontrol
WORKS
In 100’S of
thousands
of acres in
the US!
IT WORKS
In Africa
TOO!
Aflasafe

8. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Atoxigenic Strain Identification
Collection/characterization Toxin assay
Field
efficacy
test
Lab
competition
assay
VCG/DNA characterization
cnx
nia-D
Unknown 2
+

9. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Available carriers
Cost effective
Adequate stability for transportation
Stored
Compatible application
Viability
• Rice kernels
• Wheat seeds
• Alginate pellet
• Conidial suspensions

10. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Carrier / Substrates Evaluation
A = Sorghum B = Cassava slice
C = Maize kernel D = Corn cob
E = Stalk tissue

11. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013
Why Sorghum
• Readily available
• Easy to handle
• Can support for a about three weeks
• Does not require additional nutrient supplement
• Cheap
Alginate pellets = US$2.53 – 5.76 /kg
Wheat seeds = US$1.8 – 0.26 /kg
Sorghum = < US$0.5 /kg
• Good delivery system

12. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Lab production of aflasafe
Soak in water
for 2 hours
Autoclave grains for
45 minutes at 121oC
Soak grains in
spore suspension
(1x106) for 5 min Incubate at 31oC
for 18 hours
Dry in cloth bags at 50 oC
for 4 days in an oven
Quality control in
moist chamber
Inoculum on sorghum
grain for storage
White sorghum grains

13. Product: Aflasafe
Mixture of 4 native atoxigenic strains
Nigeria

14. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
How aflasafe Works
Broadcast
@ 10 kg/ha 2-3 weeks
before flowering
Sporulation on moist soil
Spores
Insects
Aflasafe in 5 kg boxes
3-20
days
Wind
Soil
colonization
30-33 grains m-2
Fungal
network in
killed grain

15. Farmers treating maize and groundnut fields with AflaSafe
MAIZE: Aflatoxin reduction (%)
Stage 2009 2010 2011
Harvest 82 94 83
Storage 92 93 x
PEANUT: Aflatoxin reduction (%)
Stage 2009 2010 2011
Harvest - 95 82
Storage 100 80 x
71% and 52% carry-over of
inoculum 1 & 2 years after
application
Results from 382
on-farm trials

16. 16
14
14 tons inoculum produced in 2011 for deployment

17. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Lab & Manufacturing Plant
Production Process
LATEST PRODUCTION PROCESS

18. 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
• Turn-key facility for replication in other countries
• Demonstrate commercial viability for mass production
of Aflasafe.
Date: 01 – July - 2013

19. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Production Process
Lab & manf. Plant core processes:
 Production of the inoculum
 Production of the substrate
 Mixing of the inoculum and substrate at the right rate
 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 – Cleaning, Pasteurisation, Packaging

20. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Feasibility Study and Design

21. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013
Final Plan
Partition: Labs, Substrate Processing and Packaging/storage of finished product.
Packaging & Finished Product Storage
Wash Rooms
Lab
Grain Intake, Cleaning, Pasteurisation and Storage

22. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
3 Partitions:
o Inoculum
Production Lab
o Quality Control
o Resting Room
Ante Chamber 1 & 2
Aflasafe Laboratory

23. www.iita.orgA member of CGIAR consortium
Laboratory Design Steps and Considerations
Steps
• Feasibility/Programming.
• Basic/Schematic Design.
• Design Development – Prdn of floor plans, mvt analysis, equipment
details, drawers, doors, shelves etc .
• Production of Construction Documents – designs detailed and
materials specified.
• Bidding and Negotiation.
• Construction.
Key Design considerations
• Capacity to produce inoculum for 5t/hr (40 ton/day)
• Away from the grain processes/contaminants.
• Ante-chambers – 2 before inoculum lab.
• Seamless floor with cove installation, Bench tops impervious to water,
resistant to acids, alkalis and solvents.
• Recessed lighting, No open windows etc.
• Supervisor office with glass windows overlooking the 2 labs
• NAFDAC requirements
Date: 01 – July - 2013

24. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Plant

25. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Plant Plan

26. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Grain Processing Plant

27. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Design considerations
• Capacity.
• Combines loading, transferring, filling, and unloading of grain all into
one low maintenance, economical and easy to use system.

28. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Major works
• Provision of utilities - Complete
 Water and mains power supply
• Building renovation - Complete
 Two labs
 Workers’ resting room
 Rest Room
 Packing and storage
• Factory construction – Ongoing
 Equipment installations

29. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Plant

30. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Lab
Inoculum Prod. Lab QC Lab
Ante ChambersSpore Susp. RmPackaging/Storage

31. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Aflasafe Grain Roaster and Cooler
Aflasafe Equipments

32. www.iita.orgA member of CGIAR consortium Date: 01 – July - 2013
Weighers
Weigher Controller and
management on PC Process Weigher

33. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Heat sealers

34. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
2-5 and 5-20 Kg packers

35. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Ink jet printer

36. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Seed coaters

37. 37
atoxigenic strain manufacturing facility
Arizona Cotton Research & Protection Council, USA
AF36 production in USA

38. www.iita.orgA member of CGIAR consortium Date: 02 – May - 2013
06-Dec.-12 IITA - Pathology (Aflasafe)

39. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Plant equipment cost
S/N Supplier Item Total
1 Chore Time Brock Silos, Elevators, Grain Loop 178,401.48
2 Roast-A-Matic Roaster 60,270.00
3 Roast-A-Matic Cooler 36,494.00
4 Roast-A-Matic Panel and Tools 13,150.00
5 Roast-A-Matic Cyclone 7,850.00
6 Roast-A-Matic HEPA Filter 8,500.00
7 Carter Day Debearder 10,351.00
8 Carter Day Scalperator 13,914.00
9 Carter Day Fine Cleaner 48,425.00
10 Carter Day Exhaust Fan 4,698.00
11 Wintersteiger Hege 11 Seed Treater 7,815.00
12 USC AT500EXT Seed Treater 7,189.00
13 AccuTech Process Weigher 12,846/33
14 AccuTech 2-5kg Smalls Packer 15,129/62
15 AccuTech 5-20 kg packer 14,542/85
16 AccuTech Saxon Heat Sealer 16,597/61
17 AccuTech Hanato Ex-720 Sealer 7,501/15
18 AccuTech Compressor 3,366.23
19 AccuTech Inkjet 7,060.00
20 AccuTech Commissioning and Training 4,796/13
21 Sub Total 407,483.71
22 Siemens Plant Control Panel 52,530.00
Grand Total 460,013.71

40. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Lab Equipment
Item
Inoculum
Production
Lab
Quality
Control Lab Remarks
Laminar Flow Hood 2 0 Delivery Expected
Laminar Flow Hood 0 2 Delivery Expected
Autoclaves SX-700 2 1 Delivered
Incubator (Air) 5 1 Delivery Expected
Water jacket
incubators. 0 2 Delivered
Fridge. 2 1 Delivery Expected
Turbidimeter 1 1 Delivered
Water distiller 1 Delivered
Ph meter 0 1 Delivery Expected
Balance 1 1 Delivery Expected
Magnetic Stirrer 2 1 Delivered
Vortex mixer 1 2 Delivery Expected
Microscope 1 Delivered
Shaker 1 Delivered

41. www.iita.orgA member of CGIAR consortium
Installation
• Appointed contractor – Jalzak Ltd.
• Scope – installation the following equipments;
 Intake/Dump pit together with the augers.
 Elevator EL1
 Process/Bulk Weigher for determining grain weight .
 Debearder that sits below the Process weigher.
 Elevator EL2
 Scalperator and Fine Cleaner. They are combined as one machine i.e. Scalperator
sits on top of Fine Cleaner.
 Elevator EL3 for elevation to 100 ton Clean Grain Storage Silo
 Auger TS2 to convey the grain to Pasteuriser/Grain Roaster.
 Position the Roaster and cooler.
 Grain Loop system with all inlets and outlets.
 1 x 100 ton and 3 x 50 ton Roasted grain storage silos.
 Towers: 1 x 1828mm high EL3 and 2 x 1219mm high Grain Loop.
 Auger TS3 at Point B for conveyance to the Treater.
 AT500 EXT Treater.
 Auger TS4 for conveying from the Treater to packer.
 Packers: 2-5 kg and 5-20 kg.
 Heat Sealer.
 Electrical connections from the electrical panel to all the above equipments. Panel,
cables and conduits provided by IITA
Date: 01-July -2013

42. www.iita.orgA member of CGIAR consortium
Installation
• Siemens – to install the PLC panel and all process monitors; temperature, RH.
• AccuTech – Packaging equipment and management system.
Special requirements – Internet connection.
Date: 01-July -2013

43. www.iita.orgA member of CGIAR consortium
Installation
Date: 01-July -2013

44. www.iita.orgA member of CGIAR consortium
Installation Program/Schedule
Date: 01-July -2013
ITEM
NO DSCRIPTION WK1 WK2 WK3 WK4 WK5 WK6
1 MARKING OUT THE FLOOR
2 INTAKE PIT/ AUGER
3 BULK WEGHER
4 DEBEADER
5 SCALPERATOR/GRAINS CLEANER
6 AUGER TS2
7 ROASTER AND COOLER
8 AUGER TS3
9 AT500 EXT TREATER
10 THE FOUR SILOS
11 THREE ELEVATOR TOWERS
12 ELEVATOR EL1
13 ELEVATOR EL2
14 ELEVATOR EL 3
15 GRAIN LOOP SYSTEM
16 PACKERS
17 AUGER TS4
18 HEAT SEALER
19 ELECTRICAL CONNECTIONS
20 SITE CLEANING
21 SITE HANDOVER

45. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Packaging
Old and new aflasafe packaging

46. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Packing And Transportation
4646

47. Country Funding strains partners commercialization capacity
ongoing
Nigeria BMZ, MycoRED, AATF, USAID, World
Bank, Bill & Melinda Gates Foundation
Senegal AATF
Burkina Faso Austrian Development Agency
Kenya Bill & Melinda Gates Foundation, AATF,
USDA
starting
Mozambique Government of Mozambique, USDA-
FAS, USAID
Zambia USAID-Zambia
The Gambia AATF
Peru CGIAR
interested
Ghana Bill & Melinda Gates Foundation
Mali Bill & Melinda Gates Foundation
Tanzania Bill & Melinda Gates Foundation
Rwanda USAID-Rwanda
Ethiopia USAID East Africa Regional Office
Uganda USAID East Africa Regional Office
Ivory Coast Nestle
India ??
Aflasafe expansion -- The current national approach
www.iita.org
yet to start
partially started
completed

48. www.iita.orgA member of CGIAR consortium Date: 01-July -2013
Aflasafe Development in Africa
www.iita.org
Products ready for registration
Products under testing in farmers’ fields
Strain development in progress
Aflasafe-NigeriaTM
Aflasafe-SenegalTM
Aflasafe-KenyaTM etc…
Senegal
Mali
Burkina
Ghana
Nigeria
Kenya
Tanzania
Mozambique
Zambia

49. www.iita.orgA member of CGIAR consortium Date: 02 – July - 2013
National vs. Regional Approach
strains: regional strains
manufacturing: regional hubs
registration: regional protocols
www.iita.org
Aflasafe-NigeriaTM
Aflasafe-SenegalTM
Aflasafe-KenyaTM
Aflasafe-ZambiaTM
Aflasafe-MozambiqueTM
etc…
Aflasafe-WestTM
Aflasafe-EastTM
Aflasafe-SouthTM
PACA – Meridien Institute

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