DG board room 1 iita-ibadan-04 march 2014

1. Date: 04-03-2014 www.iita.orgA member of CGIAR consortium
Manufacture and Distribution of aflasafe
TM
Lawrence K. Kaptoge
Peter Cotty
Joseph Atehnkeng
Joao Augusto
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: 04-03-2014

3. www.iita.orgA 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

4. www.iita.orgA member of CGIAR consortium
Scaling Up
Date: 04-03-2014
LAB PRODUCTION PROCESS
PILOT PLANT PRODUCTION PROCESS

5. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
Beginning and Progress So far
STARTING POINT

6. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
Final Plan
Packaging & Finished Product Storage
Wash Rooms
Lab
Grain Intake, Cleaning, Pasteurisation and Storage

7. www.iita.orgA member of CGIAR consortium
Final Plan
Date: 04-03-2014

8. www.iita.orgA member of CGIAR consortium 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)

9. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
Progress So Far: Building Renovation
Despatch of aflasafe

10. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
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: 04-03-2014
Progress So Far: Packaging

12. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
Plant Progress

13. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
Plant Progress

14. 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: 04-03-2014

15. www.iita.orgA member of CGIAR consortium
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
%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.
10%
9%
8%
7%
6%
5%
4%
3%
2%
1%
0%

16. www.iita.orgA member of CGIAR consortium
Quality Control
Date: 04-03-2014
0%
10%
20%
30%
40%
50%
Silo Roaster Exit Cooler Exit Treater Exit
Germinating
%ofseedstogerminateorrevealfungalcontamination
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.
Fungal contamination reported within acceptable levels.

17. www.iita.orgA member of CGIAR consortium
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
PercentofseedscontaminatedbyfungiotherthanA.flavus
Fig.1. 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%

18. www.iita.orgA member of CGIAR consortium Date: 04-03-2014
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.

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