Publication

2|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com

INJECTION MOULDINGPLASTIC pallet

ZA–P1: 4 way entrynon-rackable1200 mm1000 mm120 mm8 kg2000 kg1000 kgPP (Virgin/Recycled)-20 º to 40 ºCOptional

DESCRIPTION

LENGTH WIDTHHEIGHT WEIGHTSTATIC LOADDYNAMIC LOADMATERIALTEMPERATURE RANGERFID

KwaZulu Natal +27 (0)31 767 4009/4026

Western Cape +27 (0)21 551 2310

Gauteng +27 (0)11 677 1200

Open topdeck for

improvedventilation

Label or barcode area

Chamfered top,bottom and side

pillar deck foreasy entry offorklift andpallet jacks Non-slip grommets

(Standard pallet has 8 inserts,4 top deck and 4 forklift entry,

additional can be addeddependant on requirements)

Stretchwrap

grip lip

Every MCG plastic pallet has consistent1200 mm x 1000 mm dimensions.

Weighing 8 kg each, MCG pallets are signi�cantly lighter than equivalent wooden pallets and more importantly do NOT increase in weight when wet.

MCG plastic pallets are manufactured from polypropylenein virgin or recycled material ensuring long life.

Our plastic pallets are 100% recyclable.

No protruding nails or broken boards to injure employees or damage equipment or products.

MCG pallets do not absorb liquids and areimpervious to infestation and contamination.Do not need to be heated or chemically treated.(Ideally suited for export pallets.) Can be washed.

CONSISTENT

LIGHTWEIGHT

DURABLE &STRONG

RECYCLABLE

SAFE

HYGIENIC

Features

Speci�cationsStrappingtie down

holder

Anti slip insertsunderneath pallet

Official journal of the SA Assoc of the Flavour & Fragrance Industry.

FBR is a member of the Audit Bureau of Circulations.

Endorsed by SAAFoST.

Published quarterly by PS Publishing. Reg No CK 2011/084261/23 PO Box 650484, Benmore, 2010, South Africa.

Tel: 27 11 462-5645 • Fax: 27 11 704-3962 • Email: [email protected]

May2012MayMay 20122012

Cont ten s

22 Solar refrigerators designed to solve electricity shortage challenges

26 New projects

16

1018

5 The latest events

10 Extruded snacks: trends, barriers, machinery and potential

16 Moringa to purify water and provide nutritional benefits

18 Small-scale chicken farming solution

20 Affordable, portable and reusable building system saves on construction and transport costs

Africa’s Big 7 Expo ...................................... 6Continental Beverages ............................17DEF ...............................................................19Extru Africa ................................................25Heat & Control ..........................................13Insta-Pro International .............................. 8MGC Industries .......................................... 2Nicola-J Flavours & Fragrances ........4, 11Savoury Food Ingredients .......................28Stumbelbloc ...............................................14

Index of advertisers


nicola-jflavoursandfragrances

The core of the founding team has

considerable experience in the flavour

industry, and our growth since

inception has been exceptional.

Our flexibility and quality of products

and service has established Nicola-J as one of

South Africa’s premier independent flavour

manufacturers. All of our efforts are focused

extensively on satisfying the needs of our

customers.

We understand the demand for continual

improvement of costs and quality, and

therefore like to work closely with our clients

to assist them in new product developments

and reformulation of existing lines. Our

team of food flavourists

and technicians gladly

assist in the development

or matching of existing

flavours to suit customer

requirements.

By offering a complete

range of products and

services, we aim to satisfy

not only our customers,

but also to contribute to

the quality of their final products, which is

demanded by consumers.

In keeping abreast with the latest rules

and regulations governing our industry - from

food safety issues to labelling requirements

- our regulatory department ensures that we

comply with the ever-changing legislative

landscape.

CustomercoverageWe have an extensive customer base within

South Africa, as well as many other African

countries. All local customers are serviced

from our base in Midrand, Johannesburg. Our

sales staff undertake regular visits to all our

customers throughout South Africa to ensure

that we maintain high levels of service and

build solid relationships.

South Africa has become the “gateway”

to Africa, and our expertise and ability to

customise flavour solutions put us in an

ideal position to increase our presence and

market share in other African countries.

Although we have established distributors

in Mozambique and Zimbabwe, our aim is to

establish distributors in all the countries that

we service. Regular trips are undertaken to

visit our African distributors and customers to

ensure that we understand their markets and

requirements.

We are HACCP (hazard analysis critical

control points)-certified by the South African

Bureau of Standards, and strictly adhere to

our HACCP plan and procedures to ensure

that we manufacture products to the highest

safety standards.

Nicola-J is a full member of the South

African Association of the Flavour and

Fragrance Industry (SAAFFI). We have signed

and adhere to the SAAFFI “Code of Conduct”, a

prerequisite for membership.

ManufacturingcapabilitiesOur new and modern manufacturing

facility in Midrand was designed and built

in strict accordance to HACCP requirements.

The factory consists of eight independent

manufacturing rooms and two warehouses

spanning over 1,800 sq metres.

For the manufacture of powder flavours,

we are equipped with a variety of ribbon and

high-speed “Diosna” blenders, giving us a

manufacturing range for batches from 25kg

to 1.5 tons.

Similarly, for liquid flavours and

emulsions, we have a range of high-

speed mixers, blending tanks, and an APV

homogeniser, giving us the capacity to

manufacture batches from 5kg up to 3,500kg.

SweetflavoursInnovation and creativity is core to our success.

We have developed an extensive range of sweet

flavours suitable for almost all applications.

These flavours are available in either powder or

liquid form depending on application.

Our flavours are developed for specific

product applications, and are tested in

products before being commercialised.

We offer these flavours in a range of

concentrations and reasonable pack sizes,

depending on your requirements.

The sweet flavour range includes popular

flavours for baking, including biscuits and

muffins; beverages, including carbonated

beverages; dairy, including yoghurts and

flavoured milks, as well as desserts and toppings.

SavouryflavoursOur ever-increasing range of savoury flavours

has proved very popular and successful within

the marketplace. We have the expertise and

experience to develop just about any type of

savoury flavour to suit your exact requirements.

Key to our success

has been our innovative

development of cost-

effective savoury flavours

that do not compromise on

taste and quality.

Depending on your

requirements, we offer

savoury flavours in various

concentrations in both

powder and liquid form.

The range includes flavours for snack dustings,

soups and stews, savoury baking, pet foods,

sauces and marinades, meat and processed

meat, fish, cheese, etc.

AgenciesinSANicola-J is the official distributor in SA for the full

range of food colours and lakes manufactured

by Vidhi Dyestuffs (MFG) Ltd, India. We carry

large stocks of the primary colours and lakes,

which are available “off the shelf” for immediate

dispatch. In addition to these primary colours,

we also blend and match colours to offer you

the exact colour to suit your needs.

Nicola-J is also the official distributor

for the full range of caramel colours

manufactured by Alvin Caramel Colours

(India) Pvt. Ltd. We carry stocks of the more

popular caramels, but offer the full Alvin

range.

Customer collaboration ensures continual product improvement Nicola-J Flavours and Fragrances (Pty) Ltd, a wholly-owned South

African company, was founded in 1996.

www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|5

events

Extru Africa 2012Hosted by South Africa’s North-West University, CFAM Technologies and Department of Trade & Industry, as well as Texas A&M University, the two-day practical training seminar on food, feed, and pet food extrusion, on 31 July and 1 August, will teach delegates about:

• The principles and characteristics of extruders and support systems for effective selection and operation

• Current practices for preparation of full-fat soy meal, processing raw animal products, preparation of pet food, aquaculture, poultry, and swine feeds

• Equipment in actual operation to familiarise delegates with practical aspects of food, feed, and pet food extrusion technology

• How to run an extrusion operation smoothly• Employing a preventative maintenance philosophy for

extrusion plants• The commercial applications of extrusion• The availability of mechanical energy in dry and wet

extruded full-fat soy, as well as the digestibility of solvent soy oilcake and extruded/expelled oilcakes.

The two-day conference on food and feed extrusion, on 2-3 August, will take delegates through global developments in extrusion, including the policies, strategies and initiatives concerned; agro-business development and processing; the potential of extrusion for texturising vegetable proteins; the latest technology on extrusion processing and its support systems for effective operation; product development and product registration; the principles of food safety; the design of a processing operation; managing energy in an extrusion plant; and how to run an extrusion operation smoothly.Costs:Seminar only = R5,900 ($753) per delegate (includes one boma dinner). Conference only (includes one boma dinner) = R4,350 ($555) per delegate, student rate of R3,250 ($415) and a discount group booking rate (5+ delegates) at R3,950 ($505) per delegate. Full-week package = R8,500 ($1,085, includes the seminar, conference and two boma dinners). Bookings:Onlineatwww.extruafrica.org.za.Alternatively,

contacttel+27(0)182994492;fax+27(0)182935110;

[email protected]

Extru Africa 2012

31July-3August,ProteaHotelKrugerGate,Mpumalanga,SouthAfrica

Food Security Summit 2012 The Institute for International Research’s (IIR’s) Food Security Summit will draw on the political, environmental, financial, economic, and technological challenges of increasing food security across the agribusiness sphere in southern Africa; its implications for the supply of food to both international and local markets; as well as the wholesale, distribution, processing, and retail of food products.Costs: R9,499 ($1,213 excl. VAT) for registrations received between 3 and 31 May, and R10,499 ($1,341 excl. VAT) for registrations after 31 May. Formoreinformationortoregister:Tel+27(0)117717000;

[email protected];website:www.iir.co.za

Food Security Summit 2012

18-22June,TheWanderersClub,Johannesburg,SouthAfrica

15-17July,2012,GallagherConventionCentre,Midrand,SouthAfrica

Africa’s Big Seven Expo The food and beverage, retail and FMCG trade fair for the continent incorporating a basket of expos: • Agri-Food: manufacturers and producers expo• DrinkTech Africa: beverage processing and packaging

machinery, equipment and technology• FoodBiz Africa: food service and equipment• FoodTech plus Drinktech: production, processing and

packaging• IFMA: dedicated meat industry expo• InterBake Africa: equipment, processes and ingredients for

the baking industry • Pan Africa Retail Trade Exhibition: food, beverages,

merchandise and fast moving consumer goods• Retail Solutions Africa: technology for retailers ContactLinekevanderBrugghen,ExhibitionManagementServices

(theorganiser):Tel+27(0)117837250/1/6/9;

[email protected];www.exhibitionsafrica.com

www.fbreporter.com


exhibitions

“This year, we have partnered with Trade Conferences International to host the inaugural Retail

Solutions Africa Conference in South Africa,” says John Thomson, MD of Exhibition Management Services (EMS), organisers of AB7 and SAITEX. “We are also hosting the On-line Retailing Conference for the third successive year.”

AB7 has been tempting trade visitor tastebuds for over a decade, while SAITEX has been enticing entrepreneurs for almost 20 years. Both exhibitions take place at Gallagher Convention Centre in Midrand, Johannesburg, from 15-17 July.

AB7 is the biggest food and beverage trade exhibition on the African continent. This seven-shows-in-one event covers the entire gamut of the food and beverage business, from farm to shelf and everything in between - a veritable “crop-to-shop” experience. It happens at the same place and time as SAITEX, a full spectrum trade show with product categories from A to Z.

SAITEXhostsFutureofTradeAfrica“There’s another big value-add for visitors this year, and it’s all about learning how to do business in Africa,” adds Thomson. “SAITEX is hosting the Future of Trade Africa 2012 conference for the first time.”

“The world really is coming to Africa,” says Sven Boermeester, director of The Future of Trade Initiative. “The Future of Trade Africa is a sophisticated, in-depth commerce exchange and business matchmaking platform that primes delegates with the knowledge and tools needed to succeed in business in Africa.”

“Everyone is aware of Africa’s immense potential - the mineral resources, infrastructure development opportunities, and the growing demand from Africa’s emerging middle-class for goods, services and know-how. But Africa

is not a country, it’s a continent with 46 unique political, economic and social environments; a myriad of languages and never-ending reams of regulations and red tape. In such an environment, traders absolutely need to engage with local knowledge, partners and stakeholders.

“It is our mission to boost inter-trade and cultural relations across the continent by connecting business people at events, as well as showcasing Africa to the world through print and online publishing,” says Boermeester.

“Companies currently active in Africa who wish to network and explore growth opportunities will find the Future of Trade Africa extremely helpful. Likewise, investors who are serious about growing business in Africa and need local skills and knowledge should also attend.”

RetailconferencesaddvalueThe two retail conferences being hosted by SAITEX - Retail Solutions Africa 2012 and On-line Retailing 2012 - will focus on the latest trends and challenges regarding technology, innovation, systems and products in the retail industry. “The conferences provide a great opportunity for networking with people from South Africa and abroad,” says Mariette Broodryk, project manager for the events. “It gives local delegates the chance to meet global players that they always hear about.”

MajorconsumerbodysupportsAB7andSAITEXTeaming up with AB7 and SAITEX for the first time is the Consumer Goods Council of South Africa (CGCSA). “As proud partners to the event, we fully endorse and support AB7 and SAITEX 2012 and look forward to helping more local companies and entrepreneurs come together and explore business opportunities,” says Gwarega Mangozhe,

CEO of the CGCSA.EMS’ John Thomson is thrilled to have

the CGCSA as an official strategic partner. “Having the Consumer Goods Council on board sends a very strong, positive message to our exhibitors and visitors. It shows that the CGCSA is committed to serving stakeholders, businesses and South Africa’s consumers.”

MatchmakingserviceAs a unique and free service offered by the organisers, AB7 and SAITEX attendees have access to an easy-to-use, internet-based business matchmaking programme. It provides exhibitors and visitors with the ability to pre-profile, pre-select and pre-schedule meetings for all three days of the shows. Visitors can pre-register to visit at www.exhibitionsafrica.com. They can also preview product profiles on this site.• To see what SAITEX and AB7 are all

about, view the 2011 event video on YouTube - simply go to www.youtube.com and in the top search window type “Saitex & Africa’s Big Seven”.

Two of South Africa’s biggest trade expos - Africa’s Big Seven (AB7) and Southern African International

Trade Exhibition (SAITEX) - get even bigger this year with the addition of three new components.

Value-added events to enhance Africa’s Big Seven & SAITEX 2012 Expos

• AB7: contact Lineke van der Brugghen at EMS, tel +27 11 783 7250;

[email protected]. Website: www.exhibitionsafrica.com

• SAITEX: contact Anina Hough at EMS, tel +27 11 783 7250;

[email protected]. Website: www.exhibitionsafrica.com

• Retail Solutions Africa Conference 2012: contact Mariette Broodryk, tel +27 11 803 0009; [email protected]

• On-line Retailing Conference: contact Danie Herbst, tel +27 11 803 0009; [email protected]

• Future of Trade Africa 2012: for more information, visit www.futureoftrade.com or www.ProudlyAfrica.info

Contact details


Brought to you by

“Packaging for success in African markets”

Join us for a workshop-ing lunch

Brought to you by FoodProcessing Africa digizine – sister publication to Food & Beverage Reporter (incorporating Packaging Reporter) – three speakers from leading packaging and processing firms will guide you on successful packaging approaches to the markets of Africa.

Agenda11.30am: Markus Dreier, Kraft Foods’ packaging design manager for Middle East and Africa on Innovative packaging being utilised by Kraft Foods in its African markets

12pm: Jeff Rossouw, Heat and Control general manager - Africa on Understanding snack production in Africa: consumer types, sales outlets, snack types and packaging, and processing challenges and solutions

12.30pm: Lunch

1pm: Chandru Wadhwani, Extrupet’s chief operating officer on Food-safe recycled PET: the benefits and opportunities for African processors and converters

Target audienceFood processing manufacturers from all countries who intend expanding up the African continent, or further developing their African endeavours.

Why you should attend the seminar In addition to attending the BRICS Africa Export/Import Forum and Africa’s Big 7 Exhibition (the continent’s largest food and beverage industry trade expo) you will get tips and advice on how to tackle packaging for the varied countries of Africa, and pitfalls to be avoided, from leading experienced experts in the packaging industry with first-hand knowledge.

The cost

Early bird special (before 15 June) R555 including VAT (US$85); thereafter R655 (US$97.50) per person. Price includes:

To registerPhone Alice Osburn on +27 (0)11 462 5645 Email: [email protected] www.foodprocessingafrica.com

Our banking detailsAccount name: PS Publishing, Bank: First National Bank, RandburgBranch code: 254 005, Account No: 62315015570 Swift No: FIRNZAJJ

Fax the form below to +27 (0)11 704 3962 together with your deposit slip

Title: First name: Surname:

Company: Job title:

Tel no: Fax no:

Email address:

Company VAT no: Invoice required? Yes No

Gallagher 1 Meeting Room, Gallagher Convention Centre, Midrand

Chandru Wadhwani

Jeff Rossouw

(emailed to you)

To be held alongside the BRICS Africa Export/Import Forum – a new feature at the 2012 edition of “Africa’s Big Seven”

Food & Beverage Reporter (value: R455 and other subscriber benefits)F&B Reporter’s fortnightly electronic newsletter, giving updates and hot news

FoodProcessing Africa digizine

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#401

4


insta-prointernational

A large number of studies have been performed over the past few decades to investigate different

aspects of applying extruded full-fat soybeans in animal and poultry diets. These studies have demonstrated that properly processed extruded soybeans can: 1) Be effectively used by poultry species2) Completely replace other protein

sources in the diet3) Replace dietary fat supplements.

Using Insta-Pro equipment, studies have shown that extruded full-fat soybeans contain about 3,815Kcal/kg of true metabolisable energy (TMEn) for poultry and 4,446Kcal/kg TMEn for swine species. The moisture content, crude protein and crude fat content of Insta-Pro’s extruded full-fat soybean is about 7%, 38% and 18% respectively, says Dr Poureslami.

Researchers at the University of Arkansas have used extruded full-fat soybeans at 52% in the broilers diet (see the table). Extruded full-fat soybeans in this study replaced solvent-extracted

soybean meal and poultry oil, which contributed to a significant improvement in growth performance, body weight and feed conversion ratios.

Poureslami adds that extruded full-fat soybean is a great ingredient in many countries where the price of energy is high and imported soybean meal is the major protein source in the feed. Other advantages that have been attributed to the full-fat soy are: 1) It can be processed locally at a relatively

low price2) It is a grainy material that can be

handled at a lower cost than oil in the feed mill

3) Having fat within the matrix of the diet rather than mixing/spraying fat leads to a lower rancidity rate

4) Having fat within the matrix of the feed decreases dustiness of the diet

5) The quality of fat is higher than that obtained from most sources of added fat.

Dr Reza Poureslami, poultry

nutritionist at Insta-Pro

International, explains that

extruded full-fat soybeans

have been used as a high-

quality source of energy (due

to the oil content of 18-22%)

and protein (38-42%), in the

diet of poultry species since

the early 1970s.

Extruded full-fat soybeans and ExPress® soybean meal are high-quality sources of energy and protein for poultry species

Amino Amino Amino AAAcids cids cids

ExtrudExtrudExtrudEEEd d d full-ffull-ffull-fAAAfull-fAfull-ffull-ffull-fAfull-fAfull-fAfull-ffull-ffull-fAfull-f t t t At AAAt At At AAAt A

soybsoybsoybEAEAEAnsnsns

ExPrExPrExPrEEEEEEss® ss® ss® soybsoybsoybEAEAEAn n n

mmmEAEAEAEAEAEAlll

ArgArgArg 93.7 93.7 93.7 92.192.192.192.192.192.1HisHisHis 91.291.291.2 92.392.392.392.392.392.3Ile Ile Ile 92.792.792.7 93.193.193.193.193.193.1LeuLeuLeu 93.593.593.5 93.893.893.893.893.893.8LysLysLys 92.092.092.0 92.192.192.192.192.192.1MetMetMet 89.789.789.7 91.191.191.191.191.191.1CysCysCys 94.294.294.2 94.794.794.794.794.794.7PhePhePhe 94.394.394.3 94.894.894.894.894.894.8ThrThrThr 92.392.392.3 91.591.591.591.591.591.5

ValValVal 92.892.892.8 92.892.892.892.892.892.8

AlaAlaAla 90.890.890.8 90.790.790.790.790.790.7

GluGluGlu 95.295.295.2 95.595.595.595.595.595.5

ProProPro 96.496.496.4 94.894.894.8

Trueaminoaciddigestibility(%)ofextrudedfull-fatsoybeansandExPress®mealproducedthroughtheInsta-Prosystem,asreportedbyDrNickDaleoftheUniversityofGeorgia,USA(2011).Thesedigestibilityvaluesindicateahighproteinbioavailabilityofextrudedfull-fatsoybeansforpoultryspecieswhencomparedtootherproteinsources.

Model2000Extruderwhichisshowninamirrorimage,thusproducingtwotimesthecapacity.

4043 120th StreetUrbandale, Iowa 50323 USA

[email protected]

www.youtube.com/instaproint

Processing Technologies for Food and Feed

PROCESSING SOLUTIONSFlexible Scale of Operation

Environmentally Friendly, Chemical-Free ProcessesLow Capital Investment

Produces Superior, Quality IngredientsDurable Equipment

Easy to Operate

PRACTICAL APPLICATIONS

OilseedsPet and Aquatic Feeds

By-productsNovel Ingredients

FoodFeed

PRACTICAL APPLICATIONS

OilseedsIdeal for Specialty Seeds

i.e. Organic

Other Oil Bearing Products

EXTRUSION

MECHANICALOIL EXTRACTION

dairy

Insta-ProInternational’sModel5005OilPress.

Extruded-pressed(ExPress®)soybeanmealExPress® soybean meal is an alternative to solvent-extracted soybean meal. Extruded soybeans go through the pressing process where about 12% of oil is extracted. This extracted oil can further be used in the feed and/or food applications.

Basically, ExPress® soybean meal contains less crude fat when compared to extruded soybeans (6% versus 18%). The crude protein (48%) and energy content (3,344Kcal/gg TMEn) of ExPress® meal is different to that of extruded full-fat soybeans. Amino acid digestibility of ExPress® meal is presented in the table.

In a recent study at the University of Illinois, conventional solvent-extracted soybean meal was substituted with ExPress® meal in the broiler diet. Results of this study indicated that feeding ExPress® meal supports maximal growth and performance, Poureslami states. The feeding value of ExPress® meal in this study was similar to that of conventional solvent-extracted soybean meal.


Although designing snack foods today can be a complex process to meet changing consumer

tastes and expectations, extrusion technology provides snack makers with the opportunity to process a variety of products by changing minor ingredients and processing conditions on the same machine. The extrusion process can therefore produce innovative snacks with different shapes, textures and colours to capture the consumer’s imagination.

Prof LJ Grobler, head of the Centre of Excellence in Advanced Manufacturing at North West University in South Africa, says: “Extrusion can be described as a process during which a material is forced through a defined opening. When extrusion is used for food or feed product manufacturing, mechanical cooking also forms part of the process. Products such as breakfast cereals, puffed chips, animal feed and plastic wood composites can be produced using this technology.”

He adds that extrusion technology is ideal for establishing small to medium-sized processing plants on farms or in rural areas to produce food or feed products in close vicinity to where the feed-in produce - such as maize, wheat

or sorghum - is grown. “There are many opportunities for developing new products in Africa by using extrusion. It is a relatively inexpensive, energy-efficient and easily-operated method to produce a wide range of ready-to-eat foods and animal feeds.”

MarketstatusAccording to Jeff Rossouw, Heat and Control’s general manager - Africa, the African snack industry has grown considerably over the last few years as companies have invested in an industry that offers certain growth. “The global trend is positive for the snack industry, and Africa has plenty of opportunity to receive benefit from a growing snack market, but there are also significant barriers,” Rossouw concedes.

“More often than not, snacks in emerging markets are a replacement meal and not a snack in the true sense of the word,” he states. “Do not be surprised to see a corn or cassava chip soaked in milk eaten as breakfast, or mixed with a meat sauce as lunch or dinner.”

Rossouw explains that baked extruded products are popular in markets where distribution channels are limited and roads are bad. “These types of snacks do not travel well and in-bag-damage often occurs. Shelf time for informal products is often a few days only.

Nitrogen gas flush is uncommon. Cost is also a prohibitive factor and price

wars are common. In South Africa’s informal market, for example, prices have remained almost unchanged for the last 10 years due to fierce competition.

“In certain countries where temperatures are

extremely hot, processors often use thicker BOPP film to overcome

quality problems resulting from the environment, despite short shelf time.

“Outside of South Africa and especially in East and West Africa, homemade snacks are sold through street vendors and many home-style snacks do not always lend themselves to commercial processing. With many subsistence farmers producing raw products such as potato, cassava, yam, taro and plantain, quality is still a subjective term. Commercially-viable volumes can only be produced if quality

FoodProcessing Africa

investigates extrusion in the

growing African savoury snack

market, the trends in different

markets, and the equipment

available to service the needs

of producers in this sector.

Extruding new snack opportunities

Fromrighttoleft:theClimbackSystem,FastbackRevolutionGateSystemandFastbackOnMachineSeasoningSystem,allmountedontoaHeatandControldesignedandconstructedplatform.TheClimbackusesaFastbackdrivetrainandstainlesssteelpantoconveyproductataninclineangle.


food

is ensured through proper agronomy,” Rossouw remarks.

Gary Boast of Nicola J Flavours & Fragrances confirms that the most popular snacks remain extruded puffs and naks, with some regions preferring them with a high level of chilli or “heat”, while others prefer much milder flavours. “Broadly speaking the old favourites such as cheese, spicy tomato, chutney, beef are the common sellers, often with their own local twist.”

Rossouw adds: “In Nigeria you will find a seafood flavour called ‘snoek’ that has its origins in Scandinavian fish imported years ago. The taste is not remotely close to the game fish known in South Africa.”

ThechallengesBoast says market research, funding, bureaucracy and punitive duties and levies are all barriers to growth in the

African snack market. “Many business people have no access to market research-or indeed there isn’t any - and thus find it difficult to maximise potential, identify opportunities for different products and expand existing markets,” Boast states. “Funding is always a problem leading to many businesses being undercapitalised and thus unable to grow.”

Rossouw adds that import duties, transit services and raw material or energy source supply are also big barriers. “Prohibitive import duties on raw materials or significant equipment investment, rather than consumer preference, often determine future trends. Raw pellet snacks are, for example, taxed between 5% and 20% depending on the raw materials they contain,” he says. “A real barrier to entry is also the capital tied up as stock in transit, when shipping -from abroad.”

“Currently, cassava and plantain processing enquiries dominate West Africa, while corn and cassava dominate East Africa. Egypt in recent years has become a major player in the snacks market, and there is movement in Mozambique, Zambia, Nigeria, Ghana and Cameroon.” - Jeff Rossouw, Heat and Control’s general manager, Africa

SnackQuipoffersasuperlow-oilvolume-friedlinethatutilisesexternalheatexchangertechnology,whichallowsclientstoselectdifferentfuel/energyoptionsthatmaybeavailableinoutlyingandharder-to-serviceareas.Typically,theselinesstartat200kg/hourwithoneextruder,andcanbeexpandedwithasecondextruder.


OpportunitiesandconstraintsEven with all the barriers to entry in the market outlined above, Rossouw says that there are some opportunities to be exploited. “With a strong Indian influence throughout Africa, there are opportunities to produce Namkeen (Indian) snacks with an African ‘twist’. And if the trend to export tree nuts, such as macadamias and cashews, to other emerging countries for further value adding and processing can be reversed. A whole new industry can be established with all the socio-economic benefits that go with this. Coated spicy nuts

have already been established as a good product line in certain regions.”

He also believes that the potential for pellet-type snacks is huge as equipment investment is reasonably low and the producer can run any number of different raw pellets and offer a basket of products with bases such as corn, potato, rice and multigrain, off one machine.

Rossouw adds that the product range for the smaller, entrepreneurial type of processor, so often found in Africa, is very limited and that the initial investments required are out of reach for most. “The typical system that would be replacing roadside ‘woks’ would be a small gas or electrically-heated batch fryer. The availability of gas, electricity and the fact that these types of units are not mobile, in itself poses a challenge, as most vendors pack up their shops at the end of

a trading day. These machines are more suitable to fixed premises with services supply in place.”

Boast adds that small-scale producers often also have difficulty obtaining the volumes required to be profitable due to a lack of funding. “Producing snack foods is generally a low-profit, high-volume business, making economies of scale necessary to achieve profitability.” -MelissaJaneCook

ExtruAfrica,ProfLJGrobler:

Tel+27(0)182991329;[email protected];

www.extruafrica.org.za

HeatandControl:Tel+27(0)219485934;

www.heatandcontrol.com

NicolaJFlavours&Fragrances:

Tel+27(0)113156582;www.njflavours.co.za

SnackQuip:Tel+27(0)119650582;

www.snackquip.com

“With a population of 150 million, Nigeria should be a big market for all kinds of snacks. But manufacturing is a challenge because electricity supply is a significant problem along with poor infrastructure, poor support services and other necessary services to run a factory. Clearing from the ports can take upwards of 15 days and the political environment impedes significant progress in the snacks market.” - Jeff Rossouw, general manager Africa, Heat and Control

“Potential snack manufacturers should select a company to supply not only the equipment, but also all of the surrounding services, including assistance with sourcing raw materials, flavouring and packaging,” says a Snack Quip spokesperson. “They should ensure that the prospective equipment supply company can

offer them growth with innovative new ideas and the ability to implement service into Africa.”

The spokesperson adds: “We also advise clients not to underestimate the quality demanded by the little client, even in outlying rural conditions. People across Africa demand very high-quality products, and

generally, high-quality machinery is required to achieve this.”

Jeff Rossouw of Heat and Control says that one of the most common mistakes made by inexperienced processors or investors is to buy equipment on price alone, or to acquire second-hand equipment from a reputable manufacturer that has been modified

by an equipment broker. “The cheaper equipment often has no history of research and development, resulting in failure and unreliability. And the OEM parts used are more often than not unknown brands and not readily available for emergency maintenance.

“Second-hand equipment, on the other hand, is often

more than 20 years old and has been modified over the years, or the brokers have matched filter fryers and heat exchangers that are not designed to function together,” he notes. “Almost every single call we receive on our own brand of second-hand equipment is a case of the latter and endless problems are the order of the day.”

Equipment considerations

Pellets,whicharedehydratedpre-formedstarchproducts,canbeorderedinmanydifferentshapesandbasematerials,forexample,wheatorpotato.Thisincreasesthenumberofproductsasmallproducercanofferthemarket.Positioningamobilevibratoryin-feedhopperbehindthefrylineenablestheproducertocontinuouslyfry“pellet”products.ShownhereisaSnackQuipfryerwithheatexchanger.

food

www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|13www.heatandcontrol.com

Progress through innovation

Heat and Control is one of the world’s leading manufacturers of snack food processing and packaging equipment systems with over 60 years food industry experience. Complete systems are provided to deliver the highest quality food products and a combination of experience and expertise and the commitment to innovation and quality, will guarantee world class solutions for product requirement.

Complete Snack Processing & Packaging Systems

Potato Chips; from hard bite to classicCorn & Tortilla ChipsTaco Shells, Corn Tortillas & TostadasFabricated ChipsPellet SnacksExtruded SnacksRoasted Nuts, Peas & LegumesNamkeen [Traditional Indian savoury snacks]

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Food Proc Africa12_FULL_281x205 with 5mm bleed_HeatandControl_Snacks.indd 1 02 May 2012 10:04:24


“The system’s versatility means that farmers are able to build anything from houses and swimming pools to warehouses and all the way down to septic tanks and

French drains,” says André Esterhuizen, inventor of Stumbelbloc.Farmers can make blocks for as little as R4 ($0.51) if they

have the right sand or gravel in dry river beds says Esterhuizen. This means that they can construct walls for less than R98/m² ($12.49/m²).

“The plastic moulds with which you make the blocks are very unique in the sense that you can start a small do-it-yourself factory with as little as 34 moulds or grow to any limit, depending on the size of the project,” he adds. “34 blocks are produced with one bag of cement; three wheelbarrows of sand and two wheelbarrows of 13mm stone. This mixture produces 5.5 megapascal (MPA) blocks (3.5 MPA is required for single-storey buildings up to 3.3 metres high with a gable of 5.2 metres high.) You can also determine the strength of the blocks by simply changing the cement percentage.”

“The tendency for farmers to finance moulds and train workers to build their own houses is growing fast,” says Esterhuizen. “A typical example of how Stumbelbloc has been used as an upliftment and employment tool is in Marydale in South Africa’s Northern Cape province. Here Pastor Hennie Mare convinced farmers to invest in the upliftment of the town’s 2,500 people - 85% of whom are unemployed. Not only did the farmers buy the moulds through the church to start a brick factory, they are also buying the blocks, training and paying the workers to do construction, which is creating employment for the benefit of all.”

“While this particular project was launched as a charity initiative, it is fast becoming a self-sustaining business that benefits the whole community, and similar towns are watching them closely and investigating the opportunity.”

Pastor Mare says: “The demand for the blocks is so great at the moment that we are turning away orders because the factory cannot meet the demand. We have also had to change our non-profit organisation status to a not-for-profit company, and we plan to use the profits for further upliftment.”

Formoreinformation,contactAndréEsterhuizenon+27(0)832288036

orvisitthewebsite:www.stumbelbloc.com

Stumbelbloc is fast becoming the farmer’s first

choice of do-it-yourself construction because it is

economical and easy-to-use, and the durability and

versatility of structures impress.

Stumbelbloc is growing from strength to strength

stumblebloc

ThesephotographsshowatypicalStumbelblocconstructioninMaun,Botswana.



According to Sonia Marais of Moringa South Africa, moringa is the sole genus in the flowering

plant family Moringaceae. It contains 13 species that grow in tropical and sub-tropical climates, which range in size from tiny herbs to massive trees. The most widely cultivated species is Moringa oleifera, a multi-purpose tree native to the foothills of the Himalayas in northwestern India, and cultivated throughout the tropics. M. stenopetala, an African species, is also widely grown, but to a much lesser extent than M. oleifera.

Marais says: “Moringa oleifera silviculture is being promoted as a means to combat poverty and malnutrition. It grows quickly in many types of environments, and much of the plant is edible. The leaves contain all essential amino acids and are rich in protein, vitamin A, vitamin B, vitamin C, and minerals. They are often called ‘super food’ because scientists have found that they contain the calcium equivalent of four glasses of milk, the vitamin C content of seven oranges, the potassium of three bananas, three times the amount of iron found in spinach, four times the amount of vitamin A found in a carrot, and twice the amount of protein in milk.”

Pilot nutritionprojectIn Tooseng village in South Africa’s

Limpopo province, a 15-hectare plantation of Moringa has made a positive change to the individuals there. Mavis Mathabatha, a former school teacher in the village, has set up a Moringa farm that will produce enough leaves to make a dramatic difference in South Africa and further afield.

In 2009, Mathabatha started harvesting, drying and grinding Moringa leaves from the first few trees she had planted. She sprinkled the crushed leaves on meals provided to about 400 poor children at the local Sedikong sa Lerato (meaning “Circle of Love” in Sesotho) drop-in centre.

“The results were visible almost immediately. The health of the children improved in a short period of time,” says Elizabeth Serogole, the drop-in centre’s manager, who works closely with Mathabatha. She says many children had been showing signs of malnutrition, like open sores on their skins, which started to heal soon after regularly eating one teaspoon of leaf powder a day. “Supplementing their meals with Moringa also notably increased children’s ability to ward off new illness and infection and boosted their mental development, as most can now concentrate better at school.”

Mathabatha’s farm produces and packages up to 10,000 tons a year of

Moringa leaf powder, which is distributed within South Africa and exported to Botswana, Swaziland and Lesotho. “I am hoping to further extend my market in the next few years. There is a lot of interest in my product,” she says.

“Planting and distributing Moringa is a holistic approach to deal with the problem of food insecurity,” says Ashley Green-Thompson, who managed Mathabatha’s project grant. “The level of household food insecurity is one of the key indicators of poverty, and it’s very high in Limpopo.”

VarietyofbenefitsDr Samson Tesfay, a post doctoral scholar at the South African University of KwaZulu-Natal’s Horticultural Science Department, confirms that Moringa is truly a multi-purpose wonder. “The Moringa plant is unique in that every part can be utilised for beneficial purposes. It has medicinal, therapeutic, nutritive, and practical uses. It is extremely effective in combating malnutrition,” Tesfay states. •Nutritionalvalue. “In addition, the

leaves, stems, and seed pods (full of essential amino acids) of the tree can be prepared in a variety of different ways, in order to provide solid nutritional value.

-Theseedpods. Also known as a drumstick, the green seed pods are typically prepared in much the same way as green beans, and have a characteristically asparagus-like flavour. The seeds themselves can be roasted or boiled, while the roots are used to

food

Miraculous moringaMoringa is a fast-growing, drought-resistant tree with incredibly

nutritious leaves that could aid poor, arid nations in fighting food

insecurity and undernourishment.


prepare a horseradish-like condiment or sauce. When pressed, the seeds produce edible oil that can be used for preparing food.

-Theleaves. Especially nutritious, these can be eaten raw or served as a boiled greens dish that resembles spinach. The dried powder can be stirred into soups or sauces as a thickening agent or used to brew a healthful drink. Moringa leaves can also be used for medicinal purposes, to treat skin infections, lower blood pressure and blood sugar, reduce swelling, heal gastric ulcers and to calm the nervous system.”

•Waterpurifier.Tesfay further explains that the seeds of the tree can be used to purify water in rural areas where access to clean drinking water is difficult and is often a cause of disease. “The seeds are effective in removing about 98% of impurities and microbes from contaminated water,” he states.

Researchers at Leicester University in the UK have found that mixing crushed moringa seeds with polluted water helps settle silt and other

contaminants. This is highly cost-effective because the seeds can replace expensive imported material usually used for water purification in rural areas. The seed-filtered water still needs a final filtration before it is completely drinkable, but the seeds make the process easier and help other water filters to last longer.

•Agriculturaluses.Moringa trees are also used in agroforestry and mixed cropping because the shade provided can protect other crops from the sun.

While smoke from household fires can pollute the air, the soft, spongy moringa wood burns cleanly with little smoke or smell, making it a healthier source of fuel,” he concludes.

Moringa can be grown all over Africa from Tanzania downwards. In South Africa the most suitable provinces are Mpumalanga, KwaZulu-Natal and Limpopo. -MelissaJaneCook

MoringaSouthAfrica,contactSoniaMarais:

[email protected]

Miraculous moringa

“The Moringa tree is non-invasive, needs little water and grows

fast, reaching a height of three metres within a year. The tree can

survive in relatively unfavourable conditions, and does not require

sophisticated and expensive farming methods or inputs. Food

experts predict that Moringa could become a widely-used hunger

prevention method, as it can grow in all of the world’s sub-tropical

areas, where droughts and malnutrition are prevalent - in most

parts of Africa, Central and South America, the Middle East and

South-East Asia. - Dr Samson Tesfay, a post doctoral scholar at

University of KwaZulu-Natal’s Horticultural Science Department

in South Africa

Continental Beverages

Continental Beverages is a division of The Ceres Beverage Company, one of South Africa’s leading beverage manufacturers.

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Its inventor Philip Kilian from Kiki Agri (Pty) Ltd describes this “chicken house” as affordable, fully equipped

and providing unlimited opportunities for anyone who wants to be successful in their pursuit of becoming a chicken farmer.

Poultry is the biggest and fastest growing meat sector in South Africa, and the Nkoko 20 promotes controlled speed and ease in the process of raising broiler chickens. These chickens are specially developed to grow tender meat in a very short period of time - they are ready to consume or sell in approximately 42 days.

Kilian says that farming with the Nkoko can start within a short time as the “house” is easy to assemble with two people simply following the steps in the instruction manual. “No experience, low capital input and minimum space is required by the farmer. The grower’s manual is simple to read and understand.

The Nkoko broiler comes with guidelines and record-keeping per batch. It explains a measured farming approach, resulting in birds weighing in excess of 2.3 to 2.5kg each on day 42 (live weight). Farmers

are also exposed to entrepreneurial skills development in the Nkoko training manual to assist them in establishing their own markets.”

ManufacturingandmaterialsThe Nkoko structure has a steel frame with a smart lightweight design. “It is easy to transport the components, assemble, and is rust-resistant. The powder-coated cladding is durable and the premium 550gm PVC tarpaulin is manufactured by professional tent makers in South Africa. The cladding is cat and dog-proof, rodent-resistant and UV protected,” says Kilian

The equipment supplied for this turnkey operation includes a ground sheet, tube feeders, water feeders, infrared and white lamps, a thermometer, a 3kg kitchen scale, grower’s manual, day old chicks, feed and saw-dust.

There are three Nkoko models to choose from at affordable prices:1. Nkoko 20 - 2m² turnkey house 2. Nkoko 50 - 4m² turnkey house3. Nkoko 100 - 8m² turnkey houseAvailable outside South African borders -

terms and conditions apply for delivery, etc.

ContactMariannaduPlessisatAgrificaforthe

pricelist.

Tel:+270128049729;[email protected]

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Although there are many variations of chicken coops and related

products on the market, Nkoko has been designed with the small

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buildingbuilding

Hennie Botes, CEO of Moladi, explains that a “house in a container” concept is employed

for social housing initiatives, whereby all the materials supplied are packaged conveniently into a container that is then delivered to the building site. “All the tools and equipment required to train local unskilled communities are on hand, and as a result the success of the construction process is completely independent of its location. “

Moladi is able to meet any building standards or regulations, as the system produces walls that are of high-quality.Botes says that the company employs a distribution model whereby anyone who would like to use Moladi for his/her housing projects is able to access

the technology in his/her local territory through a designated distributor or directly through headquarters in South Africa.

Technologyandcomponents“Moladi’s housing solution combines a reusable, patented, recyclable, lightweight plastic injection moulded formwork system with a South African Bureau of Standards (SABS)-approved lightweight aerated mortar mix to produce a cast in-situ steel reinforced monolithic structure,” Botes states.

“The formwork components are fully interlocking and are assembled into easy-to-handle panels, which are configured into a full-scale mould of the desired structure. The formwork panels are joined

to create the external and internal walls cavities and all of the steel reinforcing, window and door block-outs, conduits, pipes and other fittings are positioned within the wall cavity to be cast in-place when filled with the Moladi mortar mix.

“The wall cavities are filled simultaneously with a SABS-approved mortar mix which contains, cement, water, river sand, and Moladi Chem. The mortar mixture produces a fast-curing aerated mortar that flows easily, and results in a wall that is waterproof and possesses good thermal and sound insulating properties,” he says. “After the wall cavities have been filled with the mortar, the mortar is left to set overnight and the formwork panels are removed the following morning to be re-erected on the next foundation.

“The wall has a smooth and flat finish that does not require any plastering, beam filling or chasing. All Moladi structures have steel reinforced internal and external walls. The reinforcing design is specified by a structural engineer, who independently certifies the structure after construction is completed and the final inspections are carried out.

Moladi moulds mortarMoladi is a compact building system that can be used anywhere and

transported to virtually any part of the world, including remote and rural

areas as well as informal settlements, which may be difficult to access.

Erecting a structure does not require heavy machinery or electricity, and

the building materials required are easily accessible and sourced locally,

spreading the benefits to local communities.


buildingbuilding

“The result is a fast track, cost-effective and transferable construction technology that is amortised over 50 re-uses, reducing the cost of construction and transportation significantly. It also facilitates the possibility for many in-situ structures to be built in just one day,” he states.

According to Botes, the Moladi mould is easily adapted to suit any required design or layout - there are no limitations with regard to the size, or room arrangements of a house. There is also no ‘standard’ mould as each mould is specifically manufactured (assembled) to meet the specifications of each client’s architect or draughtsman. “Moladi is

able to accommodate any type of roof design or covering, any finishing material, any type of window or door, so there are no limitations in terms of cultural preferences,” he says. “We also produce an acoustically solid wall (sounds like a brick wall) with a smooth plastered finish. Should a client/contractor have a preference to clad or plaster the finished wall, this can also be done.”

LabourHe says most traditional and alternative construction methods require certain skilled and trained artisans to contribute towards the structural integrity of a building. “In many cases, especially within

South Africa, skilled artisans are not available or skilled workers are wrongfully replaced with a cheaper, unskilled workforce, resulting in shoddy and unfit structures.

“With its streamlined and simplistic approach to construction, the application of our technology is not dependent on skilled labour or artisans for construction, enabling the community to become involved in building their own homes. Over 90% of the construction team on a Moladi housing site consists of unskilled labourers, and women are encouraged to participate in this non labour intensive building process.” Botes says that the Moladi construction method has been specifically designed with the objective to allow for an unskilled team of people to follow the company’s optimised, repetitive and sequential processes that eliminate the probability of any errors occurring, which is crucial to the outcome of the structural quality or integrity of the housing unit.

Moladi:Tel+27413722152;

fax+27865026930;www.moladi.net

“The speed, affordability, quality, adaptability, ease of construction,

use of sustainable local materials and the opportunity created

to facilitate ‘sweat equity’, are key advantages that will greatly

improve the efficiency with which the world addresses the

problems relating to the world’s poor, homeless and unskilled

communities.” - Hennie Botes, CEO of Moladi

Hennie Botes, CEO of Moladi, explains that the selection and use of building materials relating to the Moladi construction process is considered a crucial aspect in determining the environmental sustainability of the technology. “Although the calculation of embodied energy is a complex matter and differs from region to region, building materials used in the Moladi construction process have been carefully considered according to the initial and recurring embodied energy that is used or expended during the life cycle and operation of each material,” says

Botes. “Some additional, but notable, factors which affect the overall energy consumption of a structure - and which are often mismanaged within the affordable housing industry - include non-essential transportation, wasteful packaging, plentiful waste of materials resulting from processing and construction methods, and also poor dumping and disposal methods.”

“Materials are rarely recycled or even re-used and poor workmanship, the utilisation of sub-standard materials and the use of materials and components which have a dissimilar and inconsistent durability, leave the home owner with a high-

maintenance home which requires frequent repair and even large-scale restoration.

“Lastly, passive design principles for the appropriate climate that help to minimise the energy required to heat, cool, ventilate and light a building responsibly are largely ignored in favour of a cheaper initial cost outlay,” Botes states.

“These factors are all taken into account to ensure that Moladi buildings provide environmental value by challenging members of the construction industry who are quick to ignore the long term use and quality of a building in favour of the short term savings enjoyed by the developer.”

Sustainability


solarrefrigerationsolarrefrigeration

ThefridgeladyofNamibiaEmily Cummins (21) came up with the idea of a “sustainable” fridge that works through evaporation and can be used to keep perishable goods such as milk and meat cool for several days at a temperature of 6°C, while working on a high school project in her grandfather’s potting shed in England.

After her A-levels, Cummins spent five months in Africa perfecting and demonstrating her product. She gave away the design plans in townships across southern Africa because she wanted to enable as many people as possible to build their own fridges.

Cummins, who became known as “the fridge lady” in Namibia, explains that her prototype comprises two metallic cylinders - one inside the other, between which a locally-sourced material such as sand or wool is packed tightly before being soaked with water. “When the fridge is placed in a warm environment, the sun’s energy causes the outer part to ‘sweat’ - water then evaporates from the sand or wool and heat energy is transferred away from the inner cylinder,

cooling it down.”She adds that the design is ideal for

use in developing countries because it doesn’t require electricity, and can be built using barrels, spare car parts and ordinary household materials, such as wood and plastic. “Unlike previous pot-in-pot coolers, the contents are kept dry and hygienic because the water does not come into contact with the product,” says

Cummins. “The cylindrical shape of the fridge also ensures that there are fewer areas where bacteria can build up.”

Cummins is currently developing a second generation fridge that maintains an even lower temperature and is more energy-efficient.Formoreinformation,visit

www.emilycummins.co.ukor

email:[email protected]

Refrigerators that thrive in the sunElectricity shortages are common in many emerging economies,

often resulting in food wastage as items spoil with the rising

temperatures. While some businesses can afford to use diesel

back-up generators to power their equipment, solar-powered

refrigerators offer a sustainable, long term alternative that

combats energy shortages and global warming.

1.Fridgeismadeupoftwocylinders-oneinsidetheother-andisnotconnectedtoanypowersource.Outercylinderismadeofanysolidmaterialwithholesdrilledinthesides.2.Innercylinderismadeofmetalandhasnoholestoensurecontentsremaindry.3.Thegapbetweentheinnerandoutercylinderisfilledwithamaterialsuchassand,woolorsoil,thatcanbesoakedwithwater.4.Inhotweatherthesun’sraysheatthiswetmaterialandthewaterevaporatesoff.Asthematerialisheldagainsttheinnercylinderwall,heatisremovedfromtheinnerchamberbytheevaporationprocess,keepingitatacooltemperatureof6°C.5.Resoakingmaterialwithfreshwaterwillkeepthefridge“working”.

solarrefrigerationsolarrefrigeration

Industrial Insulation Systems (IIS) has developed a solar-powered fridge/freezer that can be tailored to meet the needs of off-the-grid scenarios. The custom made-to-order IIS solution will maintain temperatures as cold as -20°C for at least 24 hours between charges. This is according to the company’s Jason Luedtke, who stresses that with the (up to) 400amp hour battery capacity and the solar panels working in harmony as well as regular exposure to sunlight, users should be able to go completely off-grid indefinitely.

“Our initial goal was to create a unit that would maintain the power source to the fridge/freezer for three full days with no sun exposure,” says Luedtke. “Our prototype testing proved that the

unit maintained adequate power to hold temperature for nine days, before we drifted out of proper temperature range. We considered this a success but each unit (based on size and therefore power draw) and ambient temperature will have slightly varying results. Ambient temperature during the above-mentioned test was 25°C on average.”

“The batteries are a crucial element - even during consistent full sun. Both elements must work in a regulated balance for the system to be nearly perpetual,” he states.

“If you already have your own low-voltage (DC) fridge and would rather not pay extra cash for a new one, then you can just buy the solar kit and fit it to the fridge,” says Luedtke.

He explains that the solar panel canopy works in balance with batteries to make sure that the chosen unit doesn’t run out of power. “If you want your fridge kept out of the sun then you’ll need extra long cables to link it up with the solar canopy, which can then be optimally placed to get the most direct sunlight. You might need extra storage space on your trolley if you intend to use your unit for street vending. You may also need some air conditioning outlets.

“Alternatively, users can pick the model of fridge/freezer from our range, tell us how to mount it, then how to power it, and we’ll customise it to fit their optimal needs,” Luedtke concludes.Formoreinformation,visitwww.iis-inc.com

oremail:[email protected]

DC-powered freezers

Portable, durable and adaptable, Cold Chain DC-powered freezers are ideal for remote storage of food and beverages, especially for vendors who have access to DC power and a commonly available adapter.

This is according to the company’s Robert Spence, who says the Solar Power System is designed to work in conjunction with any of the Cold Chain DC Freezers. “Users can choose the right features for their unique needs. For instance, if you are looking to be completely self-contained you can choose a trolley system. If you want to be mobile, add casters or you can include a traditional AC plug if you need to run a cash register or hot plate.”

Spence adds that the Cold Chain Solar Power System gives users omplete off-the-grid flexibility, while maintaining temperatures as cold as -20°C.ColdChainLLC:www.coldchainllc.com

Customisedfridge/freezer

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solarrefrigeration

Sorin Grama, CEO of Promethean Power Systems, explains that dairies located in large cities

have the need and the buying power to purchase refrigeration units for preserving milk at collection points located in remote farming villages. “Cold storage at the village level minimises the number of collection trips and reduces transportation costs by 50%,” says Gama. “However, the only option available was to use commercial refrigerators with diesel-powered backup generators, a no-win situation that further exposed dairies to escalating energy costs.”

In April 2010, when Boston-based Grama and Sam White set up their Solar Hybrid Milk Chiller - which runs partly on solar energy and partly on electricity - as a pilot project in Savoiverem near Goa in southern India, they were not sure how successful it would be. In just one month, though, the system significantly boosted the milk supply in the village - where electricity is not regularly available - and reduced losses due to bacterial spoilage.

White explains that a detailed study of the milk collection process resulted in a system tailored to suit the requirements of this village. “Farmers milked the cows or buffaloes and brought the milk to the village collection centre. After measuring the quantity and the fat content, the milk was transported to the chilling centre, where it was cooled before being pumped from the chiller to tankers to be taken to the dairy plant.

“We observed that there were many small farmers with just one or two cows or buffaloes. Everyday, they used to bring one to two litres to the collection centres that were very far from their villages. The time taken to cover the distance used to result in milk spoilage,” he says.

The duo addressed this problem by installing the milk chiller midway between the villages and the collection centre. “The result was like a milk revolution - an individual’s supply of milk to dairies increased two-fold and more,” says White.

The Solar Hybrid Milk Chiller, which has a capacity of 500 litres and can store milk for up to 48 hours, is divided into

two parts - a slow cooler and a fast cooler. While the fast cooler chills the milk from 33°C to 10°C in less than a minute, it then takes three hours to chill from 10°C to 4°C in the slow cooler. The fast cooling is the result of a special heat exchanger through which the milk is passed, chilling it in the process.

The milk chiller also keeps track of information such as the total milk collected, payment due to farmers and so on. The temperature is constantly monitored by a machine with a battery that runs on solar power. “Since we use solar energy, we eliminate the cost of

diesel generators that are generally used in refrigeration systems. And as we scale up, we will lower the capital cost and the next unit will be an improvement over the previous one,” says Rajat Gupta, Promethean Power Systems’ India operations general manager.

Grama adds that the chiller unit is 66% less expensive to run than other refrigerators and is intended to be a

“complete, stand-alone rural refrigeration system that stimulates businesses, reduces dependency on fossil fuels and increases the quality of life in emerging markets by enabling its users to reliably store food, vaccines and other perishable items.”

Promethean Power Systems is currently in the process of developing and testing a modular thermal energy battery that can be used as a backup to the unreliable power grid.

Grama, says: “In India, we charge the battery using the five or six hours of available electricity, usually at night, and discharge it when the grid is off in order to cool and preserve raw milk.” Promethean, however, envisions developing a battery that can be used for any cooling application. “Our vision is to

enable customers to connect multiple batteries together to store energy as needed, in order to make the thermal energy battery a technology platform that allows third-party manufacturers to develop attachments such as vaccine or beverage coolers,” he states. “While our thermal battery acts like an electrical battery, it supplies a stream of cold fluid rather than an electrical current. This fluid is then be used to chill food products, such as milk, down to 4°C.”Formoreinformation,visit

www.coolectrica.comor

email:[email protected]

Hybrid milk chillerAn extensive market and human factor study revealed a large

business opportunity in India for an efficient cold storage

solution targeted at the dairy industry.


There are three types of solar fridges: ones that use batteries and solar panels, ones that use just solar panels, and ones that use neither batteries nor panels and are constructed from household materials.1. A solar fridge that

uses batteries actually uses a combination of solar panels and lead batteries - the batteries serve as back up overnight and on sunless days. While it can be effective, this type of solar fridge has many disadvantages. For instance, it is expensive to buy and the batteries are heavy and deteriorate quickly in hot climates. It is maintenance-intensive and only lasts about three years. The batteries also need to be disposed of properly, otherwise they leak and cause lead pollution.

2. Solar-powered refrigerators that generate electricity with the help of solar panels, then use this electricity like a normal plug-in refrigerator. Although this type of refrigerator is powered by solar energy, it is not 100% eco-friendly as the cooling gases that are used in the refrigerator and the ones generated due to cooling, contribute to global warming and depletion of the ozone layer.

3. Solar-powered fridges that don’t require batteries or solar panels are better suited to developing

countries, as they can be made from basic household materials. Although these fridges are technically solar-powered, they rely on conduction, convection and evaporation to operate at an even 6°C.

These refrigerators work according to atmospheric temperatures - the drop and rise in the heat of the sun directly affects the rate of cooling. The greater the heat of the sun, the lower the temperature will be in the

inner cylinder. Many scientists

predict that solar-powered refrigerators will totally replace all electricity-powered refrigerators as the most energy-efficient refrigerators.

Solar fridge types

solarrefrigeration

PAGE 25 NW UNIVERSITY/EXTRU

AFRICA

Training Seminar & Conference Week on Food, Feed and Pet Food Extrusion

31 July – 3 August 2012Protea Hotel Kruger Gate | Mpumalanga | South Africa

Contact: [email protected] | +27 (0) 18 299 1330

www.extruafrica.org.za

Media Partners:


SouthAfricaMabeleFuels’$216.9mbioethanolplantinBothavillePending promulgation of the proposed mandatory bioethanol blending regulations in South Africa, construction of Mabele Fuels’ 153m litres per annum fuel-grade bioethanol plant in Bothaville, Free State is set to start in June, and is expected to take 24 months.

This is according to Phillip Bouwer, executive director of Mabele Fuels, who says: “We will need about 400,000t of grain sorghum to meet a 2% annual blending rate. All indications are that government will announce the compulsory inclusion of at least 2% bioethanol in fuel before the end of May.”

Bouwer says that Vogelbusch GmbH, a leading Austrian bioethanol process design company - which has designed over 30 similar grain-based plants - has been subcontracted to the project to provide the technology designing package and quality warranty for the ethanol production line, documentation, specifications, as well as the operating licence. “Vogelbusch will be responsible for proprietary equipment supply for the distillation and dehydration systems and technical assistance during procurement, manufacturing, and acceptance of equipment. It will also supervise the installation, pre-commissioning, commissioning and field training for the project.”

Bouwer describes Mabele Fuels as a unique co-operation between historically-disadvantaged individuals and specialists in the clean energy market. “After the exclusion of the use of maize for ethanol production in the Biofuels Industrial Strategy in 2007, our shareholders, Sterling Waterford Holdings and Mvelaphanda, specifically chose grain sorghum to meet the requirements of the strategy and because of its potential to promote commercially-successful emerging farmers,” he states. “Grain sorghum is

indigenous to South Africa and can prosper on marginal land with soil that is low in potential, shallow, and has reasonably-high clay content. According to the Department of Agriculture, the Free State is South Africa’s largest sorghum-producing area, producing on average 52% of the total domestic crop. We have undertaken a detailed area analysis and are implementing an emerging-farmer development programme in conjunction with our primary procurement partners.”

Bouwer explains that there is an added advantage to using grain

sorghum as feedstock - the dried distillers’ grain and solubles (DDGS), a by-product of bioethanol production, has about three times the protein content and the same energy levels as the original feedstock. Consequently, it receives a price in the US and European animal feeds market of between 0.8 and 1.2 times that of maize. “South Africa’s animal feed market comprises approximately 7.3m tons per annum. We anticipate that DDGS will replace yellow maize in this feed market, and that the market is capable of absorbing our entire production capacity of 107,000t/annum. We have already entered into proposed off-take agreements for the sale of the DDGS to national animal feed producers,” he states.MabeleFuels:Tel+27(0)214184490;www.mabelefuels.com

MozambiqueJapantofinancenewfishmarketThe Japanese International Co-operation Agency (JICA) is to provide $11.6m for the construction of a new fish market in the neighbourhood of Triunfo, along the Maputo coast road.

The future market, covering an area of two hectares, will contain stalls for the sale of fish and shellfish, an ice-making plant, a unit for processing and conserving fisheries produce, and an administrative office - as well as an area for the restaurants that are one of the main attractions of the current fish market.

Maputo City Council is responsible for the project, in partnership with JICA, and anticipates that the new market will become operational in 2013. -MozambiqueNewsAgency

RwandaS10mcassavaprocessingplantA $10m cassava processing plant set up by the Rwanda Development Bank (BRD) in Kinazi sector, Ruhango district, is due to produce and sell its first batch of products in late May.

Jack Nkusi Kayonga, BRD’s CEO says that the bank plans to allow farmers to acquire shares and ultimately enable them to own and manage the plant themselves. The factory has an installed capacity of 20t of flour per day, and will require a daily supply of 60t of cassava to achieve full capacity.

Kayonga says that the bank is working with farmers in the leading cassava-producing districts of Ruhango, Muhanga, Gisagara and Kamonyi to ensure adequate supply.

BRD official, Philibert Mbanje, adds that the bank has already given loans to more than 20 farmers to grow quality cassava, and that the formation and strengthening of cassava-producer co-operatives is also being prioritised, in order to ensure enough raw materials and provide local farmers with the ability to maximise their profits from the new facility.

As the plant is set up in a remote area near Akanyaru river - over 30km from Ruhango town - road construction and rehabilitation is another priority to be undertaken in the next few months, in order to facilitate transport.

Apart from flour production, the remaining waste will be treated and turned into fertilizer and animal feed, says Robert Runazi, general manager of the plant.-RwandaFocus

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RwandaNewbeanvarietylaunchedHarvest Plus, a leader in breeding and dissemination of micronutrient-rich staple food crops, has introduced a new Iron Bean seed in the country, which it will distribute in collaboration with the Rwanda Agriculture Board (RAB).

According to Harvest Plus country representative, Tiwirai Lister Katsvairo, the new bean will help fight and reduce hunger among malnourished residents in Rwanda. The new seed is being distributed across Nyagatare and Gatsibo in the Eastern Province, and other parts of the country.

Josephine Mukakigeri, an agriculture researcher at RAB, says: “The seed is a new hybrid in the bean sector. First of all, it is nutritious, a staple food, grows in the shortest period of time and has good harvests. Secondly, we sell a kilo of beans at Rwf 500 ($0.84) to farmers and in return buy all their produce at harvest. This is a fixed market that farmers should exploit.”-TheNewTimes

KenyaSh400mforavocadoprojectinMurang’aCEO Gary Hannan says that Alivando has engaged 1,030 farmers in quality production of the avocados and has started a pilot factory in Murang’a to boost production.

Hannan explains that central Kenya is better placed to produce high-quality avocado products, as this area has the potential to produce avocados with a high concentration of oil and wax.

He adds that Kenya could be producing 0.3m litres of high-quality avocado oil for export and local consumption in five years time, if farmers embrace the practice. -NairobiStar

EthiopiaWinerybeginsbottlingCastel Winery Plc, a sister company of BGI Ethiopia, recently began producing wine in the environs of Batu Town in Oromia State, 163km south of Addis Ababa.

Winery manager, Fetehanegest Aynalem, says that the winery built at a cost of 300m Birr ($17.2m), will export over a million bottles of wine abroad, and that the winery and the vineyard have created more than 900 new jobs.

According to Fetehanegest, Castel has been cultivating varieties such as Syrah, Merlot, Cabernet Sauvignon and Chardonnay since May 2008. -EthiopianNewsAgency

NigeriaProvitaminAfortifiedcassavaNigeria has produced a pro vitamin A (beta carotene rich) fortified cassava, which is more nutritious than existing varieties. This is according to Dr Akinwumi Adesina, Minister of Agriculture and Rural Development, who adds that the production of the

improved varieties has placed Nigeria on the global map in terms of research on micronutrient (vitamin A, iron, zinc and iodine) improvement in staple foods.

Adesina says: “The federal government’s focus is to create new markets for cassava, including high-quality cassava flour to be used in replacing some of the wheat flour being imported to produce bread; high fructose cassava syrup to replace the 200,000t of sugar currently being used in the juice manufacturing industry; dried cassava chips; and the production of ethanol.”

“Our goal is to add another 17m tons of cassava to our domestic food supply of 34m tons. The Agricultural Transformation Action Plan hopes to create 1.3m jobs across the cassava value chains, but producing more food is not enough; we must also ensure that there is enhanced food nutrition and health.”

Acting executive director of the National Root Crops Research Institute (NRCRI), Dr Thomas Ezulike, expressed confidence in the ability of NRCRI to continue to improve crops, both nutritionally and in resistance and adaptation to changing climatic conditions. “NRCRI has transformed into a leading research centre of

excellence for root and tuber crops, and has blazed the trail of biotechnology through the establishment of a culture tissue laboratory; molecular breeding of root crops; confined field trials of genetically modified crops, and recently bio-fortification of staple crops,” he stated. -DailyTrust

MoroccoInvests$1.18minmeatindustrytrainingThe Moroccan employment and training industry has teamed up with the country’s top processor Koutoubia Holdings to train 3,000 young people to work in the meat slaughtering and processing industry by 2016.

The project, costing a total of MAD10m ($1.18m), aims to guarantee a job to young people at a time when school drop-out rates are peaking, and to secure qualified staff for the meat processing industry.

In the first phase of the programme, Koutoubia’s Training Centre in Mohammedia - which has a capacity of 1,200 students - will be used, but the government plans to open two more training

facilities in Bouskoura and Settat by 2016. Four courses will be offered to students, and Koutoubia

employees will also have the option to get a diploma validating their experience, allowing non-trained staff to get recognition outside the company. -GlobalMeatNews.com

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