challenges & opportunities to produce super cereal plus (csb++) bertrand salvignol – head food...
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Challenges & Opportunitiesto produce Super Cereal Plus (CSB++)
Bertrand Salvignol – Head Food Safety & Quality Unit – WFPIFADC - Kansas City – May 8, 2012
Super Cereal Plus (SC+)
New brandingDifferent target / programme
‘New flavour’ New formula
New packagingNew process / factories
Nutritional values, …
Parameters Values SC+ Values SC
Protein (% min)Vegetable 13.50% 14.00%
Animal 2.50% -
Fat (% min) 9.00 % 6.00%
Fibre (% max) 2.00% 5.00%
Moisture (% max) 7.00% 10.00%
Microbiology X 10 stricter
Aflatoxin 5 ppb 20 ppb
Bostwick (mm/30 sec (45◦C) 100 mm (50g/250g water)90 Kcal / 100 ml porridge
55 mm (40g/250g water)60 Kcal / 100 ml porridge
New formulaIngredients (in %) Super Cereal Plus (SC+) Super Cereal (SC)
Corn 58.24 78.24
Soybean (de-hulled) 20.00 20.00
Soybean oil 3.00
Dry Skim Milk 8.00
Sugar 9.00
Vitamin/Mineral mix 0.20 0.20
Ca(H2PO4)2.H2O 0.80 0.80
KCl 0.76 0.76
Micronutrients composition:-Under review to match the latest ‘WHO’s guidance’-KCl will be decreased based on acceptability studies carried out in Burkina & Cambodia (WFP / DSM Ltd.)-Ca++ in dicalcium phosphate to rebalance Ca/P (ratio: 1 – 1.5)
New packaging
Protection of the product•N2 flushing / AO in oil•Vacuum packing•Improved barrier (O2, H2O, Vapour, …)•Low Moisture Content•Shelflife studies (on-going)
Easier usage•Smaller quantity / one week ration•Instructions (drawings)
Legal requirements•Composition, producer, BUBD, etc.
New process
mixed & milled
Wet extrusion
Oil injection
Drying MixingPre-Conditioning
Sugar Vit & Min
Packaging
Maize De-hulledsoybean
Milk
Milling
WFP’s requirements
• Supplier’s assessment • Specific process – Wet extrusion (or twin-screw extrusion, drum dryer)– Control of fortification (coefficient of variation)
• Improved Quality Assurance– Traceability– ISO 22000 type– Shelf-life study (under discussion)
• Production capacity: > 2,000 MT/month
Suppliers & WFP’s involvement• Investment– US$ 2 Million: 3 MT/h capacity– US$ 2.9 Million: 6 MT/h (extruder), 4.5 MT/h (packaging)
• Machinery– Buhler, Wenger, Clextral, Setrem, etc.
• Timing– 2 years from the acceptance of the idea
• Support from WFP– (process, building set up), formulation, trial runs, on-
line checks, analysis in lab, quality …
Shelf life & Stability studies (I)
• Risks: microbiology, oxidation, nutritional value, packaging, palatability, …
• Partners: Kemin Industry / DSM • How: accelerated & real-time (oven & field)• Conditions:
Incubator W/H in Africa
Temperature (°C) 40 20 – 50
Humidity (%) 75 20 – 80
Day/Night variation No Yes
Conditions Lab Field/Thermo tracers
Stability studies (II)• Duration: 24 months• Where: Niger, Chad, DRC• Parameters: PV, FFA, Hexanal, Tocopherol,
Ascorbyl Palmitate, Oxygen bomb, Aw, Microbiology, Composition, Moisture Content, Vitamin A & C, residual O2, …
• Figures: – 358 samples– 2 dedicated staffs (WFP+Kemin) + field focal points– Estimated cost: about US$ 45,000 (excl. staff)
Conclusion• Market: from nothing in 2010 to
…– Jan-July 2012: 30,000 MT
• It is feasible:• It requires some involvements
from – Suppliers (investment, engagement)– WFP Procurement / Programme
(commitments)– WFP Food Technologists (technical
assistance: to ensure suppliers are confident in the product)