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Challenges & Opportunities to produce Super Cereal Plus (CSB++)

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Presentation on theme: "Challenges & Opportunities to produce Super Cereal Plus (CSB++)"— Presentation transcript:

1 Challenges & Opportunities to produce Super Cereal Plus (CSB++)
Bertrand Salvignol – Head Food Safety & Quality Unit – WFP IFADC - Kansas City – May 8, 2012

2 Super Cereal Plus (SC+)
New branding Different target / programme ‘New flavour’ New formula New packaging New process / factories

3 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

4 Super Cereal Plus (SC+)
New formula Ingredients (in %) Super Cereal Plus (SC+) Super Cereal (SC) Corn 58.24 78.24 Soybean (de-hulled) 20.00 Soybean oil 3.00 Dry Skim Milk 8.00 Sugar 9.00 Vitamin/Mineral mix 0.20 Ca(H2PO4)2.H2O 0.80 KCl 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)

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.

6 New process De-hulled soybean Milk Maize Sugar Vit & Min
mixed & milled Wet extrusion Pre-Conditioning Drying Milling Mixing Oil injection Packaging

7 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 type Shelf-life study (under discussion) Production capacity: > 2,000 MT/month

8 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 …

9 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

10 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)

11 Conclusion Market: from nothing in 2010 to … It is feasible:
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)

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