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

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Presentation on theme: "Challenges & Opportunities to produce Super Cereal Plus (CSB++) Bertrand Salvignol – Head Food Safety & Quality Unit – WFP IFADC - Kansas City – May 8,"— 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, … ParametersValues SC+Values SC Protein (% min) Vegetable13.50%14.00% Animal2.50%- Fat (% min)9.00 %6.00% Fibre (% max)2.00%5.00% Moisture (% max)7.00%10.00% MicrobiologyX 10 stricter Aflatoxin5 ppb20 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 New formula Ingredients (in %)Super Cereal Plus (SC+)Super Cereal (SC) Corn Soybean (de-hulled)20.00 Soybean oil3.00 Dry Skim Milk8.00 Sugar9.00 Vitamin/Mineral mix0.20 Ca(H2PO4)2.H2O0.80 KCl0.76 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 (O 2, H 2 O, 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 mixed & milled Wet extrusion Oil injection Drying Mixing Pre-Conditioning Sugar Vit & Min Packaging Maize De-hulled soybean Milk Milling

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: IncubatorW/H in Africa Temperature (°C)4020 – 50 Humidity (%)7520 – 80 Day/Night variationNoYes ConditionsLabField/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 O 2, … 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 … – 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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