CREATING THE CASSAVA REVOLUTION. Cassava Processors

Transcription

1 CREATING THE CASSAVA REVOLUTION Cassava Processors

2 Our Motivation: Why: Create a future in the village What: Develop a village economy How: Provide a market for cassava *Building small but many resilient communities

3 Social and financial return on investment One operational mobile cassava starch plant (capex 3 million Euro) generates: 2,3 million Euro every year on Forex Saving 1,3 million Euro every year in the local economy X 1000 EURO 1,3 million Euro every year to 5000 farmer families Pay back time for investors 5 years Investment Forex Saving Local Economy Farmer's Income Pay Back 0 Year0 Year1 Year2 Year3 Year4 Year5 Year6 Year7 Year8 Year9 Year10 *4 times impact with 1 investment

4 Our Pride and Proof in Mozambique The only successful food grade cassava processing company in Africa Bridge between smallholder farmers and Food industries with our mobile technology Lifted 8000 of the most deprived farmer families out of poverty *Mobile technology the only approach to realisation

5 Cassava, Africa s best kept secret EASY TO GROW ALL YEAR ROUND HIGH YIELDING GOOD QUALITY STARCH BUT: ROTS IMMEDIATELY AFTER HARVESTING ONLY GROWN BY SMALLHOLDER FARMER *Its starch exceeds the quality of other starch crops

6 Global distribution of cassava *Cassava grows particularly well in the agro-ecological zones of Sub Saharan Africa

7 Composition starch crops 13% 14% 3% 71% 79% Water 70% 2% Protein+Minerals 4% 23% 2% 15% 4% Fibers Starch Maize Cassava Potatoes *High water content needs FARM SITE processing to reduce transport costs

8 Failed cassava processing projects Africa Nigeria; Ekha Agro Syrup glucose plant Matna Foods Company Limited Nigerian Starch Mills Psaltry processing plant TFI cassava flour plant Uzere starch factory Ghana; Ayensu Rwanda; Kinazi Cassava Processing Swaziland; Casquip Cameroon; Sotramas starch factory Tanzania; Scheer foundation Ivory Coast; Yopougon Mozambique; Cleanstar Malawi; Universal Industries Zambia; Nisha starch plant And many others *NO ROOTS MEDIUM SCALE Nigeria, 178 locally built small flash dryers. *NOT FOOD GRADE

9 What needs to be addressed when processing cassava Perishability Technology Smallholder crop Cyanide Transport costs Quality Plantation Farming Over-invoicing *Industrial customers need quality food grade ingredients

10 *Food grade processing essential Major quality issues Cassava Flour >20 Cottage Industry cassava flour Cyanide content (ppm) Cottage Industry HQCF SME HQCF DADTCO Cassava Starch Flour 0 Cottage Industry cassava flour Cottage Industry HQCF SME HQCF DADTCO Cassava Starch Flour > Total bacterial counts 0 DADTCO Cassava Starch Flour SME HQCF Cottage Industry HQCF Cottage Industry cassava flour 100% Released starch 10%

11 DADTCO Solution; 6 essential technologies Demand driven cassava farmer management Mobile processing technology Full release of all starch from plant cells Removal of fibres and non starch substances Removal of all cyanide containing contents Reducing moisture content (drying) Continuous Roots Supply Brings the factory to the farmers Same day processing No transport of fruit water No Starch loss MRU (Mobile Refining Unit) DADTCO enzymatic process Mobile Drying / Flash Drying *Mobile food grade processing

12 Root supply management, a core skill: Visible processing in the villages Team of trained mobilizers in the field organizing farmers Alliances with local governments, farmers, research institutes and agricultural organisations. Guaranteed market; farmers know the price at planting date Cash Payment DADTCO ID cards Track & Trace of all root supplies *Our biggest challenge is over supply!

13 DADTCO supports farmers with knowhow Mobilizers spread know-how on 4 most limiting factors : Use clean tools Select healthy plants 1. Access to disease free high yielding varieties 2. Production, stocking, treatment and planting of stems. Store under shade for 10 days Make 30 cm long cuttings 3. Replanting dead stems. 4. Increase plant density Cut off the top and basal parts of the stems Make sure the cuttings have 5 to 8 nodes *Doubles next year s yields

14 Why Mobile Processing? Same day processing No post harvest losses Better quality starch Transport costs Transport of starch instead of roots is four times more efficient Pollution Centralized fruit water causes pollution Pollution Close to farmer s fields Management regular supply workable

15 Autonomous Mobile Processing Unit (AMPU) AMPU Washing& Peeling Chopping Rasping Dewatering by decanter Cassava Cake Assembled in a 45 foot high cube container *Roots are processed into cake with 98% release of starch and 50% reduction of water.

16 Mobile Refinery Unit Mobile Refinery Unit Centri- Sieving Rotary Sieving Concentrating starch slurry Dewatering by decanter Cassava Starch Cake Assembled in a 20 foot container *Two thirds of the fibres are removed

17 Mobile dryer Mobile Dryer Drying Cooling Sieving Bagging Cassava Starch Flour Fluid bed drying system, fitted in two 40 foot containers Energy source LPG *Cassava Starch Flour, 12-13% moisture and 2% fibres

18 Production Capacity Mobile Starch Plant Input 5 MT cassava roots per hour. On a 2 shift basis it processes 80 MT roots per day or MT per annum. Output MT Cassava Starch Flour Cassava Starch Flour Dry matter 87% Starch Min 97% Fibers 2% (dry matter basis) Ash <0.3% Protein <0.2% HCN <1 ppm ph 5 6 Starch granule Shelf life Storage Excellent integrity for modification process >12 months Shade, ventilated, ambient temperature *One Mobile Starch Plant creates a market for 5000 smallholder farmer families.

19 Multiple sites for one mobile starch plant Sourcing roots 3 Months Km Sourcing roots 3 Months Km. Farmers Site 2 Site Farmers 1200 Farmers Site 3 Site 4 Sourcing roots 3 Months Km Farmers Sourcing roots 3 Months Km. *If the farmer cannot come to the factory, let s bring the factory to the farmer

20 Site Overview

21 Employment Mobile Starch Plant Roots off-loading and weighing 1 weigh master 3 casuals Feeding roots in AMPU 3 casuals Processing of roots 1 Technical & Site Manager 1 Electrician and 1 Mechanic Irrigation fruit water 1 casual Big bags handling & storage 1 stacker driver 3 casuals Loading of trucks 1 stacker driver 2 casuals Farmer reception area 1 data enterer 1 pay master Administration 1 administrator/accountant LAB 1 LAB technician 1 Hygiene officer Cleaning site and toilet building 2 casuals Farmer management 4 mobilisers 1 supply chain assistant/agronomist 2 drivers 1 logistical officer 19 trained staff and 14 casuals *Trained staff stay with the mobile starch plant, casuals change per site

22 Removal of cyanide: a Must! Cassava roots contain cyanogenic glucosides which can cause neurological disorders when eaten. Cottage processing is ineffective to reduce HCN to safe levels. There are two ways to remove cyanide: Rip open the cell walls with industrial raspers. Treat the cake with special enzymes With the support of the Peter Kutemann Fund, DADTCO developed an enzyme to remove all cyanide. *This know-how is made available in the Public Domain

23 CASSAVA PROCESS FLOW End to end process with less than 2% starch losses EXPORT OPTION SMALLHOLDER FARMERS AMPU Mobile Refinery Unit REFINERY Mobile Drying LAND PREPARATION WASHING FIBER EXTRACTION CAKE BUFFERING CAKE STARCH BUFFERING PLANTING PEELING SLURRY BUFFERING RESLURRYING MIXING REPLANT DEAD STEMS CHOPPING STARCH CONCENTRATION SLURRY BUFFERING DRYING WEEDING RASPING DEWATERING EXTRACTION SOLUBLES MILLING HARVESTING CYANIDE REMOVAL FIBER EXTRACTION COOLING DEWATERING STARCH MILK BEFFERING SIEVING DEWATERING BAGGING CASSAVA ROOTS CASSSAVA CAKE CASSAVA STARCH CAKE WET CASSAVA STARCH DADTCO CASSAVA STARCH FLOUR TRANSPORT TRANSPORT *Problem areas must be addressed with care

24 Two possible production set-ups Mobile Starch plant: Preferred set-up Medium Volume Close to customer base Low in transport costs Central flash dryer (refinery): Large volumes Large customer base 1Ampu 1 MRU 1 Mobile dryer *Market conditions determine optimum set-up 3Ampus 3 MRUs 1 Flash dryer

25 Dadtco Cassava Product Flows SMALLHOLDER FARMER SMALLHOLDER FARMER SMALLHOLDER FARMER SMALLHOLDER FARMER AMPU AMPU AMPU AMPU MRU MRU CASSAVA CAKE *MRU REFINERY MOBILE/ FLASH DRYER CASSAVA STARCH CAKE CENTRAL FLASH DRYER Cassava starch Flour Starch grade A or Cassava starch Flour *The MRU; Mobile refinery unit, reducing 70% of the fibre content in the cake

26 Match products with client s real needs 100% 90% 13% 13% 80% 70% 72% 56% 50% 60% 50% 85% 86% 40% 30% 40% 48% 20% 23% 10% 0% 5% 4% 2% 2% 1% Cassava Roots Cassava raw cake Cassava starch cake Cassava starch flour Tapioca starch Ash & Fibres Starch Moisture *Removal of moisture and fibres equals starch

27 DADTCO Starch II DADTCO Cassava Cake: 8% fibres on dry matter basis Removal of 75% fibres DADTCO cassava starch flour with 2% fibres on dry matter basis 9% fibres 2% fibres fibres 90% Starch 98% Starch *Two-third removal of fibres gives large impact

28 Conversion to Dry Matter (DM) Taking out the moisture content from the different cassava products leads to its composition on DM basis. Products Moisture Starch Ash&Fibers Conversion factor to DM Starch Ash&Fibers Cassava Roots 72% 23% 5% % 18% DADTCO Raw Cake 56% 40% 4% % 9% DADTCO Starch Cake 50% 49% 2% % 3% DADTCO Starch Flour 13% 84% 3% % 3% Thai Tapioca 13% 86% 1% % 1% *Dry matter calculations crucial in cassava business

29 Average roots requirement per DADTCO product Product Intermediate product Roots 1 Mt cake requires 1.8 Mt roots* 1 Mt cassava starch cake requires 1.1 Mt Cassava cake requires 2.0 Mt roots 1 Mt Starch Flour reqiures 1.8 Mt Cassava starch cake 3.6 Mt roots *For rough calculation purposes only

30 Conversion rates on basis of weight Product Product 1 Mt of Roots can produce 0.56 Mt Cassava Cake Roots 0.50 Cassava Starch Cake Roots 0.28 Cassava Starch Flour Roots 0.28 Starch grade A (tapioca starch) Cassava cake 0.91 Cassava starch cake Cassava Starch cake 0.56 Cassava Starch Flour Cassava Starch Cake 0.56 Starch grade A (tapioca starch) *Dry matter calculations are the basis for pricing

31 Application 1: Bread (20% Starch II) AB Mauri, part of Associated British Foods (ABF), 2 nd largest globally in yeast and bakery ingredients, operates in 26 countries. Inclusion of 20% DADTCO s Cassava Starch Flour showed perfect results in: bread volume, colour, crumb structure, crumb resilience, taste and shelf life: Taste Colour Volume Crumb structure *Results will exceed your expectations, 20% of DADTCO s Cassava Starch Flour gives excellent bread

32 Application 2: Beer The launch of the world s first commercially produced cassava lager in Mozambique. DADTCO and SABMiller Africa entered into a partnering arrangement whereby DADTCO s cassava know-how and AMPU technology would be made available to the brewer to complement its own cassava beer brewing technology. DADTCO Mandioca Mocambique (DMM): Steep increase in cake sales volumes. SABMiller has invested in a cassava starch refinery based on cassava cake. Cassava content Impala 70% cassava cake and 30% malted barley Increase in cassava cake sales DMM 2,000 1,800 1,600 1,400 1,200 1, Sep Dec 2013 Jan April 2014 May Aug 2014 Sep Dec 2014 Jan April 2015 * Beer with cassava from our own farms..

33 DADTCO s activities in Africa NIGERIA MOZAMBIQUE Flash Dryers Taraba State + 3 AMPUS Drying 2 AMPUS Milling Sieving Cooling Superior Flour/ Starch II Bagging Rivers State + 3 AMPUS GHANA 1 AMPU

34 What is in it for the smallholder cassava farmers? A BRIGHT FUTURE