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Very low cost extruders (VLEC) for small scale production of food and feeds

Very low cost extruders (VLEC) for small scale production of food and feeds. D. Bounie, E. Van Hecke USTL (Université des Sciences et Technologies de Lille) IAAL (Institut Agricole et Alimentaire) Bâtiment C6 59655 Villeneuve d’Ascq Cedex - France

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Very low cost extruders (VLEC) for small scale production of food and feeds

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  1. Very low cost extruders (VLEC) for small scale production of food and feeds D. Bounie, E. Van Hecke USTL (Université des Sciences et Technologies de Lille) IAAL (Institut Agricole et Alimentaire) Bâtiment C6 59655 Villeneuve d’Ascq Cedex - France Tel : +33 (0)3 20.43.49.21, Fax : +33 (0)3 20.43.44.86 E-Mail : Bounie@univ-lille1.fr, vanhecke@univ-lille1.fr Smart Extrusion Workshop, Sydney 2 december 1997

  2. PLAN • Very Low Cost Extrusion Cooking (VLEC) vs. Low Cost Extrusion Cooking (LEC) and classical Extrusion Cooking • Possible applications of VLEC • feeds at farm-level • integrated traceability from feeds to livestock • locally processed nutritious weaning foods (development projects) • on going project in Viet Nam • destruction of antinutritional factors and optimisation of energy density through improvment of formula and control of thermomechanical treatment • precooked blended flours for relief aid • present situation in Africa • small scale production at « camp level » vs. centralized production in remote countries : from emergency to rehabilitation and development • Pilot equipment developped at the University of Lille

  3. PLAN • Very Low Cost Extrusion Cooking (VLEC) vs. Low Cost Extrusion Cooking (LEC) and classical Extrusion Cooking • Possible applications of VLEC • feeds at farm-level • integrated traceability from feeds to livestock • locally processed nutritious weaning foods (development projects) • on going project in Viet Nam • destruction of antinutritional factors and optimisation of energy density through improvment of formula and control of thermomechanical treatment • precooked blended flours for relief aid • present situation in Africa • small scale production at « camp level » vs. centralized production in remote countries : from emergency to rehabilitation and development • Pilot equipment developped at the University of Lille

  4. ENERGY DENSITY OF BABY FOODS Energy requirements for a 65 months child 765 kcal / day Breast feeding 520 ml milk /day, at 65 kcal / 100 ml (540 ml in Africa, 500 ml in Viet Nam) 340 kcal / day Baby-food 765 - 340 = 425 kcal / day + one meal = 170 ml max. if two meals / day : 340 ml / day Energy density of gruels 425 / 340 = 125 kcal / 100 ml calorie content of blended flours ~ 4 kcal / g d.b. (4 for carbohydrate and protein, 9 for fat) Dry content of baby food > 30 g. d.b. / 100 ml ! ! Max. viscosity of gruel to be ingested is 1.6 Pa.s

  5. ENERGY DENSITY OF BABY FOODS Influence of dry matter content on viscosity Feeding of infants and preschool children with gruels - either instant or boiled - is limited by : volume (170 ml max.) and consistency of gruels (1.6 Pa.s max.) Viscosity (Pa.s) 1.6 dry matter (g) / 100 ml 10 15 20 25 30 30 35 traditional home treatment • Ways to increase energy density by decreasing gruel viscosity : • addition of fat • hydrolysis of starch : • synthesis of endogeneous amylases (germination) • addition of exogeneous amylases • drastic thermomechanical treatments : extrusion cooking

  6. PROCESSING OF PRECOOKED BLENDED FLOUR with alternatives for supplementation with vitamin/mineral mix VMS (Vitamin/mineral supplement) Roasting Extrusion cooking Grinding VMS Mixing + cooking Milling Grinding VMS VMS Mixing Mixing Drum drying Precooked flour

  7. VIETNAMESE BABY FOOD : FLOWSHEET Whole corn seeds Full fat soya seeds Rice Mung beans Sesame Salt 1 - Drying 2 - Dehulling Dehulling Winnowing 3 - Winnowing Hulls Hulls Dehulled soya seeds Dehulled mung beans Wheighing 4 - Mixing 5 - Extrusion cooking 6 - Cooling / drying Other ingredients : dried meat powder, mushrooms, carrots, yeast, malt 7 - Milling 8 - Mixing 9 - Bagging

  8. TRADITIONAL VIETNAMESE FOOD Cereals and legums, eggs, mushrooms and spices ... fruits ... dried fishes ...

  9. WEANING FOOD : Raw materials Salt Sesame Soya Rice Corn

  10. WEANING FOOD : Process 1 - Preconditioning of soya : moisturizing + drying 2 - Dehulling of soya

  11. WEANING FOOD : Process 3 - Winnowing of soya 4 - Mixing of ingredients Coarse premix

  12. WEANING FOOD : Process 5 - Extrusion cooking Extrusion-cooker Die outlet Starved and choked screw Barrel and screw

  13. WEANING FOOD : Process 6 - Cooling / drying 7 - Milling

  14. WEANING FOOD : Process 8 - Post mixing with mineral/vitamins premix 9 - Bagging

  15. WEANING FOOD : End product

  16. PLAN • Very Low Cost Extrusion Cooking (VLEC) vs. Low Cost Extrusion Cooking (LEC) and classical Extrusion Cooking • Possible applications of VLEC • feeds at farm-level • integrated traceability from feeds to livestock • locally processed nutritious weaning foods (development projects) • on going project in Viet Nam • destruction of antinutritional factors and optimisation of energy density through improvment of formula and control of thermomechanical treatment • precooked blended flours for relief aid • present situation in Africa • small scale production at « camp level » vs. centralized production in remote countries : from emergency to rehabilitation and development • Pilot equipment developped at the University of Lille

  17. REFUGEE CAMPS IN GREAT LAKES REGION South Kivu (ex-Zaïre) Rwanda

  18. SEVERE MALNUTRITION IN REFUGEE CAMPS Marasmus Kwashiorkor

  19. STORAGE AND GENERAL DISTRIBUTION OF RELIEF FOOD

  20. GENERAL DISTRIBUTION

  21. INDIVIDUAL RATION & FAMILY COOKING Individual weekly ration (1200 kcal/day) Beans 50 g Oil 15 g Corn 250 g Salt 15 g

  22. CENTRALIZED PRODUCTION OF RELIEF BLENDED FLOURS( > 20 MT/day - Kenya) Workshop Stocks of raw materials Cleaner Area of manual mixing Screw or Dust pneumatic removal elevator Hammer mills Scew Dust conveyor removal Belt conveyor Stocks of end-products Extrusion cooker Fan Cutter Screw conveyor Conveyor Continuous mixer Bagging and sewing Batch mixer (500 Kg) Batch mixer (500 Kg) Hammer mill

  23. CENTRALIZED PRODUCTION OF RELIEF BLENDED FLOURS ( > 5 MT/day - Kenya) Toilets + bathroom Stocks (raw materials) Stocks (raw materials) Wheighing Mill Screw conveyor Cleaning Mixer Wastes Screw elevator Feeding bin Water Screw extractor Extrusion cooker Stocks (end products) Stocks (end products) Cutter Electrical cabinet Fan Screw conveyor Fan Pneumatic conveyor Mill Delivery bin Stocks (raw materials) Horizontal batch mixer Wheighing Packaging + sewing Warehouse (CMV, sugar,salt spare parts) Office Office Electrical station Trucks unloading

  24. PLAN • Very Low Cost Extrusion Cooking (VLEC) vs. Low Cost Extrusion Cooking (LEC) and classical Extrusion Cooking • Possible applications of VLEC • feeds at farm-level • integrated traceability from feeds to livestock • locally processed nutritious weaning foods (development projects) • on going project in Viet Nam • destruction of antinutritional factors and optimisation of energy density through improvment of formula and control of thermomechanical treatment • precooked blended flours for relief aid • present situation in Africa • small scale production at « camp level » vs. centralized production in remote countries : from emergency to rehabilitation and development • Pilot equipment developped at the University of Lille

  25. CAPITAL COST REQUIREMENT FOR A 0.5 MT/HR LEC WEANING FOOD FACTORY (Harper, 1995) Cost (US$x103) Item sub-total Total • Land (2 ha) • Site preparation • electrical • water/sewer • roads • building (450 m2) • bulk grain storage handling • Machinery • cleaning/dehulling module • processing module • blending module • packaging module (manual) • ancillary machinery • spare parts @ 10% • crate, insurance, freight @ 20% • contingency @ 10% • Engineering, installation, • management training • Cost subtotal • (machinery & installation) • VAT (14%) on investment • expense • Cost total 25 20 15 60 112 63 49 57 34 68 34 51 60 354 102 341 136 156 168 1,200 1,368 Expected cost for VLEC : 11,000 US$

  26. TYPICAL MANUFACTURING COSTS FOR A PACKAGED FORTIFIED BLENDED FOOD (Harper, 1995) (500 kg/hr or 12 MT/day; 3 8-hr shifts/day, 5 days/week; formula : 70% cereal, 30% oilseed; packaging 250g poly bags) Cost Category Materials Salaries/wages Depreciation Electricity Other utilities Maintenance Spare parts Tranport Misc. Subtotal VAT @ 14% Total Category component White maize Soya beans Vitamins Minerals Poly bags Master bags Manager QC technician Supervisor Mech./Elec. Operators Labourers Clerical Accountant Packers Equipm. (10 yr) Building (40 yr) Daily requirement (A) 2.65 1.14 12.0 kg 31.2 kg 48,000 480 1 2 3 2 12 12 4 1 60 7,200 kW-hr 1,200 MT/km Unit cost US$ (B) 136.2/MT 282/MT 75/kg 50/kg 22/1,000 480/1,000 49/shift 31.3/shift 43.6/shift 21.8/shift 4.1/shift 1.4/shift 2.7/shift 19.1/shift 1.4/shift 179.8/day 49/day 0.05/kW-hr 21.8/day 13.6/day 65.4/day 0.3/MT-km 409/day Total daily costs (US$) (C= AxB) 1327 1179 245 425 288 63 49 63 131 44 49 17 11 19 82 180 49 334 22 14 27 332 409 Specific cost (US$/MT) (D=C/12) 110.5 98.2 20.4 35.4 24.0 5.2 4.1 5.2 10.9 3.6 4.1 1.4 0.9 1.6 6.8 15.0 4.1 27.8 1.8 1.1 5.4 27.3 34.1 449 or US$ 0.45 62.9 512 or US$ 0.51

  27. LOW COST EXTRUDERS FOR DRY EXTRUSION Main manufacturers • Almex (Netherlands) • Anderson (USA) • Brady Corp. (USA) • Croix (France) • France Extrusion (France) • Insta-Pro (U.K.) • Millbank (New Zealand) • Setrem Inotec (France) Principal technical specifications Equipment Anderson 4,5 Anderson 8 Anderson 12 Brady 206 Croix T 95 Insta-Pro 500 Insta-Pro 2000R Insta-Pro 2500 Millbank 500 Millbank 1000 Setrem S50 Setrem X125 Power (kW) 19 56-93 186-373 74.5 22 37 55 90 35 55 37 90 Heating Autogenous (+steam) Autogenous (+steam) Autogenous (+steam) Autogenous Autogenous Autogenous Autogenous Autogenous Autogenous Autogenous Autogenous (+steam) Autogenous (+steam) Output (kg/hr) 250 1,000 10,000 340-450 200-300 200-300 590-910 900-1,350 350 750 200-500 500-1,500 Screw diameter (mm) 114 203 305 95 95 138 L/D ratio 12 12 12 8 8 Screwspeed (RPM) 280 360 360 900-1000 550 550 550 550 550 Moisture content during extrusion (%) < 18 % (> 20 % with steam) 20 % max > 14 % > 14 % > 14 % Temperature content during extrusion (°C) 205 ° max 205° max 205° max 140 (soja) 170 (cereals) 130-170 150-170 (cereals) 135-145 (soya) 150 150

  28. V.L.E.C. AT UNIVERSITY OF LILLE

  29. TECHNICAL SPECIFICATIONS BARREL AND SCREW (L/D = 3.25) Head space (adjustable die clearance) Barrel with helicoidal or longitudinal grooves Screw Clamping ring Die plate D = 24 mm D = 40 mm A B C D L = 130 mm • drive motor : electric motor (power rating : 7.5 kW) ; motor speed : 1500 RPM • transmission : single ribbed, no-split belt + set of pulleys (reduction =1/3) • screw speed : 0 to 500 rpm ; continuous variation of speed using electronic speed variator working at controlled torque • cast iron frame • capacity : 30 to 60 kg/hr • pototype’s price: < 20,000 US$ (price of serial machine is expected to be less than 10,000 $)

  30. BIBLIOGRAPHY • Bounie D., Briend A. and Greletty Y., 1994. Précuisson des aliments de l’aide d’urgence : comportement rhéologique de bouillies énergétiques préparées à partir de divers mélanges obtenus par cuisson-extrusion. In Proc. Conf. Agoral 94 : La Cuisson des Aliments, Nantes, 5-6 octobre 1994, pp 427-439. • Bressani R., Harper J.M., Wickstrom B., 1984. Processed and packaged weaning foods : development, manufacturing and marketing. In : Improving the nutritional status of children during the weaning period, Mitzner K. and al. Eds., Intl Food and Nutrition Program, MIT, Cambridge, MA, pp 117-148. • Coll., 1979. Low cost extrusion cookers. Second International Workshop Proceedings, Dar Es Salaam, Tanzania, Wilson D.E. and Triebelhorn R.E. Eds., Fort Collins, Colorado State University • Coll., 1989. Pour améliorer l’alimentation des jeunes enfants en Afrique Orintale et Australe : une technologie à la portée des ménages. Proceedings of International Symposium, Nairobi, 12-16 Oct. 1989, Alnwick D. and al. Eds., CRDI, Ottawa • Harper J.M., 1995. Low-cost extrusion : possibilities for Africa. The SA J. of Food Sci. and Nutrition,7(4), pp 142-147. • Harper J.M. and Jansen G.R., 1985. Production of nutritious precooked foods in developing countries by low-cost extrusion technology. Food Review Intl., 1(1), pp 27-97 • Jansen G.R., O’Deen L., Triebelhorn R.E. and Harper J.M., 1981. The caloric densities of gruels made from extruded corn-soy blends. UNU Food Nutr Bull, 3(1), pp 39-44 • Jansen G.R., 1992. Centrally processed weaning foods for use in developing countries. Food Reviews Intl, 8(3), 307-345 • Walker A.F., 1990. The contribution of weaning-food to protein-energy malnutrition. Nutrition Research reviews, 3, pp 25-47

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