2|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.

com
PLASTIC pallet
ZAP1: 4 way entry
non-rackable
1200 mm
1000 mm
120 mm
8 kg
2000 kg
1000 kg
PP (Virgin/Recycled)
-20 to 40 C
Optional
DESCRIPTION
LENGTH
WIDTH
HEIGHT
WEIGHT
STATIC LOAD
DYNAMIC LOAD
MATERIAL
TEMPERATURE RANGE
RFID
KwaZulu Natal +27 (0)31 767 4009/4026
Western Cape +27 (0)21 551 2310
Gauteng +27 (0)11 677 1200
Open top
deck for
improved
ventilation
Label or
barcode area
Chamfered top,
bottom and side
pillar deck for
easy entry of
forklift and
pallet jacks
Non-slip grommets
(Standard pallet has 8 inserts,
4 top deck and 4 forklift entry,
additional can be added
dependant on requirements)
Stretch
wrap
grip lip
Every MCG plastic pallet has consistent
1200 mm x 1000 mm dimensions.
Weighing 8 kg each, MCG pallets are signicantly lighter
than equivalent wooden pallets and more importantly
do NOT increase in weight when wet.
MCG plastic pallets are manufactured from polypropylene
in virgin or recycled material ensuring long life.
Our plastic pallets are 100% recyclable.
No protruding nails or broken boards to injure
employees or damage equipment or products.
MCG pallets do not absorb liquids and are
impervious to infestation and contamination.
Do not need to be heated or chemically treated.
(Ideally suited for export pallets.) Can be washed.
CONSISTENT
LIGHTWEIGHT
DURABLE &
STRONG
RECYCLABLE
SAFE
HYGIENIC
Features
Specications
Strapping
tie down
holder
Anti slip inserts
underneath pallet
Official journal of the SA
Assoc of the Flavour &
Fragrance Industry.
FBR is a member of
the Audit Bureau of
Circulations.
Endorsed by SAAFoST.
Published quarterly by PS Publishing. Reg No CK 2011/084261/23
PO Box 650484, Benmore, 2010, South Africa.
Tel: 27 11 462-5645 Fax: 27 11 704-3962 Email: [email protected]
May2012
Con
t t ens
22 Solar refrigerators
designed to solve
electricity shortage
challenges
26 New projects
16
10
18
5 The latest events
10 Extruded snacks: trends,
barriers, machinery and
potential
16 Moringa to purify water
and provide nutritional
benefits
18 Small-scale chicken
farming solution
20 Affordable, portable and
reusable building system
saves on construction
and transport costs
Africas Big 7 Expo ...................................... 6
Continental Beverages ............................ 17
DEF ............................................................... 19
Extru Africa ................................................ 25
Heat & Control .......................................... 13
Insta-Pro International .............................. 8
MGC Industries .......................................... 2
Nicola-J Flavours & Fragrances ........4, 11
Savoury Food Ingredients ....................... 28
Stumbelbloc ............................................... 14
Index of advertisers
4|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
nicola-jflavoursandfragrances
T
he core of the founding team has
considerable experience in the flavour
industry, and our growth since
inception has been exceptional.
Our flexibility and quality of products
and service has established Nicola-J as one of
South Africas premier independent flavour
manufacturers. All of our efforts are focused
extensively on satisfying the needs of our
customers.
We understand the demand for continual
improvement of costs and quality, and
therefore like to work closely with our clients
to assist them in new product developments
and reformulation of existing lines. Our
team of food flavourists
and technicians gladly
assist in the development
or matching of existing
flavours to suit customer
requirements.
By offering a complete
range of products and
services, we aim to satisfy
not only our customers,
but also to contribute to
the quality of their final products, which is
demanded by consumers.
In keeping abreast with the latest rules
and regulations governing our industry - from
food safety issues to labelling requirements
- our regulatory department ensures that we
comply with the ever-changing legislative
landscape.
Customercoverage
We have an extensive customer base within
South Africa, as well as many other African
countries. All local customers are serviced
from our base in Midrand, Johannesburg. Our
sales staff undertake regular visits to all our
customers throughout South Africa to ensure
that we maintain high levels of service and
build solid relationships.
South Africa has become the gateway
to Africa, and our expertise and ability to
customise flavour solutions put us in an
ideal position to increase our presence and
market share in other African countries.
Although we have established distributors
in Mozambique and Zimbabwe, our aim is to
establish distributors in all the countries that
we service. Regular trips are undertaken to
visit our African distributors and customers to
ensure that we understand their markets and
requirements.
We are HACCP (hazard analysis critical
control points)-certified by the South African
Bureau of Standards, and strictly adhere to
our HACCP plan and procedures to ensure
that we manufacture products to the highest
safety standards.
Nicola-J is a full member of the South
African Association of the Flavour and
Fragrance Industry (SAAFFI). We have signed
and adhere to the SAAFFI Code of Conduct, a
prerequisite for membership.
Manufacturingcapabilities
Our new and modern manufacturing
facility in Midrand was designed and built
in strict accordance to HACCP requirements.
The factory consists of eight independent
manufacturing rooms and two warehouses
spanning over 1,800 sq metres.
For the manufacture of powder flavours,
we are equipped with a variety of ribbon and
high-speed Diosna blenders, giving us a
manufacturing range for batches from 25kg
to 1.5 tons.
Similarly, for liquid flavours and
emulsions, we have a range of high-
speed mixers, blending tanks, and an APV
homogeniser, giving us the capacity to
manufacture batches from 5kg up to 3,500kg.
Sweetflavours
Innovation and creativity is core to our success.
We have developed an extensive range of sweet
flavours suitable for almost all applications.
These flavours are available in either powder or
liquid form depending on application.
Our flavours are developed for specific
product applications, and are tested in
products before being commercialised.
We offer these flavours in a range of
concentrations and reasonable pack sizes,
depending on your requirements.
The sweet flavour range includes popular
flavours for baking, including biscuits and
muffins; beverages, including carbonated
beverages; dairy, including yoghurts and
flavoured milks, as well as desserts and toppings.
Savouryflavours
Our ever-increasing range of savoury flavours
has proved very popular and successful within
the marketplace. We have the expertise and
experience to develop just about any type of
savoury flavour to suit your exact requirements.
Key to our success
has been our innovative
development of cost-
effective savoury flavours
that do not compromise on
taste and quality.
Depending on your
requirements, we offer
savoury flavours in various
concentrations in both
powder and liquid form.
The range includes flavours for snack dustings,
soups and stews, savoury baking, pet foods,
sauces and marinades, meat and processed
meat, fish, cheese, etc.
AgenciesinSA
Nicola-J is the official distributor in SA for the full
range of food colours and lakes manufactured
by Vidhi Dyestuffs (MFG) Ltd, India. We carry
large stocks of the primary colours and lakes,
which are available off the shelf for immediate
dispatch. In addition to these primary colours,
we also blend and match colours to offer you
the exact colour to suit your needs.
Nicola-J is also the official distributor
for the full range of caramel colours
manufactured by Alvin Caramel Colours
(India) Pvt. Ltd. We carry stocks of the more
popular caramels, but offer the full Alvin
range.
Customer collaboration
ensures continual
product improvement
Nicola-J Flavours and Fragrances (Pty) Ltd, a wholly-owned South
African company, was founded in 1996.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|5
events
Extru Africa 2012
Hosted by South Africas North-West University, CFAM
Technologies and Department of Trade & Industry, as well
as Texas A&M University, the two-day practical training
seminar on food, feed, and pet food extrusion, on 31 July
and 1 August, will teach delegates about:
The principles and characteristics of extruders and
support systems for effective selection and operation
Current practices for preparation of full-fat soy meal,
processing raw animal products, preparation of pet food,
aquaculture, poultry, and swine feeds
Equipment in actual operation to familiarise delegates
with practical aspects of food, feed, and pet food
extrusion technology
How to run an extrusion operation smoothly
Employing a preventative maintenance philosophy for
extrusion plants
The commercial applications of extrusion
The availability of mechanical energy in dry and wet
extruded full-fat soy, as well as the digestibility of solvent
soy oilcake and extruded/expelled oilcakes.
The two-day conference on food and feed extrusion,
on 2-3 August, will take delegates through global
developments in extrusion, including the policies, strategies
and initiatives concerned; agro-business development
and processing; the potential of extrusion for texturising
vegetable proteins; the latest technology on extrusion
processing and its support systems for effective operation;
product development and product registration; the
principles of food safety; the design of a processing
operation; managing energy in an extrusion plant; and how
to run an extrusion operation smoothly.
Costs:Seminar only = R5,900 ($753) per delegate (includes
one boma dinner). Conference only (includes one boma
dinner) = R4,350 ($555) per delegate, student rate of R3,250
($415) and a discount group booking rate (5+ delegates)
at R3,950 ($505) per delegate. Full-week package = R8,500
($1,085, includes the seminar, conference and two boma
dinners).
Bookings:Onlineatwww.extruafrica.org.za.Alternatively,
contacttel+27(0)182994492;fax+27(0)182935110;
[email protected]
31July-3August,ProteaHotelKrugerGate,
Mpumalanga,SouthAfrica
Food Security Summit 2012
The Institute for International Researchs (IIRs) Food
Security Summit will draw on the political, environmental,
financial, economic, and technological challenges of
increasing food security across the agribusiness sphere
in southern Africa; its implications for the supply of food
to both international and local markets; as well as the
wholesale, distribution, processing, and retail of food
products.
Costs: R9,499 ($1,213 excl. VAT) for registrations received
between 3 and 31 May, and R10,499 ($1,341 excl. VAT) for
registrations after 31 May.
Formoreinformationortoregister:Tel+27(0)117717000;
[email protected];website:www.iir.co.za
18-22June,TheWanderersClub,Johannesburg,
SouthAfrica
15-17July,2012,GallagherConventionCentre,
Midrand,SouthAfrica
Africas Big Seven Expo
The food and beverage, retail and FMCG trade fair for the
continent incorporating a basket of expos:
Agri-Food: manufacturers and producers expo
DrinkTech Africa: beverage processing and packaging
machinery, equipment and technology
FoodBiz Africa: food service and equipment
FoodTech plus Drinktech: production, processing and
packaging
IFMA: dedicated meat industry expo
InterBake Africa: equipment, processes and ingredients for
the baking industry
Pan Africa Retail Trade Exhibition: food, beverages,
merchandise and fast moving consumer goods
Retail Solutions Africa: technology for retailers
ContactLinekevanderBrugghen,ExhibitionManagementServices
(theorganiser):Tel+27(0)117837250/1/6/9;
[email protected];www.exhibitionsafrica.com
6|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
exhibitions
T
his year, we have partnered with
Trade Conferences International
to host the inaugural Retail
Solutions Africa Conference in South
Africa, says John Thomson, MD of
Exhibition Management Services (EMS),
organisers of AB7 and SAITEX. We are also
hosting the On-line Retailing Conference
for the third successive year.
AB7 has been tempting trade visitor
tastebuds for over a decade, while SAITEX
has been enticing entrepreneurs for
almost 20 years. Both exhibitions take
place at Gallagher Convention Centre in
Midrand, Johannesburg, from 15-17 July.
AB7 is the biggest food and beverage
trade exhibition on the African continent.
This seven-shows-in-one event covers
the entire gamut of the food and
beverage business, from farm to shelf
and everything in between - a veritable
crop-to-shop experience. It happens
at the same place and time as SAITEX, a
full spectrum trade show with product
categories from A to Z.
SAITEXhostsFutureofTradeAfrica
Theres another big value-add for visitors
this year, and its all about learning how
to do business in Africa, adds Thomson.
SAITEX is hosting the Future of Trade
Africa 2012 conference for the first time.
The world really is coming to Africa,
says Sven Boermeester, director of The
Future of Trade Initiative. The Future of
Trade Africa is a sophisticated, in-depth
commerce exchange and business
matchmaking platform that primes
delegates with the knowledge and tools
needed to succeed in business in Africa.
Everyone is aware of Africas
immense potential - the mineral
resources, infrastructure development
opportunities, and the growing demand
from Africas emerging middle-class for
goods, services and know-how. But Africa
is not a country, its a continent with 46
unique political, economic and social
environments; a myriad of languages and
never-ending reams of regulations and
red tape. In such an environment, traders
absolutely need to engage with local
knowledge, partners and stakeholders.
It is our mission to boost inter-
trade and cultural relations across the
continent by connecting business people
at events, as well as showcasing Africa
to the world through print and online
publishing, says Boermeester.
Companies currently active in Africa
who wish to network and explore growth
opportunities will find the Future of
Trade Africa extremely helpful. Likewise,
investors who are serious about growing
business in Africa and need local skills
and knowledge should also attend.
Retailconferencesaddvalue
The two retail conferences being hosted
by SAITEX - Retail Solutions Africa 2012
and On-line Retailing 2012 - will focus
on the latest trends and challenges
regarding technology, innovation, systems
and products in the retail industry. The
conferences provide a great opportunity
for networking with people from South
Africa and abroad, says Mariette Broodryk,
project manager for the events. It gives
local delegates the chance to meet global
players that they always hear about.
Majorconsumerbodysupports
AB7andSAITEX
Teaming up with AB7 and SAITEX for
the first time is the Consumer Goods
Council of South Africa (CGCSA). As
proud partners to the event, we fully
endorse and support AB7 and SAITEX
2012 and look forward to helping more
local companies and entrepreneurs
come together and explore business
opportunities, says Gwarega Mangozhe,
CEO of the CGCSA.
EMS John Thomson is thrilled to have
the CGCSA as an official strategic partner.
Having the Consumer Goods Council
on board sends a very strong, positive
message to our exhibitors and visitors.
It shows that the CGCSA is committed
to serving stakeholders, businesses and
South Africas consumers.
Matchmakingservice
As a unique and free service offered
by the organisers, AB7 and SAITEX
attendees have access to an easy-to-use,
internet-based business matchmaking
programme. It provides exhibitors and
visitors with the ability to pre-profile, pre-
select and pre-schedule meetings for all
three days of the shows. Visitors can pre-
register to visit at www.exhibitionsafrica.
com. They can also preview product
profiles on this site.
To see what SAITEX and AB7 are all
about, view the 2011 event video on
YouTube - simply go to www.youtube.
com and in the top search window type
Saitex & Africas Big Seven.
Two of South Africas biggest trade expos - Africas Big Seven (AB7) and Southern African International
Trade Exhibition (SAITEX) - get even bigger this year with the addition of three new components.
Value-added events
to enhance Africas Big Seven
& SAITEX 2012 Expos
AB7: contact Lineke van der Brugghen
at EMS, tel +27 11 783 7250;
[email protected].
Website: www.exhibitionsafrica.com
SAITEX: contact Anina Hough at EMS,
tel +27 11 783 7250;
[email protected].
Website: www.exhibitionsafrica.com
Retail Solutions Africa Conference 2012:
contact Mariette Broodryk, tel +27 11
803 0009; [email protected]
On-line Retailing Conference: contact
Danie Herbst, tel +27 11 803 0009;
[email protected]
Future of Trade Africa 2012: for more
information, visit www.futureoftrade.
com or www.ProudlyAfrica.info
Contact details
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|7
Brought to you by
Packaging for success in African markets
Join us for a workshop-ing lunch
Brought to you by FoodProcessing Africa digizine sister publication to Food & Beverage Reporter
(incorporating Packaging Reporter) three speakers from leading packaging and processing rms will
guide you on successful packaging approaches to the markets of Africa.
Agenda
11.30am: Markus Dreier, Kraft Foods packaging design manager for Middle East and Africa on Innovative
packaging being utilised by Kraft Foods in its African markets
12pm: Jeff Rossouw, Heat and Control general manager - Africa on Understanding snack production in
Africa: consumer types, sales outlets, snack types and packaging, and processing challenges and solutions
12.30pm: Lunch
1pm: Chandru Wadhwani, Extrupets chief operating ofcer on Food-safe recycled PET: the benets and
opportunities for African processors and converters

Target audience
Food processing manufacturers from all countries who intend expanding up the African continent,
or further developing their African endeavours.
Why you should attend the seminar
In addition to attending the BRICS Africa Export/Import Forum and Africas Big 7 Exhibition
(the continents largest food and beverage industry trade expo) you will get tips and advice
on how to tackle packaging for the varied countries of Africa, and pitfalls to be avoided, from
leading experienced experts in the packaging industry with rst-hand knowledge.
The cost
Early bird special (before 15 June) R555 including VAT (US$85);
thereafter R655 (US$97.50) per person.
Price includes:
To register
Phone Alice Osburn on +27 (0)11 462 5645 Email: [email protected]
www.foodprocessingafrica.com
Our banking details
Account name: PS Publishing, Bank: First National Bank, Randburg
Branch code: 254 005, Account No: 62315015570 Swift No: FIRNZAJJ
Fax the form below to +27 (0)11 704 3962 together with your deposit slip
Title: First name: Surname:
Company: Job title:
Tel no: Fax no:
Email address:
Company VAT no: Invoice required? Yes No
Tuesday 17 1uIy 2012 11.30am - 1.30pm
Gallagher 1 Meeting Room, Gallagher Convention Centre, Midrand
Chandru
Wadhwani
Jeff Rossouw
Semihar aIIehdahce
2 course luhcheoh
Coodie bag
NoIes oh speaker's presehIaIiohs
(emailed to you)
To be held alongside the BRICS Africa Export/Import Forum
a new feature at the 2012 edition of Africas Big Seven
Year's subscripIioh Io Food & Beverage Reporter
(value: R455 and other subscriber benets)
F&B Reporters fortnightly electronic newsletter,
giving updates and hot news
QuarIerly FoodProcessing Africa digizine
A
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r
a
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a
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8|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
insta-prointernational
A
large number of studies have
been performed over the past few
decades to investigate different
aspects of applying extruded full-fat
soybeans in animal and poultry diets.
These studies have demonstrated that
properly processed extruded soybeans
can:
1) Be effectively used by poultry species
2) Completely replace other protein
sources in the diet
3) Replace dietary fat supplements.
Using Insta-Pro equipment, studies
have shown that extruded full-fat
soybeans contain about 3,815Kcal/kg
of true metabolisable energy (TMEn) for
poultry and 4,446Kcal/kg TMEn for swine
species. The moisture content, crude
protein and crude fat content of Insta-
Pros extruded full-fat soybean is about
7%, 38% and 18% respectively, says Dr
Poureslami.
Researchers at the University of
Arkansas have used extruded full-fat
soybeans at 52% in the broilers diet (see
the table). Extruded full-fat soybeans
in this study replaced solvent-extracted
soybean meal and poultry oil, which
contributed to a significant improvement
in growth performance, body weight and
feed conversion ratios.
Poureslami adds that extruded full-fat
soybean is a great ingredient in many
countries where the price of energy is
high and imported soybean meal is the
major protein source in the feed. Other
advantages that have been attributed to
the full-fat soy are:
1) It can be processed locally at a relatively
low price
2) It is a grainy material that can be
handled at a lower cost than oil in the
feed mill
3) Having fat within the matrix of the diet
rather than mixing/spraying fat leads to
a lower rancidity rate
4) Having fat within the matrix of the
feed decreases dustiness of the diet
5) The quality of fat is higher than that
obtained from most sources of added
fat.
Dr Reza Poureslami, poultry
nutritionist at Insta-Pro
International, explains that
extruded full-fat soybeans
have been used as a high-
quality source of energy (due
to the oil content of 18-22%)
and protein (38-42%), in the
diet of poultry species since
the early 1970s.
Extruded full-fat soybeans and
ExPress soybean meal are high-
quality sources of energy and
protein for poultry species
Trueaminoaciddigestibility(%)ofextruded
full-fatsoybeansandExPressmealproduced
throughtheInsta-Prosystem,asreportedby
DrNickDaleoftheUniversityofGeorgia,USA
(2011).Thesedigestibilityvaluesindicatea
highproteinbioavailabilityofextrudedfull-fat
soybeansforpoultryspecieswhencompared
tootherproteinsources.
Model2000Extruderwhichisshowninamirrorimage,thusproducingtwotimesthecapacity.
4043 120th Street
Urbandale, Iowa 50323 USA
+1.515.254.1260
[email protected]
www.insta-pro.com
www.youtube.com/instaproint
Processing Technologies for Food and Feed
PROCESSING SOLUTIONS
Flexible Scale of Operation
Environmentally Friendly, Chemical-Free Processes
Low Capital Investment
Produces Superior, Quality Ingredients
Durable Equipment
Easy to Operate
PRACTICAL APPLICATIONS
Oilseeds
Pet and Aquatic Feeds
By-products
Novel Ingredients
Food
Feed
PRACTICAL APPLICATIONS
Oilseeds
Ideal for Specialty Seeds
i.e. Organic
Other Oil Bearing Products
EXTRUSION
MECHANICAL
OIL EXTRACTION
dairy
Insta-ProInternationalsModel5005OilPress.
Extruded-pressed(ExPress)
soybeanmeal
ExPress soybean meal is an alternative
to solvent-extracted soybean meal.
Extruded soybeans go through the
pressing process where about 12% of
oil is extracted. This extracted oil can
further be used in the feed and/or food
applications.
Basically, ExPress soybean meal
contains less crude fat when compared to
extruded soybeans (6% versus 18%). The
crude protein (48%) and energy content
(3,344Kcal/gg TMEn) of ExPress meal
is different to that of extruded full-fat
soybeans. Amino acid digestibility of
ExPress meal is presented in the table.
In a recent study at the University of
Illinois, conventional solvent-extracted
soybean meal was substituted with
ExPress meal in the broiler diet. Results
of this study indicated that feeding
ExPress meal supports maximal growth
and performance, Poureslami states. The
feeding value of ExPress meal in this
study was similar to that of conventional
solvent-extracted soybean meal.
10|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
A
lthough designing snack foods
today can be a complex process
to meet changing consumer
tastes and expectations, extrusion
technology provides snack makers with
the opportunity to process a variety of
products by changing minor ingredients
and processing conditions on the same
machine. The extrusion process can
therefore produce innovative snacks with
different shapes, textures and colours to
capture the consumers imagination.
Prof LJ Grobler,
head of the Centre
of Excellence
in Advanced
Manufacturing
at North West
University in
South Africa, says:
Extrusion can be
described as a process
during which a material is
forced through a defined opening. When
extrusion is used for food or feed product
manufacturing, mechanical cooking also
forms part of the process. Products such
as breakfast cereals, puffed chips, animal
feed and plastic wood composites can be
produced using this technology.
He adds that extrusion technology is
ideal for establishing small to medium-
sized processing plants on farms or
in rural areas to produce food or feed
products in close vicinity to where the
feed-in produce - such as maize, wheat
or sorghum - is grown. There are many
opportunities for developing new
products in Africa by using extrusion. It is
a relatively inexpensive, energy-efficient
and easily-operated method to produce
a wide range of ready-to-eat foods and
animal feeds.
Marketstatus
According to Jeff Rossouw, Heat and
Controls general manager - Africa,
the African snack industry has grown
considerably over the last few years as
companies have invested in an industry
that offers certain growth. The global
trend is positive for the snack industry,
and Africa has plenty of opportunity to
receive benefit from a growing snack
market, but there are also significant
barriers, Rossouw concedes.
More often than not, snacks in
emerging markets are a replacement
meal and not a snack in the true sense of
the word, he states. Do not be surprised
to see a corn or cassava chip soaked in
milk eaten as breakfast, or mixed with a
meat sauce as lunch or dinner.
Rossouw explains that baked
extruded products are popular in markets
where distribution channels are limited
and roads are bad. These types of snacks
do not travel well and in-bag-damage
often occurs. Shelf time for informal
products is often a few days only.
Nitrogen gas flush is uncommon. Cost
is also a prohibitive factor and price
wars are common. In South
Africas informal market,
for example, prices have
remained almost unchanged
for the last 10 years due to
fierce competition.
In certain countries
where temperatures are
extremely hot, processors often
use thicker BOPP film to overcome
quality problems resulting from the
environment, despite short shelf time.
Outside of South Africa and
especially in East and West Africa,
homemade snacks are sold through
street vendors and many home-style
snacks do not always lend themselves
to commercial processing. With many
subsistence farmers producing raw
products such as potato, cassava, yam,
taro and plantain, quality is still a
subjective term. Commercially-viable
volumes can only be produced if quality
FoodProcessing Africa
investigates extrusion in the
growing African savoury snack
market, the trends in different
markets, and the equipment
available to service the needs
of producers in this sector.
Extruding new
snack opportunities
Fromrightto
left:theClimback
System,Fastback
Revolution
GateSystem
andFastback
OnMachine
SeasoningSystem,
allmounted
ontoaHeatand
Controldesigned
andconstructed
platform.The
Climbackusesa
Fastbackdrive
trainandstainless
steelpantoconvey
productatan
inclineangle.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|11
food
is ensured through proper agronomy,
Rossouw remarks.
Gary Boast of Nicola J Flavours &
Fragrances confirms that the most
popular snacks remain extruded puffs
and naks, with some regions preferring
them with a high level of chilli or heat,
while others prefer much milder flavours.
Broadly speaking the old favourites such
as cheese, spicy tomato, chutney, beef are
the common sellers, often with their own
local twist.
Rossouw adds: In Nigeria you will
find a seafood flavour called snoek
that has its origins in Scandinavian fish
imported years ago. The taste is not
remotely close to the game fish known in
South Africa.
Thechallenges
Boast says market research, funding,
bureaucracy and punitive duties and
levies are all barriers to growth in the
African snack market. Many business
people have no access to market research-
or indeed there isnt any - and thus find
it difficult to maximise potential, identify
opportunities for different products and
expand existing markets, Boast states.
Funding is always a problem leading to
many businesses being undercapitalised
and thus unable to grow.
Rossouw adds that import duties,
transit services and raw material or
energy source supply are also big
barriers. Prohibitive import duties on
raw materials or significant equipment
investment, rather than consumer
preference, often determine future
trends. Raw pellet snacks are, for example,
taxed between 5% and 20% depending on
the raw materials they contain, he says.
A real barrier to entry is also the capital
tied up as stock in transit, when shipping
-from abroad.
Currently, cassava and plantain processing enquiries dominate West
Africa, while corn and cassava dominate East Africa. Egypt in recent
years has become a major player in the snacks market, and there is
movement in Mozambique, Zambia, Nigeria, Ghana and Cameroon.
- Jeff Rossouw, Heat and Controls general manager, Africa
SnackQuipoffersasuperlow-oilvolume-
friedlinethatutilisesexternalheatexchanger
technology,whichallowsclientstoselect
differentfuel/energyoptionsthatmaybe
availableinoutlyingandharder-to-service
areas.Typically,theselinesstartat200kg/
hourwithoneextruder,andcanbeexpanded
withasecondextruder.
12|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
Opportunitiesandconstraints
Even with all the barriers to entry in
the market outlined above, Rossouw
says that there are some opportunities
to be exploited. With a strong Indian
influence throughout Africa, there are
opportunities to produce Namkeen
(Indian) snacks with an African twist.
And if the trend to export tree nuts, such
as macadamias and cashews, to other
emerging countries for further value
adding and processing can be reversed.
A whole new industry can be established
with all the socio-economic benefits
that go with this. Coated spicy nuts
have already been established as a good
product line in certain regions.
He also believes that the potential for
pellet-type snacks is huge as equipment
investment is reasonably low and the
producer can run any number of different
raw pellets and offer a basket of products
with bases such as corn, potato, rice and
multigrain, off one machine.
Rossouw adds that the product range
for the smaller, entrepreneurial type of
processor, so often found in Africa, is very
limited and that the initial investments
required are out of reach for most. The
typical system that would be replacing
roadside woks would be a small gas
or electrically-heated batch fryer. The
availability of gas, electricity and the fact
that these types of units are not mobile,
in itself poses a challenge, as most
vendors pack up their shops at the end of
a trading day. These machines are more
suitable to fixed premises with services
supply in place.
Boast adds that small-scale producers
often also have difficulty obtaining the
volumes required to be profitable due to
a lack of funding. Producing snack foods
is generally a low-profit, high-volume
business, making economies of scale
necessary to achieve profitability.
-MelissaJaneCook
ExtruAfrica,ProfLJGrobler:
Tel+27(0)182991329;[email protected];
www.extruafrica.org.za
HeatandControl:Tel+27(0)219485934;
www.heatandcontrol.com
NicolaJFlavours&Fragrances:
Tel+27(0)113156582;www.njflavours.co.za
SnackQuip:Tel+27(0)119650582;
www.snackquip.com
With a population of 150
million, Nigeria should be
a big market for all kinds of
snacks. But manufacturing is
a challenge because electricity
supply is a significant problem
along with poor infrastructure,
poor support services and other
necessary services to run a
factory. Clearing from the ports
can take upwards of
15 days and the political
environment impedes
significant progress in the
snacks market.
- Jeff Rossouw, general manager
Africa, Heat and Control
Potential snack
manufacturers should
select a company
to supply not only
the equipment,
but also all of the
surrounding services,
including assistance
with sourcing raw
materials, flavouring
and packaging,
says a Snack Quip
spokesperson. They
should ensure that the
prospective equipment
supply company can
offer them growth
with innovative new
ideas and the ability to
implement service into
Africa.
The spokesperson
adds: We also
advise clients not to
underestimate the
quality demanded
by the little client,
even in outlying
rural conditions.
People across Africa
demand very high-
quality products, and
generally, high-quality
machinery is required
to achieve this.
Jeff Rossouw of
Heat and Control says
that one of the most
common mistakes
made by inexperienced
processors or investors
is to buy equipment
on price alone, or
to acquire second-
hand equipment
from a reputable
manufacturer that
has been modified
by an equipment
broker. The cheaper
equipment often has
no history of research
and development,
resulting in failure and
unreliability. And the
OEM parts used are
more often than not
unknown brands and
not readily available
for emergency
maintenance.
Second-hand
equipment, on the
other hand, is often
more than 20 years old
and has been modified
over the years, or the
brokers have matched
filter fryers and heat
exchangers that
are not designed to
function together,
he notes. Almost
every single call we
receive on our own
brand of second-hand
equipment is a case of
the latter and endless
problems are the order
of the day.
Equipment considerations
Pellets,whicharedehydratedpre-formedstarchproducts,canbeorderedinmanydifferent
shapesandbasematerials,forexample,wheatorpotato.Thisincreasesthenumberofproductsa
smallproducercanofferthemarket.Positioningamobilevibratoryin-feedhopperbehindthefry
lineenablestheproducertocontinuouslyfrypelletproducts.ShownhereisaSnackQuipfryer
withheatexchanger.
food
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|13 www.heatandcontrol.com
Progress through innovation
Heat and Control is one of the worlds leading manufacturers of snack food processing
and packaging equipment systems with over 60 years food industry experience. Complete
systems are provided to deliver the highest quality food products and a combination of
experience and expertise and the commitment to innovation and quality, will guarantee
world class solutions for product requirement.
Complete Snack Processing & Packaging
Systems
Potato Chips; from hard bite to classic
Corn & Tortilla Chips
Taco Shells, Corn Tortillas & Tostadas
Fabricated Chips
Pellet Snacks
Extruded Snacks
Roasted Nuts, Peas & Legumes
Namkeen [Traditional Indian savoury snacks]
Cape Town, South Africa / Tel: +27 21 948 5934 / [email protected]
Food Proc Africa12_FULL_281x205 with 5mm bleed_HeatandControl_Snacks.indd 1 02 May 2012 10:04:24
14|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
T
he systems versatility means that farmers are able to
build anything from houses and swimming pools to
warehouses and all the way down to septic tanks and
French drains, says Andr Esterhuizen, inventor of Stumbelbloc.
Farmers can make blocks for as little as R4 ($0.51) if they
have the right sand or gravel in dry river beds says Esterhuizen.
This means that they can construct walls for less than R98/m
($12.49/m).
The plastic moulds with which you make the blocks are
very unique in the sense that you can start a small do-it-
yourself factory with as little as 34 moulds or grow to any limit,
depending on the size of the project, he adds. 34 blocks are
produced with one bag of cement; three wheelbarrows of sand
and two wheelbarrows of 13mm stone. This mixture produces
5.5 megapascal (MPA) blocks (3.5 MPA is required for single-
storey buildings up to 3.3 metres high with a gable of 5.2 metres
high.) You can also determine the strength of the blocks by
simply changing the cement percentage.
The tendency for farmers to finance moulds and train
workers to build their own houses is growing fast, says
Esterhuizen. A typical example of how Stumbelbloc has been
used as an upliftment and employment tool is in Marydale in
South Africas Northern Cape province. Here Pastor Hennie Mare
convinced farmers to invest in the upliftment of the towns
2,500 people - 85% of whom are unemployed. Not only did the
farmers buy the moulds through the church to start a brick
factory, they are also buying the blocks, training and paying the
workers to do construction, which is creating employment for
the benefit of all.
While this particular project was launched as a charity
initiative, it is fast becoming a self-sustaining business that
benefits the whole community, and similar towns are watching
them closely and investigating the opportunity.
Pastor Mare says: The demand for the blocks is so great
at the moment that we are turning away orders because the
factory cannot meet the demand. We have also had to change
our non-profit organisation status to a not-for-profit company,
and we plan to use the profits for further upliftment.
Formoreinformation,contactAndrEsterhuizenon+27(0)832288036
orvisitthewebsite:www.stumbelbloc.com
Stumbelbloc is fast becoming the farmers first
choice of do-it-yourself construction because it is
economical and easy-to-use, and the durability and
versatility of structures impress.
Stumbelbloc
is growing
from strength
to strength
stumblebloc
ThesephotographsshowatypicalStumbelblocconstructioninMaun,
Botswana.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|15
16|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
A
ccording to Sonia Marais of
Moringa South Africa, moringa is
the sole genus in the flowering
plant family Moringaceae. It contains 13
species that grow in tropical and sub-
tropical climates, which range in size
from tiny herbs to massive trees. The
most widely cultivated species is Moringa
oleifera, a multi-purpose tree native to the
foothills of the Himalayas in northwestern
India, and cultivated throughout the
tropics. M. stenopetala, an African species,
is also widely grown, but to a much lesser
extent than M. oleifera.
Marais says: Moringa oleifera
silviculture is being promoted as a means
to combat poverty and malnutrition.
It grows quickly in many types of
environments, and much of the plant is
edible. The leaves contain all essential
amino acids and are rich in protein,
vitamin A, vitamin B, vitamin C, and
minerals. They are often called super
food because scientists have found that
they contain the calcium equivalent of
four glasses of milk, the vitamin C content
of seven oranges, the potassium of three
bananas, three times the amount of iron
found in spinach, four times the amount
of vitamin A found in a carrot, and twice
the amount of protein in milk.
Pilot nutritionproject
In Tooseng village in South Africas
Limpopo province, a 15-hectare
plantation of Moringa has made a
positive change to the individuals there.
Mavis Mathabatha, a former school
teacher in the village, has set up a
Moringa farm that will produce enough
leaves to make a dramatic difference in
South Africa and further afield.
In 2009, Mathabatha started
harvesting, drying and grinding Moringa
leaves from the first few trees she had
planted. She sprinkled the crushed leaves
on meals provided to about 400 poor
children at the local Sedikong sa Lerato
(meaning Circle of Love in Sesotho)
drop-in centre.
The results were visible almost
immediately. The health of the children
improved in a short period of time,
says Elizabeth Serogole, the drop-in
centres manager, who works closely with
Mathabatha. She says many children
had been showing signs of malnutrition,
like open sores on their skins, which
started to heal soon after regularly
eating one teaspoon of leaf powder
a day. Supplementing their meals
with Moringa also notably increased
childrens ability to ward off new
illness and infection and boosted their
mental development, as most can now
concentrate better at school.
Mathabathas farm produces and
packages up to 10,000 tons a year of
Moringa leaf powder, which is distributed
within South Africa and exported to
Botswana, Swaziland and Lesotho. I
am hoping to further extend my market
in the next few years. There is a lot of
interest in my product, she says.
Planting and distributing Moringa
is a holistic approach to deal with
the problem of food insecurity, says
Ashley Green-Thompson, who managed
Mathabathas project grant. The level of
household food insecurity is one of the
key indicators of poverty, and its very high
in Limpopo.
Varietyofbenefits
Dr Samson Tesfay, a post doctoral
scholar at the South African University
of KwaZulu-Natals Horticultural Science
Department, confirms that Moringa
is truly a multi-purpose wonder. The
Moringa plant is unique in that every part
can be utilised for beneficial purposes. It
has medicinal, therapeutic, nutritive, and
practical uses. It is extremely effective in
combating malnutrition, Tesfay states.
Nutritionalvalue. In addition, the
leaves, stems, and seed pods (full
of essential amino acids) of the
tree can be prepared in a variety of
different ways, in order to provide solid
nutritional value.
-Theseedpods. Also known as a
drumstick, the green seed pods are
typically prepared in much the same
way as green beans, and have a
characteristically asparagus-like flavour.
The seeds themselves can be roasted
or boiled, while the roots are used to
food
Miraculous moringa
Moringa is a fast-growing, drought-resistant tree with incredibly
nutritious leaves that could aid poor, arid nations in fighting food
insecurity and undernourishment.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|17
prepare a horseradish-like condiment
or sauce. When pressed, the seeds
produce edible oil that can be used for
preparing food.
-Theleaves. Especially nutritious, these
can be eaten raw or served as a boiled
greens dish that resembles spinach. The
dried powder can be stirred into soups
or sauces as a thickening agent or used
to brew a healthful drink. Moringa
leaves can also be used for medicinal
purposes, to treat skin infections, lower
blood pressure and blood sugar, reduce
swelling, heal gastric ulcers and to calm
the nervous system.
Waterpurifier.Tesfay further explains
that the seeds of the tree can be used
to purify water in rural areas where
access to clean drinking water is
difficult and is often a cause of disease.
The seeds are effective in removing
about 98% of impurities and microbes
from contaminated water, he states.
Researchers at Leicester University
in the UK have found that mixing
crushed moringa seeds with polluted
water helps settle silt and other
contaminants. This is highly cost-
effective because the seeds can replace
expensive imported material usually
used for water purification in rural
areas. The seed-filtered water still
needs a final filtration before it is
completely drinkable, but the seeds
make the process easier and help other
water filters to last longer.
Agriculturaluses.Moringa trees are
also used in agroforestry and mixed
cropping because the shade provided
can protect other crops from the sun.
While smoke from household fires
can pollute the air, the soft, spongy
moringa wood burns cleanly with little
smoke or smell, making it a healthier
source of fuel, he concludes.
Moringa can be grown all over Africa
from Tanzania downwards. In South
Africa the most suitable provinces
are Mpumalanga, KwaZulu-Natal and
Limpopo. -MelissaJaneCook
MoringaSouthAfrica,contactSoniaMarais:
[email protected]
Miraculous moringa
The Moringa tree is non-invasive, needs little water and grows
fast, reaching a height of three metres within a year. The tree can
survive in relatively unfavourable conditions, and does not require
sophisticated and expensive farming methods or inputs. Food
experts predict that Moringa could become a widely-used hunger
prevention method, as it can grow in all of the worlds sub-tropical
areas, where droughts and malnutrition are prevalent - in most
parts of Africa, Central and South America, the Middle East and
South-East Asia. - Dr Samson Tesfay, a post doctoral scholar at
University of KwaZulu-Natals Horticultural Science Department
in South Africa
Continental Beverages
Continental Beverages is a division of The Ceres Beverage Company, one of South Africas leading beverage manufacturers.
Tel : 0860 100 599 (Republic of South Africa) International : +27 21 700 4787 E-mail :[email protected].
Your Quality Bulk Fruit Concentrate Supplier.
Bulk Nectar concentrates Dairy Blend concentrates Squash concentrates Ice Lolly concentrates
Technical Expertise & Service Highest Quality Ingredients Manufacturing Excellence
XXXX CONBEV TRADE AD.indd 1 2012/04/17 9:16 AM
18|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
I
ts inventor Philip Kilian from Kiki
Agri (Pty) Ltd describes this chicken
house as affordable, fully equipped
and providing unlimited opportunities
for anyone who wants to be successful
in their pursuit of becoming a chicken
farmer.
Poultry is the biggest and fastest
growing meat sector in South Africa, and
the Nkoko 20 promotes controlled speed
and ease in the process of raising broiler
chickens. These chickens are specially
developed to grow tender meat in a very
short period of time - they are ready to
consume or sell in approximately 42 days.
Kilian says that farming with the
Nkoko can start within a short time as
the house is easy to assemble with
two people simply following the steps in
the instruction manual. No experience,
low capital input and minimum space
is required by the farmer. The growers
manual is simple to read and understand.
The Nkoko broiler comes with guidelines
and record-keeping per batch. It explains
a measured farming approach, resulting
in birds weighing in excess of 2.3 to 2.5kg
each on day 42 (live weight). Farmers
are also exposed to entrepreneurial
skills development in the Nkoko training
manual to assist them in establishing
their own markets.
Manufacturingandmaterials
The Nkoko structure has a steel frame
with a smart lightweight design. It
is easy to transport the components,
assemble, and is rust-resistant. The
powder-coated cladding is durable and
the premium 550gm PVC tarpaulin
is manufactured by professional tent
makers in South Africa. The cladding is cat
and dog-proof, rodent-resistant and UV
protected, says Kilian
The equipment supplied for this
turnkey operation includes a ground
sheet, tube feeders, water feeders,
infrared and white lamps, a thermometer,
a 3kg kitchen scale, growers manual, day
old chicks, feed and saw-dust.
There are three Nkoko models to
choose from at affordable prices:
1. Nkoko 20 - 2m turnkey house
2. Nkoko 50 - 4m turnkey house
3. Nkoko 100 - 8m turnkey house
Available outside South African borders -
terms and conditions apply for delivery,
etc.
ContactMariannaduPlessisatAgrificaforthe
pricelist.
Tel:+270128049729;[email protected]
food
Although there are many variations of chicken coops and related
products on the market, Nkoko has been designed with the small
and emerging farmer in mind.
Small-scale chicken farming
in your backyard
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|19
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20|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
building
building
H
ennie Botes, CEO of Moladi,
explains that a house in a
container concept is employed
for social housing initiatives, whereby
all the materials supplied are packaged
conveniently into a container that is
then delivered to the building site. All
the tools and equipment required to
train local unskilled communities are
on hand, and as a result the success of
the construction process is completely
independent of its location.
Moladi is able to meet any building
standards or regulations, as the system
produces walls that are of high-quality.
Botes says that the company employs
a distribution model whereby anyone
who would like to use Moladi for his/
her housing projects is able to access
the technology in his/her local territory
through a designated distributor or
directly through headquarters in South
Africa.
Technologyandcomponents
Moladis housing solution combines
a reusable, patented, recyclable,
lightweight plastic injection moulded
formwork system with a South African
Bureau of Standards (SABS)-approved
lightweight aerated mortar mix to
produce a cast in-situ steel reinforced
monolithic structure, Botes states.
The formwork components are fully
interlocking and are assembled into easy-
to-handle panels, which are configured
into a full-scale mould of the desired
structure. The formwork panels are joined
to create the external and internal walls
cavities and all of the steel reinforcing,
window and door block-outs, conduits,
pipes and other fittings are positioned
within the wall cavity to be cast in-place
when filled with the Moladi mortar mix.
The wall cavities are filled
simultaneously with a SABS-approved
mortar mix which contains, cement,
water, river sand, and Moladi Chem. The
mortar mixture produces a fast-curing
aerated mortar that flows easily, and
results in a wall that is waterproof and
possesses good thermal and sound
insulating properties, he says. After the
wall cavities have been filled with the
mortar, the mortar is left to set overnight
and the formwork panels are removed
the following morning to be re-erected on
the next foundation.
The wall has a smooth and flat finish
that does not require any plastering,
beam filling or chasing. All Moladi
structures have steel reinforced internal
and external walls. The reinforcing design
is specified by a structural engineer, who
independently certifies the structure
after construction is completed and the
final inspections are carried out.
Moladi moulds mortar
Moladi is a compact building system that can be used anywhere and
transported to virtually any part of the world, including remote and rural
areas as well as informal settlements, which may be difficult to access.
Erecting a structure does not require heavy machinery or electricity, and
the building materials required are easily accessible and sourced locally,
spreading the benefits to local communities.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|21
building
building
The result is a fast track, cost-
effective and transferable construction
technology that is amortised over 50
re-uses, reducing the cost of construction
and transportation significantly. It also
facilitates the possibility for many in-situ
structures to be built in just one day, he
states.
According to Botes, the Moladi
mould is easily adapted to suit any
required design or layout - there are no
limitations with regard to the size, or
room arrangements of a house. There is
also no standard mould as each mould
is specifically manufactured (assembled)
to meet the specifications of each clients
architect or draughtsman. Moladi is
able to accommodate any type of roof
design or covering, any finishing material,
any type of window or door, so there
are no limitations in terms of cultural
preferences, he says. We also produce
an acoustically solid wall (sounds like
a brick wall) with a smooth plastered
finish. Should a client/contractor have a
preference to clad or plaster the finished
wall, this can also be done.
Labour
He says most traditional and alternative
construction methods require certain
skilled and trained artisans to contribute
towards the structural integrity of a
building. In many cases, especially within
South Africa, skilled artisans are not
available or skilled workers are wrongfully
replaced with a cheaper, unskilled
workforce, resulting in shoddy and unfit
structures.
With its streamlined and simplistic
approach to construction, the application
of our technology is not dependent on
skilled labour or artisans for construction,
enabling the community to become
involved in building their own homes.
Over 90% of the construction team on a
Moladi housing site consists of unskilled
labourers, and women are encouraged to
participate in this non labour intensive
building process.
Botes says that the Moladi construction
method has been specifically designed
with the objective to allow for an
unskilled team of people to follow the
companys optimised, repetitive and
sequential processes that eliminate the
probability of any errors occurring, which
is crucial to the outcome of the structural
quality or integrity of the housing unit.
Moladi:Tel+27413722152;
fax+27865026930;www.moladi.net
The speed, affordability, quality, adaptability, ease of construction,
use of sustainable local materials and the opportunity created
to facilitate sweat equity, are key advantages that will greatly
improve the efficiency with which the world addresses the
problems relating to the worlds poor, homeless and unskilled
communities. - Hennie Botes, CEO of Moladi
Hennie Botes, CEO of
Moladi, explains that
the selection and use
of building materials
relating to the Moladi
construction process
is considered a crucial
aspect in determining
the environmental
sustainability of the
technology. Although the
calculation of embodied
energy is a complex
matter and differs from
region to region, building
materials used in the
Moladi construction
process have been
carefully considered
according to the initial
and recurring embodied
energy that is used or
expended during the
life cycle and operation
of each material, says
Botes. Some additional,
but notable, factors
which affect the overall
energy consumption of
a structure - and which
are often mismanaged
within the affordable
housing industry -
include non-essential
transportation, wasteful
packaging, plentiful waste
of materials resulting
from processing and
construction methods, and
also poor dumping and
disposal methods.
Materials are rarely
recycled or even re-used
and poor workmanship,
the utilisation of sub-
standard materials and
the use of materials and
components which have a
dissimilar and inconsistent
durability, leave the
home owner with a high-
maintenance home which
requires frequent repair
and even large-scale
restoration.
Lastly, passive
design principles for the
appropriate climate that
help to minimise the
energy required to heat,
cool, ventilate and light a
building responsibly are
largely ignored in favour
of a cheaper initial cost
outlay, Botes states.
These factors are
all taken into account
to ensure that Moladi
buildings provide
environmental value by
challenging members of
the construction industry
who are quick to ignore
the long term use and
quality of a building in
favour of the short term
savings enjoyed by the
developer.
Sustainability
22|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
solarrefrigeration
solarrefrigeration
Thefridgelady
ofNamibia
Emily Cummins (21) came up with
the idea of a sustainable fridge that
works through evaporation and can be
used to keep perishable goods such as
milk and meat cool for several days at a
temperature of 6C, while working on a
high school project in her grandfathers
potting shed in England.
After her A-levels, Cummins spent
five months in Africa perfecting and
demonstrating her product. She gave
away the design plans in townships
across southern Africa because she
wanted to enable as many people as
possible to build their own fridges.
Cummins, who became known as
the fridge lady in Namibia, explains that
her prototype comprises two metallic
cylinders - one inside the other, between
which a locally-sourced material such
as sand or wool is packed tightly before
being soaked with water. When the
fridge is placed in a warm environment,
the suns energy causes the outer part
to sweat - water then evaporates from
the sand or wool and heat energy is
transferred away from the inner cylinder,
cooling it down.
She adds that the design is ideal for
use in developing countries because it
doesnt require electricity, and can be
built using barrels, spare car parts and
ordinary household materials, such as
wood and plastic. Unlike previous pot-
in-pot coolers, the contents are kept dry
and hygienic because the water does not
come into contact with the product, says
Cummins. The cylindrical shape of the
fridge also ensures that there are fewer
areas where bacteria can build up.
Cummins is currently developing a
second generation fridge that maintains
an even lower temperature and is more
energy-efficient.
Formoreinformation,visit
www.emilycummins.co.ukor
email:[email protected]
Refrigerators
that thrive
in the sun
Electricity shortages are common in many emerging economies,
often resulting in food wastage as items spoil with the rising
temperatures. While some businesses can afford to use diesel
back-up generators to power their equipment, solar-powered
refrigerators offer a sustainable, long term alternative that
combats energy shortages and global warming.
1.Fridgeismadeupoftwocylinders
-oneinsidetheother-andisnot
connectedtoanypowersource.
Outercylinderismadeofanysolid
materialwithholesdrilledinthe
sides.
2.Innercylinderismadeofmetal
andhasnoholestoensurecontents
remaindry.
3.Thegapbetweentheinnerand
outercylinderisflledwithamaterial
suchassand,woolorsoil,thatcanbe
soakedwithwater.
4.Inhotweatherthesunsraysheat
thiswetmaterialandthewater
evaporatesoff.Asthematerialisheld
againsttheinnercylinderwall,heat
isremovedfromtheinnerchamber
bytheevaporationprocess,keeping
itatacooltemperatureof6C.
5.Resoakingmaterialwithfreshwater
willkeepthefridgeworking.
solarrefrigeration
solarrefrigeration
Industrial Insulation Systems (IIS) has
developed a solar-powered fridge/
freezer that can be tailored to meet
the needs of off-the-grid scenarios. The
custom made-to-order IIS solution will
maintain temperatures as cold as -20C
for at least 24 hours between charges.
This is according to the companys Jason
Luedtke, who stresses that with the (up
to) 400amp hour battery capacity and
the solar panels working in harmony as
well as regular exposure to sunlight, users
should be able to go completely off-grid
indefinitely.
Our initial goal was to create a unit
that would maintain the power source
to the fridge/freezer for three full days
with no sun exposure, says Luedtke.
Our prototype testing proved that the
unit maintained adequate power to hold
temperature for nine days, before we
drifted out of proper temperature range.
We considered this a success but each
unit (based on size and therefore power
draw) and ambient temperature will
have slightly varying results. Ambient
temperature during the above-mentioned
test was 25C on average.
The batteries are a crucial element
- even during consistent full sun. Both
elements must work in a regulated
balance for the system to be nearly
perpetual, he states.
If you already have your own low-
voltage (DC) fridge and would rather not
pay extra cash for a new one, then you
can just buy the solar kit and fit it to the
fridge, says Luedtke.
He explains that the solar panel
canopy works in balance with batteries to
make sure that the chosen unit doesnt
run out of power. If you want your fridge
kept out of the sun then youll need extra
long cables to link it up with the solar
canopy, which can then be optimally
placed to get the most direct sunlight.
You might need extra storage space on
your trolley if you intend to use your unit
for street vending. You may also need
some air conditioning outlets.
Alternatively, users can pick the
model of fridge/freezer from our range,
tell us how to mount it, then how to
power it, and well customise it to fit their
optimal needs, Luedtke concludes.
Formoreinformation,visitwww.iis-inc.com
oremail:[email protected]
DC
-powered
freezers
Portable, durable and adaptable, Cold Chain DC-powered
freezers are ideal for remote storage of food and
beverages, especially for vendors who have access to DC
power and a commonly available adapter.
This is according to the companys Robert Spence,
who says the Solar Power System is designed to work
in conjunction with any of the Cold Chain DC Freezers.
Users can choose the right features for their unique
needs. For instance, if you are looking to be completely
self-contained you can choose a trolley system. If you want
to be mobile, add casters or you can include a traditional
AC plug if you need to run a cash register or hot plate.
Spence adds that the Cold Chain Solar Power
System gives users omplete off-the-grid flexibility, while
maintaining temperatures as cold as -20C.
ColdChainLLC:www.coldchainllc.com
Customisedfridge/freezer
If you know anyone in the industry who
could use the news and information
supplied by FoodProcessingAfrica digital
magazine, send us their details and with
their consent, we will gladly add them to
our distribution list at no cost.
WHO COULD USE OUR NEWS?
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24|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
solarrefrigeration
S
orin Grama, CEO of Promethean
Power Systems, explains that
dairies located in large cities
have the need and the buying power
to purchase refrigeration units for
preserving milk at collection points
located in remote farming villages. Cold
storage at the village level minimises the
number of collection trips and reduces
transportation costs by 50%, says Gama.
However, the only option
available was to use commercial
refrigerators with diesel-
powered backup generators, a
no-win situation that further
exposed dairies to escalating
energy costs.
In April 2010, when Boston-
based Grama and Sam White set
up their Solar Hybrid Milk Chiller
- which runs partly on solar
energy and partly on electricity
- as a pilot project in Savoiverem
near Goa in southern India, they
were not sure how successful
it would be. In just one month,
though, the system significantly
boosted the milk supply in the
village - where electricity is not
regularly available - and reduced
losses due to bacterial spoilage.
White explains that a
detailed study of the milk
collection process resulted in
a system tailored to suit the
requirements of this village. Farmers
milked the cows or buffaloes and brought
the milk to the village collection centre.
After measuring the quantity and the fat
content, the milk was transported to the
chilling centre, where it was cooled before
being pumped from the chiller to tankers
to be taken to the dairy plant.
We observed that there were many
small farmers with just one or two cows
or buffaloes. Everyday, they used to bring
one to two litres to the collection centres
that were very far from their villages. The
time taken to cover the distance used to
result in milk spoilage, he says.
The duo addressed this problem
by installing the milk chiller midway
between the villages and the collection
centre. The result was like a milk
revolution - an individuals supply of milk
to dairies increased two-fold and more,
says White.
The Solar Hybrid Milk Chiller, which
has a capacity of 500 litres and can store
milk for up to 48 hours, is divided into
two parts - a slow cooler and a fast cooler.
While the fast cooler chills the milk from
33C to 10C in less than a minute, it then
takes three hours to chill from 10C to
4C in the slow cooler. The fast cooling
is the result of a special heat exchanger
through which the milk is passed, chilling
it in the process.
The milk chiller also keeps track
of information such as the total milk
collected, payment due to farmers and
so on. The temperature is constantly
monitored by a machine with a battery
that runs on solar power. Since we use
solar energy, we eliminate the cost of
diesel generators that are generally used
in refrigeration systems. And as we scale
up, we will lower the capital cost and
the next unit will be an improvement
over the previous one, says Rajat Gupta,
Promethean Power Systems India
operations general manager.
Grama adds that the chiller unit is
66% less expensive to run than other
refrigerators and is intended to be a
complete, stand-alone rural
refrigeration system that
stimulates businesses, reduces
dependency on fossil fuels and
increases the quality of life in
emerging markets by enabling
its users to reliably store food,
vaccines and other perishable
items.
Promethean Power Systems
is currently in the process
of developing and testing a
modular thermal energy battery
that can be used as a backup to
the unreliable power grid.
Grama, says: In India, we
charge the battery using the
five or six hours of available
electricity, usually at night, and
discharge it when the grid is off
in order to cool and preserve raw
milk. Promethean, however,
envisions developing a battery
that can be used for any cooling
application. Our vision is to
enable customers to connect multiple
batteries together to store energy as
needed, in order to make the thermal
energy battery a technology platform
that allows third-party manufacturers
to develop attachments such as vaccine
or beverage coolers, he states. While
our thermal battery acts like an electrical
battery, it supplies a stream of cold fluid
rather than an electrical current. This fluid
is then be used to chill food products,
such as milk, down to 4C.
Formoreinformation,visit
www.coolectrica.comor
email:[email protected]
Hybrid milk chiller
An extensive market and human factor study revealed a large
business opportunity in India for an efficient cold storage
solution targeted at the dairy industry.
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|25
There are three types of
solar fridges: ones that
use batteries and solar
panels, ones that use just
solar panels, and ones that
use neither batteries nor
panels and are constructed
from household materials.
1. A solar fridge that
uses batteries actually
uses a combination
of solar panels and
lead batteries - the
batteries serve as back
up overnight and on
sunless days. While it
can be effective, this
type of solar fridge has
many disadvantages.
For instance, it is
expensive to buy
and the batteries are
heavy and deteriorate
quickly in hot climates.
It is maintenance-
intensive and only lasts
about three years. The
batteries also need to
be disposed of properly,
otherwise they leak and
cause lead pollution.
2. Solar-powered
refrigerators that
generate electricity
with the help of solar
panels, then use this
electricity like a normal
plug-in refrigerator.
Although this type of
refrigerator is powered
by solar energy, it is not
100% eco-friendly as the
cooling gases that are
used in the refrigerator
and the ones generated
due to cooling,
contribute to global
warming and depletion
of the ozone layer.
3. Solar-powered fridges
that dont require
batteries or solar
panels are better
suited to developing
countries, as they can
be made from basic
household materials.
Although these fridges
are technically solar-
powered, they rely on
conduction, convection
and evaporation to
operate at an even 6C.
These refrigerators
work according to
atmospheric temperatures
- the drop and rise in the
heat of the sun directly
affects the rate of cooling.
The greater the heat of
the sun, the lower the
temperature will be in the
inner cylinder.
Many scientists
predict that solar-powered
refrigerators will totally
replace all electricity-
powered refrigerators as
the most energy-efficient
refrigerators.
Solar fridge types
solarrefrigeration
PAGE 25
NW UNIVERSITY/EXTRU
AFRICA
Training Seminar & Conference Week on Food, Feed and
Pet Food Extrusion
31 July 3 August 2012
Protea Hotel Kruger Gate | Mpumalanga | South Africa
Contact:
[email protected] | +27 (0) 18 299 1330
www.extruafrica.org.za
Media Partners:
26|MAY2012|FOODPROCESSINGAFRICA www.foodprocessingafrica.com
SouthAfrica
MabeleFuels$216.9mbioethanolplantinBothaville
Pending promulgation of the proposed mandatory bioethanol
blending regulations in South Africa, construction of Mabele Fuels
153m litres per annum fuel-grade bioethanol plant in Bothaville,
Free State is set to start in June, and is expected to take 24 months.
This is according to Phillip Bouwer, executive director of
Mabele Fuels, who says: We will need about 400,000t of grain
sorghum to meet a 2% annual blending rate. All indications are
that government will announce the compulsory inclusion of at
least 2% bioethanol in fuel before the end of May.
Bouwer says that Vogelbusch GmbH, a leading Austrian
bioethanol process design company - which has designed over
30 similar grain-based plants - has been subcontracted to the
project to provide the technology designing package and quality
warranty for the ethanol production line, documentation,
specifications, as well as the operating licence. Vogelbusch
will be responsible for proprietary equipment supply for the
distillation and dehydration systems and technical assistance
during procurement, manufacturing, and acceptance of
equipment. It will also supervise the installation, pre-
commissioning, commissioning and field training for the project.
Bouwer describes Mabele Fuels as a unique co-operation
between historically-disadvantaged individuals and specialists in
the clean energy market. After the exclusion of the use of maize
for ethanol production in the Biofuels Industrial Strategy in 2007,
our shareholders, Sterling Waterford Holdings and Mvelaphanda,
specifically chose grain sorghum to meet the requirements of the
strategy and because of its potential to promote commercially-
successful emerging farmers, he states. Grain sorghum is
indigenous to South Africa and can
prosper on marginal land with soil
that is low in potential, shallow, and
has reasonably-high clay content.
According to the Department of
Agriculture, the Free State is South
Africas largest sorghum-producing
area, producing on average 52% of
the total domestic crop. We have
undertaken a detailed area analysis
and are implementing an emerging-
farmer development programme
in conjunction with our primary
procurement partners.
Bouwer explains that there is
an added advantage to using grain
sorghum as feedstock - the dried distillers grain and solubles
(DDGS), a by-product of bioethanol production, has about three
times the protein content and the same energy levels as the
original feedstock. Consequently, it receives a price in the US and
European animal feeds market of between 0.8 and 1.2 times
that of maize. South Africas animal feed market comprises
approximately 7.3m tons per annum. We anticipate that DDGS
will replace yellow maize in this feed market, and that the
market is capable of absorbing our entire production capacity
of 107,000t/annum. We have already entered into proposed off-
take agreements for the sale of the DDGS to national animal feed
producers, he states.
MabeleFuels:Tel+27(0)214184490;www.mabelefuels.com
Mozambique
Japantofinancenewfishmarket
The Japanese International Co-operation Agency (JICA) is to
provide $11.6m for the construction of a new fish market in the
neighbourhood of Triunfo, along the Maputo coast road.
The future market, covering an area of two hectares, will
contain stalls for the sale of fish and shellfish, an ice-making
plant, a unit for processing and conserving fisheries produce, and
an administrative office - as well as an area for the restaurants
that are one of the main attractions of the current fish market.
Maputo City Council is responsible for the project, in
partnership with JICA, and anticipates that the new market will
become operational in 2013. -MozambiqueNewsAgency
Rwanda
S10mcassavaprocessingplant
A $10m cassava processing plant set up by the Rwanda
Development Bank (BRD) in Kinazi sector, Ruhango district, is due
to produce and sell its first batch of products in late May.
Jack Nkusi Kayonga, BRDs CEO says that the bank plans to
allow farmers to acquire shares and ultimately enable them
to own and manage the plant themselves. The factory has an
installed capacity of 20t of flour per day, and will require a daily
supply of 60t of cassava to achieve full capacity.
Kayonga says that the bank is working with farmers in the
leading cassava-producing districts of Ruhango, Muhanga,
Gisagara and Kamonyi to ensure adequate supply.
BRD official, Philibert Mbanje, adds that the bank has already
given loans to more than 20 farmers to grow quality cassava, and
that the formation and strengthening of cassava-producer co-
operatives is also being prioritised, in order to ensure enough raw
materials and provide local farmers with the ability to maximise
their profits from the new facility.
As the plant is set up in a remote area near Akanyaru
river - over 30km from Ruhango town - road construction and
rehabilitation is another priority to be undertaken in the next
few months, in order to facilitate transport.
Apart from flour production, the remaining waste will be
treated and turned into fertilizer and animal feed, says Robert
Runazi, general manager of the plant.
-RwandaFocus
projects
projects
www.foodprocessingafrica.com FOODPROCESSINGAFRICA|MAY2012|27
Rwanda
Newbeanvarietylaunched
Harvest Plus, a leader in breeding and dissemination of
micronutrient-rich staple food crops, has introduced a new Iron
Bean seed in the country, which it will distribute in collaboration
with the Rwanda Agriculture Board (RAB).
According to Harvest Plus country representative, Tiwirai
Lister Katsvairo, the new bean will help fight and reduce hunger
among malnourished residents in Rwanda. The new seed is
being distributed across Nyagatare and Gatsibo in the Eastern
Province, and other parts of the country.
Josephine Mukakigeri, an agriculture researcher at RAB, says:
The seed is a new hybrid in the bean sector. First of all, it is
nutritious, a staple food, grows in the shortest period of time and
has good harvests. Secondly, we sell a kilo of beans at Rwf 500
($0.84) to farmers and in return buy all their produce at harvest.
This is a fixed market that farmers should exploit.
-TheNewTimes
Kenya
Sh400mforavocadoprojectinMuranga
CEO Gary Hannan says that Alivando has engaged 1,030 farmers
in quality production of the avocados and has started a pilot
factory in Muranga to boost production.
Hannan explains that central Kenya is better placed to
produce high-quality avocado products, as this area has the
potential to produce avocados with a high concentration of oil
and wax.
He adds that Kenya could be producing 0.3m litres of high-
quality avocado oil for export and local consumption in five years
time, if farmers embrace the practice. -NairobiStar
Ethiopia
Winerybeginsbottling
Castel Winery Plc, a sister company
of BGI Ethiopia, recently began
producing wine in the environs of
Batu Town in Oromia State, 163km
south of Addis Ababa.
Winery manager, Fetehanegest
Aynalem, says that the winery
built at a cost of 300m Birr
($17.2m), will export over a million
bottles of wine abroad, and that
the winery and the vineyard have
created more than 900 new jobs.
According to Fetehanegest,
Castel has been cultivating
varieties such as Syrah, Merlot,
Cabernet Sauvignon and
Chardonnay since May 2008. -
EthiopianNewsAgency
Nigeria
ProvitaminAfortifiedcassava
Nigeria has produced a pro vitamin A (beta carotene rich)
fortified cassava, which is more nutritious than existing varieties.
This is according to Dr Akinwumi Adesina, Minister of Agriculture
and Rural Development, who adds that the production of the
improved varieties has placed Nigeria on the global map in terms
of research on micronutrient (vitamin A, iron, zinc and iodine)
improvement in staple foods.
Adesina says: The federal governments focus is to create
new markets for cassava, including high-quality cassava
flour to be used in replacing some of the wheat flour being
imported to produce bread; high fructose cassava syrup to
replace the 200,000t of sugar currently being used in the juice
manufacturing industry; dried cassava chips; and the production
of ethanol.
Our goal is to add another 17m tons of cassava to
our domestic food supply of 34m tons. The Agricultural
Transformation Action Plan hopes to create 1.3m jobs across the
cassava value chains, but producing more food is not enough;
we must also ensure that there is enhanced food nutrition and
health.
Acting executive director of the National Root Crops Research
Institute (NRCRI), Dr Thomas Ezulike, expressed confidence in the
ability of NRCRI to continue to improve crops, both nutritionally
and in resistance and adaptation to changing climatic conditions.
NRCRI has transformed into a leading research centre of
excellence for root and tuber crops, and has blazed
the trail of biotechnology through the establishment
of a culture tissue laboratory; molecular breeding
of root crops; confined field trials of genetically
modified crops, and recently bio-fortification of
staple crops, he stated. -DailyTrust
Morocco
Invests$1.18minmeatindustrytraining
The Moroccan employment and training industry
has teamed up with the countrys top processor
Koutoubia Holdings to train 3,000 young people
to work in the meat slaughtering and processing
industry by 2016.
The project, costing a total of MAD10m ($1.18m),
aims to guarantee a job to young people at a time
when school drop-out rates are peaking, and to
secure qualified staff for the meat processing
industry.
In the first phase of the programme, Koutoubias
Training Centre in Mohammedia - which has a
capacity of 1,200 students - will be used, but the
government plans to open two more training
facilities in Bouskoura and Settat by 2016.
Four courses will be offered to students, and Koutoubia
employees will also have the option to get a diploma validating
their experience, allowing non-trained staff to get recognition
outside the company. -GlobalMeatNews.com
projects
projects