Challenges & Opportunitiesto produce Super Cereal Plus (CSB++)

Bertrand Salvignol – Head Food Safety & Quality Unit – WFPIFADC - Kansas City – May 8, 2012

Super Cereal Plus (SC+)

New brandingDifferent target / programme

‘New flavour’ New formula

New packagingNew process / factories

Nutritional values, …

Parameters Values SC+ Values SC

Protein (% min)Vegetable 13.50% 14.00%

Animal 2.50% -

Fat (% min) 9.00 % 6.00%

Fibre (% max) 2.00% 5.00%

Moisture (% max) 7.00% 10.00%

Microbiology X 10 stricter

Aflatoxin 5 ppb 20 ppb

Bostwick (mm/30 sec (45◦C) 100 mm (50g/250g water)90 Kcal / 100 ml porridge

55 mm (40g/250g water)60 Kcal / 100 ml porridge

New formulaIngredients (in %) Super Cereal Plus (SC+) Super Cereal (SC)

Corn 58.24 78.24

Soybean (de-hulled) 20.00 20.00

Soybean oil 3.00

Dry Skim Milk 8.00

Sugar 9.00

Vitamin/Mineral mix 0.20 0.20

Ca(H2PO4)2.H2O 0.80 0.80

KCl 0.76 0.76

Micronutrients composition:-Under review to match the latest ‘WHO’s guidance’-KCl will be decreased based on acceptability studies carried out in Burkina & Cambodia (WFP / DSM Ltd.)-Ca++ in dicalcium phosphate to rebalance Ca/P (ratio: 1 – 1.5)

New packaging

Protection of the product•N2 flushing / AO in oil•Vacuum packing•Improved barrier (O2, H2O, Vapour, …)•Low Moisture Content•Shelflife studies (on-going)

Easier usage•Smaller quantity / one week ration•Instructions (drawings)

Legal requirements•Composition, producer, BUBD, etc.

New process

mixed & milled

Wet extrusion

Oil injection

Drying MixingPre-Conditioning

Sugar Vit & Min

Packaging

Maize De-hulledsoybean

Milk

Milling

WFP’s requirements

• Supplier’s assessment • Specific process – Wet extrusion (or twin-screw extrusion, drum dryer)– Control of fortification (coefficient of variation)

• Improved Quality Assurance– Traceability– ISO 22000 type– Shelf-life study (under discussion)

• Production capacity: > 2,000 MT/month

Suppliers & WFP’s involvement• Investment– US$ 2 Million: 3 MT/h capacity– US$ 2.9 Million: 6 MT/h (extruder), 4.5 MT/h (packaging)

• Machinery– Buhler, Wenger, Clextral, Setrem, etc.

• Timing– 2 years from the acceptance of the idea

• Support from WFP– (process, building set up), formulation, trial runs, on-

line checks, analysis in lab, quality …

Shelf life & Stability studies (I)

• Risks: microbiology, oxidation, nutritional value, packaging, palatability, …

• Partners: Kemin Industry / DSM • How: accelerated & real-time (oven & field)• Conditions:

Incubator W/H in Africa

Temperature (°C) 40 20 – 50

Humidity (%) 75 20 – 80

Day/Night variation No Yes

Conditions Lab Field/Thermo tracers

Stability studies (II)• Duration: 24 months• Where: Niger, Chad, DRC• Parameters: PV, FFA, Hexanal, Tocopherol,

Ascorbyl Palmitate, Oxygen bomb, Aw, Microbiology, Composition, Moisture Content, Vitamin A & C, residual O2, …

• Figures: – 358 samples– 2 dedicated staffs (WFP+Kemin) + field focal points– Estimated cost: about US$ 45,000 (excl. staff)

Conclusion• Market: from nothing in 2010 to

…– Jan-July 2012: 30,000 MT

• It is feasible:• It requires some involvements

from – Suppliers (investment, engagement)– WFP Procurement / Programme

(commitments)– WFP Food Technologists (technical

assistance: to ensure suppliers are confident in the product)