Challenges Opportunities to produce Super Cereal Plus CSB

Challenges & Opportunities to produce Super Cereal Plus (CSB++) Bertrand Salvignol – Head Food Safety & Quality Unit – WFP IFADC - Kansas City – May 8, 2012

Super Cereal Plus (SC+) New branding Different target / programme ‘New flavour’ New formula New packaging New process / factories

Nutritional values, … Parameters Values SC+ Values SC 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% Protein (% min) Microbiology Aflatoxin Bostwick (mm/30 sec (45◦C) X 10 stricter 5 ppb 20 ppb 100 mm (50 g/250 g water) 55 mm (40 g/250 g water) 90 Kcal / 100 ml porridge 60 Kcal / 100 ml porridge

New formula Ingredients (in %) Super Cereal Plus (SC+) Super Cereal (SC) Corn 58. 24 78. 24 Soybean (de-hulled) 20. 00 Soybean oil 3. 00 Dry Skim Milk 8. 00 Sugar 9. 00 Vitamin/Mineral mix 0. 20 Ca(H 2 PO 4)2. H 2 O 0. 80 KCl 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 • N 2 flushing / AO in oil • Vacuum packing • Improved barrier (O 2, H 2 O, Vapour, …) • Low Moisture Content • Shelflife studies (on-going) Easier usage • Smaller quantity / one week ration • Instructions (drawings) Legal requirements • Composition, producer, BUBD, etc.

New process Maize De-hulled soybean Milk Sugar Vit & Min mixed & milled Pre-Conditioning Oil injection Wet extrusion Drying Milling Mixing Packaging

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, online 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 O 2, … • 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)