(p 1) iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2 nd 97 Very low cost...
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Transcript of (p 1) iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2 nd 97 Very low cost...
(p 1)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
Very low cost extruders (VLEC)for small scale production of food and feeds
D. Bounie, E. Van HeckeUSTL (Université des Sciences et Technologies de Lille)
IAAL (Institut Agricole et Alimentaire)Bâtiment C6
59655 Villeneuve d’Ascq Cedex - FranceTel : +33 (0)3 20.43.49.21, Fax : +33 (0)3 20.43.44.86E-Mail : [email protected], [email protected]
Smart Extrusion Workshop, Sydney2 december 1997
(p 2)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
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 Namdestruction 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
(p 3)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
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 Namdestruction 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
(p 4)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
ENERGY DENSITY OF BABY FOODS
Energy requirementsfor a 65 months child
765 kcal / day
Breast feeding520 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! !
(p 5)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
ENERGY DENSITY OF BABY FOODSInfluence of dry matter content on viscosity
Viscosity(Pa.s)
15 20 25 30 35
dry matter (g) / 100 ml
10
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.)
1.6
traditionalhome treatment
30
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
(p 6)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
PROCESSING OF PRECOOKED BLENDED FLOURwith alternatives for supplementation with vitamin/mineral mix
Grinding
Drumdrying
Mixing+ cooking
VMS
Precooked flour
Grinding
Roasting
Mixing
VMS
Extrusion cooking
Mixing
VMS
VMS
Milling
(Vitamin/mineralsupplement)
(p 7)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
Full fat soya seedsWhole corn
seedsRice Mung beans Sesame Salt
VIETNAMESE BABY FOOD : FLOWSHEETVIETNAMESE BABY FOOD : FLOWSHEET
2 - Dehulling
3 - Winnowing
Dehulled soya seeds
1 - Drying
Hulls
Wheighing
Dehulling
Dehulled mung beans
Hulls
Winnowing
4 - Mixing
5 - Extrusion cooking
6 - Cooling / drying
7 - Milling
8 - Mixing
9 - Bagging
Other ingredients :dried meat powder, mushrooms, carrots, yeast, malt
(p 8)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
TRADITIONAL VIETNAMESE FOOD
Cereals and legums,eggs,mushrooms and spices ...
fruits ...
dried fishes ...
(p 9)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :Raw materials
Soya
Rice
Corn
Sesame
Salt
(p 10)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :Process
1 - Preconditioning of soya :moisturizing + drying
2 - Dehulling of soya
(p 11)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :Process
3 - Winnowing of soya
4 - Mixing of ingredients
Coarse premix
(p 12)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :Process
Extrusion-cooker
5 - Extrusion cooking
Barrel and screw Starved and choked screw
Die outlet
(p 13)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :Process
6 - Cooling / drying
7 - Milling
(p 14)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
8 - Post mixing withmineral/vitamins premix
WEANING FOOD :Process
9 - Bagging
(p 15)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
WEANING FOOD :End product
(p 16)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
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 Namdestruction 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
(p 17)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
REFUGEE CAMPSIN GREAT LAKES REGION
South Kivu (ex-Zaïre)
Rwanda
(p 18)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
SEVERE MALNUTRITIONIN REFUGEE CAMPS
Marasmus Kwashiorkor
(p 19)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
STORAGE AND GENERAL DISTRIBUTION
OF RELIEF FOOD
(p 20)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
GENERAL DISTRIBUTION
(p 21)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
INDIVIDUAL RATION& FAMILY COOKING
Individual weekly ration (1200 kcal/day)
Corn250 g
Beans50 g
Oil15 g
Salt15 g
(p 22)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
Area ofmanual mixing
Cleaner
Dustremoval
Stocks of raw materials
Dustremoval
Hammer mills
Belt conveyor
Fan
Screwconveyor
Extrusion cooker
Cutter
Hammer millBatchmixer(500 Kg)
Continuousmixer
Conveyor
Bagging and sewing
Stocks ofend-products
Screw orpneumaticelevator
Scewconveyor
Workshop
Batchmixer(500 Kg)
CENTRALIZED PRODUCTIONOF RELIEF BLENDED FLOURS ( > 20 MT/day - Kenya)
(p 23)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
MillScrew conveyor
Mixer
Screwelevator
Feedingbin
Screw extractor
Extrusioncooker
Cutter
Screw conveyor
Fan
Fan
Mill
Pneumatic conveyor
Deliverybin
Horizontalbatchmixer
Cleaning
Wheighing
Wastes
Stocks(raw materials)
Stocks(raw materials)
Stocks(end products)
Water
Warehouse(CMV, sugar,salt
spare parts)
Packaging+ sewing
Office
OfficeTrucks unloading
Electricalcabinet
Wheighing
Stocks(raw materials)
Stocks(end products)
Electricalstation
Toilets +bathroom
CENTRALIZED PRODUCTIONOF RELIEF BLENDED FLOURS ( > 5 MT/day - Kenya)
(p 24)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
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 Namdestruction 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
(p 25)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
CAPITAL COST REQUIREMENTFOR A 0.5 MT/HR LEC WEANING FOOD FACTORY
(Harper, 1995)
Land (2 ha)
Site preparationelectricalwater/sewerroadsbuilding (450 m2)bulk grain storage handling
Machinerycleaning/dehulling moduleprocessing moduleblending modulepackaging module (manual)ancillary machineryspare parts @ 10%crate, insurance, freight @ 20%contingency @ 10%
Engineering, installation,management training
Cost subtotal(machinery & installation)
VAT (14%) on investmentexpense
Cost total
252015
60112
634957346834
51
60
354102
341
136
156
168
Item sub-total
Cost (US$x103)
1,200
1,368
Total
Expected costfor VLEC :11,000 US$
(p 26)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
TYPICAL MANUFACTURING COSTSFOR 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
ElectricityOther utilitiesMaintenanceSpare partsTranportMisc.
Subtotal
VAT @ 14%
Total
Categorycomponent
White maizeSoya beansVitaminsMineralsPoly bagsMaster bags
ManagerQC technicianSupervisorMech./Elec.OperatorsLabourersClericalAccountantPackers
Equipm. (10 yr)Building (40 yr)
Dailyrequirement(A)
2.651.1412.0 kg31.2 kg48,000480
123212124160
7,200 kW-hr
1,200 MT/km
Unit costUS$(B)
136.2/MT282/MT75/kg50/kg22/1,000480/1,000
49/shift31.3/shift43.6/shift21.8/shift4.1/shift1.4/shift2.7/shift19.1/shift1.4/shift
179.8/day49/day
0.05/kW-hr21.8/day13.6/day65.4/day0.3/MT-km409/day
Totaldailycosts (US$)(C= AxB)
1327117924542528863
4963131444917111982
18049
334221427332409
Specificcost(US$/MT)(D=C/12)
110.598.220.435.424.05.2
4.15.210.93.64.11.40.91.66.8
15.04.1
27.81.81.15.427.334.1
449or US$ 0.45
62.9
512or US$ 0.51
(p 27)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
LOW COST EXTRUDERS FOR DRY EXTRUSION
• Almex (Netherlands)• Anderson (USA)• Brady Corp. (USA)• Croix (France)• France Extrusion (France)• Insta-Pro (U.K.)• Millbank (New Zealand)• Setrem Inotec (France)
Main manufacturers
Equipment
Anderson 4,5Anderson 8Anderson 12
Brady 206
Croix T 95
Insta-Pro 500Insta-Pro 2000RInsta-Pro 2500
Millbank 500Millbank 1000
Setrem S50Setrem X125
Power
(kW)
1956-93186-373
74.5
22
375590
3555
3790
Heating
Autogenous (+steam)Autogenous (+steam)Autogenous (+steam)
Autogenous
Autogenous
AutogenousAutogenousAutogenous
AutogenousAutogenous
Autogenous (+steam)Autogenous (+steam)
Output
(kg/hr)
2501,00010,000
340-450
200-300
200-300590-910900-1,350
350750
200-500500-1,500
Screwdiameter
(mm)
114203305
95
95138
L/Dratio
121212
88
Screwspeed
(RPM)
280360360
900-1000
550550550
550550
Moisturecontentduringextrusion(%)
< 18 %(> 20 % with steam)
20 % max
> 14 %> 14 %> 14 %
Temperaturecontentduringextrusion(°C)
205 ° max205° max205° max
140 (soja)170 (cereals)
130-170
150-170 (cereals)135-145 (soya)
150150
Principal technical specifications
(p 28)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
V.L.E.C. AT UNIVERSITY OF LILLE
(p 29)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
TECHNICAL SPECIFICATIONS
• 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 $)
BARREL AND SCREW (L/D = 3.25)
Barrel with helicoidalor longitudinal grooves Screw Clamping ring
A B C
D = 24 mm
D = 40 mm
L = 130 mm
Die plate
D
Head space(adjustable die clearance)
(p 30)iaal D. Bounie, E. Van Hecke : Very low cost extruders - Sydney, dec. 2nd 97
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