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    September 29 Webinar Slides PDF

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    Wunkey Wunkru
    The document discusses packaging techniques that can improve the shelf life of soy foods produced by small-scale soy dairies in Ghana and Mozambique supported by the Soybean Innovation Lab, noting that current packaging methods include plastic and glass bottles that are filled by hand, with shelf lives ranging from 24 hours to over 3 months depending on the packaging and preservation method used. Research presented found that a mechanized pasteurization and bottling system would be impractical and too expensive for the small scale of these soy dairy operations.

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    September 29 Webinar Slides PDF

    Uploaded by

    Wunkey Wunkru
    97 views19 pages
    The document discusses packaging techniques that can improve the shelf life of soy foods produced by small-scale soy dairies in Ghana and Mozambique supported by the Soybean Innovation Lab, noting that current packaging methods include plastic and glass bottles that are filled by hand, with shelf lives ranging from 24 hours to over 3 months depending on the packaging and preservation method used. Research presented found that a mechanized pasteurization and bottling system would be impractical and too expensive for the small scale of these soy dairy operations.

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    The document discusses packaging techniques that can improve the shelf life of soy foods produced by small-scale soy dairies in Ghana and Mozambique supported by the Soybean Innovation Lab, noting that current packaging methods include plastic and glass bottles that are filled by hand, with shelf lives ranging from 24 hours to over 3 months depending on the packaging and preservation method used. Research presented found that a mechanized pasteurization and bottling system would be impractical and too expensive for the small scale of these soy dairy operations.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    97 views19 pages

    September 29 Webinar Slides PDF

    Uploaded by

    Wunkey Wunkru
    The document discusses packaging techniques that can improve the shelf life of soy foods produced by small-scale soy dairies in Ghana and Mozambique supported by the Soybean Innovation Lab, noting that current packaging methods include plastic and glass bottles that are filled by hand, with shelf lives ranging from 24 hours to over 3 months depending on the packaging and preservation method used. Research presented found that a mechanized pasteurization and bottling system would be impractical and too expensive for the small scale of these soy dairy operations.

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    PACKAGING TECHNIQUES

    TO IMPROVE SOY FOOD


    SHELF LIFE
    Presented by:
    USAID Feed the Future Innovation Lab for Soybean Value Chain Research
    Webinar Agenda
    11am: Introductory Remarks by Maggie Cornelius, SIL Human Nutrition Program Manager
    11:10: Overview of Preservation and Packaging Options for Soy Dairies by Hart Jansson, Vice President of
    Malnutrition Matters
    11:15: SIL Soy Dairy Entrepreneur Flora Amagloh in Tamale, Ghana
    11:20: SIL Soy Diary Entrepreneur Frank Peget in Accra, Ghana
    11:25: SIL Soy Dairy Entrepreneur Dr. Joseph Osei in Agona, Ghana
    11:30: SIL Soy Dairy Entrepreneur Edison Rwodzi in Namaacha, Mozambique
    11:35: SIL Soy Dairy Entrepreneur Dr. Asa Maria Tham in Mocuba, Mozambique
    11:40: Lucas Mujuju, Managing Director of So Soja in Chimoio, Mozambique
    11:45: Presentation of SIL research on mechanized bottling systems and
    price analyses of packaging methods
    11:50: Q & A
    12:00pm: Conclusion
    Soybean Innovation Lab
    Soy Dairy Entrepreneur Network
    • SIL funded the installation of 5 soy dairies in Ghana and Mozambique.
    • Network was founded in 2015

    • Soy Dairy Entrepreneurs produce soy milk, soy yogurt, tofu, and okara.
    • Sell their products to schools, hospitals, groceries, and on-site.
    • Also administer local nutrition trainings

    • The Entrepreneurs collect data on their operation costs and production rates.

    • SIL provides technical support for each dairy.


    • Resources for improving operation, increasing production,
    and developing business plans
    Soy Dairy Entrepreneur Network Services
    • Webinars and Networking • Capacity Building
    • On-site technical training • Soy Cooking and Utilization Training
    • New Product Development • Access to Credit
    • Packaging Designs • Storage Designs
    • Branding and Marketing Plans • Integration into School Feeding
    Programs
    • Food Labeling and Certification
    • Other Institution Feed Programs
    • Food Safety and Sanitation Training
    • Business Development
    State of Packaging Among SIL Soy Dairies
    • Plastic and glass bottles are used
    • Cans and plastic bags have also been tried, but entrepreneurs settled on bottles.

    • All bottling is done by hand


    • But entrepreneurs use a variety of bottling methods.
    • SIL research demonstrates the impracticality of a mechanized full pasteurization/bottling
    system.

    • Ice chests filled with ice/ice packs are a popular method for transporting soy food.
    • Attached to bicycles or put in cars

    • Shelf life ranges from 24 hours to 3+ months.


    • Some entrepreneurs’ milk can only be refrigerated.
    • Others can keep their milk on a shelf.
    Speaking: Hart Jansson
    Vice President of Malnutrition Matters
    Preservation and Packaging
    for Small-Scale Soy Dairy
    Preservation Technique Overview

    1) Bulk Milk Distribution & Consumer Vessel Use


    2) Plastic Bag Filling and Cooling
    3) Plastic Bottle Filling and Cooling
    4) “Hot Filling” Glass or Plastic Bottles and Jars
    5) Pasteurization (Partial Sterilization)
    6) Sterilization for Long Life Without Refrigeration
    Speaking: Flora Amagloh
    Managing Director of Soy Plus Natural Soymilk
    Savannah Agricultural Research Institute, Tamale, Ghana

    http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif Photo Credits: Flora Amagloh and Krystal Montesdeoca


    Speaking: Frank Peget
    SIL Soy Dairy Managing Assistant of En Soy Milk
    CSIR-Food Research Institute in Accra, Ghana

    http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif Photo Credits: Frank Peget and Dr. Marilyn Nash


    Speaking: Professor Joseph Kwame Osei
    Managing Director of AA Pure Soya Milk
    Agona Ashanti, Ghana

    http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif

    Photo Credits: Dr. Joseph Osei


    Speaking: Edison Rwodzi
    Plant Manager of Associaçao Pala Wassokot
    Namaacha, Mozambique

    Image Credit: http://www.bizbilla.com/country-maps/maps/mozambique-map.jpg Photo Credits: Edison Rwodzi and Dr. Marilyn Nash
    Speaking: Dr. Asa Maria Tham
    Managing Director of Winnua Ltd.
    Mocuba, Mozambique

    Photo Credits: Dr. Marilyn Nash and Krystal Montesdeoca


    Drawbacks of a mechanized
    full pasteurization & bottle system
    Research conducted by SIL in Mozambique shows that these systems are impractical
    for the following reasons:

    1) process control and assuring food safety along the cold chain would be difficult;
    2) costs of filling equipment and bottles would be expensive
    3) maintenance of equipment would be difficult and parts availability would be limited
    4) a full ultra-high temperature system would be cost prohibitive given the scale and
    price point for soy foods. This is a barrier to producing soy foods that are acceptable,
    affordable, and nutritious to low income populations.
    SIL Soy Dairy Packaging Costs
    • Packaging is a large expense for a small-scale soy dairy.
    • Packaging Costs range from 20-50% of operation costs
    SIL Soy Dairy in Mozambique: Components of Production Costs: Month 1

    capital depreciation
    transportation
    16%
    21%
    working capital
    other inputs
    2%
    4%
    personnel
    5%

    ingredients
    12%

    packaging
    40%
    Packing Materials used by
    SIL Soy Dairies and their costs
    • Material costs vary by location, urban v. rural, etc.
    • Glass Bottles are more expensive than plastic bottles

    Northern Ghana Northern Ghana Accra, Ghana Southern


    Mozambique

    Type of packaging Recycled glass bottles HDPE Plastic bottles PET Plastic bottles HDPE Plastic bottles

    Packaging capacity 300ml 330ml 300ml 350ml

    Price of bottle 0.5 GH 0.4 GH 0.28 GH 1.1 MT


    $0.13 USD $0.10 USD $0.07 USD $0.01 USD
    Glass Bottle v. Plastic Bottle Price Analysis
    • Both SIL Dairies have similar soymilk outputs but different
    packaging methods.
    • The glass bottler pays more for glass bottles and uses more gas.
    Average Production Day Glass Bottle/Double Boil Plastic/Normal Fill
    Soymilk Production 39L milk 39L milk

    Number of bottles used: 130 bottles (300ml) 118 bottles (330 ml)
    Price per bottle: 0.5 GH 0.4 GH
    Total bottle expenditure: 65 GH 47 GH
    Daily Electricity expenditure 25 GH 32 GH

    Daily Gas expenditure 26 GH 4 GH

    Shelf life 1-3 months on shelf Can’t last on shelf

    3+ months in fridge 24 hours in fridge


    Glass Bottle v. Plastic Bottle Price Analysis
    • Changing to glass bottles would mean a 28% increase in
    bottle expenditure for the entrepreneur currently using plastic
    bottles.

    • Double boiling the milk, as well as boiling the bottles for 30mn
    after filling, would entail paying 8 times more for gas.

    • Using glass bottles and the boiling methods can increase


    shelf life by 30-90 days.
    THANK YOU!
    Q & A: Send in your questions using the chat box!

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