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MODERN CASSAVA PROCESSING

PLANT

(HIGH QUALITY CASSAVA PROCESSING FACTORY)

BY

EMMANUEL ALEX IYOYO

November, 2016
The proposed New Modern cassava processing Plant will produce three derivatives from Cassava which are
namely (1) industrial Starch and Modified Starch,(2) Cassava flour and (3) garri, the finished products will
be for local industries and export market. Our aim is to create a value chain for cassava product in the area
of marketing and processing by building a world class production factory in Nigeria, that will produce
competitive commodities that can compete globally using advance technology.

3.1 PROPOSED NEW MODERN CASSAVA GARI PRODUCTION

Garri is produced from Cassava Tubers and is the common food in Nigeria consumed by over 130 million
people. We consume about 7.7 million tons of gari per year and it is about 30.7 million tons of our cassava
production. This shows that about 75 percent of our cassava output is consumed as garri, while only 25
percent is used as raw materials for starch, chips, pellets and flour which are industrial raw materials that
can be exported.
Our actual annual demand for gari is 12 million tons but to accomplish this, the production facilities must
be improved and up graded and Cassava Product must also improve.
Our population grows at the rate of 3.5 percent annually and this means that the food capacity must also
grow commensurately. Gari is produced in the rural areas by local women and the process is full of
drudgery and stress thus most of them are giving up the trade and the younger ones are not interested
because they prefer life in the cities. The modern Gari Processing Plant is designed to fill this void, the
proposed Ijero cassava processing has been put in place to correct the issue.
In Nigeria, gari is the most consumed and traded of all food products made from cassava root. It is
consumed either soaked in cold water or stirred in boiling water to make a stiff paste. (Oduro et. al., 2000).

3.1.1 DETAIL OF NEW MODERN GARI PROCESSING PLANT

Gari Production process: The processing of cassava into high quality gari involves peeling, washing,
grating, fermenting, de-water pressing, sifting, fire drying, screening, packing and storage.

This long and strenuous process has given us an insight to propose this project of cassava factory in Ijero-
Ekiti, we have put in place modern machine to solve this problems. It is rugged, resilient and made of
stainless steel to satisfy both SON and NAFDAC requirements. It reduces drudgery and stress which are the
bane of local gari production.

Garri Production Line Garri Processing Machine - Brief flow chart

3.2 PROPOSED NEW MODERN CASSAVA STARCH PRODUCTION LINE

The Nigerian demand for starch is estimated at 230,000 tonnes per year. Out of the 5 modern large-scale
cassava starch factories existing in Nigeria, only two are in operation. Cassava starch is an important
domestic and industrial raw material used in the manufacture of various products including food, adhesives,
thickening agents, paper, and pharmaceuticals (IITA, 1990). It has many remarkable characteristics
including high paste viscosity, high paste clarity and high freeze-thaw stability, which are advantageous to
many industries. To make cassava starch, its roots being highly perishable, with enzymatic processing
accelerate their deterioration within 1-2 days, it needs to be processed almost immediately after harvest.

The Flow Chat of our cassava starch processing line

The whole product line includes 4 main sections such as: the washing and
cleaning section, extraction and refining section, the drying section and
the packing section.
Commercial cassava starch processing machine - Equipment list and function
3.3 PROPOSED NEW MODERN CASSAVA FLOUR PRODUCTION LINE

Nigeria imports over one million tonnes of wheat annually. At 10% substitution of cassava flour in wheat
flour and with the current national demand, 300,120,000 metric tonnes of High Quality Cassava Flour (HQCF)
is required. IITA has confirmed that 30% of the total wheat can be replaced by cassava flour in bread
making, and 100% cassava flour is currently being used in pastries and confectioneries (Onabolu et al ).
However, with poor regulation and standardization, some bakeries have complained about problems,
including:
Presence of impurities such as sand, ticks etc
Odour;
Shorter product shelf life (e.g. biscuits);
Brittleness;
Gradual change of colour (biscuits turning pale);
Unreliable supply;
Poor final product quality in cases where the cassava flour had partially fermented.
The propose project has been put in place to address this issue.

The Flow Chat of our cassava starch processing line

The processing of cassava into high quality flour involves peeling, washing, grating, fermenting, de-water
pressing, sifting, fire drying, re-milling, screening, packing and storage.
4.1 PROJECT PLAN
Activities Time (Month)
Pre-design and feasibility 1
Master plan and Budget preparation 1
Project layout and Design 2
Manufacturing and construction 3
Pre-opening operation and commission 2
Total 9

5.0 OWNERSHIP/ TEAM

For a start, the managerial structure of the processing plant is going to be simple. A total of 55 workers will

be required for initial commencement of operations. The cassava processing plant (gari, starch and flour)

will be run as a public private partnership initiative between the private sector, the state government and the

local governments. There will be a board of directors and a Chairman, but those will be on non-executive

capacity. The plant will be managed by a General Manager and assisted by a Deputy General Manager, who

will have considerable experience in food processing, procurement, marketing and accounting. There will

also be machine operators, drivers for logistics, security men and unskilled labourers.

.6.0 PRE-DESIGN AND FEASIBILITY

a. Acquisition of appropriate capacity of the factory production.

b. Study the operation of the equipments.

c. Evaluation of the raw materials: water and Cassava tubers the plant needed for the

smooth running of the factory.

d. Acquisition of splendid ideas about site planning requirements.

e. Acquisition of adequate site selection criteria.

f. Acquisition of amount and cost of energy required for the smooth running of the

factory.
6.1 EXPECTED FINDINGS

The total cost required for equipment of both the gari, starch and flour processing plant,

installation and workers training is 282,464,600.00 ( two hundred and eight-two million,

four hundred and sixty-four thousand, six hundred naira)

7.0 CASSAVA FACTORY WASTE

The waste product of cassava processing factory is in two categories. They are solid waste,

and liquid waste. The under listed measures are to be used to manage the waste products.

a. Provision of a solid waste store with a drying area where it is sun dried for proper storage

to prevent odour that can emanate from it if wet especially in cases where collection is

delayed.

b. Provision of liquid waste sediment pond containing a storage tank made of thermoplastic

material wrapped with elastically deformable sealant (cellular material) at the sides and

beneath to permit the relative movements that may occur as a result of shrinkage ,

temperature effect and also variation in the weight of the tank all contained in a

supporting wall made of concrete and tensioning wires received in special grease plastic

tube incorporated to ensure that the safety wall resist liquid pressure when the storage

tank collapse. This is to prevent it from spreading into the surrounding which will cause

harmful effects due to its hydrocyanic acid content.

General procedure for production


Sorting Weighing Peeling Washing Grating Machine/Milling

Detoxification Dewatering Granulation Drying Milling

Sieving Packaging