MAFE Marketing & Enterprise Program
(MEP)
Mid-Phase Report on Activities,
Achievements and Prospects
Strategic
species, potential product and by-product uses and marketing,
raw
materials procurement, process monitoring and adaptive research,
qualitative and quantitative analysis,
environmental
impact and economic assessment
November
2001
J.H.
Pratt &
L.B.
Satali, Enterprise Development and Training Agency (EDETA)
Companion
documents:
1.
MAFE Dossier on
Mechanical Oil Extraction Systems
November 2001
University
of Malawi Bunda College of Agriculture (BCA)
Agricultural
Engineering Department Reports:
Ø
Design Modifications to Sundhara Sayari
Oil Expeller for Moringa Oleifera and other Agroforestry Tree Seeds
Ø
Oil
Extraction ….. using Tinytech Expeller
Ø
Optimization of Oil Extraction from
Moringa
Oleifera, Trichilia Emetica and Jatropha curcas
using
Ram and Spindle Presses
H.F.
Mbeza, M. Chawala & K. Nyirenda
2. Malawi Bureau of Standards (MBS)
Qualitative/Quantitative Assessment of Plant Oils (MAFE)
July
2001
R.P.
Banda et al
3. University
of Malawi
Chancellor
College Chemistry Department (CCCD)
Qualitative
and Quantitative Assessment of MAFE Plant Oils and
By-products,
and Recommendations
November
2001
E.M.T.
Henry, PhD et al
Table of Contents
ACKNOWLEDGEMENTS.............................................................................................................. 5
EXECUTIVE
SUMMARY................................................................................................................. 8
1 INTRODUCTION................................................................................................................... 10
1.1 Malawi Agroforestry
Extension Project (MAFE)............................................................. 10
1.2 Policy Environment........................................................................................................ 11
1.3 Program Definition......................................................................................................... 12
1.3.1 Scope of Work,
Personnel and Timetable................................................................. 12
Aims
of the Program............................................................................................................. 12
1.4 Operating Methods and
Budget..................................................................................... 13
2 Information CAPTURE.......................................................................................................... 14
2.1 Sources of Information................................................................................................... 14
2.2 Ethnobotanical
Challenges............................................................................................ 14
2.2.1 Challenges addressed............................................................................................... 14
2.2.2 Immediate benefits..................................................................................................... 14
3 Product/STRATEGIC Species
Selection Criteria................................................................. 15
4 Products/STRATEGIC
SPECIES Identified and Justification............................................... 17
4.1 Moringa tree (Moringa oleifera) and Jatropha tree (Jatropha curcas)........................... 17
4.2 Other Oil-bearing
Agroforestry Trees of Interest........................................................... 20
4.3 Fish Bean (Tephrosia
vogelii)........................................................................................ 23
4.4 Related MAFE Core
Species Considerations............................................................... 23
5 Development of a Market
Database for targeted Products................................................... 24
5.1 MAFE Strategy............................................................................................................... 24
5.2 Some Commercial
Benchmarks................................................................................... 24
5.3 A-SNAPP linkage........................................................................................................... 26
5.4 SANProTA linkage.......................................................................................................... 26
5.5 A-SNAPP Proposed
Collaboration in Market Investigations.......................................... 26
5.6 Immediate Plans with
Local/Sub-Regional Partners..................................................... 26
6 means of production: OIL
Extraction TECHNOLOGies AND ADAPTIVE engineering RESEARCH required 27
6.1 Manual Oil Extraction
Systems...................................................................................... 27
6.1.1 Background................................................................................................................ 27
6.1.2 Summary of results of
adaptive research.................................................................. 28
6.1.2.1 Engineering......................................................................................................... 28
6.1.2.2 Economics.......................................................................................................... 29
6.2 Motorized Oil
Extraction Systems................................................................................. 30
6.2.1 Background................................................................................................................ 30
6.2.2 Summary of results of
adaptive research.................................................................. 31
6.2.2.1 Engineering......................................................................................................... 31
6.2.2.2 Economics.......................................................................................................... 32
6.3 Overall Results of
Research on Mechanical Extraction Systems................................ 33
6.4 Conclusions Drawn and
Next Steps to be Taken.......................................................... 33
7 Filling the OIL PRODUCTION
Qualitative and Quantitative Data vacuum........................... 34
7.1 Production Research
Required..................................................................................... 34
7.2 Oil Extraction Trials
And Assay Of Samples: Plant Oils Stage 1.................................. 35
7.2.1 Sites and roles of
partners......................................................................................... 35
7.2.2 Seed Procurement..................................................................................................... 35
7.2.3 Assay of Production
Samples.................................................................................... 36
7.2.4 Lessons and challenges
from Production Trials....................................................... 36
7.2.5 Producers Request a
Motorized Expeller.................................................................. 36
7.3 Social Factors in MAFE
Small Scale Oil Production..................................................... 37
7.3.1 The family and its
business associates..................................................................... 37
7.3.2 Peer groups and
training offered................................................................................ 37
7.3.3 Traditional beliefs........................................................................................................ 37
7.4 Methods and Labor
Required......................................................................................... 38
7.4.1 Technology and
production system........................................................................... 38
7.4.2 Special characteristics
of KOR operations................................................................ 38
7.4.3 Aqueous extraction
method........................................................................................ 38
7.4.4 Seed preparation........................................................................................................ 39
7.4.4.1 Drying.................................................................................................................. 39
7.4.4.2 Shelling................................................................................................................ 39
7.4.4.3 Effects of depodding
/shelling on existing domestic workload........................... 40
7.4.4.4 Pre-heating.......................................................................................................... 40
7.4.5 Extraction.................................................................................................................... 41
7.4.6 Labor requirements for
ram pressing systems......................................................... 42
7.5 Economic Analysis of
Stage 1 Trials............................................................................. 42
7.5.1 Production economics............................................................................................... 42
7.5.2 Kernel/seed extraction
ratios...................................................................................... 43
7.5.3 Seed procurement
considerations............................................................................. 44
7.5.4 Summary of crude oil
yields....................................................................................... 44
7.5.5 Lessons learnt............................................................................................................ 44
7.5.5.1 Processing Labor................................................................................................ 45
7.5.5.2 Equipment Costs
(Capital Repayment) Over Projected Life............................. 45
7.5.5.3 Projected Operating,
Capital Repayment and Seed Cost of Crude Oil............. 45
7.5.6 Conclusions for Application
(Moringa oil)................................................................... 45
8 SUMMARY OF FINDINGS AND
RECOMMENDATIONS OF CHEMISTS............................ 46
9 ENVIRONMENTAL IMPACT
ASSESSMENT........................................................................ 49
9.1 Introduction..................................................................................................................... 49
9.2 Direct Benefits from
Cultivation..................................................................................... 49
9.3 Harvesting...................................................................................................................... 49
9.3.1 Effects on Flora /
Fauna............................................................................................. 49
9.3.2 Mitigation Measures.................................................................................................... 49
9.3.3 Risks of Accidents...................................................................................................... 49
9.4 Depodding /Shelling....................................................................................................... 50
9.4.1 Effects on Land / Flora
/ Fauna.................................................................................. 50
9.4.2 Effects of Depodding
/Shelling on Labor.................................................................... 50
9.4.3 Mitigation Measures.................................................................................................... 50
9.4.4 Risks of Accidents...................................................................................................... 50
9.5 Conditioning the Seed.................................................................................................... 50
9.5.1 Effects on Humans..................................................................................................... 50
9.5.2 Effects on Air and Climate.......................................................................................... 50
9.5.3 Mitigation Measures.................................................................................................... 50
9.5.4 Risks of Accidents...................................................................................................... 51
9.6 Extracting the Oil............................................................................................................ 51
9.6.1 Risks of Accidents...................................................................................................... 51
9.7 Clarifying Crude Oil........................................................................................................ 51
9.7.1 Risks of Accidents...................................................................................................... 51
9.8 Packaging...................................................................................................................... 51
9.8.1 Effects on Land.......................................................................................................... 51
9.8.2 Mitigation Measures.................................................................................................... 51
9.8.3 Risks of Accidents...................................................................................................... 51
9.9 Selling............................................................................................................................. 51
10 mid-phase STAKEHOLDERS
MEETING: SWOT ANALYSIS and conclusions drawn........ 52
11 immediate plans of action
after stakeholders’ meeting......................................................... 56
11.1 Market study................................................................................................................... 56
11.2 Oil chemistry and
filtration............................................................................................. 56
11.3 Fieldwork plan: Plant Oils Stage 2................................................................................. 56
12 SUMMARY OF MEP
INSTITUTIONAL ARRANGEMENTS.................................................... 62
12.1 Partnerships in Malawi................................................................................................... 62
12.2 Partnerships Abroad:
Laboratory Services.................................................................... 63
13 OVERALL ASSESSMENT OF IMMEDIATE
POTENTIAL..................................................... 64
14 INSTITUTIONAL
RECOMMENDATIONS.............................................................................. 66
14.1 Consolidation of the
Group of Partners......................................................................... 66
14.2 Existing and Ongoing
Human Resources Development............................................... 67
15 THE FUTURE........................................................................................................................ 67
15.1 Moringa........................................................................................................................... 67
15.2 Other Species................................................................................................................ 67
15.3 Next Review................................................................................................................... 67
15.4 Sustainability.................................................................................................................. 68
Bibliography.................................................................................................................................. 69
Tables and Annexes
Table 1: MAFE Study of Saturation of Fatty Acids in Tree Seed Oils.......................................... 22
Table
2: Comparison of Efficiency of Mechanical Extraction Systems....................................... 33
Table
3: Kernel Extraction Rates (%) For Various Seeds against extraction methods............... 43
Table 4: Crude oil yield (% of
kernels) obtained from ram press................................................ 44
Table
5: Summary of Chemical Analysis of Samples.................................................................. 47
Table
6: MAFE Marketing & Enterprise
Program (MEP) SWOT session results...................... 54
ANNEX
1: MEP ANNUAL WORKPLAN 2000 – 01....................................................................... 72
ANNEX
2: MATRICES OF POTENTIAL PRODUCTS FROM STRATEGIC SPECIES............... 72
ANNEX
3: MIRTDC QUOTATION FOR BRIQUETTE PRESSES............................................... 72
ANNEX
4: PLANT OILS STAGE 1 – NARRATIVE OF EVENTS.................................................. 72
ANNEX
5: PLANT OILS STAGE 1 – DIARY OF ACTIVITIES....................................................... 72
ANNEX
6: PLANT OILS STAGE 1 – PRODUCTION ECONOMICS SPREADSHEETS............. 72
ANNEX
7: BCM ASSOCIATES OUTLINE BUSINESS PLAN (with EDETA)................................ 72
ANNEX
8: MEP EXPENDITURE ON COLLABORATIONS AND ESTIMATED FUTURE EXPENSES 72
ANNEX
9: MAFE – EDETA COLLABORATION AGREEMENT TO 31/12/01.............................. 72
MAFE gratefully
acknowledges the advice received in 2000 from Wells Kumwenda and colleagues at
Chitedze Agricultural Research Station and from Dr Irmgard Hoeschle-Zeledon of
the Malawi-German Plant Protection Project.
Guidance from Dr
Christine Witte and Lovemore Mvula of the International Eye Foundation, Kenneth
Gondwe and John Taulo of Malawi Industrial Research and Technology Development
Centre and Cosmas Chigwe of Blantyre Polytechnic encouraged MAFE to commence
investigation of the commercial feasibility of tree seed oils extraction.
Sander Donker and
colleagues at Cheetah (Malawi) Ltd generously provided copies of the Company’s
reports on tree oilseeds. This was matched by helpful guidance to literature
from Cyril Lombard of the Southern Africa Marula Oil Producers’ Network in
Namibia. Helpful information was also given by Reinhard Henning, Consultant,
Nikolaus Foidl of the BIOMASA Project in Nicaragua, Lowell Fuglie of Church
World Service in Senegal and Keith Machell of Harmony Foods Ltd in Zimbabwe.
We would like to
express our appreciation to Mr and Mrs Denson Bonomali and their family for the
very special support that they provided in our initial research and to the
numerous University of Malawi contributors, notably Dr Elizabeth M.T. Henry and
Mr Henry Mbeza.
CORRESPONDENTS & ACRONYMS
Agribusiness in Sustainable Natural
African Plant Products, Stellenbosch
(A-SNAPP);
Community Partnership for Sustainable
Resource Management (COMPASS);
USAID NATURE Program);
Forestry Research Institute of Malawi
(FRIM);
National Herbarium and Botanical
Gardens (NHBG);
Malawi Chamber of Commerce and Industry
(MCCI);
Enterprise Development and Training
Agency (EDETA);
Malawi Bureau of Standards (MBS);
Naming’omba Tea Estate Ltd (Macadamia
Nut Division)
Malawi Export Promotion Council (MEPC);
Malawi Industrial Research and
Technology Development Centre (MIRTDC);
Training for Enterprise in Exports in
Malawi (TEEM) Project; and Business Consult Africa Ltd (Busconsult);
Shire Highlands Organic Growers
Association (SHOGA) and private estate farmers;
Tea Association of Malawi (TAM);
Cheetah Industries Ltd (Cheetah);
Harmony Foods, Harare
ZOPP (Pvt) Ltd, Harare;
Freshtainer (Pvt) Ltd, Harare;
FAKT Consult, Germany;
PROPAGE – Association for the Promotion
of and Propagation of Arid and Semi-Arid Plant Resources, Paris;
Promotion of Soil Conservation and
Rural Production Project (PROSCARP);
Wildlife Society of Malawi (WSM);
GTZ Integrated Food Security (GTZIFSP)
Promotion of Horticulture (GTZPH) and Plant Protection (GTZPPP) Projects;
Nyika-Vwaza Border Zone Project (BZDP);
Department of Agricultural Research and
Technical Services (DARTS): Chitedze Agricultural Research Station Farm
Mechanisation Unit (CARS-FMU);
Plan International (PI);
University of Malawi: Chancellor
College Chemistry (CCCD) and Physics Departments, Blantyre Polytechnic (BP) and
Bunda College of Agriculture (BCA);
Blantyre Water Board;
Southern Region Water Board;
National Smallholders Farmers
Association of Malawi (NASFAM);
Southern Africa Development Community –
International Centre for Research in Agroforestry at Makoka (SADC-ICRAF);
SADC Forest Sector Technical
Coordination Unit (SADC-FSTCU);
International Eye Foundation (IEF) and
IEF-assisted smallscale plant oil producers;
World Bank project for Community based NRM in Southern Malawi
National Parks;
soap manufacturers and paint
manufacturers,
process plant manufacturers (incl.
Tanzania & Zimbabwe),
vegetable oil and presscake
producers/refiners;
NRM and process engineering consultants
(including Germany and UK)
Department for International
Development (DfID), Lilongwe: National Forestry Programme;
Agribusiness in Sustainable Natural
African Plant Products (A-SNAPP), Stellenbosch;
Centre for Scientific and Industrial
Research (CSIR), Pretoria;
Leatherhead Food Research Association
(LFRA), UK;
Southern Africa Natural Products Trade
Association (SANProTA) and Southern Alliance for Indigenous Resources (SAFIRE),
Harare;
Binga Trees Project, Kariba (BTP);
CRIAA Southern Africa – Development and
Consulting (CRIAA SA-DC), Windhoek and Southern Africa Marula Oil Producers
Network (SAMOPN);
Veld Products Research and Development
of Botswana (VPRDB);
Optima of Africa Ltd, Dar Es Salaam
(Optima);
Evangelical Lutheran Church in Tanzania
VYAHUMU Oil Seed Project (VYAHUMU);
Church World Service, Senegal (CWS-S);
BIOMASA Project , Nicaragua;
Leicester University (LU), UK;
GTZ GATE information service;
Rutgers University, New Jersey;
Technological Education Institute of Athens (TEIA);
Washington State University International Programs
(WSUIP) staff and its library and internet services.
CBNRM community-based natural
resources management
NPP natural plant
product
NR natural resource
based
Malawi
Agroforestry Extension Project (MAFE) operates under a cooperative agreement
between Government of Malawi, USAID and Washington State University.
MAFE Project
launched a Marketing and Enterprise Program (MEP) in 2000. Objectives are to
investigate, research, pilot, select and promote production and marketing of natural resource-based (NR) products,
with the view to enhancing rural incomes and the adoption of natural resources management (NRM)
practices.
MEP research and
development and test marketing aim to provide the genesis of one or more community-private sector partnerships
that sustainably exploit under-utilized agroforestry and wild plant species. Early-maturing species promoted for NRM
purposes have been given priority in the screening process. They have been
scrutinized against economic, social and environmental selection criteria
devised by MAFE and its partners.
A cluster of seven strategic species has been selected. They all share potential as sources of seed oils for various
subsistence/food security and commercial applications and, in some cases,
offer interesting by-products and/or
plant extracts. Most of the focus of effort is directed towards Moringa oleifera/ Moringa tree and Jatropha curcas/Jatropha, which are
naturalized, fast-growing homestead/hedgerow species for which a rich
bibliography has been traced. Both are under research and development at other
focal points in Africa and show some success in commercialization; in West
Africa Moringa is heavily promoted as a ‘food security’ vegetable crop.
Five other indigenous oil-bearing species are under
investigation:
Natal Mahogany (Trichilia emetica)
Manketti (Schinziophyton rautanenii)
African
Star-Chestnut (Sterculia africana)
Marula (Sclerocarya birrea)
Neem (Azadirachta indica)
A national and
regional market survey is being mobilized by MAFE and is expected to reveal
commercial opportunities for products from these and other plants. Coverage
will include the leguminous under-sown fallow crop Tephrosia vogelii/Tephrosia, as well as a few species targeted by
the USAID-supported continental ‘project’, Agribusiness in Sustainable Natural
African Plant Products (A-SNAPP). The survey will include a focus on potential
medicinal, pesticide and anti-feedant applications.
MAFE and its
partners, notably University of Malawi and the Enterprise Development and
Training Agency (EDETA), an NGO, have investigated manual and motorized seed
oil extraction technologies and, out of necessity, have successfully improved
their suitability for tree seeds. Motorized systems extract significantly more
oil than manual systems; they involve technical complexity and significant
capital outlays. Where seed supplies are not limiting, the lifetime capital cost of motorized extraction equipment/unit volume
of oil produced is not a major determinant of profitability and is not
materially different from the capital cost/unit volume in manual systems.
MAFE calculations
indicate that in a free market, provided that seed transport is economic,
owners of motorized oil extraction systems would probably be in a position to
provide more on-farm added value from purchasing seeds than producers
themselves can generate from manual systems. However, MAFE will not promote
motorized extraction systems for tree seeds (it could for sunflower) until it
is certain about the market potential of the ‘products’.
Test batches of
tree seed oils have been produced in partnership with a small-scale business,
Khumbo Oil Refinery and the economics of the processes involved have been
monitored, principally by EDETA.
Oil samples have
been assayed and partly characterized by University of Malawi and Malawi Bureau
of Standards (MBS). On their recommendations, detailed analysis and full
product characterization is being commissioned abroad.
To enable edible
tree oils to meet MBS Standards, current small-scale edible oil production
systems need to be complemented by effective filtration and refining. The
partners are finding means to address these problems.
Pending
completion of the national and regional market survey, the partners are
supporting a producers’ association, BCM Associates, to scale up experimental
production of Moringa oil. The association will explore its potential in the
national market, determine the feasibility and logistics of seed procurement
and, with partner support, find solutions to quality control problems. Although
MAFE is underwriting certain elements, this program will not directly involve
MAFE personnel; it is felt that MAFE’s physical presence would disturb the
normal processes of negotiation between buyers and sellers and possibly distort
day-to-day management.
The partnerships
developed over the last 12 months remain strong. The work is topical to the
interests of the Southern Africa Natural Products Trade Association (SANProTA)
- of which EDETA is a founding member - and of the DfID-assisted Southern
Africa Marula Oil Producers’ Network (SAMOPN).
For the period
until the end of January 2002 all Project efforts are to be directed to :
full
characterization of potential ‘products’ (by overseas laboratories); and
generation of
comprehensive national, regional and international market information for the
respective products.
Once products
have been fully characterized and market opportunities have been identified it
will be important to establish that seed
acquisition costs and extraction
efficiency can assure commercial viability for each species. Provided that
market research reveals potential for a strategic species, it should be
subjected to an expanded product extraction and trial marketing program along
the lines now applying for BCM Associates’ work with Moringa.
Given the forecast timetable of market research, future extraction and trial marketing programs may not commence until February 2002 at the earliest. According to opportunities identified, this could catch the harvests for three species before MAFE closes in July 2002 but would probably miss the window for one. The 2002 harvest seasons for two species will arise after MAFE’s closure.
This report covers work undertaken up to 30/09/01[1].
Analysis of opportunities will be completed upon conclusion of on-going market
investigations.
In October 2001 the draft document was circulated for peer
review internally, among partner organizations and a small number of
organizations engaged in similar work. In addition to guidance from Washington
State University - International Programs, the following organizations provided
helpful comments:
BTP
COMPASS
SADC-ICRAF
SHOGA
Pirimiti Limited
A separate report on the proceedings of a Stakeholders’ Mid-Phase Review
(25/07/01) is also available.
MAFE is a cooperative agreement between USAID and Washington State
University (WSU) with the Ministry of Agriculture and Irrigation (MAI).
The project purpose is to improve
natural resource management with sustained improvements in smallholder farming
by increasing the adoption of agroforestry. MAFE’s vision is for Malawi’s people to use and manage their
natural resources in ways that will improve their quality of life today and
sustain improvements into the future.
The current MAFE LandCare Phase is
broadening the nature of support services to better reflect the range of NRM
technologies offered. The program maintains MAFE’s basic management and
programmatic structure with its affiliation under the Land Resources
Conservation Department (LRCD) in the Ministry of Agriculture and Irrigation
(MAI). It continues its core operational framework to aggressively
maximize the adoption of proven NRM practices through MAFE’s
support services and partnerships with an added dimension on value-added
benefits. Many NRM practices
yield products that offer tremendous opportunities for domestic and export
markets, particularly in the manufacture of environmentally friendly bio-chemicals,
insecticides, medicines and cosmetics. The identification and development of
market niches for these products will help transform the narrow base of
Malawi’s smallholder agriculture to a more vibrant, market economy that offers
sustained productivity in harmony with the environment. The approach is
consistent with the USAID’s evolving development plans for Malawi’s
agricultural sector, which has a key focus on increasing smallholder
productivity and incomes through improved crops and practices, and the
development of new markets for high-value NRM products.
Materials and
services will be provided on a semi-commercial basis through the new MAFE
Resource Center (now located in LRCD premises) to meet real market demands and
to build capacity for sustainability where partners and clients share costs for
services received. Basic support will be offered to field partners and other
implementers on a scaled down level as they become more self-sufficient.
Support will include quality germplasm, extension and training
materials on recommended practices, and technical advice and training on
establishing and managing NRM practices. The nature of Resource
Center support will include:
·
Formal Partnerships based on a record of successful field-based
programs. These include specific ADDs under the MAI, the Forestry Department,
PROSCARP, VIFOR, and several NGOs, namely ELDP, CSC, CRS, WVI, OXFAM and CARE
International.
·
Informal Support to individuals, groups, communities, clubs, small
NGOs and others that come to the project for information or support on NRM
practices.
·
Investigation of production and new market opportunities for NRM products that
offer value-added benefits through research and linkages with the private
sector.
LRCD
describes the Policy of Government of Malawi on agroforestry as follows:
·
Establish long-term sustainable use of soil and related
natural resources, with a focus (MAFE) on improving soil fertility;
·
Expand agroforestry support generally, with assistance from
NGO and donor communities;
·
Establish a conducive investment climate to support
investors in commercial production that has positive soil
improvement/conservation benefits;
·
Through the Planning Division of MAI, monitor prices and identify (seasonal)
market windows inside and outside
Malawi;
·
Support production up to the level of foreseen market
demand, and avert gluts;
·
Resuscitate former institutional R & D in
agroforestry-based products, specially from Moringa;
·
Actively encourage agroforestry investment according to a
farming system-compatible approach.
MAFE collaborates closely with the Forestry Research Institute of Malawi
(FRIM) supporting two of the four FRIM core programs, i.e. Trees on Farm and Seed
and Tree Improvement, and is
a member of the National Agroforestry
Steering Committee.
The following Strategies of the National
Forestry Programme 2001 (Priorities for Improving Forestry and Rural
Livelihoods) are routinely pursued by MAFE although it is not directly
associated with it:
·
Support community-based forest management,
·
Improve individual smallholder livelihoods, and
·
Sharpen research and information systems.
MAFE operates under USAID 2001 –
06 Natural Resources Management Design Areas for Key Intermediate Result
1.3: Increased Local participation in NRM, i.e:
·
Design Area 1: Improved CBNRM
·
Design Area 2: Increased NRM-based
Enterprise Development
The USAID-supported Community
Partnership for Sustainable Resource Management (COMPASS) project is also active in these Design areas and is a
potential facilitator of enterprises that may be supported by MAFE after the
results of MEP R&D have been assessed.
The MAFE Marketing and Enterprise Program (MEP) was launched in October
2000 upon recruitment of a Marketing and Enterprise Specialist. He collaborates
closely with the Head of the MAFE Resource Center and with LRCD’s National
Coordinator. MAFE employees support specific activities of the MEP when their
commitments permit.
The overall MEP Workplan[2]
for October 2000 to July 2002 was presented in the MAFE Annual Workplan 2000 –
2001 and is reproduced at Annex 1of this document.
The main aims are as follows:
Goal
Enhance rural livelihoods
through production and marketing of natural resource based (NR) products[3]
from plants that contribute to the sustainable use and management of farm
resources.
Purpose
Identify potential
production and marketing opportunities of existing and new NR products for
income generation (among farmers and others) and to enhance adoption of natural
resources management (NRM) practices.
Principal Objectives
Investigate, research,
pilot, select and promote the production and marketing of NR products having
high commercial potential in Malawi.
MAFE research and development and the results of test
marketing of products are expected to provide the genesis of one or more community-private sector enterprise
partnerships[4] that
sustainably exploit selected under-utilized agroforestry and wild plant
species.
It is expected that by July 2002 MAFE and its partners will
be in a position to provide technical assistance to private interests that wish
to apply developed technology at a pilot commercial level. Where sourcing of
investment and working capital finance were a constraint, MAFE could consider
facilitating discussions between the private interests and the funds
provider/lender.
Favorable impact and sustainability assessment of pilot production
would provide the foundation for systematic promotion by the Resource Center
and MAFE partners of expanded planting and management of prescribed strategic
species/cultivars.
The 2000 – 01 Annual Workplan stipulated primarily focusing on
potential products from species currently promoted by MAFE. This criterion has
dominated the initial process of product identification and selection.
Formulation of the MEP anticipated that associated
investigation, research and development would draw upon the specialist
technical and other skills offered among MAFE partners and other
organisations/institutions in Malawi. Such work would be organised through
Collaboration Agreements. Most technical activities of the Program are now
carried out in this manner. Typically these comprise contracts for surveys,
analysis, research and/or design. Some of this work is being contracted with
foreign laboratories.
MAFE’s principle collaborator in all aspects of the MEP is the
Enterprise Development and Training Agency (EDETA), a Malawian NGO. Trial
production is carried out in partnership with small-scale producers. University
of Malawi Colleges have major roles in chemical analysis, product
characterization and engineering. Engineering research and design has involved
extensive international discussion and on the practical level has been carried
out in both Malawi and Tanzania.
Details of the respective partnerships are described in Chapter 12.
Most of the remaining MAFE/USAID funds allocated to the MEP
are planned to be applied as follows:
·
detailed characterization of ‘products’,
·
market investigations (including regulatory environment) and market probing with sample products,
·
procurement of prototype processing equipment, and
·
its trial and demonstration in various field settings within
respective production areas.
MAFE has undertaken and is continuing a literature and internet search
of products offering potential commercialization of agroforestry species
included in the MAFE Extension Program. Very useful professional contacts have
been made worldwide through subject searches and accessing institutional and
commercial websites.
MAFE has also consulted over 50 organisations for advice and to
identify areas of complementary interest in NR product development, as set out
in the schedule of Correspondents.
A selected
Bibliography is presented in this document.
Products in international
trade
Some NR products considered to have potential for production
in Malawi are already made in other countries, have been fully analyzed and
characterized, and are routinely traded.
However, none of the foreseen equivalent ‘products’ from Malawi has been
fully characterized for commercial introduction purposes.
Some local variation in NR product properties can be
expected due to genetic and/or agro-ecological variance from other countries
and/or differences in manufacturing processes. This immediately created
problems for MAFE and its partners in defining the respective NR products that
Malawi may have to offer. So, early in this Program, while the Project and its
partners shared certain commercial hunches, they reached a consensus that the
Project should commission local laboratories to determine the basic biochemical
properties of products that could be offered before embarking on detailed market research.
Bio-prospecting for Novel
‘Products’
Some potential NPPs identified by the Project and its partners as being
of possible commercial potential are so novel that – although they may have
very localized subsistence uses – they are not traded anywhere. They need to be
carefully characterized and such work, unlike that on known products in
international trade, amounts to pure
research. Where applicable, “bio-piracy”
must be prevented: the work must respect and internalize the (value of) respective “intellectual property” of the community(ies) that invented the
use.
This work especially necessitates determination of the basic
biochemical properties of the respective ‘unknown’ products that could be
offered before carrying out any
market investigations.
Hazardous
materials
This approach
has enabled MAFE Project to examine the safety of some of the substances it is
dealing with and, in consultation with WSU, to determine the basis upon which
further research and development, if any, on hazardous materials may be
undertaken.
Scientific
capacity
The work of
local laboratories revealed the resources available for analytical services in
Malawi and prompted preparations by the partners for further work to be
undertaken in overseas laboratories. The absence of functional gas
chromatography – mass spectrophotometer equipment (machines were out of order)
frustrated efforts to identify components of the ‘products’ under review.
Advice from the foregoing institutions, projects, the private sector
and international sources enabled MAFE to begin screening their recommendations
against various criteria. After examining ongoing research in NR product
development by SADC-ICRAF, COMPASS and other organizations, MAFE took up the
advice of University of Malawi and other partners to consider resuscitation of,
and further develop former research on oilseed
tree species meeting provisional
product/species selection criteria[5].
The provisional criteria included:
Potential for short-term development;
Abundance of raw material to allow immediate production trials and
testing of product samples;
Probable suitability for small-scale production and marketing; and
Environmental impact benign or positive.
The seeds of the respective oilseed tree species have potential for
production of oils for food, cosmetic and industrial purposes and offer
interesting by-products, including products with water purification
applications.
By July 2001 the criteria had been refined in consultation with WSUIP
staff and A-SNAPP as follows:
All products should:
1.
Have sizeable potential national and regional markets;
2.
Be of interest to two or more regional countries, where cross-border
trade will be analyzed, and possibly (at a suitable scale of production[6])
have international market potential;
3.
Have significant local subsistence or commercial use (so they will
still be of interest to producers if market conditions are temporarily poor);.
4.
Allow production and processing operations that are technically and
economically feasible on a small or medium scale (i.e. determined as requiring
capital investment of $30,000 or less);
5.
Be widely grown or abundant, at least locally, allowing rapid
production response to market promotion without
depletion of the species.
Special favor will be shown to plants that:
6.
Offer benefits in addition to commercial development, such as food
security, soil fertility or conservation, or wood supply.
7.
Offer production and processing opportunities/synergies that have the
potential to increase value added within existing farming systems.
Useful discussions have taken place between MAFE and COMPASS[7] on product/species selection.
By January 2001, the screening process had led to identification of two
early-maturing agroforestry species
with potential products for short-term research and development. Both species
had been subject to previous product research in Malawi that had given
promising results but research funding ran out in 1997. The Moringa Tree[8]
(Moringa oleifera) and Jatropha Tree[9]
(Jatropha curcas) thus became a focus
of Program attention. Both had been promoted by MAFE and its partners for
several years as part of the agroforestry extension package.
Moringa oil
Moringa had already been promoted in Malawi as a vegetable and oil crop
for food security/vitamin nutrition purposes, notably by IEF for several years.
IEF has embarked (2001) on a new COMPASS-assisted CBNRM program in the areas
adjacent to Lengwe and Majete Wildlife Reserves involving, among other things,
promotion of Moringa planting. IEF hopes to benefit from MAFE Project’s results
of research and product development. This attitude is shared by SADC-ICRAF.
SADC-ICRAF and GTZIFSP promote Moringa cultivation. This and the IEF
work has been principally modeled on work elsewhere to exploit the
nutritional/food security benefits of Moringa leaves, notably by Lowell Fuglie
and partners in Senegal; Moringa flower buds are a popular savoury dish in
India. In West Africa preparation of Moringa leaf powder food supplements from
dense, plots of cash-cropped ‘dwarf’ trees is an expanding smallscale
commercial enterprise[10],
notably in Niger. In Southern Ethiopia coffee lands (also Northern Kenya) Moringa stenopetala, an upland species[11], is cultivated as a shade tree and
dry-season vegetable crop that is used in the daily diet. It has relatively large, fleshy leaves that are ideal
for this purpose.
In Southern India almost the entire focus of the Moringa oleifera industry is on intensive
horticultural enterprise in which vegetable pods are marketed. Unlike many
vegetables, they have several days’ “shelf life”. It is a lucrative business
for which new cultivars such as PKM1
and PKM2 have been developed. These
give exceptionally long pods, have a dwarf habit and require intensive
cultivation methods. Replanting takes place every 4 years.
Malawi and Tanzania (to some extent Senegal) are considered to be the
only countries in Africa engaged in systematic research and development on
Moringa for oil commercialization. In the mid-1990s Chancellor College, FRIM
and other research organizations demonstrated that Moringa yielded a seed oil
(26% of whole seed content by weight[12])
suitable for culinary use. Moringa had a remarkable 1800s history of commercial
production in Jamaica, notably as a source of watchmakers ‘Ben oil’, before
being superseded by Sperm Whale oil. Moringa oil has a very similar fatty acids
profile to Macadamia nut oil[13]
and has been perceived as a potential, highly stable substitute for olive oil –
which has a price in bulk of about
£1.80[14]/kg
($2.50; K150/kg).
Moringa oil contains about 76% monounsaturated fatty acids of which
nearly all is oleic; moreover cold-pressed
Moringa oil is rich in natural antioxidants, notably the powerful
anti-oxidant ∂-tocopherol.
Moringa water treatment
Adaptive research on Moringa was undertaken at Thyolo in the early
1990s by Blantyre Polytechnic, Southern Region Water Board and Leicester
University with DfID support, based on technology developed in the Sudan by
Jahn, SAA in the 1980s. This proved a
cationic polyelectrolyte protein in Moringa powdered seed (& expressed
seedcake) to
be an effective sediment flocculant[15]
(instead of alum) for drinking water preparation. The Thyolo work is understood
to have been carried out with a crude mixture; further work was required at
Leicester University to develop a proprietary pure flocculant extract from
Moringa. Without isolation of the active principle, the Moringa powder would be
too bulky to handle and (probably) cause contamination of water from microbial
action on the sugars, celluloses and other proteins present in the seed.
In response to a ‘Le Monde” French journal article on Moringa, in 1996
four Swiss venture capitalists established Optima in Tanzania as a Company to
adapt and commercialize the above technology developed in Malawi. MAFE staff met Optima’s Tanzania management in
June 2001. Optima has established 62 hectares of its own Moringa plantations
and, promising an attractive purchase price for seeds, is promoting major
investment by outgrowers to develop 12,000 hectares of Moringa plantations for:
·
oil production of up to 8,000 t/year (food, skincare and cosmetic
applications) and
·
commercial development of a proprietary cationic polyelectrolyte
extract, “Phytofloc” [16]for
water treatment; also, subject to research
·
commercial utilization of (protein-rich) detoxified filter cake.
The Optima Product Development Manager formerly worked in Malawi on
behalf of Leicester University and Optima has linkages with faculty of the
University. While much of the Optima development concerns intellectual property
and is commercially sensitive, this industrial development needs to be tracked.
MAFE has benefited from informal advice from the Product Development Manager, a
Leicester University associate who formerly worked in Malawi, and Blantyre
Polytechnic.
Following a hiatus of 4 years, in June 2001 CCCD convened a meeting of the Blantyre and Southern Region Water Boards, MAFE and the National Research Council of Malawi (NRCM) to initiate investigations into possible substitution of proprietary water treatment products (polyelectrolytes and alum) by Moringa extracts. These would follow up the earlier work of Blantyre Polytechnic. At the time of writing it is uncertain whether the Polytechnic will participate in this future work.
International Moringa products
workshop
The MAFE Resource Center Coordinator, Dr Henry S.K. Phombeya and the
Program Specialist will attend an
international Moringa products workshop[17]
in Dar Es Salaam in November.
Jatropha uses
Jatropha is a poisonous plant that yields a non-edible oil (30% of
whole seed content by weight[18]).
This makes an excellent smokeless lamp oil and has potential as an insecticide,
for instance in the control of cotton bollworm; methanol extracts of Jatropha
seed (which contains biodegradable toxins) are being tested in Germany for
control of bilharzia-carrying water snails. Jatropha presscake contains curcin,
a highly toxic protein similar to ricin in Castor. Jatropha oil can be used as
an expensive[19] diesel
motor fuel, for which purpose it is at its most effective when transesterified.
Binga Trees Project (BTP) reports Jatropha oil use by tanneries in Zimbabwe. It
is also used extensively in West Africa, Zambia, Tanzania and Zimbabwe as a
soapstock. MAFE will investigate the respective oil extraction and soap
industries in Zambia and Zimbabwe to determine the scope for technology
transfer to Malawi. A Jatropha variety of Mexican provenance is edible but no
experience of this has been gained in Central Africa.
Habitat of Moringa and
Jatropha
Conveniently, both species above grow fast and are normally planted
around homesteads as a hedge/living screen; Jatropha is widely distributed,
while Moringa is localised in the lowlands, notably Lower Shire Valley and the
Lakeshore[20]. Both meet
Criteria Nos. 5 and 6. above, i.e. they are widely grown and offer benefits in
addition to commercial development. Moringa can be grown from seed or
propagated from truncheons. It yields seeds within 1 - 2 years.
Taxonomy and agronomy
With regard to Moringa, Coote et al (1997) had recommended:
………. existing trials should ………… investigate the potential for adoption and promotion of more productive and vigorous varieties. Should the socio-economic value of continued work on Moringa oleifera be proven there will be a need to develop a focused national breeding and improvement programme. ……
On the advice of the proprietors of KOR[21],
MAFE has approached the National Herbarium and FRIM[22]
with the view to commissioning an investigation to determine the different
races of Moringa that have
naturalized in Malawi. There are thought to be at least 3 races, each of which
has distinct morphological and oil-bearing characteristics[23].
Jatropha, and possibly other species, may receive similar investigation. This
research theme is to be raised in the Triennial National Forestry Research
Symposium in early December 2001.
Depending upon the results of oil extraction trials, MAFE may engage
FRIM to assist investigation of, and possible field experiments on household/hedgerow (but not plantation)
production costs, inputs and outputs for Moringa and Jatropha. Some useful Moringa plantation management guidelines have
already been provided by Optima but MAFE has been unable to locate any
information on long-term yield of Moringa under plantation conditions. Optima
Company forecasts of yields from mature plantations therefore may need to be
treated with some caution.
Through advice from BTP and initiative of MAFE Field Technical
Associates and with assistance from PROSCARP and LRCD, Natal Mahogany (Trichilia emetica) is being investigated
for its seed[24] oil
properties and yield, and uses of aril paste[25]
and bark extracts. This tree is common
in Karonga and already promoted by MAFE. Very little literature on this species
exists yet the tree has numerous traditional food and medicinal uses and
formerly sustained significant soap industries in Southern Tanzania and
Mozambique (Williamson, J. 1975). Through informal assistance from the Centers
for Diseases Control and Prevention (CDC), MAFE has acquired insight into
confirmed pesticidal properties of this plant. The respective information is
confidential.
Taking up the interest of the Southern Africa Natural Products Trade
Association (SANProTA), Wildlife Society of Malawi, World Bank project for
Community based NRM in Southern Malawi National Parks and Nyika-Vwaza Border
Zone Project, investigation of the scope for manufacture and marketing of seed
oils of Marula (Sclerocarya birrea)
and Manketti (Schinziophyton rautanenii)
has been initiated. Manketti is a target species of SANProTA. Marula is already
receiving significant R & D attention from various organizations in four
Southern African countries[26]
and MAFE plans to collaborate with them. African Star-Chestnut[27],
or Tick tree (Sterculia africana) and
the naturalized species Neem (Azadirachta
indica) may also be investigated. Excepting Neem which is a farm species,
four of these species are found both in natural
forest (including Forest Reserves and National Parks) and as on-farm trees. All the species under
this section take longer to reach maturity than Moringa and Jatropha.
For the species under MAFE consideration, the proximity of
the fatty acid composition (where available) of their oils to the composition
of commercial vegetable oils are mapped in Table 1, along with relative fatty
acids saturation. It is thought that
some tree oils could possibly be marketed as substitutes for higher-priced
oils, notably Sweet Almond and Jojoba, that are used as body/massage oils,
cosmetic bases and carriers, in addition to finding food/edible oil uses.
Seasonality
The seasonality of “seed drop” of the foregoing cluster of
oil-bearing species has been considered. Although harvesting, sun-drying and
storage of Neem and Natal Mahogany may be frustrated by rainfall and high
humidity in their respective harvest seasons, the overall annual sequence of
harvesting for the indicated species may, subject to feasibility assessment, provide opportunities for one or more
commercial processors to specialize and orient their entire operations to tree
seeds. Respective harvest seasons are:
Moringa (Moringa
oleifera) Oct
– Nov
Neem (Azadirachta indica) Dec
– Jan
Natal Mahogany (Trichilia emetica) Jan – Mar
Manketti (Schinziophyton rautanenii) Mar - Apr
Jatropha (Jatropha curcas) Apr
– Jun
Marula (Sclerocarya birrea) Apr
- Jul
African Star-Chestnut (Sterculia africana) May – Sep
Synergy with other oilseeds
In some locations it may become attractive for businesses that crush
conventional oilseeds, such as sunflower and/or groundnut, to integrate some
tree seed oil production into their annual program, specially during the
oilseeds “off-crop”, i.e. December – April.
MAFE is committed to investigation of properties and potential uses of
Fish Bean (Tephrosia vogelii). SHOGA
has repeatedly expressed interest in promotion of this plant for both (organic
management system) soil improvement and, possibly, NPP purposes.
Opportunities to investigate this species have been limited. CCCD Tephrosia specialists have been unable
to find time to assist MAFE, however the Natural Products Research team led by
Prof Berhanu M. Abegaz at the University of Botswana, with which WSU is
associated, is undertaking leaf and seed analysis[28].
Since Fish Bean , Moringa, Marula, Natal Mahogany and Neem
are promoted in the MAFE 1995
Agroforestry Field Manual, they have been afforded special consideration in
this Program; all decisions on selection of strategic species have been made
jointly with LRCD.
Investigation of the commercial potential of other
agroforestry species is being pursued as time permits.
MAFE’s approach to commercialization is holistic. Possibly a
targeted species will become economically viable only when several of its uses/product applications are all fully
exploited. Thus, although plant oils
and their by-products are the current focus of MAFE research and development,
it is intended that all potential subsistence and commercial products will be
captured in market surveys for the targeted species.
MAFE accordingly plans to supplement the study of plant oils
and by-products with inquiries into local usage and marketing of other products
from the strategic species. These can range from food uses of plant materials
to timber and firewood, also specialized uses such as traditional medicines and
pesticides, where dosage rates need to be noted. Additionally, efforts will be made to value the environmental
benefits (and costs, if any) of exploiting the species and their implications
for NRM will be described.
Botanical pesticides and anti-feedants derived from Fish
Bean, Neem and Jatropha are to receive special consideration.
Matrices of potential products of strategic species have been prepared
by MAFE (Annex 2).
Market investigations will follow three principal thrusts:
·
Assessment of Malawi’s comparative advantage (if any) to supply
respective NPPs, including chemical isolates/fractions, that are already traded
nationally, regionally and internationally;
·
Determination of the opportunities for Malawi NPPs to replace and
compete with other products in trade – by virtue of similarity of
physico-chemical properties;
·
Reporting on the means of compliance with national regulatory/safety
standards in the more promising markets.
The nature of the marketing and distribution systems and market
segmentation for identified products will be examined and, where possible,
trends in supply and demand will be reported upon.
Price formation and the costs of production and processing will be
studied and principal actors in trade will be interviewed. Institutions that
are committed to supporting NPP development, including providers of finance,
will be identified.
For experimental control purposes,
commercial oilseeds, i.e. groundnuts (+/- 44% oil content) and sunflower
(+/- 40% oil content), have – when available - been included in MAFE
trials. Their current bulk wholesale prices, delivered Blantyre are K40/kg
(shelled) and K12/kg (whole seed) respectively. Castor seed would have been included
in the benchmarking exercise as its oil is popular with paint
manufacturers but samples could not be obtained in time for trials. Its
cultivation has declined markedly in recent years as a result of the
withdrawal of Agricultural Development and Marketing Corporation (ADMARC)
from this business. The Lilongwe soya bean processing
business, SEBA Foods (SEBA) was visited in September 2001. SEBA processes
about 2,500 t of beans annually, supplied by a trader network. It manufactures
various SEBA food products. Oil is produced as a by-product and probably
amounts to up to 400 tonnes annually. Insoluble foots/fibrous matter is
removed by filtration and settlement (6 vessels before filter; two after
filter). The filtered oil is sold unrefined to other industries. Industrial/Mineral
Oils International wholesale price
benchmarks for crude oils taken for reference on July 5, 2001[1]
were: US$/kg K/kg
(K80 = $1) Palm Oil 0.27 21.60 Soya Oil 0.35 28.00 After allowing for handling and
transportation charges and taking advice from importers it was considered
by MAFE that the landed (Blantyre) price of such crude oils for food and
mineral/fuel/paint oil use should be taken as some K39/kg. Cooking Oil In July 2001, refined sunflower oil
was being sold by Blantyre-based refineries ex-factory at retail prices
(unpackaged) of some K80/litre (K89/kg) upwards; they were also selling
the presscake by-product for animal feed (unmilled) at some K9/kg. Naming’omba Tea Estates Ltd produces
about 20,000 litres of (by-product) macadamia nut oil annually. It sells
to its employees and the general public at a price (excluding packaging
and surtax) of K117/litre, and K149 including container; the same oil can
be bought in Zomba at about K215/litre (retail, packed). MAFE has taken K80/litre, as a
benchmark price for considering the feasibility of marketing ‘substitute’
cooking oils derived from tree seeds. We hope that in due course some tree
oils will command far higher prices locally and internationally by lending
themselves to specialized applications or as substitutes for costly oils
such as olive oil. For example, Sweet Almond Oil B.P. (KTC brand) has been
found in a Lilongwe supermarket priced at K695/500 ml (17.5 fl oz). It is used
as body oil. The price of Sunflower seed in
Morogoro, Tanzania is (June 2001) TSh130/kg, equivalent (at K1=TSh 11.70)
to some K11.10/kg, and the Tanzania unrefined sunflower oil price is
TSh900/litre ,i.e. K76.90/litre or about $1/litre. These closely resemble
prices in Malawi. [1]Financial
Times 06/07/01
Commercial Benchmarks:
Industrial/mineral oils and cooking oils
During 2000, after attending an A-SNAPP Roundtable[29]
in Cape Town, MAFE applied for associate membership of this USAID-supported,
pan-continental Natural Resource-based (NR) product development organization
with the view to:
·
sharing experiences,
·
networking of information and
·
possible collaboration in NR product market research, etc.
Malawi has little information on the international marketing system,
demand and respective product specifications for agroforestry tree products.
This constraint is being partly addressed through a regional joint market research project arranged by USAID between MAFE
and A-SNAPP, commencing November 2001. Further work may be undertaken with
A-SNAPP from 2002 in the international market.
MAFE’s NGO partner in NR product development, EDETA is a founder member
of SANProTA. SANProTA and its Zimbabwe member, SAFIRE are very interested in
collaborating with MAFE generally in market investigations.
In June 2001 USAID, Washington summoned a meeting with WSU and
A-SNAPP/Rutgers representatives to consider collaboration in market
investigations; lessons had been learned from an A-SNAPP study in West Africa.
It was felt that MAFE and WSU could work with A-SNAPP to build on that and
conduct a study in Southern Africa.
Agreement in principle was reached for MAFE to organize a Southern
Africa Natural Plant Product Marketing and Production Study in up to 5
countries for a shortlist (to be agreed) of strategic
species that broadly satisfied the selection
criteria. Specialists in market
analysis and production from within the Region would be contracted by MAFE for
this purpose and with the possible view to future “market update” studies.
WSU and MAFE Project developed a questionnaire for data capture and
formats for data analysis and reporting, ready for inspection/comment by
A-SNAPP.
MAFE plans to initiate independent surveys in Malawi in
November with assistance from SANProTA, EDETA and SAFIRE, following the
approach that has been proposed. Malawi investigations are expected to continue
until January 2002.
Having settled on a cluster
of oil-bearing species for initial investigation, MAFE Project and LRCD decided
to investigate and take advice on available mechanical oil extraction
technologies suited to small or medium-scale operation (species selection
criterion No. 4). Another technology, aqueous extraction, is discussed in
Chapter 7, Section 7.4.3.
The Project’s inquiries revealed that although suitable mechanical oil
extraction systems were available for Jatropha, technical problems were
encountered worldwide in extracting Moringa oil. With the exception of Natal
Mahogany (Zimbabwe: BTP) and Marula (Namibia: SAMOPN), no secondary data could
be obtained on efficiency of oil extraction with the minor species of interest
to the partners.
It was agreed that a systematic investigation of mechanical oil
extraction systems and associated adaptive research should be carried out by
BCA. In order to avoid delaying efforts to characterize products (for which no
samples were available) it was decided that the investigation would be
commissioned by MAFE concurrently with
a program to manufacture product samples.
In 1997 with financial support from PROSCARP and with the view to
assisting the smallholder sector, CARS-FMU carried out oil extraction trials on
seeds of both Moringa and Jatropha on a CAMARTEC[30]
BP30 manual ram press bought from Zimbabwe. The key components of this machine
are a lever-operated piston (diameter 30 mm) with a stroke of 75 mm moving
through a reinforced cage of 15 longitudinal iron bars spaced typically at some
0.8 mm (0.5 or 0.6 mm for Sunflower), through which oil is released. Press cake
is released from an adjustable end-of-cylinder choke cone. The press is
operated by one person but the work necessitates frequent rests. CARS-FMU crude
oil extraction rates by weight were 7.7% for Moringa and 18.3% for Jatropha
with output at the rate of some 0.30 kg and 1.36 kg of oil/hour respectively.
It was felt that the design was inappropriate for Moringa and not ideal for
Jatropha and that further experimentation and (later) demonstration were
necessary at the farm level.
Jatropha oil extraction by ram press has in recent years been promoted
by Appropriate Technology International (renamed Enterprise Works in 1998) and
Africare (sponsored by USAID), GTZ and their respective partners in Mali,
Tanzania, Zambia and Zimbabwe. A press manufacturing and sales facility was
established in Zimbabwe in partnership with Shamen Engineering Ltd and ZOPP
Pvt. Ltd.
For several years Malawi Industrial Research and Technology Development
Center (MIRTDC), International Eye Foundation (IEF), Plan International (PI)
and other organizations[31]
have promoted the use of versions of the ram press mainly for sunflower oil
extraction. IEF and its partners have supported demonstration and development
of Sunflower and Moringa oil extraction using ram presses in various locations
in Lower Shire as part of a food security support strategy. Most presses in
Malawi have been manufactured by MIRTDC (which continues to offer this product
at a price of some K9,000); some have been bought from Tanzania and Kenya (PI)
at a cost ex-factory of some $275 (K22,000) each. Khumbo Oil Refinery (KOR) was
one of the family businesses assisted by IEF and has continued operating a
MIRTDC prototype ram press[32]
for 4 years; its main business is groundnut oil extraction. PI-assisted
communities in Kasungu press Sunflower with a Kenyan ram press where a
potential extraction rate of 41.7% has been claimed. ZOPP Pvt. Ltd considers
that for sunflower a mean extraction rate of 25.5% (whole seeds) is normal.
Manufacturers’ performance statistics for pressing conventional (but not tree)
oilseeds are enclosed in the MAFE Dossier
on Mechanical Oil Extraction Systems that accompanies this report.
In 1994, under a Moringa collaboration between Blantyre Polytechnic
(BP) and Leicester University (LU), the Intermediate Technology Development
Group, Zimbabwe (ITDG-Z) carried out Moringa oil extraction experiments. The
first was with a Ram Press, the second - with Valmore Paints Ltd - on a Tinytech mechanical expeller from
India and the third on a manual Spindle Press made by Malawi Entrepreneurs
Development Institute (MEDI). The Ram Press (design unspecified) was quickly
discarded as being of too low labour efficiency, yielding oil under trials at
the rate of just 170 ml/hour. Work at Mponela with the MEDI Spindle Press gave
a maximum Moringa oil yield of 21.6%
from crimped seeds but the oil was of poor quality because there was charring
during seed pre-treatment.
In early 2001 MAFE and Bunda College of Agriculture (BCA) staff
attended an EDETA field demonstration of manual oil extraction from Groundnuts
and Moringa at Neno. The MIRTDC ram press could not be made to operate
efficiently.
Based on the results of the work of CARS-FMU and the results of its own
collaborative trials in early 2001 (see below), MAFE commissioned (BCA) to
carry out adaptive research to improve the performance of ram presses and a
spindle press with tree seeds. The report on this work has been received and
distributed.
The complete results are presented in the accompanying Dossier on Mechanical Extraction Systems.
It should be noted that when used principally for groundnut
or sunflower seed crushing, the capital cost of imported ram presses and
expellers becomes almost insignificant in relation to output, i.e. it reduces
to about one sixth that estimated for Moringa and amounts to about K3/kg crude
oil. Durable ram presses may have a working life greatly in excess of 3 years
but, excepting one special case, MAFE has no data on ram press life.
Komet
The Chitipa District Health Project (assisted by GTZ[37])
has helped the Kafora community to establish a Sunflower oil extraction
business that uses a “high-tech” electrically powered German “Komet” expeller.
This is a bench-sized 2-stage machine fitted with seed pre-heaters. In the 1999
trial season some 800 litres of Sunflower oil were produced over a period of 3
months (62 litres/week) at an oil extraction rate of 18.1%. Small tests with
Groundnut variety CG7 and Moringa gave reported extraction rates of 45%
(unlikely) and 10% (credible) respectively. Groundnut oil was palatable;
Moringa oil colour was unexpectedly dark and thick (probably polymerised). The
same make of machine is used by Optima in Tanzania for small-scale Moringa oil
extraction[38], where an
extraction ratio of 1:7 (14.3%) is achieved but clogging of cake is a problem.
This machine is thought to cost some $15,000.
Tinytech
The Tinytech expeller of Valmore Paints Ltd is a machine fitted with a
steam seed pre-treatment apparatus and suitable for conventional oilseeds
including Castor (for paint-making). Tinytechs are operated by at least one
Blantyre sunflower oil refiner on a full-time basis. Several of these machines
were imported in the 1980s through a credit program administered by the Small
Enterprise Development Organisation of Malawi (SEDOM).
In a 1994 trial run organized by Machell, K. of ITDG-Z at Valmore using
Moringa, the Tinytech was found to give unsatisfactory oil extraction from
crimped kernels; oil leaked out with presscake and cake clogged in the worm.
In 2001 MAFE commissioned Bunda College of Agriculture (BCA) to test
the Valmore Tinytech and ascertain the causes of its 1994 failure. The report
has been received.
ITDG-Z work in Zimbabwe in 1995, cold-pressing with a small, motorised
expeller (no seed pre-treatment) gave a Moringa oil extraction rate of 10.8%.
BTP reports poor extraction rates and clogging of Moringa on both manual
presses and mechanical expellers.
Sundhara
The Zimbabwe soap industry based on Jatropha oil was developed with
assistance from ITDG-Z and other organizations. Oil is extracted by Tinytech
and Sundhara expellers. The Sundhara was developed in Nepal under a GTZ
assistance program through FAKT-Consult and has been adapted for use with
Jatropha in a number of countries, notably Mali.
The Sundhara is manufactured in two factories in Zimbabwe and in a
factory in Tanzania. BTP uses a Zimbabwe Sundhara on Jatropha, Natal Mahogany[39]
and Moringa seeds. It initially experienced frequent clogging with the latter;
it considers Moringa oil extraction efficiency can be raised by reducing the
rotation speed from 44 rpm to 36 rpm.
Sundhara manufacturers do not require copyright permission since the
Sundhara is not patented. The Tanzanian Sundhara (8 h.p.power rating) is
advertised at a rated sunflower seed (local variety; whole) throughput of some
60 kg/hr and an impressive crude oil extraction rate of about 26%.
MAFE ranked manufacturers of this machine within the region according
to several criteria and decided that the Tanzanian source scored highest on
several points (see Dossier). Price details are given in Footnote 41on the next
page.
MAFE then commissioned BCA to investigate the Tanzania machine,
determine its suitability for tree seed oil extraction and conduct adaptive
research to configure it for use with tree seeds. In June 2001 the Head of
Agricultural Engineering of BCA, Mr Henry F. Mbeza, carried out the assignment
in Morogoro, Tanzania according to agreed terms of reference, submitting his
final report in September (see Dossier).
Ø Komet
MAFE and its partners have no experience of this expeller.
Valmore owns a new, unused Komet that could be commissioned and tested.
Information is being sought (October 2001) on machines operated by Naming’omba
Tea Estate Ltd.
Ø Tinytech
MAFE and BCA have no experience of working with a new
machine. MAFE and MIRTDC visited a commercial refinery in Blantyre to see an
old model crushing sunflower; this machine had been extensively rebuilt.
The machine owned by Valmore provided useful experience to BCA and
MIRTDC staff in the technical challenges of expelling tree seeds but, as was
the case for Machell, major mechanical problems were encountered. The machine
could not be made to run effectively and no useful production data could be
generated.
Ø Sundhara
The Sundhara model from Tanzania is an adaptation of the original
design and is called a Sundhara Sayari
.
The principal findings of BCA were as follows:
-
Reconfiguration of settings of the Sayari to graduated cage bar spacing
of 0.4 mm – 0.2 mm and cone diameters of 90-98-98 respectively achieved
satisfactory Moringa oil extraction of 14.7% on whole seeds, equaling a ratio
of 1:6.8, i.e. about the same as achieved by Optima with a Komet.
-
In its ‘standard’ setting of 0.8 – 0.4 mm and 86-96-98 the Sayari is
suitable for Groundnuts, Sunflower and Jatropha.
-
For ease of operation, a complete set of spare worms and cones should
be kept with the machine so that cleaning of one set (hot water and detergent)
can take place during running time.
-
Further work is required to configure the Sayari for Natal Mahogany and
Neem. Results for Natal Mahogany were disappointing with a very low rate of
extraction.
-
For eye safety, oil splash guards should be fitted.
-
V-belt grooves should be fitted on pulleys.
-
An electric motor of less than 5.5 kw may be adequate.
-
Lubrication of the machine with high-temperature grease may be
required.
-
The effect of high operating temperatures (from friction) on Moringa[40]
and other oils should be compared with that from cold pressing with ram
presses.
-
Cage holders are over-designed and the bottom of the oil receiver
should be uncovered.
-
BCA ideas for replacing the bar cage with a prototype perforated
cylinder in tree seed oil extraction should be tested in a further adaptive
research project.
Ø Sundhara
-
BCA recommended that detailed cost analysis of this machine, and the
scope for economizing on the cage holder and oil receiver specification should
be investigated.
-
MAFE calculations (see Dossier) indicated that on an estimated life of
5 years the capital repayment and single-shift
operating cost of a Sundhara Sayari expeller (diesel driven), as quoted[41],
would be as follows:
Kwacha/litre crude oil
Sunflower oil (12 months’ operation/year) 13
Consideration of equipment utilization leads to a conclusion that,
provided suitable cones and worms are available for fitting, integration of
Moringa and/or other tree seed oil production with Sunflower or Groundnut oil
production could be advantageous.
Overall results of BCA, MAFE and EDETA
research and development on mechanical oil extraction systems for
Moringa were as follows:
Table 2: Comparison of Efficiency of Mechanical Extraction Systems
|
Parameter |
Manual Ram
Press (improved) Seasonal
use only |
Small
motorized expeller Seasonal
use only |
Larger
motorized expeller (source: Optima of Africa Ltd) Full-time
use |
|
Efficiency
of extraction: |
25% |
50% |
53% |
|
Extraction
ratio weight % whole seeds: |
6.6% |
14% |
16%
(?) |
|
Ratio
of oil to whole seeds: |
1:15 |
1:7 |
1:6 |
|
Capital
and operating cost/kg oil produced |
$1 |
$0.76 |
$0.40
(approx) |
|
Minimum
capital investment/ processor |
$200 K12,000 |
$5,000 K300,000 |
$300,000
(?) K18,000,000
(?) |
Motorized extraction systems always achieve a higher extraction ration
than manual methods but they depend upon a minimum throughput for economic
operation. The partners consider that respective expellers should not be
imported for trial on tree seeds in Malawi until:
oils and their by-products
have been characterized and their ‘quality’ determined;
their market potential and
likely prices have been assessed; and
the available seed resources
has been quantified.
However, recent discussions with Naming’omba Tea Estate suggest an
attempt should be made to run available tree seed samples, specially Moringa,
through one of the Estate’s Macadamia Nut oil expellers to compare extraction
efficiency with that achieved by BCA in Tanzania.
Notwithstanding a comprehensive literature search and consultations
with MIRTDC and the other organizations listed, secondary data was lacking from
Malawi and abroad on
·
input-output economics of village-scale
extraction of seed oils of Moringa and Jatropha and
·
respective qualitative/compositional
data (see Chapter 2) for the output.
Such information is vital for determining
feasibility of any respective small to medium scale enterprise development and
for justification of any related project/investment proposal.
&n