CASSAVA ROOTS
PEELING
WASHING
GARTING/RASPING
CHIPPING
GRINDING
MIXING WITH WATER
FILTERING (SCREENING)
SETTLING
STARCH WASHING
SETTLING OR DEWATERING IN A CLEAN BAG BY PRESSING
DRYING
MILLING
CASSAVA STARCH
Simple process for cassava starch production
CASSAVA ROOTS
PEELING
WASHING
CHIPPING/SLICING
DRYING
PACKAGING
Production of cassava chips
Cassava Chips
Cassava Chips
Name of product
Description
Cassava Chips is a cassava product made by peeling, washing, chipping,
drying, packaging and storage. 3-5mm thick chips from peeled/or
Packaging
Conditions of Storage
soaked cassava root dried to <12% moisture content.
Jute bag line with food grade high density polyethylene film
Room temperature (28 + 2oC), low RH, raised platform.
Shelf-life
Not more than 2 years
Instructions on the label
Process before consuming, except for animal feeding.
Use within 30 days after opening
Humans, Animals and Flour Mills
1) Grind into flour, sieve and use for human food
2) Grind into small granules mix with other feed ingredients and
pelletizer for animal feed
3) Steam into cooked chips, steep in cold water, drip dry and mix
with ingredients to make salad.
Target consumer groups
Recommendations for further processing
required before consumption
CASSAVA CHIPS
SAND/IMPURITIES REMOVAL
GRINDING/SIZING
Steam
STEAMING
EXTRUSION/PELLETIZING
COOLING
SIEVING
CASSAVA PELLETS
PACKAGING
Process for production of cassava pellets
CASSAVA ROOTS
PEEL AND WASH
GRATE (MECHANICAL GRATER)
DEWATER (SCREW OR HYDRAULIC PRESS)
PULVERISE
SUN DRY IN A THIN LAYER
MILL FINELY
CASSAVA FLOUR
PACKAGE
Production of unfermented cassava flour in Nigeria
(Source: Onabolu, Abass and Bokanga 1998)
High Quality Cassava Flour
High quality cassava flour
Name of product
Description
Definition of Cassava Flour
 Cassava (Manihot esclenta Crantz) flour
shall be the product prepared from dried
chips or paste by pounding, grinding or
milling process followed by sifting to
separate the fibre from the flour.
 In case of flour prepared from bitter
cassava
(Manihot
utilisima
Pohl),
detoxification is carried out by soaking the
peeled tubers in water for a few days
before under go drying in the form of
whole, pounded tuber (paste) or in small
pieces. (SON, 2004)
Moisture content of the dried product should be <12%.
Packaging
Conditions of Storage
Shelf-life
Instructions on the label
Target consumer groups
Recommendations for further processing
required before consumption
Food grade, moisture proof material (polyethylene, polypropylene)
of thick guage (specify).
Cool, dry and rodent and insect free environment.
12 months
1. Cassava flour for bakery and confectionary purposes
2. Use at 10% for bread production
3. Use at 100% for cakes and chin-chin
4. Use at 20% for other confectionery preparations
Bakeries
Other food industries
Caterers and housewives
Food product in which it is used should pass through a heat
process such as baking, frying or grilling
Harvest/Sorting of cassava
Peeling
Washing
Grating
Fermentation
Pressing
Sifting
Garifying
Cooling
Sieving (optional)
Packing
Storing
Process Flow Chart for Gari from Cassava
Gari
Name of product
Description
Packaging
Conditions of Storage
Shelf-life
Instructions on the label
Target consumer groups
Recommendations for further processing
required before consumption
Gari is defined as a fermented acidic granular free flowing dry product
made from fresh cassava or Partially gelatinised dried granular
fermented cassava product. Process involves peeling, washing,
grating, fermentation, dewatering, pulverisation, sifting, garification,
cooling and packaging. Gari is commonly consumed either by soaking in
cold water with sugar, coconut, roasted peanut, fish, or boiled cowpea as
complements or as a paste made with hot water and eaten with vegetable
sauce.
High density polythene bags and hessian / Jute bags
Dry cool place (below 36oC)
12 Months
Constitute into dough with boiling water. One part product to 1.5
water(v/v) or according to consumers preference
Adults and children
1) Add half cup gari into 1 cup of cold water. Add sugar to taste.
Eat as a snack or compliment to cooked beans
2) Boil 2 cups of water in a pot. Add 1 cup of gari. Cover for
1min. Stir until smooth. Serve with soup of choice. Can be eaten
for lunch or dinner
Cassava Fufu/Akpu
Odourless fufu flour
Name of product
Description
Packaging
Conditions of Storage
Shelf-life
Instructions on the label
Target consumer groups
Fermented dried, fine four produced from fresh cassava roots. The
processing includes peeling, washing fermenting, sieving,
dewatering, drying, milling, sieving and packaging. It should have
a moisture content of less than 10%, pH 4 to 5 and particle size of
0.2mm.
1kg in transparent moisture proof properly sealed food grade
polyethylene bags
Cool, dry place that in insect and rodent proof
Six months
Preparation instruction
Storage conditions
Best before date
Nutritional information
NAFDAC number
Name and address of manufacturer
All age groups. When cooked, fufu is creamy/white smooth textured
product.
Recommendations for further processing
required before consumption
Cook before consumption
Follow instructions given on the label
Abacha
Abacha variously referred to as eberebe, jigbo, mpakata, nsisa etc. in different places was observed in Nike
market in Enugu in Eastern Nigeria. But in Enugu, the sellers reported that abacha is widely prepared
throughout the Ibo speaking areas of Nigeria. Fresh cassava root is the only raw material but other inputs are
firewood fresh clean water, and labor. Abacha is eaten in wet form without sun drying. If sun dried, it can be
eaten dry but in most cases dry abacha is soaked in water for a short time. Abacha is eaten as snack with nuts or
as a delicacy with a palm oil source along with smoked fish or meat. Abacha is also a ceremonial food served
during indigenous festivals such as agricultural festivals, funerals, naming ceremonies, etc.
Process Flow Chart
Peel fresh cassava roots
Wash the peeled roots
Boil the peeled roots for about 10 minutes in thrice its volume of water and allow to cool
Shred (perforated metal plate)
Soak in cold water for between 5 to 24 hours
Wash in cold water until wash water is clear, and optionally
Sun dry
Process Flow chart of Abacha From Cassava
Equipment Required
Peeler
Knife
Metal plate
Dryer
Tapioca
Tapioca meal is made from partly gelatinized cassava starch through application of heat treatment to moist mash
in shallow pans. When heated, the wet granules gelatinize, burst, and stick together. The mass is stirred to
prevent scorching. They are manufactured in the form of irregular lumps called grits or of perfectly round
beads. The grit is finer-grained product obtained by milling gelatinized lumps, and siftings. It is consumed in
many parts of West Africa. It is usually soaked or cooked in water and sugar and or milk are added.
Cassava
Peeling
Peels
Washing
Grating
Sieving
Mash and Fibre
Extraction
Dewatering
Effluent
Wet starch
Pressing
Effluent
Screening
Moist flour
Roasting
Tapioca grits
Flow chart for production of Tapioca grits.
The shelf life of the tapioca runs into years provided that it does not come in contact with moisture.
PROCESSING EQUIPMENT
1.
Weighing Balance
2.
Washing machine
3.
Presser
4.
Grater
6.
Extractor
7.
Sieves
8.
Fryers/Rotary Dryer
9.
Hammer milling machine
10.
Sealer
Glucose syrup
Glucose syrup is a concentrated aqueous solution of glucose maltose and other nutritive saccharides from edible
starch. Glucose or dextrose sugar is found in nature in sweet fruits such as grapes or honey. It is less sweet than
sucrose (cane sugar). Glucose syrup is used in large quantities in fruits, liquors, crystallized fruits, bakery
products, pharmaceuticals and breweries.
Production of Glucose Syrup
Glucose syrup production from cassava can be subdivided into the process areas shown below:
(a)
(b)
(c)
Liquefaction
Saccharification
Purification
Native starch consists of microscopic granules having a complex internal structure. At room temp, these
granules are insoluble in water. However, if a starch slurry is heated above 60 0C, the granules will swell and
eventually rupture. This results in a dramatic increase in viscosity. At this point, the starch has been
“gelatinized”. The gelatinized starch is now susceptible to attack by amylase enzymes. In practice, cassava
starch is gelatinized and partially hydrolyzed very rapidly in one step (Fig 11) by heat stable amylase – this step
is called liquefaction. The partially degraded starch chains called dextrins are suitable starting materials for the
later steps in syrup production.
Liquefaction
A starch slurry is made with 30%-35% dry solids and its pH is adjusted to 6.0 – 6.4. Calcium is added using
calcium hydroxide or calcium chloride. Calcium ions stabilize the enzyme. A heat-stable α-amylase (Novo’s
Termamyl 120L) is mixed into the slurry, then the slurry is instantaneously heated to 100 o C and held at this
temperature for 10 min before it is cooled to 90 oC. This temperature is maintained for 1-3hrs to further
hydrolyze the starch.
At the end of this step, the starch has been converted to dextrins with a dextrose equivalent (DE) between 8
and 15 (The physical properties of the syrup vary with the DE and the method of manufacture – DE is the total
reducing sugar in the syrup expressed as dextrose on a dry weight basis.
Saccharification
After liquefaction, the pH is reduced to between 4.2-4.5 and the solution is cooled to 600c. A glucomylase
(Novo’s AMG 300L) is added immediately. The reaction time for saccharification is usually between 24-48h
depending on enzyme dose. Glucoamylase releases single glucose units from the ends of dextrin molecule.
Syrups of 95% glucose or higher are manufactured e.g. a typical 98 DE syrup could have the sugar profile
presented below:
Cassava Starch Slurry [35% DS, pH 6.6, Ca >40ppm
(Heat Stable –Amylase; Termamyl 120L, 0.05%)
Gelatinization (jet cook & hold) [95-103oC, 8min]
Liquefaction
Dextrinization [95oC, 1-3h]
Dextrin syrup [8-15% DE]
Glucoamylase [AMG 200L, 0.15%]
Saccharification Saccharification [60oC, pH 4.5, 48h, 30% DS]
Glucose syrup [95-96% Glucose]
Purification
[Filter activated carbon, cation-exchange resin/anion-exchange resin]
Purification
Evaporate [40-45% DS]
Final adjustments [55-60oC, pH 7.5-7.8, Magnesium >12ppm]
Process Flow Chart for Glucose Syrup from Cassava
Noodles
oodles are long thin piece of food made from a mixture of flour, water and eggs usually cooked in soup or
boiling water. They are a form of staple food very popular among the Asians from China to Indonesia and from
Japan to Vietnam. It is also a quick cooking paste that can be prepared in a microwave or by immersion in hot
water for 2-3 minutes. They can be made either by hand or by machine and, by the way they are made, are
divided into “cut noodles” or “dried noodles”. Made in whatever way, they may be of different width varying
from ribbons to threads. As a prepared dish, they can be served warm or cold dressed with chili oil or not, eaten
with fried bean sauce, chicken sauce, duck chops and soup of any concoction.
Cassava based Adhesives
The word adhesive as an adjective or a noun refers to substances, which tend to adhere or stick to other
substances, the interaction which develops between an adhesive and other dissimilar substance(s) when they
contact is called adhesion. Thus adhesives are used to unit or bind materials. Hence, they are very useful at
home and industries. Cassava based Adhesives, like the cereal starch adhesives, are of three main types viz:
(a)
Liquid Starch Adhesives
Liquid Starch Adhesives are supplied by the Adhesives manufacturer in liquid forms usually in plastic
or lined metal drums or in jerricans and bottles. They are used by consumers as supplied or diluted
further, depending on specification, with suitable solvent (usually water). They have limited shelf life
(6 to 18 months) and are not usually considered for export. The high solvent/water content and the
relative low cost of these adhesives do not also recommend them for export.
(b)
Pre-gel Starch Adhesives
Pre-gel starch Adhesives are produced in dry flakes and milled to specific adequate particles sizes.
They are packed in water proof lined multi-wall paper bags/sacks. They are very suitable for export.
(c)
Dextrin based Adhesives
Dextrin based Adhesives are delivered to consumers both in liquid and dry forms depending on
specification or requirement. The liquid Dextrin Adhesives are packed as the liquid starch Adhesives
while the Dry Dextrin Adhesives are packed as the milled pre-gel Adhesives. Dry Dextrin Adhesives
are very suitable for export especially to Europe and America where they are consumed in very large
quantities.
Process 2 Manufacture of Adhesives from starch cakes
Starch Cake
Chemical
Chemical
S/S Reaction vessel
Flash dryer cabinet
dryer
Rotary dryer
Roller/ Drum dryers
Pre-gel Adhesive
flakes
Enzyme
chemicals
or pyrolysis
S/.S Dextrin vessel
Dextrin
Miller
Packaging
Chemicals
M/S mixer
Packaging
Machinery & Equipments for Starch Adhesives Manufacture
The main equipments used for manufacture of starch based Adhesives are:
b)
For Liquid Starch Adhesive
Baurme (specific gravity tube)
Reactor.
Temperature gauges/Thermometers
PH meters
Packaging materials
Steam boiler or source
For Pre-gelatinized Adhesive
- Dry milling machine
- Packaging material-bags & sealers
(d)
(e)
For Dextrin Adhesives
-
Reactor
-
Dextrin pans
-
PH meters
-
Temperature gauge/thermometers
-
Sifters
Quality Control Equipments
-
Viscometers (Brookfield & scott)
-
Fluidity cups
-
Oven
-
Baurme
S/S Reaction vessels
Liquid Starch
Adhesive
Packaging
-
PH meter
-
Temperature gauges
-
Vacuum pump
-
Laboratory glass wares (filtration)
-
Microscope
-
Moisture tester
-
Visco Bradender Amylograph
Sources of the Machines & Equipment
Details of the local and Export components of machine and equipment sourcing will be discussed on
request.
Weighing of Ingredients
Production of alkali mixture
[4% guargum, 4% iodized salt, 0.03% tartrazine, 1.8% sodium phosphate,
1.2% potassium carbonate and 0.02% water]. pH 10-11
Mixing of cassava flour (50-80%), wheat flour (5-15%) and soybean flour (3-7%)
Addition of alkali mixture
Thorough mixing at high speed for 10 minutes
Kneading of the formed dough
Slitting into strands [1.00 – 1.05mm thick]
Steaming of strands [2 – 4min]
Deep frying [2 minutes at the temperature of 170oC].
Cooling
Packaged
Flow Chart Showing Production flow of Instant Cassava Noodles
Equipment Requirements
Major Equipment
Bioreactor with controls and accessories
Water holding containers
Centrifuge
Filter Unit
Evaporation Unit
pH meter
Refractometer
Minor Equipment
Weighing scale (Small and Medium)
Litmus paper
Graduated cylinders
Beakers & conical flasks
Burettes & pipettes
Water Bath
Dessicator
Thermometer
Filter paper