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

Name of product

Cassava Chips

Description Cassava Chips is a cassava product made by peeling, washing, chipping,

drying, packaging and storage. 3-5mm thick chips from peeled/or

soaked cassava root dried to <12% moisture content.

Packaging Jute bag line with food grade high density polyethylene film

Conditions of Storage 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

Target consumer groups Humans, Animals and Flour Mills

Recommendations for further processing

required before consumption

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.

CASSAVA CHIPS

SAND/IMPURITIES REMOVAL

GRINDING/SIZING

STEAMING

EXTRUSION/PELLETIZING

COOLING

SIEVING

CASSAVA PELLETS

PACKAGING

Process for production of cassava pellets

Steam

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

Name of product

High quality cassava flour

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

Food grade, moisture proof material (polyethylene, polypropylene)

of thick guage (specify).

Conditions of Storage Cool, dry and rodent and insect free environment.

Shelf-life 12 months

Instructions on the label

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

Target consumer groups

Bakeries

Other food industries

Caterers and housewives

Recommendations for further processing

required before consumption

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

Name of product

Gari

Description

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.

Packaging High density polythene bags and hessian / Jute bags

Conditions of Storage Dry cool place (below 36oC)

Shelf-life 12 Months

Instructions on the label

Constitute into dough with boiling water. One part product to 1.5

water(v/v) or according to consumers preference

Target consumer groups Adults and children

Recommendations for further processing

required before consumption

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

Name of product

Odourless fufu flour

Description

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.

Packaging

1kg in transparent moisture proof properly sealed food grade

polyethylene bags

Conditions of Storage Cool, dry place that in insect and rodent proof

Shelf-life Six months

Instructions on the label

Preparation instruction

Storage conditions

Best before date

Nutritional information

NAFDAC number

Name and address of manufacturer

Target consumer groups 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) Liquefaction

(b) Saccharification

(c) 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 600C, 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 100o C

and held at this

temperature for 10 min before it is cooled to 90oC. 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 60

0c. 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

Chemical Chemical

Enzyme

chemicals

or pyrolysis

Chemicals

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) For Dextrin Adhesives

- Reactor

- Dextrin pans

- PH meters

- Temperature gauge/thermometers

- Sifters

(e) Quality Control Equipments

- Viscometers (Brookfield & scott)

- Fluidity cups

- Oven

- Baurme

Starch Cake

S/S Reaction vessel

Flash dryer cabinet

dryer

Rotary dryer

S/S Reaction vessels

Roller/ Drum dryers

Pre-gel Adhesive

flakes

S/.S Dextrin vessel

Liquid Starch

Adhesive

Packaging

Dextrin

M/S mixer

Packaging

Packaging

Miller

- 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