Cassava Processing Machine

THE REGIONAL CASSAVA PROCESSING & MARKETING INITIATIVE (RCPMI) ------ROOT AND TUBER IMPROVEMENT AND MARKETING PROGRAMME (RTIMP) MINISTRY OF FOOD AND AGRICULTURE / IFAD

DATA-BASE ON CASSAVA EQUIPMENT MAKERS AND CASSAVA EQUIPMENT PROTOTYPES IN GHANA

FINAL REPORT

Prepared by: GERALD KOJO AHORBO

IFAD, Consultant

SEPTEMBER 2008

TABLE OF CONTENTS PAGE ACRONYMS

4

EXECUTIVE SUMMARY

5

1. INTRODUCTION

8

1.1. Background

8

1.2. Description of the Study Area

8

2. METHODOLOGY

10

3. LIMITATIONS OF THE SURVEY

12

4. ANALYSIS OF SURVEY RESULTS

13

4.1. Manufacturer

13

4.1.1. Geographical Representation

13

4.1.2. Legal Status

14

4.1.3. Type of Manufacturer and Number of Permanent Workers

15

4.1.4. Type of Equipment Manufactured

16

4.1.5. Source of Inspiration for the Equipment Manufactured

16

4.2. Manufacturers’ Sale Policy

17

4.2.1. Sales Promotion

17

4.2.2. Availability of Equipment

18

4.2.3. Sales Term

18

4.2.4. Equipment Guarantee

18

4.2.5. Post-sales Services

19

4.3. Production Bottlenecks

19

4.4. Sales Bottlenecks

20

4.5. Overall Assessment of Manufacturers and Equipment

21

4.5.1. Selected Manufacturers

21

4.5.2. Assessment of Equipment Selected

22

4.5.2.1.

Cassava Grater

22 1

4.5.2.2.

Cassava Press

24

4.5.2.3.

Cassava Mill

25

4.5.2.4.

Kokonte Cracker

26

4.5.2.5.

Cassava Chipper

26

4.5.2.6.

Bagging Stand

27

4.5.2.7.

Gari Roasting Pan

27

4.5.2.8.

Stove

28

4.5.2.9.

Sifter

28

4.5.2.10. Fermentation Rack

29

4.5.2.11. Cassava Dryer

30

5. RECOMMENDATIONS AND CONCLUSIONS

31

5.1. Recommendations

31

5.2. Conclusions

31

LIST OF TABLES Table #1: Regional Representation of the Manufacturers Table #2: Membership of Professional Association Table #3: Type of Manufacturer Table #4: Number of Permanent Workers Table #5: Production Table #6: Equipment Guarantee Period Table #7: Post-sales Services Table #8: Sales Bottlenecks Table #9: Selected Manufacturers and Equipment Table#10: Cassava Grater Advantages and Pre-conditions Table#11: Cassava Press Advantages and Pre-conditions Table#12: Cassava Mill Advantages and Pre-conditions Table#13: Cassava Chipper Advantages and Pre-conditions Table#14: Cassava Sifter Advantages and Pre-conditions

13 14 15 15 18 18 19 20 21 23 24 25 27 29

LIST OF DIAGRAMS Diagram 1: Legal Status of the Manufacturers Diagram 2: Cassava Equipment Manufactured Diagram 3: Sources of Inspiration Diagram 4: Means of Sales Promotion Diagram 5: Bottlenecks in Production 2

14 16 17 17 20

LIST OF FIGURES Figure-1: Artisan Workshop Figure-2: Semi-industrial Workshop Figure-3: Disc type Cassava Grater Figure-4: Self-feed type Cassava Grater Figure-5: IITA type Cassava Grater Figure-6: Conventional type Cassava Grater Figure-7: Single Screw Press Figure-8: Double Screw Press Figure-9: Cassava grinder Figure-10: Hammer Mills Figure-11: Kokonte Cracker Figure-12: Manual Chipper Figure-13: Motorised Chipper Figure-14: Bagging Stands Figure-15: Gari Roasting Pans Figure-16: LPG Industrial Stoves Figure-17: Dough Sifter Figure-18: Flour Sifter Figure-19: Gari Sifter Figure-20: Dough/Gari Sifter Figure-21: Fermentation Rack Figure-22: Cassava chip Dryer LIST OF ANNEXES Annex 1: Interview Guide for Manufacturers Annex 2: Interview Guide for Equipment Annex 3: Details on Assessment of Manufacturers and Equipment

3

15 15 22 22 22 23 24 24 25 25 26 26 26 27 27 28 28 28 28 28 29 30

ACRONYMS

RCPMI

Regional Cassava Processing and Marketing Initiative

IFAD

International Fund for Agricultural Development

NEPAD

New Partnership for Africa’s Development

RTIMP

Root and Tuber Improvement and Marketing Programme

WCA

Western and Central Africa

KNUST

Kwame Nkrumah University of Science and Technology

WAITRO

World Association of Industrial and Technological Research

AGI

Association of Ghana Industries

IITA

International Institute of Tropical Agriculture

ToR

Terms of Reference

4

EXECUTIVE SUMMARY Background The Regional Cassava Processing & Marketing Initiative (RCPMI) for Western and Central Africa has been launched by IFAD as a response to the call from African leaders, through the New Partnership for Africa’s Development (NEPAD), to accord priority to cassava in the regional agricultural development strategies. The RCPMI work-programme includes the creation of a data-base on equipment manufacturers and their prototypes in WCA. As for Ghana, this activity is implemented jointly with the IFAD-funded “Root and Tuber Improvement and Marketing Programme (RTIMP)”. This document reports on the work implemented to this end in Ghana. Description of the Study Area The study area, Ghana, is located on the west coast of Africa, and has a total land area of 238,537 km2 (92,100 sq. miles). In the north, vegetation is predominantly savanna, while the south has rain forest interspersed with savanna. The climate is tropical with general temperature of 21-32°C (70-90°F). There are two rainy seasons, from March to July and from September to October, separated by a short cool dry season in August and a relatively long dry season in the south from mid-October to March. Annual rainfall in the south averages 2,030 mm but varies greatly throughout the country, with the heaviest rainfall in the south western part. The population of Ghana is estimated at about 23.4 million (July 2008 estimate) and grows at 1.9% annually. The country is divided into ten (10) administrative regions. Methodology As per the terms of reference (TOR) provided by the RCPMI, the assignment started off with a meeting with the RTIMP staffs involved in the assignment. All those entrusted with the coordination and supervision of the assignment were met and the contact list of manufacturers and an introductory letter to be presented to the manufacturers and the users of the equipment were collected. Fairly, to cover the whole country and collect the information on cassava equipment in an objective and homogeneous way, the RCPMI designed survey instrument that was administered in all the ten regions of the country. This assignment was then executed in two phases: First Phase: a. From a contact list of manufacturers already gathered by RTIMP, 57 equipment makers nationwide were visited to collect primary information using the RCPMI/RTIMP interview guide for manufacturers (Annex 1) and 2 or 3 purchasers of the cassava processing equipments were contacted to find out the actual performance of the equipment. b. Based on the information collected, 48 equipment makers were selected for the second phase of the study. c. An interim mission’s report and a spreadsheet storing the primary information collected during the first phase were delivered to the IFAD concerned partners (RTIMP, RCPMI and Fidafrique).

5

Second phase: a. The RTIMP/RCPMI interview guide for equipment (Annex 2) was used to collect all needed data on the 48 equipment makers selected. b. Finally 28 equipment manufacturers were selected to be posted at the Fidafrique website and three digital pictures of each equipment’s prototype were taken jointly with the other data/information collected. c. All the data and information collected were put on a spreadsheet and transferred to the IFAD-partners (RTIMP, RCPMI and Fidafrique) so as to allow for the storage and presentation of data collected on the Fidafrique web-site. d. A final mission’s report highlighting main activities undertaken, methodology followed and results achieved during the two phases was prepared. Limitations of the study The number of issues encountered on the field that posed as limitations on the survey included: a. Refusal of some respondents to provide data; b. Inadequate information on the location of some equipment manufacturers; c. Poor or no records on the users of the manufacturers’ equipment; d. Unavailable weights of installed (mounted) equipment. Manufacturer The study covered 57 manufacturers in all the ten regions of Ghana. Most (65%) of them were in the Greater Accra, Volta and Central regions. Majority (54%), of the equipment manufacturers are sole proprietors. The “limited by guarantee” businesses are 21%, the “government subvented” are 6% and those with the “limited liability” status are 15%. Most (43.8%) belongs to the National Garages Association and 14.6% are in the “Association of Ghana Industries”. About 37.5% do not belong to a professional association. The two major types of manufacturers found in the study are: “semi-industrial manufacturers” who make up the highest number (54.1%) and “artisans” who represent 43.8%. About 43.8% of the manufacturers have employed 3 to 5 permanent workers with most (16.7%) operating with 4 permanent workers. There are twelve types of cassava processing equipments identified with the manufacturers. Almost all the manufacturers (91.7%) indicated that they produce cassava graters and 77.1% indicate they produce screw presses. The cassava grinder (also used for milling corn) is produced by 33.3% of the manufacturers. Most (85.4%) of the manufacturers had their inspirations from the prototypes of their colleagues and about 18.8% derived their inspirations from designs and drawings found elsewhere. Sale Policy Customer referrals formed 95.8% of the mode of sales promotion and none of the manufacturers used catalogues or websites. All the manufacturers produce their equipment on request, though 8.3% (4 out of the 48) do serial production. About 77.1% of the manufacturers indicated that they can produce about 10 products within 4 to 8 weeks; however, majority (41.7%) indicated 4 weeks to complete that same quantity of products. The sales term employed by all the manufacturers was cash sales with a minimum upfront payment of 50% of the price of product. None of the manufacturers provided credit sales because of the limited working capital they have for their operations. Most (39.6%) of the 6

manufacturers gave 6 months guarantee period while 33.3% gave 3 months. Post-sales services thus training of users on operating the equipment is offered by 91.7% of the manufacturers, while 89.6% provide equipment installation services. Almost all (97.9%) of the manufacturers provide emergency intervention services. Production Bottlenecks The high cost of fabricating materials has been the major production bottleneck, being faced by 75.0% of the manufacturers. Unavailability of appropriate materials for the fabrication works and working capital is faced by 35.4% and 33.3% manufacturers respectively. Sales Bottlenecks The major sales bottlenecks faced by the manufacturers include high cost of advertising products (37.5%) and the fall in sale of the cassava processing equipment (22.9%). Overall Assessment of Manufacturers and Equipment Out of the total of 48 manufacturers surveyed and assessed, 28 have been selected to be posted on the website. The ranges of manufacturers’ equipment which were assessed for the website are: Cassava Grater, Cassava Press, Cassava Mill, Kokonte Cracker, Cassava Chipper, Bagging Stand, Gari Roasting Pan, Stove, Cassava Sifter, Fermentation Rack and Cassava Dryer.

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1. INTRODUCTION 1.1. Background The RCPMI for Western and Central Africa has been launched by IFAD as a response to the call from African leaders, through the New Partnership for Africa’s Development (NEPAD), to accord priority to cassava in the regional agricultural development strategies. The RCPMI, which is a three-year initiative funded by the Italian Government (with a total contribution of US$1.3 million), has its main objectives of: 1. Maximizing cross-fertilization among IFAD projects (loans and grants) in the area of cassava processing and marketing; 2. Developing new markets, both for existing and new cassava products; and 3. Enhancing policy dialogue, both at a national and regional level, to support cassava industry development efforts. To achieve these goals, the RCPMI envisages the implementation of a set of actions meant to: 1. Develop markets for both existing and new products; 2. Identify the best processing technologies and good practices – within and beyond the regions, and to adapt them to local conditions; 3. Increase integration of stakeholders within the cassava chain; 4. Promote policy dialogue with regional and national policy makers, building up new or consolidating existing partnerships; and 5. Strengthen the mechanisms for exchanging cassava market and technological information – also through the use of the Fidafrique network. The actions mentioned above will be implemented in the context of the four Roots & Tubers (R&T) projects that IFAD is financing in Western & Central Africa (WCA) –specifically, in: Benin, Cameroon, Ghana and Nigeria. After the in-house approval of its three-year work-programme in July 2007, the RCPMI has actively started providing support to the various R&T projects within the WCA region. Among the actions included in the RCPMI workprogramme, the setting up of a regional data-base on equipment makers and their prototypes are also envisaged. The RCPMI work-programme includes the creation of a data-base on equipment manufacturers and their prototypes in WCA. As for Ghana, this activity is implemented jointly with the IFAD-funded “Root and Tuber Improvement and Marketing Programme (RTIMP)”. This document reports on the work implemented to this end in Ghana. 1.2. Description of the Study Area The study area was Ghana located on the west coast of Africa. It is bounded on the north by Burkina Faso, on the west by La Cote D'lvoire, on the east by Togo and on the south by the Gulf of Guinea. 8

The country, Ghana has a total land area of 238,537 km2 (92,100 sq. miles) and stretches 672 km north-south and 536 km east-west. The land is relatively flat and the altitude is generally below 500m, with more than half of the country below 200m. In the north, vegetation is predominantly savanna, while the south has rain forest interspersed with savanna. The climate is tropical, but temperatures vary with season and elevation. The temperature is generally 21-32°C (70-90°F). There are two rainy seasons, from March to July and from September to October being separated by a short cool dry season in August and a relatively long dry season in the south from mid-October to March. Annual rainfall in the south averages 2,030 mm but varies greatly throughout the country, with the heaviest rainfall in the south western part. The population of Ghana is estimated at about 23.4 million (July 2008 estimate) and grows at 1.9% annually. Most of the population is concentrated in the southern part of the country with the highest density occurring in urban and cocoa producing areas. The country is divided into ten (10) administrative regions (listed below), all covered by this study: • • • • • • • • • •

Upper West Region; Upper East Region; Northern Region; Brong Ahafo Region; Ashanti Region; Volta Region; Eastern Region; Western Region; Central Region; and Greater Accra Region.

9

2. METHODOLOGY As per the terms of reference (TOR), the assignment started off with: a. A meeting with the RTIMP staffs involved in the assignment. The contact list of manufacturers, an introductory letter to be presented to the manufacturers and the users of the equipment were collected; b. Inception report for the assignment was prepared and presented to RCPMI and RTIMP. To fairly cover the whole country and collect the information on cassava equipment in an objective and homogeneous way, the RCPMI and RTIMP designed survey instruments that were administered in all the ten regions of the country. The assignment was then executed in two phases. First Phase: d. From a contact list of manufacturers already gathered by RTIMP, 57 equipment makers nationwide were visited to collect primary information on their enterprises, thus level of their operations, and the number/kind/quality of prototypes they produce. This information was recorded using the interview guide for manufacturers (Annex1) provided by RCPMI, the RTIMP and Fidafrique. e. For each equipment maker surveyed, 2 or 3 purchasers of the cassava processing equipments were contacted to find out the actual performance of the equipment. f. Based on the primary information collected from both the equipment makers and their clients, 48 equipment makers were selected for the second phase of the study. g. An interim mission’s report highlighting main activities undertaken, methodology followed and results achieved was prepared. h. Jointly to the report, a spreadsheet storing the primary information collected during the first phase was delivered to the IFAD-partners (RTIMP, RCPMI and Fidafrique). Second phase: a. The 48 equipment makers selected during the first phase were revisited to collect all needed data and information on their enterprises and equipment using the RCPMI/RTIMP interview guide for equipment (Annex 2). b. Information on the prototypes of interest which were not available within the equipment makers’ premises at the time of the visit was collected from the user of the equipment concerned. c. Finally 28 equipment manufacturers were selected to be posted at the website and three digital pictures of each equipment prototype were taken jointly with the other data/information collected. d. All the data and information collected were put on a spreadsheet and transferred to the IFAD-partners (RTIMP, RCPMI and Fidafrique) so as to allow for their storage and presentation on the Fidafrique web-site. e. A final mission’s report highlighting main activities undertaken, methodology followed and results achieved during the two phases was also prepared.

10

f. A one-day workshop remains to be organised to the benefit of the various RTIMP stakeholders to: ƒ inform them on the outcomes of the consultancy-work, the nature of the information that has become available by means of the data-base, ways to access and use it; and ƒ jointly decide on the new activities that the RCPMI and the RTIMP could jointly implement to continue supporting cassava equipment makers in Ghana.

11

3. LIMITATIONS OF THE SURVEY A number of issues were encountered on the field and posed as limitations on the survey. These included: a. Refusal of some respondents to provide data because similar surveys conducted in the past has not benefited their business; b. Inadequate information on the location of some of the equipment manufacturers; c. Poor or no records on the customers (users of the equipment) thereby making it difficult to locate them; and d. Unavailable weights of installed (mounted) equipment.

12

4. ANALYSIS OF SURVEY RESULTS

The results of the survey are presented as follows: ƒ Manufacturer; ƒ Manufacturer’s sale policy; ƒ Production bottlenecks; ƒ Sales bottlenecks; and ƒ Overall assessment of manufacturers and equipment. 4.1. Manufacturer 4.1.1. Geographical Representation Table #1: Regional Representation of the Manufacturers

Regions

1 2 3 4 5 6 7 8 9 10

Greater Accra Volta Central Eastern Western Ashanti Brong Ahafo Northern Upper East Upper West Total

Total Number Number selected Regional surveyed for the next phase representation of the selected (%) 16 16 33.3 13 10 20.8 8 5 10.4 4 4 8.3 5 4 8.3 2 2 4.2 2 2 4.2 2 2 4.2 4 2 4.2 1 1 2.1 57 48 100

Source: Survey, August 2008

The study covered all the ten regions of Ghana based on the list provided by RTIMP. During the study, an additional list of 10 manufacturers spread across the country was added to make up for the short fall in the number due to fold-up businesses and those which declined interview. Out of 57 manufacturers visited, 48 were selected from the ten regions for the assessment stage of the study. Most (65%) of the manufacturers interviewed are in three regions (Greater Accra 33.3%; Volta 20.8% and Central 10.4%) while the remaining 35% are in the other seven regions (table#1). From observation, the concentration of the cassava equipment manufacturing activities were influenced greatly by the availability of three phase electric power supply, the skill of labour, the patronage of cassava processing machines, and the level of cassava processing and marketing activities among others.

13

4.1.2. Legal Status Majority (54%), of these equipment manufacturers are sole proprietors. The limited by guarantee businesses are 21%, the government subvented are 6% and those with the limited liability status are 15%. Only 4% (2 out of the 48 manufacturers) do not have legal status (diagram-1).

Legal Status of the Manufacturers

6%

4%

Sole Proprietorship

15%

Limited by Guarantee Limited Liability 54%

21%

Government Subvented Non registered

Diagram-1 The three institutions (Institute of Industrial Research, KNUST Faculty of Agricultural Engineering and Food Research Institute) are government subvented organisations that have been given the mandate to commercialise their activities to absorb about 30% of their operational cost. Most of these manufacturers 43.8% (21 out of the 48 manufacturers) belong to the National Garages Association and 14.6% (7 out of the 48 manufacturers) are in the Association of Ghana Industries (table#2). Table #2: Membership of Professional Association

1 2 3 4

5

Professional Association Frequency Percentage (%) National Garages Association 21 43.8 Non registered 18 37.5 Association of Ghana 7 14.6 Industries World Association of Industrial 2 4.2 and Technological Research (WAITRO) Ghana Society of Agricultural 1 2.1 Engineers Total* 49 102.2 Source: Survey, August 2008 * Multiple respondents

A high number of 37.5% (18 out of the 48 manufacturers) does not belong to a professional association. Only one manufacturer (Hormeku Engineering Works Limited) belongs to both the Association of Ghana Industries (AGI) and National Garages.

14

4.1.3. Type of Manufacturer and Number of Permanent workers Semi-industrial manufacturers make up the highest number (54.1%) of cassava equipment manufacturers. Artisans represent 43.8% and only 2.1% was an Industrial manufacturer (table#3). Table #3: Type of Manufacturer

1 2 3

Type of Manufacturer Semi-industrial Artisan Industrial Total

Frequency 26 21 1 48

Percentage (%) 54.1 43.8 2.1 100

Source: Survey, August 2008

The typical artisan workshop has simple structure (most often temporal structure) that houses the basic working tools and operates with very limited basic tools (figure1), whiles the semi-industrial workshops have permanent structures housing machines and hand tools and perform most of the manufacturing activities with the in-house machines (figure-2).

Figure-1: Artisan Workshop

Figure-2: Semi-industrial Workshop

Table #4: Number of Permanent Workers Number of Permanent Workers Frequency Percentage (%) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 20 21 66 Total

3 2 7 8 6 3 1 1 1 2 1 4 3 1 1 1 1 1 1 48

Source: Survey, August 2008

15

6.3 4.2 14.6 16.7 12.5 6.3 2.1 2.1 2.1 4.2 2.1 8.3 6.3 2.1 2.1 2.1 2.1 2.1 2.1 100

The only cassava equipment manufacturer visited who is operating at an industrial level has the highest number of 66 permanent workers. All the other manufacturers are operating with less than 22 permanent workers (table#4). About 43.8% of the manufacturers have from 3 to 5 permanent workers with most (16.7%) operating with 4 permanent workers. Only three manufacturers are operating with a permanent worker. 4.1.4. Type of Equipment Manufactured

Percentage

Cassava Equipment Manufactured Cassava grater

100 90 80 70 60 50 40 30 20 10 0

Screw press Cassava grinder Kokonte cracker Cassava chipper Bagging stand Roasting pan LPG stove Sifter Fermentation rack

1

Dryer

Cassava equipment

Hammer mill

Diagram-2

There are twelve types of cassava processing equipment identified with the manufacturers (diagram-2). Almost all the manufacturers (91.7%) indicate that they produce Cassava grater, and 77.1% indicate they produce Screw Press. The Cassava grinder (also used for milling corn) which also serves other purposes is produced by 33.3% of the manufacturers. The least group of equipment the manufacturers indicate they make are the Hammer mill (4.2%) and the LPG Stove (6.2%). 4.1.5. Source of Inspiration for the Equipment Manufactured Most (85.4%) of the manufacturers were inspired by the prototypes of their colleagues to develop better products and designs (diagram-3). About 18.8% indicated that they derived their inspiration from designs and drawings, while 10.4% were inspired by their customers who often request for unique products and designs such as miniature equipment for domestic and mobile purposes.

16

Percentage

Sources of Inspiration 90 80 70 60 50 40 30 20 10 0

Manufacturers prototypes Internet Catalogue Trade fair Research publications Designs and drawings Customers request Challenges and problems 1

Reading books

Inspiration

Emerging opportunities

Diagram-3

Only 2.1% was inspired by pictures on the internet and none had their inspiration from catalogue. The other sources of inspirations indicated were from books read, challenges and problems associated with agro processing and the emerging opportunities. 4.2. Manufacturers’ Sale Policy 4.2.1. Sales Promotion Customer referrals formed 95.8% of the mode of promoting sales because it does not virtually involve cost (diagram-4). Means of Sales Promotion Catalogue

120

Flyer 100

Percentage

Web site 80

Radio and Television

60

Customer referals Fairs and Exhibits

40 Product display 20

Complementary cards Sign boards

0 1

Seminars, conferences, and workshops

Sale s Promotion

Diagram-4

Only 25.0% promote their sales through fairs and exhibitions and none used catalogues or websites.

17

4.2.2. Availability of Equipment All the manufacturers produced their equipment on request, though 8.3% (4 out of the 48) do serial production (table#5). Table #5: Production Specified Time (weeks) 1 2

Serial production Production request

on

Total*

2 3 4 6 8 12 35

Frequency 4 3 4 20 7 10 4 52

Percentage 8.3 6.3 8.3 41.7 14.6 20.8 8.3 108.3

Source: Survey, August 2008 * Multiple respondents

About 77.1% of the manufacturers indicated that they can produce about 10 products within 4 and 8 weeks; however, majority (41.7%) indicated 4 weeks to complete that same quantity of products. 4.2.3. Sales Term The sales term employed by all the manufacturers is cash sales with a minimum upfront payment of 50% of the price of product before the commencement of work. None of the manufacturers provided credit sales because of the limited working capital they use in their operations. 4.2.4. Equipment Guarantee With the exception of two manufacturers, all the others guarantee their products (table#6).

1 2 3 4 5 6 7

Table #6: Equipment Guarantee Period Guarantee period (months) Frequency No guarantee period 2 1 3 2 2 3 16 4 1 6 19 12 5 Total 48

Percentage 4.2 6.3 4.2 33.3 2.1 39.6 10.4 100

Source: Survey, August 2008

The guarantee period vary from 1 month to 12 months. Most (39.6%) of the manufacturers give 6 months guarantee period and 33.3% give 3 months. Within the guarantee period, all cost of correcting manufacture defects on the equipment is absorbed by the manufacturer.

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4.2.5. Post-sales Services Post-sales services in training of users on how the equipment is operated and maintained are offered by 91.7% of the manufacturers and 89.6% manufacturers provide equipment installation services (table#7). Table #7: Post-sales Services Frequency Installation of equipment 43 Equipment operation and maintenance 44 training Spare parts availability 6 Emergency interventions 47 Total* 140

1 2 3 4

Percentage 89.6 91.7 12.5 97.9 291.7

Source: Survey, August 2008 * Multiple respondents

Almost all (97.9%) of the manufacturers provide emergency intervention services. Only 12.5% make spare parts of the equipment (especially the grating plates and drum) available to the users. Some other post sale services offered by some of the manufacturers include the transporting of equipment to client and the updating of the client on improved technologies developed. 4.3. Production Bottlenecks The manufacturers of cassava processing equipment have been encountering multifaceted bottlenecks which have slowed down their production and sales. As indicated in diagram-5, the high cost of fabrication materials has been the major production bottleneck faced by 75.0% of the manufacturers. Bottlenecks in Production 80

Interrupted electric power

70

High cost of steel

60

Unavailable appropriate materials

Percentage

Institutional bureaucracy 50 Inferior materials 40 Unavailable precision tools 30

Absence of technology centre

20

Unfavourable unit manufacturing

10

Working capital Scarce skilled labour

0 1

Inadequate research work

Production Bottlenecks

Diagram-5

19

The unavailability of appropriate materials for the fabrication works was indicated by 35.4% of the manufacturers and 33.3% manufacturers cited working capital as a big production problem. The least bottlenecks mentioned (unit manufacturing, absence of technology centre, inadequate research work and institutional bureaucracy) are each indicated by 2.1% of the manufacturers. 4.4. Sales Bottlenecks The major sales bottlenecks faced by the manufacturers include the high cost of advertising products (37.5%) and the fall in sale of the cassava processing equipment (22.9%). The others as listed in table#8 are the increase in number of equipment manufacturers and the lost of cassava farm lands to land developers.

1 2 3 4

Table #8: Sales Bottlenecks Frequency Slow market for equipment 11 High cost of advertising products 19 Lot of manufacturers have emerged in the 1 past years Cassava farmers have sold out land to 1 estate developers Total* 32

Percentage 22.9 39.6 2.1 2.1 66.7

Source: Survey, August 2008 * Multiple respondents

4.5. Overall Assessment of Manufacturers and Equipment 4.5.1. Selected Manufacturers and Equipment Out of the total of 48 manufacturers surveyed and assessed, 28 have been selected to be posted on the website (table#9). The main criteria used for the selection are the comments made by the users on the performance of the equipment purchased; the type of post sales services provided by the manufacturer; the design and quality of construction of the equipment; the availability of basic manufacturing tools at the workshop and the availability of other manufacturing services within reach of the manufacturer. Though most of them are handicapped in working with engineering drawings, they rely mainly on their experience and existing patterns to fabricate the machines. All the manufacturers selected have the capacity to produce in large quantities to meet orders. The details of the assessment results of each manufacturer are attached in Annex 3.

1 2 3 4

Table #9: Selected Manufacturers and Equipment Selected manufacturers Available equipment for the website Camara Engineering Cassava grater (conventional type) Institute of Industrial Research Advance Metal Works

Cassava grater (conventional type), Dough sifter, and Gari sifter LPG industrial stove

GRATIS Foundation (Rural Technology Services Center), Techiman

Cassava grater (conventional type), Double screw press, Cassava chipper (motorised type), Bagging stand, Dough/Gari sifter, Fermentation rack, Cassava grinder (also used for

20

5

GRATIS Foundation, Upper West Region, Wa

milling corn) Cassava grater (conventional type), Double screw press, Cassava grinder (also used for milling corn)

6

GRATIS Foundation, Brong Ahafo Region, Sunyani

Cassava grater (conventional type), Double screw press, Cassava grinder (also used for milling corn), Bagging stand

7

GRATIS Foundation, Upper East Region, Bolga GRATIS Foundation, Northern Region, Tamale

Cassava grinder (also used for milling corn)

9

GRATIS Foundation, Eastern Region, Koforidua

10 11

Respect Welding Workshop Zoranu Welding and Fabrication Shop SIS Engineering Limited

Cassava grater (conventional type), Cassava grater (IITA type), Double screw press, Cassava grinder (also used for milling corn), Cassava chipper (motorised type), Bagging stand, Dough/Gari sifter, Fermentation rack, Cassava grater (conventional type) Cassava grater (disc type)

8

12 13 14 15 16 17 18 19

20

21

Agbemskod Engineering Limited Advantage Metal Construction Works GRATIS Foundation, Central Region, Cape Coast GRATIS Foundation, Western Region, Takoradi Mawuli Engineering Works (Ex John Technical) Hormeku Engineering Works Limited Engineering and Technical Services Establishment (ENTESEL) Roland Welding and Machine Shop

24

Christopher Welding Machine Shop GRATIS Foundation, Volta Region, Ho City Welding and Trading Enterprise J. K. Todoadzi Metal Works

25

Azameti Metal Works

26

Agbenyegah S. F. Metal Works Sylta Engineering Development Enterprise Food Research Institute

22 23

27 28

Cassava grater (conventional type), Double screw press, Cassava grinder (also used for milling corn), Bagging stand

Cassava grater (Self-feed type), Cassava flour mill (hammer mill type) Cassava grater (conventional type), Cassava flour mill (hammer mill type) Cassava grater (conventional type) Cassava grater (conventional type), Double screw press, Bagging stand, Dough/Gari sifter, Fermentation rack Cassava grater (conventional type), Cassava grater (IITA type), Double screw press, Bagging stand Cassava grater (conventional type), Double screw press, Cassava grinder (also used for milling corn), Gari roasting pan Cassava grater (conventional type), Gari roasting pan, Cassava dryer (mechanical type) Cassava grater (IITA type), Double screw press, Cassava chipper (electric motor type), Cassava chipper (petrol engine type), Cassava chipper (manual type), Bagging stand Cassava grater (conventional type), Cassava grater (disc type), Single screw press, Cassava grinder (also used for milling corn), Kokonte cracker Cassava grater (conventional type), Cassava grinder (also used for milling corn), Kokonte cracker Cassava grater (conventional type), Double screw press, Cassava chipper (petrol engine type), Dough/Gari sifter Cassava grater (conventional type) Cassava grater (conventional type), Mobile cassava grater (mini-conventional type), Cassava grinder (also used for milling corn) Cassava grater (conventional type) Cassava grater (conventional type) Cassava grater (conventional type) Cassava grater (conventional type), Single screw press, Cassava flour sifter

Source: Survey, August 2008

21

4.5.2. Assessment of Equipment Selected Most of the cassava processing equipment found with the users is fabricated from mild steel based on users’ affordability, however all the equipment built for industrial purposes were partly made of stainless steel. The equipment capacities stated by most of the manufacturers were higher than what was observed and estimated by the users. It was found that all the manufacturers have not conducted any comprehensive test to determine the actual capacity of the equipment they built. In this study the capacities quoted are what were observed with the users during the normal working conditions and the values quoted are closer to the actual as much as possible. The equipment of the manufacturers which were assessed for the website is discussed below: 4.5.2.1.

Figure-3: Disc type

Cassava Grater

Figure-4: Self-feed type

Figure-5: IITA type

Figure-6: Conventional type

The cassava graters are machines used to grate peeled fresh cassava into very small fine particles (pulp or dough). This study categorised the graters into two main types. The type with a circular punched sheet fitted onto a wooden disc that rotates on a vertical shaft (figure-3) and the other type that has a grating drum rotating on horizontal shaft (figure-4, 5, and 6). The horizontal shaft type comes in two forms: the grating drum made of wood or metal with saw teeth grating blades mounted on the surface and the wooden or metal drum with punched sheet rapped on the surface. Some of these graters serve other purposes such as grating copra. This was found with the conventional type of grater (figure-6) especially those designed with the saw

22

grating teeth. However, in some parts of the country, graters with the punched sheet grating drum are also used for grating copra. The graters are all power driven and are powered by either 10HP electric motor; 2.23.0kW (3-4HP) small petrol engine; or the 6kW (8HP) twin flywheel stationary diesel engine. Most of the graters found with the users are robust and of the conventional type. The capacity of the graters ranges from 550kg/hr to 2500kg/hr. The main advantages and pre-conditions for the use of these graters are summarised in table#10 below.

1

2

3

4

Table#10: Cassava Grater Advantages and Pre-conditions Cassava Grater Main Advantages Pre-conditions for use Disc type Self-feed grating; Produces very fine None uniform sizes of pulp; Grating fineness is adjustable; Easy to operate Self-feed type Self-feed grating; Produces uniform sizes Start the grater before of pulp; Very high capacity; Grating feeding; fineness is adjustable; Easy to operate; Easy to maintain Conventional type Produces uniform sizes of pulp; Cassava Start the grater before feed rate is increased with a press wood; feeding; Grating fineness is adjustable IITA type Mobile; Produces uniform sizes of pulp; Start the grater before Cassava feed rate is increased with a feeding; press board; Oval shaped hopper shape reduces spillage; Grating fineness is adjustable

4.5.2.2.

Cassava Press

Figure-7: Single Screw Press

Figure-8: Double Screw Press

The cassava press are equipments used to de-water the grated cassava. There are two main types of cassava press found with the study: the single screw press (figure7) and the double screw press (figure-8). The double screw press are found with most of the users because of the capacity (350kg/batch) and its suitability for pressing three to four big bags of grated cassava at a time. They are robust and manually operated. The single screw press requires one person to operate while the double screw press requires two persons to operate. The main advantages and pre-conditions for use of the single and double screw press are summarised in table#11 below. 23

1 2

Table#11: Cassava Press Advantages and Pre-conditions Cassava Press Main Advantages Pre-conditions for use Single screw type Low maintenance cost; Easy and fast Load evenly before lowing to operate the press plate Double screw type Low maintenance cost; Press bar Load evenly before lowing allows varied loading capacity; Easy the press bar to operate

4.5.2.3.

Cassava Mill

Figure-9: Cassava grinder

Figure-10: Hammer Mills

The cassava mill processes dried cassava chips into flour. In this study, two types of mills were identified: the cassava grinder (figure-9) and the hammer mill (figure-10). The cassava grinder (also used for milling corn) is of two types; the type with a rotating shaft that slides in a journal brass bearing and the other type with a fixed rotating shaft mounted with two ball bearings. Both works well, but the grinder with the shaft supported in a ball bearing is preferred because its maintenance cost is very low. The hammer mills are used with very fine sieves to give the desired texture of flour. The mills are powered by either 7.5kW (10HP) electric motor or 6kW (8HP) twin flywheel stationary diesel engine and their capacities range from 200kg–250kg for the grinder and 1000kg–2000kg for the hammer mill. A minimum of one operator is required on the machine. These machines are also robust and all the parts are fabricated from steel (either mild steel or stainless steel upon request). The main advantages and pre-conditions for use of the machines are listed in table#12 below.

1

2

Table#12: Cassava Mill Advantages and Pre-conditions Mill Main Advantages Pre-conditions for use Cassava grinder Robust; All parts are steel fabricated; Low Start the mill before feeding maintenance cost with the shaft using ball bearings Hammer mill Robust; Uses flexible hammers and fine mesh; Designed for cassava chips (or dried materials); Easy to operate; Easy to Start the mill before feeding maintain

24

4.5.2.4.

Kokonte Cracker

Figure-11: Kokonte Cracker

The kokonte cracker (figure-11) is a simple machine fabricated to crush dried cassava chunks (kokonte) into smaller sizes for milling. It is powered by either a 10HP electric motor or 6kW (8HP) twin flywheel stationary diesel engine. The capacity of the crackers is about 500kg/hr and a minimum of one person is required to operate it. All the crackers found with the users are robust and fabricated from mild steel. The main advantages of the cracker are robustness, simple design and ease of maintenance. The pre-condition for its usage is feeding the cracker when in operation. 4.5.2.5.

Cassava Chipper

Figure-12: Manual Chipper

Figure-13: Motorised Chipper

The cassava chipper (slicer) chops the cassava into small pieces (chips) with the rotating chipping plate which is either operated manually (figure-12) or power driven by a small 2.2-3.0kW (3-4HP) petrol engine (figure-13) or 1.5-2.2kW (2-3HP) electric motor. The capacity is about 200kg/hr for the manually operated chipper and about 500kg/hr for the power driven type. All the chippers found with the users are fabricated with a stainless steel chipping plate and mild steel frame. A minimum of one person is required to operate the chipper. The main advantages and pre-conditions for use are listed in table#13 below.

25

1

2

Table#13: Cassava Chipper Advantages and Pre-conditions Chipper Main Advantages Pre-conditions for use Manual chipper Movable and manually operated; Turn the chipping plate Simple to operate; Eliminates before feeding dewatering operation; Easy to maintain Power chipper Easy to maintain; Simple to operate; Start the chipper before Eliminates dewatering operation feeding

4.5.2.6.

Bagging Stand

Figure-14: Bagging Stands

The bagging stand (figure-14) helps fill sacks without the help of a second person. It is very simple in construction and made of mild steel. It can help bagging up to 100kg of processed material, such as the cassava dough or gari. It is light in weight (8kg) and can be moved around. The main advantages of the bagging stand are its light weight; easily movable; easy to operate; reduces spillage during bagging; easy to maintain and eliminates the need for additional manpower. It has no pre-conditions for usage. 4.5.2.7.

Gari Roasting Pan

Figure-15: Gari Roasting Pans

The gari roasting pan (figure-15) is aluminium cast and weighs from 33kg to 37kg. It holds up to 20kg of sifted cassava dough on fire for one person to roast. The main advantages of the pan are robustness, long lasting, easy to use and conduct heat very well. It has no pre-conditions for its usage.

26

4.5.2.8.

Stove

Figure-16: LPG Industrial Stoves

The LPG industrial stoves (figure-16) are robust and in use for commercial and industrial work. The main frame is made of mild steel and the burners are either cast iron or aluminium. The design is simple and could be adopted for roasting gari. The main advantages for the stove are robustness, simple design, easy to use and tailor made to support any type of cooking pan. The pre-condition for use is to strike the match before turning on the gas. 4.5.2.9.

Sifter

Figure-17: Dough Sifter

Figure-18: Flour Sifter

Figure-19: Gari Sifter

Figure-20: Dough/Gari Sifter

There are four types of sifters identified during this study: the cassava dough sifter (figure-17); cassava flour sifter (figure-18); the gari sifter (figure-19) and the cassava dough/gari sifter (figure-20).

27

The cassava dough sifter, sieves disintegrated cassava dough by a rotation action of a cylindrical sifter which is operated manually by one person. It is fabricated with mild and stainless steel and has a capacity of 500kg/hr. The cassava flour sifter has a capacity of 500kg/hr, and sifts cassava and other flour through a cylindrical sieve with a horizontal stirrer that is powered by a 1.5kW (2HP) electric motor. The sieved flour comes out through a discharge spout and the chaff is expelled through another discharge spout. It is fabricated from mild and stainless steel. The gari sifter is a vibrating sieve that separates the gari through one discharge spout and the roughage through another spout. It is powered by a 5.5HP motor and operated by one person. It is fabricated from mild and stainless steel and has a capacity of 1000kg/hr. The cassava dough/gari sifter sieves disintegrated cassava dough or gari by the shaking (or oscillating) action of a wooden box sieve filled with the material to be sifted. It has a capacity of 250kg/hr and operated manually by a person. The main advantages and pre-conditions for use are listed in table#14 below.

1

2

3 4

Table#14: Cassava Sifter Advantages and Pre-conditions Sifter Main Advantages Pre-conditions for use Cassava dough Fast and convenient than the manual Close all openings on the sieve sifter sifting; Easy to operate; Easy to before feeding maintain Cassava flour sifter Uniform sifting; Works fast and Start the sifter before feeding convenient; Reduces spread of dust; the sifting chamber Easy to operate Gari sifter Fast and convenient; Reduces wastage; Start the sifter before feeding Easy to operate Cassava Movable; Reduces spillage; Easy to None dough/gari sifter operate; Easy to maintain

4.5.2.10. Fermentation Rack

Figure-21: Fermentation Rack

The fermentation rack (figure-21) holds up to 500kg of cassava dough in a hygienic state for few hours for the water and starch to drain whiles fermenting and waiting to be dewatered with the press. The rack is constructed with wood and a minimum of one person is required to work with it. The main advantages of the fermentation rack are its simple design, it is easy to use, it is movable and allows collection of starch and water during period of fermentation.

28

4.5.2.11. Cassava Dryer

Figure-22: Cassava chip Dryer

The cassava chip dryer (figure-22) has a capacity of 1500kg/batch and fires on Liquefied Petroleum Gas (LPG). It has a 7.5kW (10HP) motor that drives the blower which circulates the hot air in the drier. It is constructed from mild steel and lined with aluminium sheet. The drier could serve other purposes such as drying of grains and a minimum of two people are required to operate it. The main advantages of the dryer are its simple design, ease of loading and emptying, ease of maintenance and can be used to dry other food materials. The pre-condition for its usage is loading the bucket before turning-on the dryer.

29

5. RECOMMENDATIONS AND CONCLUSIONS 5.1. Recommendations Manufacturers •

The selected equipment manufacturers in the cassava chain and other potential manufacturers should be equipped with the requisite basic skills of drawing, blue print reading and quality finishing of products to facilitate the transfer of new designs of cassava processing equipment.

Equipment •

Cassava Grater: High performance self-feed type of cassava graters should be promoted to eliminate the laborious operation of force feeding the grating drum with a press board or wood during grating.

•

Cassava Press: The design and manufacture of the double screw press should allow for easy removal of the screw shaft and nuts for repair or replacement when they are worn out.

•

Cassava Grinder: The cassava grinder (also used for milling corn) with fixed mounted shafts in ball bearings should be promoted to eliminate the frequent problems of repairing or replacing worn shaft that occurs as a result of poor oiling and the excessive wear of the plain bearings.

•

The well performing cassava processing machines which are already in use in the country should be identified and documented (with detail drawings, users and maintenance manual) for use on the RTIMP projects.

Equipment Users •

The equipment owners and users (operators) must be adequately equipped with the requisite knowledge and skills in operating and maintaining their equipment to avoid breakdowns.

5.2. Conclusions •

Geographical Representation: Most (65%) of the manufacturers interviewed are in the Greater Accra 33.3%; Volta 20.8% and Central 10.4%.

•

Legal Status: Majority (54%), of these equipment manufacturers are sole proprietors. The limited by guarantee businesses are 21% and the limited liability ones are 15%. Most (43.8%) belongs to the National Garages Association and a high number of 37.5% do not belong to a professional association.

30

•

Type of Manufacturer and Number of Permanent workers: Semi-industrial manufacturers make up the highest number (54.1%) of cassava equipment manufacturers and Artisans represent 43.8%. About 43.8% of them have employed 3 to 5 permanent workers with most (16.7%) operating with 4 permanent workers.

•

Type of Equipment Manufactured: Twelve types of cassava equipment (grater, screw press, grinder, cracker, sifter, stove, dryer, fermentation rack, bagging stand, hammer mill, chipper and roasting pan) were produced amongst the manufacturers and 91.7% are involved in the manufacture of the grater.

•

Source of Inspiration for the Equipment Manufactured: Most (85.4%) of the manufacturers were inspired by the prototypes of their colleagues. None had inspiration from catalogue.

•

Sales Promotion: Customer referrals formed 95.8% of the mode of promoting sales. Only 25.0% use fairs and exhibitions to promote their sales and none used catalogues and websites.

•

Availability of Equipment: All the manufacturers produced their equipment on request and 77.1% indicated that they can produce about 10 products within 4 and 8 weeks.

•

Sales Term: All the manufacturers employed cash sales with a minimum upfront payment of 50% of the cost of product before the commencement of work. None provided credit sales.

•

Equipment Guarantee: Most (39.6%) of the manufacturers guarantee their products for 6 months and 33.3% provide 3 months guarantee.

•

Post-sales Services: Post-sales services in training of users on how the equipment is operated and maintained are offered by 91.7% of the manufacturers and 89.6% manufacturers provide equipment installation services. Almost all (97.9%) of the manufacturers provide emergency intervention services.

•

Production Bottlenecks: The high cost of fabrication materials has been the major production bottleneck faced by 75.0% of the manufacturers. The others are the unavailability of appropriate materials for the fabrication works (35.4%) and the absence of working capital (33.3%).

•

Sales Bottlenecks: The major sales bottlenecks faced by the manufacturers included the high cost of advertising products (37.5%) and the fall in sale of the cassava processing equipment (22.9%).

•

Selected Manufacturers and Equipment: The 28 manufacturers selected to be posted on the website have the capacity to fabricate the cassava processing equipment indicated to their name.

•

Assessment of Equipment Selected: Most of the cassava processing machines are fabricated with mild steel material but could be stainless steel on request.

31

•

Equipment Capacity: The capacity of the cassava processing equipment are: 550kg/hr to 1200kg/hr for the conventional grater; 550kg/hr to 750kg/hr for the disc type grater; 2000kg/hr-2500kg/hr for the Self-feed type grater; 550kg/hr to 750kg/hr for the IITA type grater; about 350kg/batch for the double screw press; up to 200kg/hr for the cassava grinder; 1000kg/hr-2000kg/hr for the hammer mill; about 500kg/hr for the cracker; up to 250kg/hr for the manual chipper; 250kg/hr to 500kg/hr for the motorised chipper; up to 100kg/bag for the bagging stand; up to 20kg/batch for the roasting pan; up to 500kg/hr for the dough and flour sifters; up to 1000kg/hr for the Gari sifter; up to 500kg/batch for the fermentation rack; and 1500kg/batch for the dryer.

32

Annex 1: Interview Guide for Manufacturers

Data entry form on Cassava Equipment Manufacturers Manufacturer data 1) Name of manufacturer:..…………………………………………………..….…………… Address …………………………………………………………Email:.………..…………. Tel:………………………….…………………………...Fax:………………………………… Mobile:……….…………..…………..………………………………………………….……..... A) General data 2) Equipment, which is produced by the manufacturer (commercial name)

3) Type of manufacturer (please tick) Artisan SemiIndustrial industrial

No of employees/workers in force on permanent basis

4) Membership (of associations etc) (please provide details)

B) Details about manufacturer’s sale policy 5) Means to advertise: Equipments proposed for sale through: (please tick) Catalogue Flyer Web site Other (specify)

6) Availability of equipment (please tick) Serial production On request (specify time needed)

7) Sales term (please tick) Credit

Cash

8) Guarantee (please tick) Yes (specify number of months)

No

33

9) Post-sales services (please tick) Installation Staff Spare training parts

Emergency interventions

Other (specify)

C) Other 10) Source of inspiration for the prototypes (please tick) Other manufacturers Internet Catalogues Trade fair Other (specify)

11) Main bottlenecks a) Production level (specify)

b) Sales/ post-sales level (specify)

12) Overall assessment

13) Compiled on:…………………………………………………………….

34

Explanatory guide for information/data entry 1) Manufacturer’s coordinates: Please note down full manufacturer’s coordinates, including: postal address, relevant telephone numbers, fax, email address. 2) Kind of equipment produced: Please list all equipment, noting down the name of the cassava processing equipment according to its main use, such as: peeler, grater etc. 3) Type of manufacturer: Assess the manufacturer based on the level and size of his enterprise (“artisan”, “semi-industrial” and “industrial”). Take also note of the number of people working regularly in his enterprise. Please note down if the information on the number of people working in his enterprise provided by the manufacturer surveyed differs significantly from your own observation. 4) Membership: Please note down if the surveyed manufacturer is a member of any professional association. In case he is, please state the name and contact data of the association; e.g.: XXXXX Association in Yaoundé, tel: xxxxxxxxxx”. 5) Means used to advertise equipment: Please note down the means the manufacturer uses to advertise/sell his equipment(s), including all relevant information needed to access/contact the given source, e.g. ”catalogue produced by xxx, based in Yaoundé, tel: xxxxxxx”, or “web site: www.xxxxx.org”. 6) Availability of equipment: Please note down if the equipment is produced in large amounts (equipment is in stock and therefore deliverable at any time) or if it is be produced only on request. If on request, please specify the time required to receive the equipment from the moment the request is made. 7) Sales terms: Please specify whether the product is purchasable on a credit basis or only by cash payment. 8) Guarantee: Please note if manufacturers provides or not a guarantee. In case he does, please specify the length of the guarantee (number of months). 9) Post-sales services: Please specify if the manufacturer provides post-sales services such as: installation of the equipment/machine, training on operation/maintenance of the equipment, sale of spare parts, repair services (also under emergency situations). Other services can be added if needed (however, details need to be provided within the box). 10) Source of inspiration: Please take note where from the manufacturer gets the knowledge/inspiration/ ideas for producing the equipment(s) he is manufacturing (e.g. from talks with colleagues, targeted searches on the web, visits to/attendance of trade fairs etc). 11) Main bottlenecks: Please note down the main bottlenecks/problems encountered by the interviewed manufacturer in terms of: a) equipment production (e.g. electricity failures, lack of materials, shortage of working capital etc), and b) organization of sales/post-sales services (e.g. no information on market, lack of transport means etc). 12) Overall assessment: Please provide an overall assessment on the worthiness to include the manufacturer in the data base and explain reasons for that. 13) Compiled on: Please, note down the date at which the survey was made.

35

Annex 2: Interview Guide for Equipment

Data entry form on Cassava Equipment Manufacturers Equipment data 1) Name of Manufacturer:..………………………………………………..….… Address ………………………………………………Email:.……….……….…..…… Tel:………………………….……Mobile:…………………...Fax:……………………… 2) Kind of equipment 3) Main use (or product) 4) Other uses (or products) 5) Minimum number of operators Needed

6) Performance

7) Consumption

Main use

Other uses

Raw material intake (kg/hour)

8) Construction material utilized (steel, iron, etc)

Final Output (kg/hour) Electricity (Kw/hr)

9) Weight (Kgs) Length (cm)

Fuel/diesel (liters/hr) Water (liters/hr) Compressed air

10) Equipment size

Width (cm) Height (cm)

11) Price (GH¢) (FOB)

12) Other details about the equipment (specify)

13) Description of the way the equipment works (main steps)

14) Assessment of the equipment Main advantages

Needed pre-conditions

15) Compiled on:…………………………………………….

36

Explanatory guide for information/data entry 1) Manufacturer’s coordinates: Please note down full manufacturer’s coordinates, including: postal address, relevant telephone numbers, fax, email address. 2) Kind of equipment: Note down the name of the cassava processing equipment according to its main use, such as: peeler, grater etc. Please fill out one form for any equipment surveyed, noting always the name of the manufacturer (contact details only once needed). 3) Main use: Note down the main function the equipment is utilised for, with reference to the main product (if any). 4) Other uses: If the equipment has additional functions, please note them down. Functions are usually related to the processed products obtained by using the equipment. 5) Number of operators needed: Please write down the minimum number of people needed to operate the equipment (specify it according to main use or other uses). 6) Performance: a) Raw material: Please note down the maximum amount (in kg) of raw material that can be processed by the equipment during 1 hour. b) Final output: Please note down the maximum amount (in kg) of final output that can be obtained by operating the equipment during 1 hour. 7) Consumption: Please note down all inputs required to operate the equipment, such as: electricity (Kw/hour), water (litres/hour), fuel/diesel (litres/hour), compressed-air. 8) Construction material(s): Please specify the material(s) the equipment is made of (e.g. steel, wood, plastic etc). 9) Weight: Please note down the overall weight of the equipment. If the equipment is made of several parts, please specify the weight of each of them and then work out their total. 10) Equipment size: This question refers to the space taken up by the equipment under consideration, including: a) the length and the width (meaning the surface covered) b) its maximum height (in cm). 11) Price: Please note down the price of the equipment c/o manufacturer (FOB price in local currency). 12) Other details on the equipment: Please note any additional, relevant information referring to the equipment and which was not covered in previous points (1 to 10), e.g.:”the equipment is part of a broader processing line”; “additional xx m2 needed during operation” etc. 13) Description of the way the equipment is operating: Please provide a description of the way the equipment should be operated by its user, following a step by step approach. Information collected under this point should allow an easier understanding on the way the equipment surveyed is working for those who will see the equipment for the first time on the Fidafrique web-site (meaning, on a computer screen). 14) Assessment of the equipment: Please provide an independent assessment of the equipment surveyed, highlighting: a) the main advantages offered (as compared to similar equipments available on the domestic market) and b) the pre-conditions (if any) that are needed to have the equipment performing properly. 15) Compiled on: Please, note down the date at which the survey was made.

37

Annex 3: Details on Assessment of Manufacturers and Equipment

Equipment manufacturer

Equipment produced Overall assessment of by manufacturer manufacturer and equipment • • • • • • • •

Cassava grater Cassava press Cassava grinder Kokonte cracker LPG stove Cassava grater Cassava press Cassava grinder

Camara Engineering

• •

Cassava grater Cassava press

4

FATECO

•

Cassava grater

5

Institute of Industrial Research (IIR)

• • •

Cassava grater Dough sifter Gari sifter

6

I G Kove's Engineering and Trading Enterprise

• •

Cassava grater Cassava press

7

Agricultural Engineering Department, KNUST Advance Metal Works

• •

Cassava grater Cassava press

•

LPG stove

• • • • • • •

Cassava grater Cassava press Cassava grinder Cassava slicer Bagging stand Sifter Fermentation rack

The machines are well built and working well. The Cassava grinder (with the use of pillow block bearing instead of the brass journal bearings) works well and it is preferred. The workshops can handle large orders. Most of the machines were fabricated from drawings.

• • • • • • •

Cassava grater Cassava press Cassava grinder Sifter Fermentation rack Cassava grater Cassava press

All the machines in use have been well fabricated and the workshop has the capacity to handle large orders. Most of the machines manufactured are from drawings. All the machines have been well fabricated and are working well. The

1

MEMOT Company Limited

2

Dan Glover Metal Construction

3

8

9

GRATIS Foundation (Rural Technology Services Center), Techiman

10 GRATIS Foundation, Upper West Region, Wa

11 GRATIS Foundation, Brong Ahafo Region,

38

Could not direct us to the users to enable us assess the performance of the machine

Has stopped manufacturing equipment for more than five (5) years. None of the cassava processing equipment is available to be assessed. Cassava machines manufactured are neat and robust. The workshop is busy with the fabrication of other agricultural machines and can handle large orders. Could not give us the contacts of the users to enable us assess the performance of the machines. Set of cassava processing equipment now found in use at a cassava processing centre at Pokoase. The equipment is working effectively. As a research institution, large orders could be interrupted by research activities. Could not see any of the equipment to assess and the workshop is also not properly resourced (in terms of skilled labour and equipment) to handle serious work. Could not direct us to the users to enable us assess the performance of the machine Fabricating good stoves which are being used at the domestic and commercial level. The stoves are suitable for roasting gari in the circular roasting pans. Has the capacity to meet large orders

• •

Cassava grinder Bagging stand

•

Cassava grinder

• • • • • • • • • • • • • • • • • • • •

Cassava grater Cassava press Cassava grinder Bagging stand Sifter Cassava grater Cassava press Cassava grinder Cassava slicer Bagging stand Sifter Fermentation rack Cassava grater Cassava press Cassava grinder Cassava slicer Bagging stand Sifter Fermentation rack Cassava grater

• • • • • •

Cassava grater Cassava press Cassava slicer Dryer Cassava grater Cassava press

19 Brother J K Agbavitor

•

Cassava grater

20 Agbemskod

• • • • • • • • • • •

Cassava grater Cassava press Kokonte cracker Roasting pan Sifter Cassava grater Cassava grinder Kokonte cracker Cassava grater Cassava press Kokonte cracker

•

Cassava grater

Sunyani

12

GRATIS Foundation, Upper East Region, Bolga

13 GRATIS Foundation, Northern Region, Tamale

14 GRATIS Foundation, Eastern Region, Koforidua

15 Respect Welding Workshop

16 Zoranu Welding and Fabrication Shop

17 SIS Engineering Limited

18 Kwabena Ayeh Boafo Welding Shop

Enterprise

Engineering Limited

21 Potakey Engineering Works

22 Advantage Metal Construction Works

23 GRATIS Foundation,

39

workshop is well equipped to handle large orders. Almost all the machines manufactured have detailed drawings. The machine and equipment are working well. The Cassava grinder (with the use of ball bearing instead of the brass journal bearing) is a preferred design. The workshop has adequate machine tools to handle large orders. Quality of the manufactured machines is good and the workshop is well resourced to take on large orders. Most of the machines were manufactured from drawings. The quality of the manufactured machines is good. Most of the machines were fabricated from drawings. The manufacturing facilities are adequate to handle large orders.

Though working as an artisan with only simple hand tools for fabrication, the quality of cassava graters manufactured are very good and works well. The workshop can handle small orders. The cassava grating machine (an improved India made model) grates finely but not as fast as the hand lever control fed type of grater which is commonly used in the country. The workshop can handle small orders. The machines (especially the Selffeed type of grater) are well fabricated. The workshop is well equipped to handle large orders. Could not direct us to the users to enable us assess the performance of the machine The manufacturer has no records on the users of his machines. The workshop is not well organised and currently, cannot be relied upon to meet orders. The machines manufactured are good and performing well. The workshop can handle large orders.

Could not direct us to the users to enable us assess the performance of the machine The cassava machine is robust and well fabricated. The workshop only uses simple basic hand tools and can handle small orders. The machines are manufactured from

• • • • • • • • • • • • •

Cassava press Bagging stand Sifter Fermentation rack Cassava grater Cassava press Cassava slicer Bagging stand Sifter Fermentation rack Dryer Cassava grater Cassava press

26 Danmens

•

Cassava grater

27 Viva-Sabat Enterprise

•

LPG stove

28 Efo Machine Shop

• •

Cassava grater Cassava press

29 GRATIS Foundation,

• • • • • • • • • • • • •

Cassava grater Cassava press Bagging stand Sifter Fermentation rack Cassava grater Cassava press Cassava grinder Bagging stand Roasting pan Sifter Fermentation rack Cassava grater

The machine are well fabricated and working efficiently. The workshop is well equipped with the requisite machine tools to handle large orders.

• • • • • • • • • •

Cassava grater Cassava press Cassava grinder Kokonte cracker Roasting pan Dryer Cassava grater Cassava press Cassava slicer Bagging stand

The machines and equipment are robust and well fabricated. They are performing well. The workshop is adequately equipped to handle large orders.

• • • • • • • • • •

Cassava grater Cassava press Cassava grinder Kokonte cracker Cassava grater Cassava press Cassava grinder Kokonte cracker Cassava grater Cassava press

Central Region, Cape Coast

24 RP Engineering and Consultancy Limited

25 Sam Alor Metal Works

Western Region, Takoradi

30 Mawuli Engineering Works (Ex John Technical)

31 Anthony Technical Engineer

32 Hormeku Engineering Works Limited

33 Engineering and Technical Services Establishment (ENTESEL)

34 Roland Welding and Machine Shop

35 Christopher Welding Machine Shop

36 Angola Engineering

40

drawings and the quality of manufacture is good. The workshop has the requisite facilities and skilled labour to handle large orders Do not have records of the users to enable us see the machines and assess the performance.

Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance.

The machines are performing well and they are robust and well built. The workshop has the requisite machine tools to handle large orders.

Do not have records of the users to enable us see the machines and assess the performance.

The machines manufactured are working well. The quality of the machines and equipment are good. The workshop is well equipped to handle large orders. The machines built are working well. They are robust and well constructed. The workshop has the capacity to take large orders. The machines built are robust and performing well. The workshop has the requisite machine and is in the position to handle large orders. Do not have records of the users to enable us see the machines and assess the performance.

37 KOPPO Engineering Company

38 GRATIS Foundation, 39

Greater Accra Region, Tema Adzrah Modern Metal Engineering Works

40 Hammek Metal Works 41 GRATIS Foundation, Volta Region, Ho

42 Emmanuel Abbah 43

Manufacturing Welding Shop City Welding and Trading Enterprise

44 J. K. Todoadzi Metal Works

45

• •

Cassava press Roasting pan

• • • • • • • •

Cassava grater Cassava press Bagging stand Cassava grater Cassava press Kokonte cracker Cassava grater Cassava press

• • • • • • •

Cassava grater Cassava press Cassava slicer Sifter Dryer Cassava grater Cassava grinder

• •

Cassava grater Cassava press

• • • •

Cassava grater Cassava press Cassava grinder Cassava grater

• •

Cassava grater Cassava press

• • • • • • • •

Cassava grater Cassava press Cassava grinder Cassava grater Cassava press Hammer mill Cassava chipper Sifter

Azameti Metal Works

46 Agbenyegah S. F. Metal Works

47 Sylta Engineering Development Enterprise

48 Food Research Institute

Source: Survey, August 2008

41

Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance. Do not have records of the users to enable us see the machines and assess the performance. The machines are well built and are working well. The workshop is adequately equipped with the machine tools and skilled labour to handle large orders. Do not have records of the users to enable us see the machines and assess the performance. The machines are robust and well fabricated. The workshop is equipped with the requisite machine tools to handle large orders The machines are robust and well fabricated. The workshop can handle large orders. The machines are robust and well manufactured. The workshop can only handle small orders. The machines are robust and well fabricated. The workshop is in the position to handle large orders Quality of the manufactured machines is good. The workshop has the capacity to handle large orders. Fabricating domestic and industrial machines for processing cassava. As a research institution, large orders could be interrupted by research activities.