Value in Value-Added Food Processing

A Commercially Sustainable Business Model for Enriched Ready-to-Eat-Foods Land OLakes International Development with USAID Office of Food For Peace and PEPFAR

Rolf Campbell, consultant

International Food Aid Conference

Kansas City April 16, 2008

Value in Value-Added Food Processing Background Introducing a nutrition product development activity in Zambia. Who:
Land OLakes International Development supporting 3 Zambian food processors with a food industry advisor.
Funded by: Title II ICB Grant - USAID Office of Food For Peace, and PEPFAR Office of the Global Aids Coordinator)

What: Assist food processors over 2 years to develop and commercialize

nutrient enriched foods that are already familiar in the markets and in the diets of Zambians.

Where: Zambia: Lusaka, Ndola

Goal:

Increase the available options for nutritious, processed and packaged foods for people living with HIV/AIDS and all others who will benefit from better nutrition.

Rationale: The Call to Action

Host country Food Processors are accountable to improve the nutrition impact of their products in the diets of consumers in their country.

Under-nutrition and the presence of food aid should signal a challenge and an opportunity
for processors in countries receiving US commodities (such as wheat, maize, oil, legumes), value added fortified blended foods (such as fortified corn-soy blend, wheat-soy blend, RUTF). Because the ultimate aim of foreign assistance - including food aid - is to address a temporary gap, not to become an endless alternative to long term self-sufficiency. NOTE: Product development costs and marketing are entirely funded by the Zambian Processors who also control the rights to their formulas and processes.

Rationale
1. People require and acquire food daily from a wide variety of sources: (the food basket, grazing). Processed, packaged foods are one of these sources. 2. Ready-to-eat processed, packaged foods can be important, convenient sources of nutrition. 3. This puts the food industry in a position to contribute positively to the nutrition requirements of their consumers.

4. Adjustments to the formulation of consumer foods can improve their nutrition contribution to the diet for little increase in cost.
5. Commercially prepared enriched foods and Processors new expertise can be adapted to Food Assistance and Institutional nutrition requirements.

Commercially viable (market demand) enriched foods create their own incentive for a sustainable food supply when: they benefit consumers while returning profits to processors.

Value Adding Food Processing POTENTIAL Benefits for the Food Supply and Nutrition Quality
1. 2. 3. 4. 5. 6. 7. Commodity assembly, storage, protection, handling Cleaning, grading, sorting, standardization Safety analysis for pathogens, culling for pests, foreign materials, cleanliness Drying, milling, pealing, de-hulling, crushing, grinding, pressing Intermediate bulk packaging Refrigeration, freezing Pre-cooking (& instant-ized) ready-to-eat foods contributes convenience, reduces or eliminates need for cooking fuel, time preparing food. 8. Thermal processes: Pasteurization, sterilization, aseptic filling 9. Pickling, salting, fermentation, culturing 10. Filtration, sifting, isolation and concentration of food components 11. Formulation: blending, combining foods, seasoning, adding performance factors like enzymes, nutrition, and culinary appeal 12. Fortification with vitamins and minerals 13. Consumer Packaging protects, contains, portion controls, and identifies contents with detailed product information as well as identifying the manufacturer accountable for the contents. 14. Concentrate food nutrients and caloric density: people to ingest better nutrition while eating less volume. 15. Processed shelf stable foods remain fresh, safe, with nutrients intact, allowing for distribution and longer storage far away from manufacturers even into remote areas

Processed, Packaged, Ready-To-Eat-Foods: POTENTIAL Values to the Consumer

1. No or reduced cooking (cooking heat / time) pre-cooked

2. Improved Digestibility / Bioavailability of pre-cooked nutrients such as proteins and carbohydrates 3. Convenient no preparation including sorting, cleaning, peeling, grinding, mixing, cooking 4. Often hand-held, portable, and portion controlled 5. Nutrient preservation (reduced thermal processing) 6. Nutrients / foods can be combined & balanced 7. Increased Nutrient concentration or density 8. Safety, sanitation of food 9. Packaging for containment, protection, storage, re-closing, identification, portion control

Food and Nutrition People do not seek or eat nutrients, we choose foods.

People prefer to not eat just one food; we choose meals.

People are seeking foods and making food choices - continually. The only nutrients that count are in the foods people CHOOSE to eat.

Therefore: Make a variety of foods that people are choosing to eat - more nutritionally complete.

11 Places Zambians Find Their Food

HAWKERS STREET FOOD FRESH MARKETS NTEMBAS

SUPER MARKETS

CONVENIENCE STORES

FOOD SOURCES
SHARING

INSTITUTIONAL SCHOOLS WORK

FARM DIRECT SMALL STORES HOME GROWN

HUMANITARIAN FOOD assistance

FRESH MARKET FOODS

NTEMBAS

SMALL MARKETS

Goal: Target Places Zambians Procure Their Food

HAWKERS STREET FOOD FRESH MARKETS

NTEMBAS

SUPER MARKETS

CONVENIENCE STORES

FOOD SOURCES
SHARING

INSTITUTIONAL SCHOOLS HOSPITALS

FARM DIRECT

FOOD AID

SMALL STORES

HOME GROWN

Three Market Demand Channels - Three Market Supply Channels

Nutrition information flows to consumers; Consumer needs Information flows to Food Suppliers.
Forward Contracts

1
FOOD AID CHANNEL
HUMANITARIAN: WFP, NGOs, PVOs, buy and distribute ENRICHED FOODS

Aggregated Demand

2
ZAMBIAN FOOD PROCESSORS Make & Sell ENRICHED FOODS RETAIL CHANNELS ENRICHED FOODS bought By PLWHA and other consumers ZAMBIAN HOUSEHOLDS
,

PLWHA Multiple Access Channels for ENRICHED FOODS

INSTITUTIONAL CHANNEL
WORKPLACE, HOSPITALS, CLINICS, SCHOOLS buy and distribute ENRICHED FOODS

Forward Contracts

Aggregated Demand

Demand

Demand

Leveraging the Processing Sector for Better Nutrition: Advantages of a Commercial, Sustainable Business Model
1. Processors utilize the Zambian ingredient supply chain 2. Enriched ready-to-eat foods become available across Zambia including high need areas that may not meet humanitarian food program inclusion criteria. 3. Processors employ existing warehouse and distribution capacity for their retail business thereby increasing reach into both rural and urban markets. 4. There is dependable Quality Control; their facilities comply with good manufacturing practices (GMP) 5. Processor technical expertise is increased and leveraged for the development and marketing of enriched ready-to-eat foods leading to ongoing nutrition products innovation that benefits all Zambians 6. Processors make capital equipment investments in response to market demand increasing long term food variety, quality, and availability 7. Processors continually work on their own sustainability as a commercial enterprise so that enriched ready-to-eat foods will be available over time throughout Zambia. 8. Enriched products (supplemental foods) may be transformed into a domestic food industry surge capacity available for high need food crisis periods.

Some Key Success Factors for Commercial Sale of Enriched Foods

Market and economic analysis Set boundaries on selling price, cost of product to produce, buying intentions from key market channel leaders for these or similar replacement products Buyer and consumer education about the nutritional value of enriched ready-to-eat products. Customers and consumers must embrace the critical significance of choice: making enriched foods a regular part of their diet; the price/value of the products Foods must deliver a nutrient-dense, balanced combination of macronutrients and micronutrients Measurably contribute to improved nutrition status when eaten under the right circumstances (adherence to diet, duration, amount consumed, other foods in the diet, physical condition, needed medical interventions). Nutrition experts must recognize the products nutrition advantage and consumers must experience the implied product promise of long term health, energy, and growth from improved nutrition.

Target Product Design Criteria

Establish Product Design Criteria and Product Acceptance Criteria

Meet guidelines for nutritional needs of Zambians including those PLWHA

Conform to Zambian dietary practices and preferences Conform to National Food standards, regulatory Meet mass market consumer expectations for price, packaging, and eating appeal Formulate (enrich), process, and package based on principles of food and nutrition science and good manufacturing practices (GMP) When possible, be compatible with the operations and logistics of NGOs, PVOs, and their local partners that provide nutritional supplementation to PLWHA.

Product Description: Enriched Sandwich Biscuit Manufactured by Sunrise Biscuits Ndola, Zambia Two enriched baked whole grain-based biscuits enclosing an enriched peanut butter based cream filling Product Benefits
Ingredients include: whole wheat, whole oats, soy flour, soy protein concentrate, peanut butter, milk powder, whey protein, vegetable oil, sugar, honey, vitamins, minerals Nutrition quality and density, delivering balanced vitamins, minerals, protein, carbohydrates, fat, fiber, and energy in a compact and stable form Portability: can be carried, stored, and eaten anywhere, any time Shelf stability: 9-12 months depending on storage conditions Hand-held, no utensils or bowl needed, convenient for children Portion controlled packaging to protect the food, easy to hand out & open Ready-to-eat, fully baked, no preparation Biscuit becomes a creamy porridge when liquid is added for spoon eating They are a familiar food in our Southern African diet; such desirability encourages healthy eating and adds tasty variety to the diet Offer a variety of 11 different nutritious foods we have assembled into a Full Plate for between meal & on-the-go nutrition supplementation along with the fortification Natural Foods: NO preservatives, artificial colors, trans fats, hydrogenated fats
Sunrise Biscuits Company Ltd.
For Samples or Quotation Inquiries, Contact: Mr. S. S. Langar Lukasu Road, Light Industrial Sites; P.O. Box 70506, Ndola Zambia; Phone: +260-2- 650637 / 8; Fax: +260-2-650132; Cell: +260-955 434846; E-mail: sunrisebc@zamnet.zm

Sunrise Enriched Sandwich Biscuit Nutrient Contribution

CHILD (age 5-9)

Number Biscuits Eaten / Day

TEEN AGER (age 15-19) 6 Biscuits (180 g)

Actual Amount in 6 Biscuits Provide this % of RDA

ADULT (age 20-59) 8 Biscuits (240 g)

Actual Amount in 8 Biscuits Provide this % of RDA

4 Biscuits (120 g)
Actual Amount in 4 Biscuits Provide this % of RDA

100 g = 3.3 biscuits

Nutrient Content / 100 grams of Sandwich Biscuits

MacroNutrients

100% RDA*

100% RDA*

100% RDA*

Fat (grams)

31 23 58 2

35% 36% 25% 8%

88 64 233 25

47 35 87 3

39% 40% 27% 8%

120 88 317 38

62 47 116 4

57% 59% 40% 17%

109 80 289 25

25.9 19.5 48.3 1.7

Protein (grams)
Carbohydrate

(grams) Fiber (grams) Energy total Kcal (male) WFP**

600

30%

1980

900

33%

2700

1200

49%

2460

500

* World Health Organization: Recommended Dietary Allowance; **WFP - Assumes people living under stress

Product Description: Enriched Maheu Manufactured by Trade Kings, Lusaka, Zambia Enriched milk-maize-soy, fortified drink Product Benefits:
Culturally familiar; ancient tradition as a nutritious drink in Zambia; emotional value: (my maheu), sought out by all ages. Plain Maheu with added milk solids, fat energy, soy protein, vitamins. Shelf stable without refrigeration for 8 months Ready to drink from either 300 or 500 ml plastic bottles. Nutrition quality, a balance of micro and macronutrients in fluid form Digestibility: processing includes the use of enzymes which break down grain starches for ease of digestion. Portable, can be carried and drunk anywhere, any time Hand-held, convenient for children Can be to drunk through an elbow straw while lying down Soothing, slightly viscous, and easy to drink for anyone with mouth or teeth problems or swallowing difficulty Portion controlled packaging that is easy to open and drink from Ready-to-drink, no preparation Delicious and familiar food, adds variety to the diet Convenient for ready between meal snacks when medications necessitates food intake Contributes to food water re-hydration and enhanced nutrient absorption
TRADE KINGS LIMITED For Samples or Quotation Inquiries contact: Mr. Winani - TEL: 00-260-1286117; E-mail: tradekings@zamnet.zm; LUSAKA, ZAMBIA

Product Description: Synbiotic Fermented Milk: Mabisi Manufactured by Pamalat, Lusaka, Zambia Studies show that daily consumption of Bifidobacterium lactis, BB-12 - such as those found in one 250 mil serving of Lacto-Live Mabisi - may contribute to overall digestive health with the associated benefits.
Nutrition quality, delivers a balance of milks nutrients Proven probiotic delivery: Contains efficacious quantities of living probiotic colonies together with prebiotics that feed beneficial bacteria Probiotic therapy: probiotics modulate the innate and adaptive immune system in a doseand strain-dependent manner. In particular, some Lactobacilli and Bifidobacteria strains have been shown to induce the production of secretory IgA and IgG. [1] Digestibility: a naturally fermented milk drink with reduced amount of lactose Shelf Life, up to 36 days with refrigeration Hand-held, Portable, Ready-to-drink, no preparation, convenient for children Can be to drunk through an elbow straw while lying down Soothing, slightly viscous, and easy to drink for anyone with mouth, throat, or teeth problems or with swallowing difficulty Portion controlled packaging that is strong yet is easy to open Delicious and familiar food; Convenient for ready between meal snacks A fluid that contributes to re-hydration and nutrient absorption
[1] Cathy Alherda, et al, (2007). Effects of probiotic therapy in critically ill patients. Am J Clin Nutr 2007, 85: 816 - 823 For Order Information: Mr. Sandress Nyierenda, Zambia Sales & Marketing Manager Office Phone : 211 286 855 - 287 745; Mobile: 0977 770 318 E mail: sandress.nyierenda@parmalat.co.zm

Project Outcomes with Food Processors

Active interest and involvement in the nutrition of their consumers and the nutrition value / impact of their products.
Business Growth Opportunities & increased Customer Options Technical know-how in food fortification with vitamins and minerals Relationships with non-governmental (NGO) & community-based organizations (CBO)

Enhanced staff know-how, processing capabilities and quality control procedures

Product technical specifications, formulations, ingredients for nutrition products Enlarged capabilities into nutritional product category Relationships with Institutions for meeting nutrition requirements Development of sophisticated nutrition product and nutrition promotion material Increased collaboration with GORZ and other Donors in Zambia for contributing Zambian business-based solutions to the Zambian nutrition crisis

Potential Benefits for People Living with HIV/AIDS

Three forms of foods that are familiar, widely consumed, and found throughout Zambia, will now be enriched and more nutritious. Promotion of these products in the markets contributes to consumer knowledge about proper diet and better nutrition generally. Zambian processors manufacture enriched supplemental foods for sale not only at Retail but also to Institutions, and to NGOs, PVOs, CBOs

Sustainable Food Options:

All of the above was developed by the food businesses and will stand or fail - on its own based on value chain incentives: Consumer (buyer) Demand, Supply, Competition.

Project Contact Information

In Africa Todd Thompson Land OLakes Country Director, Zambia, Africa; E-mail: todd@landolakes.com.zm; Phone: 260 21 1 263 929 / 30; Fax: 260 1 265 053 In USA Mara Russell Land OLakes Title II Director, WDC; E mail: marussell@landolakes.com; Phone: (703) 524 1739; Fax: (703) 524 3668 Rolf Campbell consultant; E mail: rolf.campbell@att.net; Phone: 612 839 4050; Fax: 612 823 4688