Final Report Summary - AFTER (African Food Tradition Revisited by Research)
Executive Summary:
Planned over 4 years between September 2010 and November 2014, AFTER has revisited traditional African products, knowledge and know-how in the light of new technologies for the benefit of consumers, producers and processors in Africa and Europe. By applying European science and technology to 10 (ten) selected African traditional food products, AFTER turned research into quantifiable and innovative technologies and products that are commercially viable in both European and African markets. The ten traditional food products studied were chosen to represent three families of foods: (1) Fermented cereal-based: Akpan, a yoghurt-like product prepared from maize gruel and Gowé, a homogenous beverage prepared from malted sorghum, millet or maize, are both originating in Benin. Kenkey, fermented dough made from maize is originating in Ghana and Kishk Sa’eedi, made from a combination of wheat and fermented buttermilk, is originating in Egypt. (2) Fermented salted fish and meat: Lanhouin, salted/dried fish spontaneously fermented, is originating in Benin. Kong, traditional smoked fish, is originating in Senegal. Kitoza, salted/dried meat, is originating in Madagascar. (3) Vegetable and fruit based functional foods: the fruit of baobab and Hibiscus sabdariffa are respectively called “bouye” and “bissap” in Senegal. Ziziphus mauritiana, fruit of the jujube tree, is called “jaabi” in Cameroon.
First, comprehensive scientific knowledge of the existing know-how has been obtained about technologies, processes and products in the six African countries of origin of the project’s targeted products, as well as about the sensory quality criteria as perceived by the traditional processors and consumers. Analytical and sampling methods to be used have been specified. Then, improved traditional processes have been proposed according to objective criteria of acceptability of the traditional products by the consumers. The improved products, produced through reengineering and new processing technologies, have been tested for consumer acceptance, safety and nutritional quality. The market and entry requirement for new products had been assessed. Involving EU and African companies in production trials for the improved products helped to translate the results into ready-to-use information for food companies. Finally, and thanks to dissemination activities, AFTER results have been transferred to the private sector represented by SMEs and made widely available: technical guidelines have been created, one for each selected product.
The project has directly contributed to improving the competitiveness of these ten traditional products and facilitated their implementation and uptake by food companies and their marketing on the diverse types of markets for these products. Beyond these direct results, the lessons learnt and the methodologies for the assessment of traditional products and processes have been shared with other countries from both continents in order to disseminate the results among the research community involved in food research in developing countries.
Public website: http://www.after-fp7.eu/en
Contact details: Dominique Pallet, scientific coordinator of the project (CIRAD), dominique.pallet@cirad.fr
Project Context and Objectives:
1.2 Summary description of project context and objectives (max 4pages)
AFTER (African Food Tradition rEvisited by Research) intended to generate and share knowledge on food technology and to support the implementation of a range of ten (10) traditional products in African and EU markets. The project focused on one developing country continent only, Africa. The project involved seven African countries (Benin, Cameroon, Egypt, Madagascar, Senegal, Ghana and South Africa) and four EU countries (France, Portugal, Italy and the UK).
Taking novel traditional foods from viable local markets to high value international markets is attractive because of the potential for income generation, but, outside products sold in small quantities to the African diasporas, few indigenous foods have been sold in any volume outside their countries of origin. The success can be improved by applying an integrated approach with down-stream production issues such as meeting commercial volumes of production whilst over-coming market entry barriers and building partnerships with EU based companies. This complexity has so far limited the extent to which indigenous and traditional foods have penetrated the EU market. A possible hurdle to the successful introduction of traditional products into EU markets is that since 1997, new food products would be considered as ‘novel foods’ by the EU. However, there is the potential for indigenous food products to be 'fast-tracked' by the EU, especially if the food products do not substantially differ from how they are traditionally produced and consumed (http://news.bbc.co.uk/1/hi/uk/7506997.stm).
Consumer acceptance is important in marketing strategies and in product development in the EU and Africa. Along with product development and economic viability, it gives food companies confidence to adopt these products in the EU and Africa. While consumers seek convenient and healthy products, taste is consistently rated as the most important factor that drives consumption and repeat purchase of consumers. However, little is known about how food and drink products that are indigenous to Africa will be accepted in Europe. The project therefore explored the factors that influence consumer acceptance primarily from a taste perspective for the indigenous products but linked this with potential nutritional and health advantages. Consumer acceptance approach is still relatively underexploited in Africa where there are issues of culture, language and low income. Recent work has explored some of these issues; variations in acceptability within populations, with ethnicity, socio-economic factors and age. Rural and urban consumers in Africa appear to readily accept new products with distinctly different sensory characteristics and this is contrary to some views often held. However, the distinct sensory differences can have implications in product development.
Four general objectives had thus been set for the ten selected traditional food: (1) To reach comprehensive scientific knowledge of the existing know-how on technologies, processes and products, (2) To propose improved traditional processes by a reengineering of the unit operations with the aim of improving the safety and nutritional quality while keeping or improving the organoleptic characteristics of traditional products, (3) To reach objective criteria of acceptability of the traditional products by the consumers and to ensure that the products can effectively access the EU markets in view of regulatory and ethical issues while also protecting the intellectual rights of the people in Africa, (4) To present the results into ready-to-use information for food companies including SMEs via guidelines on quality management, food law and regulation and consumer protection and to transfer the results to the stakeholders from Africa and from the EU.
The 10 (ten) products on which the project focused on were organised in three groups: fermented cereal-based (Akpan, Kenkey, Gowé and Kishk Sa’eedi), fermented salted fish (Lanhouin, Kong) and meat (Kitoza), and vegetable and fruit based functional foods (Baobab, Hibiscus sabdariffa and Ziziphus mauritiania). Akpan is a yoghurt-like product prepared from a partially fermented cooked maize gruel, named ogi. It is usually mixed with condensed milk, ice and sugar by street vendors just before consumption. It is the most commonly consumed beverage in Benin. Kenkey is a popular traditional fermented food made from maize and is a staple for most of the peoples in the coastal regions of Ghana. It is a sour tasting cooked stiff porridge of elastic consistency made from fermented whole meal maize dough shaped into balls or cylindrical forms and wrapped in maize husks or plantain leaves. Gowé is a homogenous gelatinised, malted, fermented and cooked paste prepared from sorghum, millet or maize. It is consumed as a beverage after dilution in water and addition of ice, sugar and sometimes milk. It is the preferred beverage of children, pregnant women, sick and old people in Benin. The name 'kishk' refers to a group of popular fermented dairy cereal mix products common to Egypt and the Middle East. The product is made from a combination of wheat with natural local fermented buttermilk in the form of yoghurt or sour milk. On completion of fermentation, the mixture is shaped and sun dried. Lanhouin (cassava fish, Spendotolithus sp.) is a salted/dried fish spontaneously fermented. It is widely used as a condiment in Benin, Togo, and Ghana. Kong (catfish, Arius heudelotii) is traditionally smoked in Senegal for local and export markets. Such smoked fishes are not voluntarily fermented; however, a spontaneous fermentation step often takes place in the process of traditional dried fish. Kitoza is a salted/dried meat. Depending on the process conditions, the fermen¬tation can be spontaneous. Sometimes, it is smoked in order to improve organoleptic and shelf-stability properties. It is a traditional product of Madagascar. It is also known as biltong in Southern Africa. The baobab (Adansonia digitata L.) is a tree that grows wild in all semi-arid and dry sub-humid areas throughout Africa and Madagascar. The fruit of the baobab or monkey bread, called 'buy' in Senegal, is widely consumed in various forms. Dry calyx of Hibiscus sabdariffa, known as bissap, is used in Senegal and other Western African countries for the preparation of beverages and other products with high anthocyanins content. Z. mauritiana is the fruit of the jujube tree, widely spread in the Soudano-Sahelian savannas of Africa, particularly in Cameroon. The fruit is locally used fresh or dried for food purpose. It is consumed as snack food or processed into flour for the preparation of pancakes, or also associated with pastry or drinks. The dried and processed fruit has a pleasant biscuit taste and a plain aromatic flavour.
For each of the three groups of products, the specific objectives were: (1) To improve the nutritional quality and safety of four traditional fermented cereal-based products and to develop new formulations for local markets in Africa and for exports, which meant to improve the technological processes for obtaining a better and more reproducible quality and to develop new formulations of the traditional products adapted to urban consumer demand, (2) To develop new and improved meat and fish products and technological processes in view of quality and safety, which meant to improve the technological characteristics of the African processes in order to formulate products that will meet safety requirements (extended shelf life) and consumer preferences, (3) To develop products derived from extracts of baobab, hibiscus and ziziphus for local and regional export markets, which meant to develop new processes or a combination of processes to produce anthocyanins extracts from calyx of Hibiscus sabdariffa and pulp of Ziziphus mauritiana, and polyphenolic extracts from the pulp of Adansonia digitata and Ziziphus mauritiana, to optimise methods of preparation, microbiological stabilisation of the products and to develop new products from the fruit of Adansonia digitata, dry calyx of Hibiscus sabdariffa and pulp of Z. mauritiana.
The project also applied African traditional processes to European raw materials to develop new alternatives of foodstuffs thus providing new outlets for European raw materials (eg maize, pork). Simultaneously, the aim was to apply new technologies originating in Europe to African traditional production (eg bissap and baobab drink). The global strategy has been to implement the sharing of the African traditional know-how with Europe to develop new technologies and/or new products in Africa and in Europe.
Creating new markets and trade opportunities for improved traditional foods and novel products in Europe and Africa increases economic returns for all stakeholders involved in the production chain, down to the community level. Due consideration has been accorded to regulatory, ethical and IPR issues while also protecting the intellectual rights of Africans.
Project Results:
1.3 Main Scientific and Technical results/foregrounds
THE CHARACTERISATION OF TRADITIONAL PRODUCTS AND KNOW-HOW concerned the ten traditional products from Africa. It aimed to evaluate the existing knowledge and know-how on technologies, process and products variability according to socio-cultural groups, the sensorial quality criteria as perceived by the traditional processors and consumers, the corresponding instrumental quality. All these characteristics were necessary for the process reengineering and consumer and market acceptance. The results obtained are here summarized by products.
GROUP1. Gowé is a traditional fermented product made from sorghum and maize used singly or in combination. Four processes were identified: two using a mixing of malted and non-malted grains, one using only malted grains and one excluding the malting operation. Irrespective of processing, gowé had a sweet taste and was found to be slightly acidic. With a smooth texture, Gowé was recognized to have specific aroma which included 32 compounds. Lactic acid bacteria (LAB) and yeasts were the main technological flora. With regard to pathogenic germs, only Enterobacteriaceae and Echerichia coli were observed in some gowe samples collected from market. However 25% of gowe samples (N=8) were contaminated with aflatoxin and fumonisin at higher than the permissible level.
Akpan is a traditional fermented product made from maize or/and sorghum using four processing techniques: akpan from maize ogi, a wet sieved fermented maize mash, akpan from sorghum ogi, akpan obtained by kneading and fermentation of whole sorghum flour and akpan from “mixed sorghum and maize”. Akpan was recognized to be slightly acid with a low content of sugar. There was a great variability between akpan viscosities. Gelatinization level appeared very diverse for akpan, pointing out that cooking level is a critical point for this process for which gelatinization must not be completed. Akpan had a fermented ogi aroma. 25% and 12% of akpan samples (N=8) were contaminated with aflatoxin and fumonisin respectively at higher than the permissible level. Lactic acid bacteria and yeasts were the main technological flora where as Enterobacteriaceae were observed in some akpan samples.
Kishk Sa’eedi (KS) is made from a combination of parboiled whole locally fresh grown wheat with fermented butter milk from water buffalos and/or cows. Based on quality, two KS were identified: KS produced for home consumption BEITY and KS produced for commercialization SOOKY. With regard to type of fermentation agent, two others KS were reported: KS fermented with skimmed laban zeer and KS fermented with full fat laban zeer. These KS were significantly different in proximate composition. KS was recognized slightly acid, rich in amino acids, minerals (Fe and Zn) and free of mycotoxins. Among the technological flora, lactic acid bacteria were predominant except for some KS samples collected in the first round for which yeasts and moulds were predominant. With regard to pathogenic germs, Escherichia coli, Listeria sp., Clostridium sp., and Salmonella sp. were encountered in some KiskSa’eedi samples.
Kenkey is a popular traditional fermented food made from fermented whole meal maize dough shaped into balls or cylindrical forms, and wrapped in maize husks or plantain leaves. Ga and FantiKenkey were the most common and popular forms. Kenkey prepared from degermed and dehulled maize, were poorer in fiber, ash, and crude. Kenkey had also lower vitamin and essential minerals such as Zn and Fe. Kenkey was slightly acid with a low sugar content and colour differences were noticed between Kenkey process types. Particle size revealed significant differences in the process types Kenkey. Microbial counts were very low in the case of Kenkey samples with lactic acid bacteria as the main technological flora. Kenkey appeared free of pathogens and mycotoxins.
GROUP2. Lanhouin, a traditional fermented fish, is generally processed in rural and informal small scales plants. The methods of processing were developed at home and improvements were based on the observations of actors. What the actors recognize are changes in sensory properties of the product, changes which result from modifications of the process or variation in ingredients used. From the survey, the appreciation of the quality of Lanhouin by the processors, traders and consumers is mainly based on observations through a number of sensory attributes such as colour, texture, aroma, consistency of flesh and the general appearance of the product. Other attributes such as taste, absence of foreign matter were mentioned by some actors. The lack of packaging has also been pointed out by some consumers as a negative aspect for Lanhouin handling. Lanhouin is rich in protein, lipid and acidity index level within acceptable limit. The fatty fish lanhouin were rich on biogenic amines, a potential vector of food poisoning. Lanhouin is exempted of pathogenic bacteria such as Salmonella and Listeria monocytogenes.
Kong, a traditional smoked fish, is processed in traditional way by actors living generally near the coast. From the survey, the appreciation of the quality of wet smoked Kong, and dried smoked Kong by the producers, traders and consumers is mainly based on observations through a number of sensory attributes such as colour, taste, flavour, humidity ratio and calibre of these products. The dried smoked Kong were more rich in polycyclic aromatic hydrocarbons (PAH) with a levels above European standard. It is quite different for wet smoked one. A short smoking time induced a high level of moisture and less phenolics contents in the wet smoked Kong. These characteristics do not allow a long shelf-life when compare to dried smoked Kong. Smoked Kong is exempted of pathogens namely Salmonella, Staphylococcus aureus, Listeria monocytogenes, Bacillus cereus and Vibrio spp.
Kitoza, a traditional salted dried and/or smoked meat product of Madagascar, is generally processed on an artisanal or industrial scale and at family level. Kitoza, pork or beef based product is consumed with rice soup at breakfast or dinner. Kitoza is rich in protein (25.1-47.8%) and lipid (10.5 – 27.1%). From microbiological point of view, no pathogenic germ (Salmonella) was detected neither in beef nor in pork kitoza.
GROUP3. Important informations on processing, marketing system, sensory properties and attributes and therapeutic effects were obtained through the survey for Hibiscus sabdariffa (bissap) and Adansonia digitata (buy) and in Cameroon for Ziziphus mauritiania (Jaabi). In addition the quality has been determined by evaluating the composition of macronutrients, micronutrients and anti-nutritional factors, the microbiological safety and the sensory quality attributes. Buy, baobab pulp, is characterized by its low water activity of water (0.43-0.55). Density is between 0.33 and 0.40. The three products are characterized by their richness in polyphenols (up to 2 %), vitamin C (200 to 500 mg.100 g-1) (buy and jaabi) and anthocyanin (0.5 to 2.0 g.100g-1) (bissap). Baobab fruits and Hibiscus sabdariffa calyx present a good quality about chemical safety parameters. Jaabi fruits appears as safe for chemical quality. For bissap and buy, products showed no presence of pathogens germs. Some samples from jaabi showed non-conformities.
THE PROCESS REENGINEERING OF FERMENTED CEREAL BASED PRODUCTS enabled to improve fermented cereal-based products and their traditional processes with respect to safety and nutritional quality as well as their acceptability by African and European consumers. The specific objectives were: first to obtain products using improved processes that enhance the control of the safety, sensory and nutritional quality, second to obtain new forms of fermented cereal-based traditional products adapted to urban African consumers in accordance with European market and consumer expectations for the identified market segments. The work has been organized in 4 main tasks: (1) Improvement of indigenous starter cultures and selection of the best potential cultures, (2) Re-engineering for new fermented cereal-based products, which means dividing some combined operations, or reversing the order of the sequences of unit operations or adding new unit operations, starting from the traditional process diagram described, (3) Microbiological challenge testing for ensuring safety of products, defining the ability of fermented products to inhibit the growth of spoilage organisms or pathogens, (4) Laboratory scale production where hygienic, nutritional, sensory and service quality (ease of using, shelf life) has been evaluated. The results obtained are here summarized by product.
Akpan was re-engineered for increasing its shelf life and improving its sensory and sanitary qualities. Three steps (precooking-steeping maize, fermentation and cooking) were optimized and pasteurization steps were added. Two other important changes were brought to the process: the formulation step was shifted before the fermentation step and a bottling step was added; the final product is bottled ready to drink akpan that can be stored for 21 days at 4°C. Maize grain precooking-steeping: the use of hot boiling water followed by steeping at 50°C allowed reducing by a quarter the duration of steeping maize grains; it allowed producing high yield and fine wet milled dough. In addition, it significantly reduced the lactic acid bacteria load to 3.5 Log CFU/g versus 8 Log CFU/g for traditional steeping at room temperature (28-32°C). The yeast was also inhibited at this temperature. Fermentation: three Lactobacilli (Lb. brevis, Lb.Casei and Lb. fermentum) were tested for inoculating wet milled dough (ogi). Lb. Casei evidenced an intermediate behaviour in term of growth rate and lactic acid production between the two other strains; it was thus selected as a good compromise and because it can be easily provided as commercial dry active bacteria. Fermentations were achieved for plain ogi and for ogi mixed with milk and sugar (formulated product) at 42°C after inoculation with Lb casei. The fermentation of the formulated products was more rapid (shorter lag time) and final load was higher compared to plain ogi; the pH in the mixed ogi was however higher. Cooking: the temperature and duration of cooking, the ratios of cooked ogi /native ogi and ogi/water were improved to get akpan that meet consumers acceptance. The desirable viscosity by consumers can be obtained with the following pre-cooking conditions: 50% cooked ogi at 90°C for 10 minutes, ratio cooked ogi/water of 2:1 (w/v). Quality of re-engineered Akpan: the physico-chemical characteristics of the re-engineered Akpan were very close to those of the traditional Akpan. Re-engineered Akpan was exempt of pathogenic germs and the yeast count was lower than in the traditional Akpan. Beyond 21 days, the count of moulds was not conforming to the standard (NFV08-59). In addition, challenge test performed by inoculating ogi with spores of Bacillus cereus just at the beginning of the fermentation showed that the re-engineered process for producing Akpan is safe; no B. cereus could be detected at the end of the fermentation step.
The traditional process of gowé was re-engineered in the perspective of improving the reproducibility of the quality of the traditional product and for developing large scale production. For the latter, a drying step was added to the process; the final product will be ready to cook gowé flour. In addition, we focused the re-engineering essentially on the malting and and saccharification/fermentation steps. Malting: the quality criteria for high quality malt are high amylasic activity, low cyanide content and dry matter losses. The optimum conditions for malting were soaking for 15 h followed by germination for 60 h. Saccharification and fermentation: the hydrolysis rate of starch by α-amylase from the malt and effect of pre-cooking conditions on starch hydrolysis rate were modeled. Pre-cooking of sorghum flour up to 80°C increased drastically the rate of hydrolysis of starch. According to the model, a saccharification at 65°C for 2 h gave similar rate of maltose and glucose content as for the traditional saccharification process (30°C for 12h). Prior to fermentation, a pasteurization step was tested to decrease the initial microbial load of malt. Accordingly, the pasteurization at 65°C for 30 to 60 minutes allowed dividing natural microbial flora by 10. In addition, the α-amylase activity was checked to be stable at this temperature. Thus, the saccharification was performed at 65°C for 60 minutes. Additionally, a model was developed for predicting the fermentation, and then used for testing various scenarii of the fermentation of Gowé. In this respect, the inoculation with Lb. casei is particularly interesting for rapidly ferment Gowé. The inoculation of Lb. brevis could be interesting in the context of very small processing unit that cannot control the temperature and the final pH. With regard to yeasts, Kluyveromyces thermotolerans was the best to ferment Gowé since it is relatively thermoresistant with high growth rate at 40°C. It also evidenced a high stability to pH, and produces desired/liked aroma. Kluyveromyces thermotolerans can thus be used to ferment Gowé in combination with Lb casei. Drying: the fermented slurry was dried at 70°C within 5 h. The flour shelf-life was thus more than 6 months, compared to three days for the traditional product. This flour can be reconstituted in Gowé by dilution in tap water (ratio water / flour: 9 / 1) and cooked. Quality of re-engineered Gowé: the acidity of re-engineered Gowé was similar to that of the traditional Gowé. Additionally, the re-engineered Gowé had high level of maltose and glucose and was free pathogenic strains. Lactic acid bacteria and yeast and moulds counts were hundred times lower in the Gowé flour than in the traditional Gowé. In addition, challenge tests performed by inoculating Gowé with spores of Bacillus cereus showed that the re-engineered process for producing Gowé is safe.
Reengineering of kenkey was based on identifying nsiho as the type of kenkey with the best universal appeal and optimizing its processes and improving its appeal and presentation to target non-traditional consumers of kenkey. Thus dehulled rather than whole maize grains were used to produce a less sour, and more whitish coloured kenkey as compared to the standard Ga- and Fanti-kenkey. The pre-processing (steeping and fermentation) and cooking steps for producing white kenkey have been optimized and the product was given a new shape as cylindrical slices instead of the crudely round balls of kenkey. The slices were packaged in cling film or vacuum packed rather than wrapped in banana, maize or other traditional packaging leaves. Vacuum packaging extended the shelf life of kenkey from between 4 – 7 days to 6 months under refrigerated storage. Pre-process variables: steeping and fermentation during white kenkey production were optimized using both a 3 x 3 factorial and a Box-Behnken experimental designs to optimize the pre-process variables, steeping time, steeping temperature and dough fermentation time. The pre-process variables had significant influences on the physico-chemical properties and sensory quality of white kenkey. Long steeping times (over 24 h) of dehulled maize grains were clearly favorable to give finer dough after milling. The ease of milling was not related to water uptake by the dehulled maize grains that was fast during the first 5 h of steeping then levelled off at 10 h, but could be related to some degradation of the components of the grains as evidenced by the loss of water soluble proteins from the grains into the steep water that begins after 8 h. A fermentation process was also evidenced during steeping with an accumulation of lactic acid, acetic acid and ethanol and a lowering of pH. Long steeping and fermentation times as well as steeping at elevated temperatures increased titratable acidity, per cent lactic acid and lowered the pH of the fermented dough, with fermentation time having a stronger influence. Both steeping and fermentation decreased glucose content of the maize dough and white kenkey in the Box-Behnken experiments. However, this was not confirmed in the 3 x 3 factorial experiments. Increasing steeping time and temperature positively influenced acceptability of white kenkey. The optimum pre-process conditions for production of consumer acceptable white kenkey were determined to be steeping time of 30-45 hours at temperatures of 30-35ºC, and fermentation time of 12 hours. Cooking variables: a peculiar process in kenkey production, aflatalization i.e. pre-cooking part of fermented dough (aflata) and mixing it with the remaining uncooked dough before final cooking gives kenkey a characteristic elastic/sticky texture. Aflata: uncooked dough ratio and steaming time had a significant effect on both the hardness and stickiness of white kenkey. Reducing aflata proportion increased both the hardness and stickiness of white kenkey after the aflata:uncooked ratio became less than 2:1. The effect of aflata proportion on the textural characteristics was also dependent on the duration of the final steaming step. Increasing steaming duration from 15 to 30 or 45 minutes increased hardness and stickiness for all ratios of aflata and uncooked dough. The acceptability of re-engineered kenkey was much higher for long steaming time and high proportion of aflata. Consumers indeed look for kenkey with low firmness and stickiness. In addition, the taste of short time steamed kenkey was clearly rejected by the consumers. Quality of re-engineered kenkey: the characteristics of reengineered kenkey were close to those of the traditional white kenkey. It however had higher glucose content, due to a more controlled fermentation step in the re-engineered process. Significant, but low levels (far lower than the limit of acceptability), of some of the pathogenic bacteria were counted in reengineered kenkey. This may be linked to the lower duration of cooking, 30-45 minutes in the re-engineered process. Aflatoxins, the main hazard in kenkey, were not detected in reengineered kenkey. In addition, challenge tests showed that the process was safe.
The process for producing Kishk sa’eedi has been re-engineered. New lactic acid bacteria strains: three hundreds and eleven isolated strains (isolated from good quality traditional Laban Zeer) have been examined for flavor acceptability in reconstituted skim milk powder to select only strains that produce accepted flavor. The strains that produce acceptable flavor have been screened for proteolytic and esterase activities. The selected strains were then screened according to antagonistic system and antibiotic sensitive. At the end of experimental, 15 strains have been selected and used for fermenting butter milk to produce Laban Zeer. Optimization of fermentation of Laban Zeer: three selected strains exhibiting the faster acidification rate and the better aroma were selected as inoculum for KS. A concentration of milk of 15% (wet basis) was selected as an optimum; this concentration evidenced the best flavor and acceptability together with imparting a sufficient kinetic and level of acidification for insuring the microbial safety of the product. Optimization of wheat pre-cooking step: in order to optimize the processing parameters for the production of precooked whole wheat kernels, the effect of steeping as well as boiling temperature and time was tested. The level of starch gelatinization as well as particle size index PSI was measured. A level of gelatinization within the range of ~ 70-80% gives the preferred degree of grittiness. Chemical and microbiological characteristics of re-engineered KS: re-engineered KS had lower moisture content than traditional BEITY KS. Re-engineered KS had higher protein and lower fat contents than Traditional BEITY KS which is usually made using butter milk. Lactic acid was the main organic acid in re-engineered KS, as in the traditional ones, with almost the same level; around 2.5% (dry basis). Maltose was the main free sugar in the re-engineered KS, but with a much higher level (5 fold) than in the traditional KS, thus conferring a more sugary taste to the re-engineered KS. Re-engineered KS contains higher levels (almost doubled values) of some essential amino acids than the traditional KS. The Re-engineered KS had lower level of total bacterial count and Lactic acid bacteria, yeasts and mould when compared with Traditional BEITY KS. Re-engineered KS was free from pathogens and challenge tests showed that pathogens were completely eliminated due to the acidity of the fermented product. However, when the contamination occurs just before drying, pathogens can remain in the dried product for several months. New snack inspired by the traditional KS: a novel cereal-based snack inspired from KS and adapted to the preferences of the modern consumer and to the demands of modernity was developed. The new KS snack was made from a dough containing salt, cumin, mixture of butter milk and full fat milk, and either parboiled whole wheat or soaked then parboiled whole wheat. After fermentation, the dough was shaped into chips, breadsticks and mini biscuits. The novel KS snack is good source of dietary fiber and minerals besides being a way for youth to become engaged with their traditions, culture, and health through food.
THE PROCESS REENGINEERING OF MEAT AND FISH PRODUCTS brought the forces of seven partners, to secure and optimize the Kong, the Lanhouin and the Kitoza. This collective work had two goals for which we had to deal with constraints: 1) for the local market, improvements are oriented on sanitary and toxicological qualities of products to ensure, as a priority, the safety and health of consumers. All improvements have been reflected in the respect of traditional knowledge. The main obstacles to the optimization of the products were the quality of raw materials, lack of structure and specific equipment, including the conservation of products. 2) For the European market, the aim was also in priority the safety of products, whether produced locally or in Europe for the diaspora or the European consumers. The compliance of products regarding the EU regulation was an obligation. The manufacture of products by European companies rather offers an advantage to achieve quality objectives because of available equipment as cold chain. Conversely, the local manufacturing for export is a challenge because the gap between means and objective is real. The work of reengineering has expanded the product range, by acting on the final form of products (as lanhouin in powder and cubes), on organoleptic qualities (as Kitoza with a smoke flavor less intense) or yet on the storage modalities (such as packaging film or mosquito cage for kong). For the purpose of rationalization or innovation of products and processes, this work is built on a strong investment on the characterization of traditional know-how by long studies following a methodological plan. The acquisition of data on the evolution of the characteristics of the meat and fish products at key stages of the traditional process fully contributes to the success of the process reengineering.
Critical analysis of manufacture diagram of kong, lanhouin and kitoza
Reengineering activities were built with strict methodology and consistent for the three products from group 2. First, a Standard Operating Procedure (SOP) was established for the critical analysis of processes. Using this SOP, the team has thus achieved a structured and detailed survey work nearby nine local producers. The UCAD has audited 2 production sites of Kong around Dakar: Seuty Ndiaré producing wet smoked Kong and Yarakh producing dry smoked Kong. The UAC met 4 processors of Lanhouin in Grand Popo municipality, two at Ativicondji and 2 at Adovlocondji (beach and district), where the fermentation process applied is aerobic or semi-aerobic. The study of the Kitoza manufacturing process performed by the UT was held in Antananarivo with 2 producers of salted / smoked beef Kitoza, one in the Ivandry area and the other one in Behoririka area, and 1 producer of salted / smoked pork Kitoza located at Fiadanamanga. Each process flow diagram has been detailed to the scale of the unit operation (7 or 8 UO by diagram for the kong and lanhouin, 3 to 6 UO for Kitoza). This qualitative (description of inputs / outgoing, materials, human resources, arduous tasks ...) and quantitative analysis (yields, time, temperature, cost ...) of traditional diagrams manufacturing constitute an important database never acquired before. Similarly, the sampling of products at each key stage has allowed assessing the evolution of physico-chemical, toxicological, microbiological and nutritional qualities of fish and meat products.
In the case of smoked products (Kong and Kitoza), the step of smoking is critical as generating PAH compounds resulting in high levels of Benzo(a)pyrene in products consumed and greater than the threshold of the EU regulation (2μg/kg). Eating such smoked products is therefore health hazardous (risk of cancer). The length of this smoking step and the nature of the fuel have been pointed out. The quality of the raw material used by the Kong producers appears also poor, characterized by high levels of biogenic amines. On this criterion, the washing and draining catfish proved to be negative.
Finally, microbiological qualities of all products are not always satisfactory and are a priority for reengineering. The inventory of the technological flora and pathogens during process validated the impact of unit operations. For Kitoza, E. coli is present in the raw material of all producers. During the drying step, all micro-organisms concentrations increase. It is worth to mention that the drying step lasts from 45 minutes to 1 hour at 70-150°C, this allows microorganisms development, especially lactic bacteria. Conversely, the load of these germs decreases after salt addition. For Lanhouin, the total viable counts of all the samples whatever the process were under the acceptable limits. The enterobacteriaceae loads were found low in the intermediate products and final Lanhouin. No Salmonella and Listeria monocytogenes were found in any sample. Nevertheless, the lack of good hygiene and good manufacturing practices were observed with the four processors, so corrective actions to secure lanhouin had been proposed. For Kong, the total flora loads decrease in the end-products (wet and dried kong). Yeasts, lactic bacteria and coagulase negative Staphylococci are present until the end-product. No Staphylococcus aureus nor coagulase positive Staphylococci were observed during all process.
Re-enginering activities (diagram simplification, local and European improvements)
The operation of all these data from analysis of the impact of unit operations on the qualities of Group 2 products was based on common methodologies as SOP for local reengineering or in order to export or manufacture in Europe. The objective was to prioritize emergencies, imagine the different solutions but retaining only those whose application was technically and economically feasible.
Initially, simple adjustments of manufacturing diagrams have reduced the risk of PAHs in Kong and Kitoza. The traditional smoking step was split into a cooking/drying and a smoking unit operation. The objective is to reduce the water content of products, lower the water activity and reduce the duration of smoking to significantly reduce the accumulation of PAHs in products. For Kong as for Kitoza, the choice of fuel was optimized: the use of wood sawdust (for smoking) and charcoal (for cooking/drying) reduces the risk of carcinogenesis associated with PAH and B(a)P. Smoking with sawdust (30 min., 100 °C) followed by cooking with charcoal (2h, 100 °C) allows to reduce B(a)P content in the Kitoza below 2μg/kg. For Kong, 3 hours of drying and 1 hour of smoking also achieves PAH reduction, with particular interest recorded for coconut husks from the sawdust as fuel.
In the case of Lanhouin the ripening and salting operations were combined to prevent microbiological degradation, final drying was optimized by the use of a shell dryer (GERES/GRET) before sun drying (duration 18h) to reduce the contact with insects. At the end of the process, a washing step of fish fillets in a mixed solution of lemon juice (8%) and garlic extract (8%) followed by a packaging in plastic bag and a storage at 4°C have significant effect on the microbiological and physico-chemical changes since the conditions allow to reach a shelf-life of 90 days. The reengineering of Lanhouin was also adapted to the European market by 3 strategies: i) introduce marinating during the ripening step to avoid high microbial proliferation and to limit the generation of biogenic amines, ii) improve the fermentation conditions by adding commercial starter culture of Lactobacillus plantarum and strain of Staphylococcus xylosus obtained from INRA as biopreservative organisms, and iii) improve the storage and shelf life by using different packaging. The improved Lanhouin presented in forms of powder or cube, packaged in a plastic bag (Type B Walovac 90) can be stored at ambient temperature (30 ± 2°C) up to 90 days without microbial problem.
In the case of smoked Kong, technological alternatives proposed by CIRAD and UCAD in the traditional process took into account the local and European marketing with a priority for improvement sanitary qualities of products. Biopreservation strategy by inoculation of fish with Lactobacillus plantarum starter cultures is efficient to increase the shelf life from 8 to 14 days of smoked Kong only if final products are stored in paper film at ambient temperature (traditional way). No benefit is observed with storage at 4°C under vacuum. Other strategies have been tested by acting on the traditional unit operations (the intermediate washing, smoking, storage and distribution) and new unit operations have been proposed (salting, acidification). Washing the kong in bacteriostatic solutions was tested after evisceration, either bleach solution (4 water plugs bleach/30 L water/30 kg of fish) at least 5 minutes, although this condemns fish at the local market (prohibition of treatment for the EU), or in solutions with 20% of plant extracts (ginger, garlic, moringa) for 30 minutes, while constraints remain (impact on taste, costs, water consumption ...). The effectiveness of these treatments should be checked in representative conditions of local producers (raw material with high total flora). Salting is an effective strategy to reduce the microbiological risk. A 6% salt impregnation has a significant lowering effect on the water activity of the finished product which reduces the growth of pathogenic and spoilage bacteria and which results in a shelf-life increased over 3 days at 30°C and further 6 days at 4°C. The addition of an acidification step by immersion of the fish for 5 minutes in a 0.5N solution of lactic acid at 25°C, until a pH of 5.75 is also effective against microbiological risk (conservation increases further 6 days at 30°C and not more than 3 days at 4°C). However, the impact on the texture of the filets is negative (rejection by consumers). Finally, the packaging is a key step to optimize storage of smoked Kong. But the packaging by portion in trays under film causes maximum growth of the total flora at the high ambient temperature. It is therefore to be avoided or to recommend only with a chilled or frozen distribution. The “mosquito cage” tested in the project is used in southern countries and perfectly suited to the traditional local market to limit product contamination by insects and the many manipulations of customers. Coliform decrease as well as pathogens. For optimization of smoking, the use of liquid smoke is an option offered by modern technologies in Europe. A Senegalese company (Marepêche) plans to develop a smoking line for the export markets in 2015. The products are completely free of carcinogenic PAH, due to the purity of the liquid smoke used.
Reengineering of Kitoza conducted by ADIV for the European market aimed to secure products in the toxicological (reduction of PAH) and microbiological point of view (FCD criteria consistent). The initial operation of washing the raw material was suppressed in the context where cold chain is maintained. The salting and seasoning step has been optimized for the taste of European consumers. The smoking program was optimized at 60°C using specific equipment (smoke cell CCF 1001 by ARCOS, France). For beef, the sequences of the drying (30 min) and smoking (15 min) are renewed once at during 10 min by step. With pork, the program integrates three drying and smoking cycles. The biopreservation of meat by using a commercial starter (BCL77 by CHR-Hansen) is an effective strategy because combined with vacuum packaging and storage at 4°C, the shelf-life of Kitoza is 35 days minimum. The packaging under modified atmosphere confers no advantage as kitoza meat exudes on the packaging, a reason of consumer reject.
Conclusion - Most of the traditional productions of Kong, Lanhouin and Kitoza are based on very archaic and insecure workshops, with very limited financial means. The presence of pathogens and spoilage bacteria in high quantities reveals defiance of basic hygienic practices and post-production cross-contamination. Reengineering can only be done in parallel of the implementation of compliance of workshops, with the rules of good hygiene practices issued by the competent authorities. This compliance is mandatory for export (required approval) and could be progressively obtained for the local market. The product and process improvements proposed in the AFTER project are the first alternative solutions to reduce microbiological and toxicological risk. The packaging is a key element to secure the distribution of products. For modern markets, individual packages sealed in plastic film under chilled and frozen mode are to consider. For the traditional local market, without cold chain, packaged products under plastic would rapidly decay. Solution as “mosquito cage” is an affordable and available alternative.
THE PROCESS REENGINEERING OF TRADITIONAL FUNCTIONAL FOOD enabled to set up combined processes applied to traditional fruits (Adansonia digitata, Ziziphus mauritiana) and calyxes (Hibiscus sabdariffa), in order to produce ingredients and beverages with improved functional and nutritional qualities. The process of achieving these objectives involved several stages, performed over 4 years. These stages were: literature review on the relevant products, characterization investigation of raw materials, diagnostic of the processing of the end products from these raw materials, optimization and development of new products, and implementation of several sensory and consumer tests.
The literature review provides a better background knowledge of the products. The quality of the baobab fruit, bissap calyx and Ziziphus fruit was determined by evaluating the composition of macronutrients, micronutrients and antinutritional factors, the microbiological safety and the sensory quality attributes.
In order to provide good knowledge of the different products concerned, a survey was conducted in Senegal for Hibiscus sabdariffa (bissap) and Adansonia digitata (baobab), and in Cameroon for Jujuphis mauritiania (Jaabi). We carried out a lot of information gathering, such as on processing, marketing systems, sensory properties and attributes, and therapeutic effects.
After sampling various raw materials across the main production areas of the countries concerned (bissap and baobab in Senegal; jaabi in Cameroon), a complete characterization was performed. Prior laboratory standard operating protocols were optimized and validated by the various project research teams. A variety of results were obtained. For baobab chemical analysis, significant differences were observed both between geographical areas and varieties. In the case of bissap calyx, four varieties of Hibiscus sabdariffa and five production zones were chosen. In each zone, 6 samples were analysed. Significant differences were observed both between varieties of the same geographical area and between geographical areas. For Jaabi, two varieties of jaabi and four production zones were chosen. The effects of two processing techniques were also evaluated. Significant differences were observed both between varieties of the same geographical area and between geographical areas. Chemical safety results: Hibiscus sabdariffa calyxes, and fruits of Adansonia digitata and Ziziphus mauritiana in general exhibit good quality chemical safety parameters (aflatoxins and ochratoxin A). In the case of jaabi, one sample exhibits high aflatoxin and ochratoxin levels. We think that the presence of aflatoxins is due to the long storage time before analysis. Inventory of the technological flora and pathogenic germs: for all the Group 3 products (raw materials and raw material based products), the total flora, technological flora and pathogenic germs were investigated. For bissap and baobab, the products exhibited no presence of pathogenic germs. Conversely, some jaabi samples exhibit non-compliances. Results of the biochemical and nutritional quality: for all the group 3 products, biochemical and nutritional analyses of the products were conducted with regard to functional components. Analysis of the results shows significant differences, which were observed both between varieties of the same geographical area and between geographical areas. In the case of jaabi, the processing has also a strong effect on the biochemical and nutritional quality. The three products are characterized by their richness in polyphenols (up to 2 %), vitamin C (200 to 500 mg/100 g) (baobab and jaabi) and anthocyanins (0.5 to 2.0 g/100g) (bissap). This translates into high antioxidant capacity values.
Diagnostic of the processing of the end products aimed at: 1) to study the effects of local processing practices on the functional properties of products, and 2) to identify the processing limits of these practices, with regard to quality and stability of products. Report on the influence of local processing on quality: for each product, the local processing techniques were identified and validated. The influence of local processing conditions (form of utilisation, temperature, storage conditions, etc.) on their quality, with regard to functional components (anthocyanins, polyphenols and vitamins), was analysed. In the case of baobab, the results showed that the storage conditions (temperature, packaging) significantly affect the nutritional and functional compounds. Losses of 70-90% and 50-70% were noted respectively for vitamin C and total polyphenols. For bissap, the result showed that the storage conditions (temperature, packaging) significantly affect the functional compounds (anthocyanins). Losses of 40 to 70 % were observed. The form of utilisation (whole calyx, shredded calyx) also has an impact on the anthocyanins content. The drying method seems to have a strong effect on the quality. So we plan to conduct a comparative study between drying methods during the next fresh calyx season. The results for jaabi seem to indicate no significant differences between Jaabi samples, whatever the variety and origin. Conversely, the chemical analyses show chemical and nutritional differences between Jaabi grains and the resulting Yaabande depending on the processing method used. In addition, since steaming is the major processing method applied, a study of the conditions of this processing method on the quality and functionality of Jaabi is ongoing. Identification of processing limits: analysis of the diagnostic results, combined with interviews, enabled to highlight the critical stages to improve in the different manufacturing processes. It proved that reengineering work is needed to improve traditional product quality. In the case of the baobab and bissap products, the aqueous extraction and stabilization stages were considered first. While for Yabande (jaabi product), the formulation and cooking stages were considered. Characterisation of traditional products: samples collected for diagnostics were analysed using the standards operating protocols. Very clearly, the report shows that for the same product, the quality is heterogeneous, and varies according to several criteria such as the producer, the origin of raw materials, and the processes used.
OPTIMIZATION PHASE. In Senegal, this work was done in close collaboration with four companies (2 in Dakar, 1 in Thies and 1 in Kaolack) manufacturing products from Hibiscus sabdariffa and Adansonia digitata. The processing of jaabi into Yaabande was studied in northern Cameroon. So, for jaabi, the processing analysis indicates that steaming is more common and has more potential. Analysis of the critical process parameters indicates that the flour sieving operation after grinding and the steaming time are likely to have an influence on the final product quality. The analysis of these parameters shows that the fineness of jaabi flour leads to a stronger texture of Yaabande cake. Moreover, the biological properties (antioxidant properties) of the product are conserved during steaming. In Senegal, the results show that baobab and bissap products (beverages, syrups) are generally processed on a small and semi-industrial scale, with a lack of technical tools for quality control. The work was able to highlight the constraints (quality of raw material, extraction procedure, filtration, heat treatment, storage conditions, etc.). So, to improve product quality, ensure consistent quality between production batches, a reengineering stage was carried out. New improved processing protocols for bissap and baobab products (beverages, syrups) ensuring high and constant quality were proposed, and are already being applied by some companies. It is within this framework that the extraction, filtration and thermal stabilization stages were optimized. These improvements were immediately adopted by the companies. The organization of the harvesting system (production of baobab powder and crushed bissap calyx of good quality, proper packaging and good storage conditions of raw materials, traceability, etc.) would be a considerable asset. Similarly, the availability of glass and/or heat resistant plastic packaging would be a great help.
DEVELOPMENT OF NEW PRODUCTS. The literature review and survey results showed that jaabi (Ziziphus mauritiana) was traditionally processed into flour by grinding, and baked into small round cakes locally known as Yaabande. Consumer testing showed that the product texture is among the main quality attributes considered by consumers. So, with local processors, processing techniques were improved, consisting in the introduction of milling and sieving in the jaabi flour production. The proposed result is Yaabande exhibiting a fine texture which is highly appreciated by consumers. Processors in Garoua have adopted the practice. Flour of particle size 250 µm>Ø>125 µm appears to be the most appropriate selection, in view of local sieve availability. In addition, the intense aroma of jaabi raises an opportunity for its added-value use in biscuit making. Proposition of composite flour biscuit, made of wheat - jaabi (60 - 40) or maize – jaabi (70 – 30) appears to be a potential new functional product for market development of local Ziziphus. In Senegal, the literature review and survey results showed that traditional bissap and baobab products (beverages, syrups) are generally processed on a small and semi-industrial scale, with a lack of technical tools for quality control. The previous diagnostic studies were able to highlight the constraints (quality of raw material, extraction procedure, filtration, heat treatment, storage conditions, etc.). So, the reengineering stage led to many innovations which were introduced in the various processes. In the case of bissap, we developed new products such as syrups, concentrates and atomized powder, while with baobab fruit products such as powders and syrups were optimized. These products were characterized by high levels of vitamin C, acidity, polyphenols and antioxidant capacity. These new products have a high potential for use as functional foods. These products represent good opportunities with applications in various sectors, such as food & beverages, cosmetics and pharmaceuticals. The new and improved products were well accepted by consumers.
More sensory and consumer tests were conducted during the four years of the project. These tests allowed us to characterize the different products in sensory terms, and to assess the impact of operating conditions on product quality. The view of consumers was taken into account by the consumer organization tests. The Senegal and Cameroon AFTER project team conducted for the first time in their country sensory and consumer testing, following a rigorous scientific methodology. Thanks to the AFTER project, a sensory analysis team was set up in these countries. No doubt this team will be a precursor of the future first sensory analysis laboratory in Senegal and Cameroon.
CONSUMER AND MARKET ACCEPTANCE studies ensured that the products developed are acceptable to consumers in the African and Europeans markets and that issues of market access are understood in order for the products to maximise the likelihood of success. Sensory evaluation and consumer acceptance studies of the baseline products in Africa and the EU showed that in general they had higher acceptance in the African countries than in the EU, especially when the product was one that EU consumers were not familiar with such as the fermented maize products (Kenkey, Akpan and Gowe). It should be noted that not all of the baseline products were tested in the due to either regularity issues that prevented importation (meat and fish products) or sanitary issues (Kishk Sa’eedi). For the reengineered products, acceptance varied in both the EU and Africa but it should be noted that some improvements were more food safety and processing related rather than sensory one. In the EU, consumers reported mixed views with moderate to high acceptance for Kitoza made from pork, kong made with liquid smoke, bissap and baobab. Low acceptance was reported for fermented products (Akpan, Kenkey and Kishk Sa’eedi) while Gowe and Jaabi were not tested due to aflatoxin contamination and lower quality than the traditional one respectively. Similarly, African consumers also reported mixed views regarding the reengineered products. Some reengineered products were found to be more acceptable (Gowe and Akpan in Benin, white Kenkey in Ghana, liquid-smoked Kong and Lanhouin in Senegal, Bissap and Baobab in Senegal), some of similar acceptance (Kitoza in Madagascar) and some were less acceptable (Kishk Sa’eedi in Egypt and Jaabi in Cameroon). This has implications concerning the marketing and regulatory aspects. In the African markets the main issues were related to the need for standardized products of consistent quality and safety aspects which this project has met and the selection of the sector that the reengineered product would succeed in (informal, formal, supermarket, snack, tourist industry etc.). In EU markets, the issues were that for some products the size of the markets was small (e.g. reengineered akpan, gowe, kenkey) and crowded market space (kong, baobab) while bissap and kitoza appear to have potential. In all products, in the EU market, while there were no serious impediments to market access complying with private standards or certification will require high costs. The process of achieving these objectives involved several stages, performed over 4 years. These stages were: studies of the regulatory, marketing and economical aspects in the selected EU and African countries; defining the sensory properties and consumer acceptance of the initial products in the selected EU countries; defining the sensory properties and consumer acceptance of the initial products in the selected African countries; assessing the sensory properties and consumer acceptance of the improved products in the EU and assessing the sensory properties and consumer acceptance of the improved products in Africa.
Studies of the regulatory, marketing and economical aspects in the selected EU and African countries - In Africa, regulatory and market analysis and training in value chain analysis have been provided to all African partners. The training was located in Senegal, Ghana and Madagascar. The training covered value chain analysis, value chain upgrading and economics and market GAP analysis. For Group 1 products, market gap analysis identified potential market spaces in each African country that the re-engineered AFTER products could occupy. For Akpan and Gowe, the new products require standardisation and an extended shelf-life and could be introduced in the formal market place whereas for Kenkey Ghana’s fast growing supermarket sector had the greatest potential for a re-engineered product and that the products should be white Kenkey. In the case of Kishk Sa’eedi, the tourist industry and local supermarkets held the most potential for an improved traditional product. For Group 2 a new standardised Lanhouin in Benin can compete in the formal sector with existing food condiments such as ‘Maggie Cubes’ but would require investment. For a higher value Kitoza product in Madagascar, new market opportunities in the snack market were promising. Kong in Senegal has potential in the ready-to-eat products after safety and quality issues have been addressed. For Group 3 products, several opportunities were identified for baobab in Senegal (instant powders, functional ingredient, and beverages). A standardised bissap has a market gap in the growing domestic beverage market. Jaabi would seem to be for an instant food ingredient in the small-scale bakery sector in Cameroon. In the EU, surveys were carried out of the reengineered products in 2014 in the UK, France and Portugal. The market for reengineered AFTER products in the EU can be broadly divided in to two sub-markets: the African diaspora and mainstream, food markets. For Group 1, for Akpan and Gowe a re-engineered yoghurt type drink would be popular but the market size is relatively small (specialist health food stores). For Kishk Sa’eedi, links to the exciting trend for Mediterranean cuisine show great potential for niche marketing of a well-presented food safe product. For Kenkey, a survey did not see a market opportunity for this product in the UK even with the Ghanaian diaspora. For Group 2, Lanhouin has potential as a gourmet seasoning product and for reengineered Kong the product will probably not out-compete other similar, but easier to eat, smoked fish offerings. For Group 3 reengineered products, both Baobab and Bissap have potential as ingredients for different food and beverage products in all markets but Jaabi biscuits did not. There were no serious impediment exists to market access for this group of products but concerns exist with respect to these products complying with private standards or certification due to the high costs involved.
Defining the sensory properties and consumer acceptance of the initial products in the selected EU countries - Sensory and consumer acceptance studies were undertaken in the UK, France and Portugal of the AFTER products before reengineering from each group. Considering group 1 products, acceptance of gowe in France and Kenkey in the UK was low and the majority (64 %) of consumers would not buy them. Akpan had higher acceptance. No group 2 products were tested. For group 3 products, sensory profile was fully described by trained assessors’ panel using QDA methodology in Portugal. In terms of consumer acceptance, bissap was tested in the UK, France and Portugal to obtain inter-cultural comparisons. Acceptance of the drink was high and Portuguese consumers differed from UK and French ones two clusters: the first one composed by Portugal and the second by France and the UK. The Portuguese consumers preferred an instant drink followed by hot extraction drinks whereas in the UK and France consumers preferred a cold extracted bissap followed by instant drink. Besides the overall liking a new methodology, CATA was applied to improve the gathered information. Concerning Baobab the studies were conducted in Portugal. The complete sensory profile of four samples were evaluated by a trained assessors’ panel using QDA methodology and consumer studies included score their overall liking and a CATA questionnaire. Results showed that all of the drinks were on the acceptable range but product needs reengineering to be adapted to the Portuguese market, especially regarding to the texture and aroma attributes.
Defining the sensory properties and consumer acceptance of the initial products in the selected African countries - A workshop was held in Ghana in May 2011. SOP’s for sensory and consumer testing in Africa and Europe was developed and these working documents evolved during the course of the project, particularly with the introduction of the CATA methodology. In addition, in the African countries, both African and EU consumers were interviewed in order to compare them. Considering group 1, for akpan, African and non-African consumers behaved differently with respect to acceptability; Europeans had lower acceptability compared to Africans. This was probably due to the fact that most Europeans were not familiar with the product. Regarding Kenkey, African and non-African consumers differed markedly in acceptance. Non-African consumers mostly preferred the white kenkey which was less acidic. Regarding Gowe, acceptance depended on whether it was made from sorghum or maize, but no significant difference was noted with sugar was added. Consumer acceptance of Kishk Sa’eedi (KS) indicated that Egyptian consumers preferred KS with strong sour taste and spicy flavour whereas most non Egyptian consumers liked KS with off-white to light creamy colour, mild sour taste, pleasant typical KS aroma and crunchy texture. For Group 2 traditional Lanhouin was sensorially different and three classes of consumers’ behaviour were identified. Consumers’ acceptance was significantly associated with size of fish, whitish colour, dried fish odour and ammoniacal odour. Lanhouin from king fish with semi aerobic fermentation and Lanhouin from cassava fish (except for aerobic fermentation) were more accepted and could be interesting for reengineering. For Kong, four samples were compared. Most of the Kong products were on average acceptance but moist kong had a better acceptability than dried samples submitted to the same processes of smoking. For Kitoza in Madagascar, there was a clear difference between sensory profile of pork and beef samples. Pork Kitoza were more associated to fatty, salty, wet and smoked sensory characteristics. Beef Kitoza were associated to fibrous, darker, harder, roasted and elastic or, depending of the process, to spicy and sweet sensory characteristics. Four smoked Kitoza products met a good acceptance with both European and Malagasy consumers, with a slightly preference for Pork Kitoza, even if the frequency of consumption was low for both. Four groups of consumers were identified. Sensory evaluation and consumer testing of group 3 products - Hibiscus, Baobab and Jaabi was undertaken with African and EU consumers in Senegal and Cameroon. For bissap, the tested products had different sensory perceptions. Three classes of behaviour from the consumers were identified. The liking by African and EU consumers was similar but European consumers were more likely to prefer syrup. African consumers were more likely to prefer juice, consume bissap more frequently and purchase it in sachets. The sensory profile of seven samples of baobab drinks (syrup and juice) was evaluated in Senegal. The acceptability of the drink was tested and three classes of behaviour from the consumers were identified. The reengineering approach appears to have two options being products suited to milk taste or taste and odour characteristic of baobab. Sensory profile and consumer acceptability was undertaken for Jaabi, in the Cameroon. All samples tested were acceptable. The main option of reengineering approach is based on standardisation of process procedures in order to guarantee the taste of the products. Inclusion of therapeutic aspects of the products may be coupled to this option for market development.
Assessing the sensory properties and consumer acceptance of the improved products in the EU - After the AFTER products had been reengineered, they were tested by sensory panellists and consumers in France, the UK and Portugal. Not all products were tested by consumers due to either the reengineered products not being as acceptable as the traditional product (e.g. Lanhouin and Jaabi) or due to technical issues (e.g. Gowe).
Sensory Evaluation. Considering Group 1 products, the sensory properties of reengineered products of Akpan and Kenkey did not differ significantly from traditional ones, however the opposite was observed for the new Kishk Saa’edi compared to the traditional one. Gowe was not tested due technical issues as it contained aflatoxin. Concerning the group 2 products it was decided to test only Kong and Kitoza, since Lanhouin demonstrated the lowest interest in EU market. In the case of Kong, four samples were tested: The studied samples were traditionally smoked Kong, Reengineered smoked and salted Kong, Reengineered smoked, salted and garlic flavoured Kong, Reengineered smoked Kong with liquid smoke. The complete descriptive study of sensory profile was not performed. Kitoza samples were analysed in Portugal for sensory tests included two different types of reengineering products: Kitoza beef (KB) and Kitoza pork (KP) which had distinct sensory differences. For group 3 products, due to restrictions of Jaabi product only Bissap and Baobab was studied in Europe, since jaabi demonstrated low interest in EU market. Baobab samples were assessed by a Portuguese trained panel. Four different samples were included. Sensory profiling showed similar results between the four samples, however samples produced from similar raw material, Baobab powder or fruit showed to be closer in particular concerning colour hue and turbidity. The attribute that was highlighted in all samples was sweetness and all samples were considered very sweet. Concerning Bissap assessed by a Portuguese trained panel, using three hibiscus drinks, an hibiscus infusion prepared freshly from dried calyces according to Senegalese recipe for baseline comparison and two new hibiscus drinks developed under as reengineered products – an ultra-vacuum concentrate and improved syrup. The reengineered product was similar to the traditional one. The results demonstrate diverse sensory characteristics for each sample, and some identified attributes and intensities that together with consumer study provided recommendation of some improvements to facilitate increased penetration in African and European markets.
Consumer acceptance. Considering group 1 products, Kishk Sa’eedi samples were generally disliked by Portuguese consumers who were unlikely to buy or consume it; Portuguese consumers are not familiar with fermented foods based cereal and milk which could help to explain the results obtained in this study. Similarly, reengineered Akpan products, although more accepted than the traditional version, did not have high acceptance by French consumers and few would likely buy it. Reengineered white Kenkey had improved acceptance compared to traditional form, but was not high enough to be readily marketed in the UK. Gowé was not tested by consumers owing to contamination of the raw material with aflatoxins. Concerning group 2 acceptance in EU, it was decided to test only Kong and Kitoza, since Lanhouin demonstrated the lowest interest for the EU market. Reengineered pork and beef Kitoza, was tested by Portuguese consumers and the pork version was most appreciated, especially if the slices were large. Additionally, the Madagascar origin was perceived as positive. Kong was tested by French consumers. No difference was observed among the reengineered products regarding their overall acceptability (like slightly-like moderately), but the traditional one was liked less. The most liked Kong product was the one made with liquid smoke. Of the group 3 reengineered products, only Bissap and Baobab were tested by EU consumers as previously explained. Of four baobab drinks tested by Portuguese consumers, all were liked and found to be acceptable. For the two reengineered bissap drinks (ultra-vacuum concentrate and a syrup), these were tested by consumers in France, Portugal and the UK. All of the hibiscus drinks evaluated were positively appreciated by consumers and the reengineered one was more liked. Similar preference profiles were observed across EU countries although French participants gave slightly higher acceptance.
Assessing the sensory properties and consumer acceptance of the improved products in Africa. - After the AFTER products had been reengineered, they were tested by sensory panellists and then by consumers in each African country (Benin, Cameroon, Ghana, Senegal, Egypt and Madagascar). Changes and simplifications in sensory evaluation methodology have also led to modifications in the approach. Firstly, new more powerful methodologies have recently been developed (CATA) which enabled the use of consumers to estimate the sensory characteristics instead of using a separate sensory panel using the QDA method and secondly, since the sensory methodology is independent of the where the samples being tested, when test samples were common to both consumers in the EU and in Africa, there was only the need for one sensory test in either the EU or Africa instead of the need to do it in both. Hence, a single sensory evaluation result could be used in the calculations for relating sensory parameters to hedonic outputs by consumers
Sensory evaluation testing. Concerning reengineered Akpan from Benin, the sensory evaluation was undertaken in Montpellier, France. Reengineering of Akpan has focused primarily on improvement of sanitary properties of the product to enable increased production by SMEs in Africa. Sensory evaluation of the Akpan products was carried out using CATA and JAR techniques that have been developed for use with consumers instead of a trained panel. Three Akpan products were tested which had similar sensory attributes. Gowe from Benin was not tested using sensory evaluation samples provided for the French sensory panel contained a concentration of aflatoxin that was slightly higher than the minimum EU allowable limit. The sensory evaluation of Kenkey in Ghana was of a white type that has increasing popularity among urban consumers and requires larger scale production with consistent quality. Testing was conducted to determine the sensory profile of white reengineered kenkey made using the optimum pre-process conditions of steeping time, temperature and dough fermentation time. The sensory profile of white kenkey was dependent on pre-processing variables. Soft and sticky texture in white kenkey was highly appreciated. Sensory evaluation of Kishk Sa’eedi (KS) was undertaken in Egypt. Three KS samples were profiled. The re-engineered KS sample perceived as less sour and less salty, easy to fracture, and scored higher for grittiness compared to traditional ones. It was rated lower than the traditional ones with regard to Kishk taste and fermented odour. The present study showed that substantial differences in sensory character were noted between the traditional and re-engineered KS in particular, differences in colour, fresh odour, KS taste, fracutability and mouth coating. Considering Group 2 of the three products, sensory evaluation of only Kitoza was undertaken. For both Lanhouin and Kong it was not conducted because this product was only tested using a consumer panel. The reason for not testing using a sensory panel is because the product is used as a taste enhancer and hence the sensory properties were strongly influenced by the accompanying product. This makes the sensory evaluation much more complicated. Considering Kitoza, the sensory profile of the beef and pork reengineered Kitoza, was compared with 7 locally produced samples. The results of the descriptive analyses showed that the new reengineered products were not significantly different compared the traditional ones (but pork differed from beef) but offered new market potential because of improvements in safety and quality. Considering group 3 products, bissap and baobab had different sensory properties, which indicate differing consumer perceptions which may or may not improve market penetration in Africa and EU. The re-engineering of the bissap drinks was conducted with the main objectives of improving the eco-efficiency of the production process, the preservation of nutritional quality and colour of the products, while diminishing the production costs. The sensory study conducted in Portugal, the results confirmed that the new processing of bissap resulting in a beneficial softening of some of the strongest attributes present in traditional infusion, such as bitterness, acidity and astringency, while the reengineered infusion, traditionally a well appreciated drink among Senegalese consumers maintained most of the sensory characteristics of the traditional product. In the case of baobab, the reengineered juices tested in Portugal had different sensory characteristics to syrups. The attribute that was more distinguished for all samples it was sweetness. In the case of Jaabi, this was not tested by a sensory panel because the reengineered product had inferior properties to the baseline one and hence would not have a viable market.
Consumer testing. The reengineered products relating to groups 1 to 3 were tested by consumers in Africa in order to test whether the acceptance meets consumer needs. These products were widely different and tested in differing cultures and situations. A common feature, however, is that all products are already commonly consumed by the communities and accepted, particularly with respect to the baseline products. Some reengineered products were found to be more acceptable (Gowe and Akpan in Benin, white Kenkey in Ghana, liquid-smoked Kong and Lanhouin in Senegal, Bissap and Baobab in Senegal), some of similar acceptance (Kitoza in Madagascar) and some were less acceptable (Kishk Sa’eedi in Egypt and Jaabi in Cameroon). These acceptance tests indicate the challenges is reengineering products that are very different from each other and are consumed by consumers who may be familiar with them (as in Africa) or not (as in the EU). The market in the EU is very crowded and presents particular challenges to these products while in the African market, the markets are rapidly evolving as consumers start to experiment with new foods.
THE DEMONSTRATION OF THE IMPROVED PROCESSES AND TECHNOLOGIES enabled to transfer the scientific results to the private sector represented by SMEs. The process of achieving this objective involved several stages performed once the results were available, from September 2013 to the end of the project. Five pilot products were selected during the AFTER Porto meeting in June 2013. The consortium selected among the ten products the five with highest potential to be treated at pilot scale, using a spreadsheet to compare each product. Taking into account the amount of activities which remain to implement for each product, the five for those we already achieved identifiable scientific and technological results were listed: Bissap, Baobab, Kong, Gowé and Akpan. Demonstrations have been organized for all of them, including a “report on test results”. For the other five products (Kitoza, Lanhouin, Kenkey, Jaabi and Kishk) the results have been brought together and shown into the form of “showcases”: the content is not as formalised as for the demonstrations.
Successful pilot tests in African SMEs food companies
The methodology of the results demonstration used has been described in a milestone, which gives logistical & communication tools to maximize AFTER project impacts and leads into the dissemination phase. The pilot product demonstrations have been organized by the five product champions concerned, in collaboration with their Team, CIRAD and AAAFEX partners between September 2013 and May 2014.
The demonstration of Bissap & Baobab transformation (23d of September 2013 in Dakar, Senegal) focused on the improvement of traditional processes. It was divided in two phases. First, pilot tests were organized in a technical center as a global presentation of results (i.e. in ideal conditions). The research findings were then shared with each company involved (i.e. in real-life working conditions). Workshops and discussions were focused on the particular stages improved thanks to what we have learned from the research: manual or mechanical grinding, aqueous extraction, filtration, pasteurization scale and rapid cooling system (detailed in D6.1.2 and D6.1.3). The pilot tests conducted to make natural products, without aroma (like strawberry or ananas, traditionally added to the recipe). Although it requires investments in terms of equipment, the companies also showed a strong interest for the bissap concentrate, as a solution to standardize their production of drink or syrup.
A participative workshop has been organized on the 30th of November 2013 at the modern-type GIE “Seuti Ndiaré” (Dakar, Senegal) to share AFTER process improvement with local kong producers. These improvements are partly on sanitary aspects, for example by the introduction of a dipping operation into salted water for a reduction of the microbial flora and water loss prior to smoking. Moreover, the separation of the unit operations of drying and smoking, combined with the use of clean fuels, was introduced (results detailed in the D6.1.4). The workshop counted twelve participants (without counting AAFEX, UCAD and CIRAD representatives for the AFTER project).
The results obtained for Akpan and Gowe have been presented to 14 Beninese SMEs on Wednesday the 14th of May 2014 in Cotonou. With limited premises, the day was organized at the scientific library of the UAC. The main results obtained have been oraly presented before being illustrated by a mixing and bottling workshop for Akpan and a reconstitution workshop for Gowé (from Gowé flour). This event has been a really good occasion to stress the interests that private sector (SMEs) and research have in common. The richness of the discussions which took place in the meeting and debates all testify of the movement begun and invites to think about a more structured collaboration between all the actors of food processing field.
The wealth of the exchanges been born within the framework of these demonstrations of the research results testifies of the interest of companies for this type of initiative. The participants had the possibility to ask a lot of questions and the discussions offered to every participant the possibility to voice his opinion or concern. The contacts formalized on this occasion were shared to make this work bear fruit: towards a future and even richer collaboration! Good hygiene practices were also reminded and included in all the guidelines for the industry. These workshops were a good occasion to take pictures during food processing to illustrate communication tools, and also to collect data to assess the processes environment impacts.
Impact of the technologies on environment, energy and water consumption known
A parallel task was to verify whether the selected processes reduce the impact on the environment and ensure a cleaner and more sustainable production. For this, a simplified version of the Life Cycle Assessment (LCA) has been applied. As it has been done to characterize traditional processes, parameters had been recorded for reengineered processes on three or more essays. After data collection, LCI data was entered in Simapro software (Pré Consultant) to model the production processes and calculate the environmental impacts. When available, generic processes (e.g. sugar, salt, electricity…) were taken from the Ecoinvent database. Some of these processes were used as proxies, for instance wood chips available in Ecoinvent were considered equivalent to the sawdust actually used for some of the tests. These approximations were necessary to compensate for the lack of data on the environmental impacts of several of the inputs to the processes. Consequently the system boundaries were limited to the processing phase of the life cycle of the products, including the sourcing and use of the various inputs (ingredients, energy, water), but excluding the farming stage (agricultural production of Bissap, baobab, etc.) and transportation to the factory. The consumption phase was also not included in the system boundaries. Hence the study applies LCI tools to assess the environmental impacts of the target production processes, but does not constitute a full life cycle assessment as defined by the ISO14040-44 norm. The environmental impacts enable to compare conventional and reengineered processes, but the values do not represent the actual impacts. The functional unit (FU) was defined as 1 kg of product, for all the products. The same methodology was used for 5 products (Kong, Bissap, Baobab, Akpan and Gowé).
Conclusions are that Kong and Akpan revisited processes have better environmental performance comparing to traditional processes. That is mainly due to more efficient water used and cleaner energy used. So, for the limited differences between traditional and revisited Bissap and Baobab processes, those points constitute opportunities optimizing and improvement way for reengineered those products, in term of environmental performance.
Potential Impact:
1.4 Potential impact, main dissemination activities and exploitation of results
1.4.1. IMPACT
The main immediate and direct impacts of the project are the production of traditional food products with improved quality and safety and the commercialisation of new food products and additives.
AFTER has had a direct impact on the production of the ten selected traditional food products from Africa by improving their safety and their organoleptic & nutritional quality. The process reengineering of fermented cereal based products has helped to improve their safety thanks to better control of fermentation parameters. Three Lactobacilli (Lb. brevis, Lb.Casei and Lb. fermentum) were tested for inoculating wet milled dough (ogi) to produce gowé. Lb. Casei has been selected as a good compromise and because it can be easily provided as commercial dry active bacteria. A model was developed for predicting the fermentation, and then used for testing various scenarii of the fermentation of Gowé. In this respect, the inoculation with Lb. casei demonstrated his efficiency to rapidly ferment Gowé. The inoculation of Lb. brevis could be interesting in the context of very small processing unit that cannot control the temperature and the final pH. In order to improve Kishk Sa’eedi process, three hundreds and eleven isolated strains (isolated from good quality traditional Laban Zeer) have been examined for flavor acceptability in reconstituted skim milk powder to select only strains that produce accepted flavor. At the end of experimental, 15 strains have been selected and used for fermenting butter milk to produce Laban Zeer. The optimised processes also lead to improvements in end use quality (shelf-life, packaging, ease of preparation). As a result, the gowé flour shelf-life is more than 6 months, compared to three days for the traditional product. This flour can easily be reconstituted in Gowé by dilution in tap water and small time of cooking. The pre-processing (steeping and fermentation) and cooking steps for producing white kenkey have been optimized and the product was given a new shape as cylindrical slices instead of the crudely round balls of kenkey. The slices are packaged in cling film or vacuum packed rather than wrapped in banana, maize or other traditional packaging leaves. Vacuum packaging extends the shelf life of kenkey from between 4 and 7 days to 6 months under refrigerated storage.
The process reengineering of meat and fish products contributed to improvements in products safety and quality through the optimization of existing processes, through the introduction of new operations such as biopreservation or impregnation and through the utilisation of new ingredients. Simple adjustments of manufacturing diagrams have reduced the risk of PAHs in Kong and Kitoza, splitting the traditional smoking step into a cooking/drying and a smoking unit operation. For Kong as for Kitoza, the choice of fuel was optimized: the use of wood sawdust (for smoking) and charcoal (for cooking/drying) reduces the risk of carcinogenesis associated with PAH and B(a)P. In the case of Lanhouin the ripening and salting operations were combined to prevent microbiological degradation, final drying was optimized by the use of a shell dryer before sun drying to reduce the contact with insects. At the end of the process, a washing step of fish fillets in a mixed solution of lemon juice and garlic extract followed by a packaging in plastic bag and a storage at 4°C have significant effect on the microbiological and physico-chemical changes since the conditions allow to reach a shelf-life of 90 days. Reengineering can only be done in parallel of the implementation of compliance of workshops with the rules of good hygiene practices issued by the competent authorities. This compliance is mandatory for export (required approval) and could be progressively obtained for the local market. The product and process improvements proposed in the AFTER project are the first alternative solutions to reduce microbiological and toxicological risk. The packaging is a key element to secure the distribution of products. For modern markets, individual packages sealed in plastic film under chilled and frozen mode are to consider. For the traditional local market, without cold chain, packaged products under plastic would rapidly decay. Solution as “mosquito cage” is an affordable and available alternative.
The process reengineering of traditional functional food contributed to improvements in the nutritional value, the quality, the stability and the safety of the traditional food products made from hibiscus, baobab and jujube extracts. For jaabi, the processing analysis indicates that steaming is more common and has more potential, preserving the antioxidant properties. In Senegal, new improved processing protocols for bissap and baobab products (beverages, syrups) ensuring high and constant quality were proposed, and are already being applied by some companies: extraction, filtration and thermal stabilization stages were optimized.
The modifications of process practices that have been proposed respect local traditions and take into account sustainable environmental and economic criteria. The participation of organisations specialised in technology transfer (ACTIA) and of two major associations of food companies (SPES in the EU and AAFEX in Africa) helps to maximise the impact for the industry. The importance accorded to consumer acceptance from an early stage of the project also ensured a rapid uptake of the results by the industry.
Besides the improvement of existing products, AFTER also lead to the introduction and the commercialization of new food products. Results from process reengineering of fermented cereal based products could interest European cereal and milk processors for developing new products with high nutritional values and health claim (fermented vegetable yogurt-like products like Akpan and Gowé for example). A novel cereal-based snack inspired from Kishk Sa’eedi (KS) and adapted to the preferences of the modern consumer and to the demands of modernity was developed. The novel KS snack is a good source of dietary fiber and minerals besides being a way for youth to become engaged with their traditions, culture, and health through food. Results from process reengineering of meat and fish products should interest European meat producers. As a result, reengineering of Kitoza conducted by ADIV for the European market can help manufacturers to find new ways of transformation running the processes developed in this project. AFTER results also enables manufacturers to supplement their traditional dried product line using pig and bovine raw material with exotic products developed during the project. The formulation of new products from the calyx of Hibiscus sabdariffa as concentrate or instant powder opens new opportunities for the industry. The characterisation of jujube functionality and its valorisation contribute to propose new foods rich in natural antioxidants.
The expected medium-term impacts of the project are an increased competitiveness of African companies, an increase of the trade opportunities for African food companies, more opportunities for the European food industry, mutual knowledge generation and enhanced collaboration between different scientific disciplines and stakeholders, capability-building for European and international cooperation partner countries (ICPC) companies, a positive economic impact on both the EU and the targeted region, and contribution to meeting the EU’s commitment towards the United Nations Millennium Development Goals.
The implementation of the technologies studied in the project is helping food companies to improve their competitiveness. The active knowledge and know-how transfer, thanks to pilot tests, guidelines for the industry and the other dissemination activities (detailed below) directly benefits the food industry and should lead to a more competitive food industry.
As mentioned before, compliance of workshops with the rules of good hygiene practices issued by the competent authorities is mandatory for export (required approval). The demonstration and dissemination work done during the AFTER project contributed to introduce or remind good hygiene practices, also formalized in the ten guidelines for the industry.
Besides technology improvements, the project also improves knowledge and marketing ability. While consumer acceptance studies are common in the EU, this approach was still relatively underexploited in Africa where there are issues of culture, language and low income. AFTER project African teams conducted for the first time in their country sensory and consumer testing, following a rigorous scientific methodology. A sensory analysis team was set up in the six countries concerned. For successful implementation, the impact of the quality and safety improvements for each product has been evaluated and the acceptability of final products in EU and African markets has been assessed. The consumer testing studies, along with price and economic viability, bring food companies confidence to adopt these products in the EU and Africa.
AFTER helped to increase exports of traditional products to the EU by African companies. In the case of smoked Kong, technological alternatives proposed by CIRAD and UCAD in the traditional process took into account the local and European marketing. For optimization of smoking, the use of liquid smoke is an option offered by modern technologies in Europe. A Senegalese company (Marepêche) plans to develop a smoking line for the export markets in 2015. The products are completely free of carcinogenic PAH, due to the purity of the liquid smoke used. The reengineering of Lanhouin was also adapted to the European market by 3 strategies: 1) introduce marinating during the ripening step to avoid high microbial proliferation and to limit the generation of biogenic amines, 2) improve the fermentation conditions by adding commercial starter culture as biopreservative organisms, and 3) improve the storage and shelf life by using different packaging. The improved Lanhouin presented in forms of powder or cube, packaged in a plastic bag can be stored at ambient temperature up to 90 days without microbial problem.
The marketing mix for each product was determined by understanding the product, the pricing and economics, promotion branding and placement or channel by which each selected product is sold. It has been used to start developing a strategy for implementing the new improved products. An integral component of this is the implementation of consumer acceptance studies in the EU. The expertise from the consortium (NRI in particular) in regulatory and marketing issues also assists in overcoming potential hurdles to the successful introduction of these products into EU markets. Regional food products, although considered as ‘novel products’ by the EU have the potential to be 'fast-tracked' by the EU, especially if the food products do not differ from how they are traditionally produced and consumed.
European food companies are concerned with European competing market and are looking for new trade opportunities to improve their portfolio or create new food segments to expand their business. The integration of traditional food products and new functional foods with improved quality and safety is of great interest for European SMEs. The partners from France (ACTIA and CIRAD), Portugal (ESB) and UK (NRI) are transferring the results to food companies from their countries. The company RACINE, the most important importer of African food in France involved in the project as an advisor had already encouraged the development of the new smoking line in Senegal (using liquid smoke).
AFTER combines knowledge from both Europe and Africa to provide findings relevant to the food industry. The project has strengthened scientific exchange between scientists and also promoted industry-academia cooperation between the EU and Africa. The methodologies developed for assessing consumer acceptance and market potential as well as the improved technologies contributes to the development of bi-regional standards that will promote market penetration and generate new trade opportunities.
The impact will be important for the 12 research organisations involved. AFTER helped to exchange knowledge and know-how in several disciplines: food science, consumer acceptance, food regulations, intellectual property management etc. As a concrete result, AFTER Congress 1, the first congress organised on the theme of promoting traditional African foods was an international event co-organised by CIRAD, ESP and AAFEX on 11 and 12 November 2014 in Dakar, Senegal, with the theme “Promoting traditional African foods: innovations, quality and market access”. More than a hundred participants were hosted across the two days, with more than 10 countries represented in the oral communications, while in total 21 traditional African products were studied, and their research results shared.
AFTER contributes to the sustainable development of African rural areas by increasing the value of local products. The exploitation of the results provides new commercial opportunities for local communities in Africa. The commercialization of improved processed food products contributes to the economic growth of all stakeholders (food companies, farmers, equipment providers, exporters etc.).
Finally, AFTER contributes to meet the EU’s commitment towards the United Nations Millennium Development Goals (MDGs). For Africa, revalorization of the traditional food heritage and preserving the dietary diversity of traditional food systems have been identified as an important resource in strategies conceived to combat hunger and malnutrition and current soaring food prices (FAO Food Summit Action Plan, 2008). The project contributes to more than one of the eight targets set out in the UN Millennium Development Goals:
• Poverty alleviation through income generation and economic empowerment of women, who are the principal producers of traditional foods in most of the African countries, will also enhance gender equality.
• Improved mother and child health and nutrition as a result of improved standards of living can in turn reduce child malnutrition and susceptibility to infections, and result in increased educational outcomes and in eventual reduction in child mortality.
• Higher incomes will contribute to reduced school leaving rates for both girls and boys.
The above listed developmental impacts satisfy targets under MDGs 1 to 6. Ensuring environmental sustainability (MDG 7) is addressed by the project by minimizing the environmental impact of the processing technologies designed for production of the 'engineered' novel products, which maintains as far as possible the low energy consumption and environmental friendliness characteristic of the original indigenous techniques used in traditional food production. The long-term impact of poverty reduction on environmental degradation can be expected if improved living conditions are sustained. Mobilisation of resources – financial as well as technical – from donor countries (the EU) in support of the realization of the above listed expected Project outcomes satisfies targets under MDG.
1.4.2. DISSEMINATION
Dissemination and management of IPR were addressed all along the project life, in order to exploit results in concrete ways, affordable for both EU and African food companies and industrial stakeholders. This included a series of industrial property and technology transfer guidelines. Special attention was given to the rules regarding the exploitation of the generated know-how in industrial practice. Main objectives for the project duration were the following: production of traditional food products with improved quality and safety, modifications of process practices in respect to local traditions and taking into account sustainable environmental and economic criteria, enable technology transfer via the participation of organisations specialised in such methodologies (ACTIA) and via two major associations of food companies (SPES in the EU and AAFEX in Africa), maximise the impact for the industry (ensuring a rapid uptake of the results by the industry), disseminate research results to achieve increased competitiveness of African companies and trade opportunities for African food companies and for the European food industry.
Public dissemination of the project results occurred not only through publication in high-quality peer-reviewed scientific journals, but also through press releases, scientific and industrial platform meetings (posters, talks, working group) and through the web via the project website (see below). The new processing protocols and methods for the 10 products have been made available to the food industry through the publications and dissemination of 10 guidelines and articles in specialised magazines. Furthermore the involvement of SPES and AAFEX ensured wide “industry oriented” dissemination to their network at national level but also abroad, taking advantage from their several activities organised also in external countries and from the management, at country level, of the most important international food Fairs (such as SIAL in Paris, CIBUS in Parma, Alimentaria in Barcelone and Lisone).
According to the dissemination plan written by SPES with contributions from all partners, AFTER set out during its lifetime various dissemination activities aimed at promoting its research and at reaching the widest and varied audience possible.
Information sent to policy makers
• 10 technical guidelines
• Knowledge of African Traditional Food Products (throughout scientific outputs) was enhanced and awareness on the diversity of the African products on which the research is based on (i.e. Akpan, Kenkey, Gowé, Kishk Sa’eedi, Lanhouin –cassava fish, Kitoza, Kongin, Adansonia digitata, Hibiscus sabdariffa, Ziziphus mauritiana) was promoted. The support to the conservation of plant and cultural diversity was increased. At this regard the marketing regulartory reports released under WP5 were of interest to let them aware of the concrete possibilities and main constraints. Moreover concepts of health promoting foods were appreciated during the project events.
Information shared with the scientific community
• 61 events where specific focus of the project given by the Coordinator during scientific congresses or Symposium
• 13 scientific publications in peer-rewied journals
• 44 Posters during congresses (EFFOST and SAFFOST)
Dissemination to the general public
• 179 events where at least a project slide was given within national public events
• Briefs of the project regularly published via partners’ electronic newsletters
• 17 articles generalist papers (such as quartely review, newsletter, magazines)
Informations and tools provided to communities in Africa
• Specific tools for the technology transfer like brochure
• Food Fair (targeting agrofood companies and farmers associations)
• 5 Demonstrations of technical results at pilot scale
• 10 technical guidelines
• Final Conference in Saly
General communication
• Content and items in the official website regularly updated
• Preparation of dissemination material (flyers and leaflets also in national languages)
• Finalisation of the Brochure (English and French), paper and electronic version
• Video link created by SPES (ANIA)
• Twitter account managed by NRI
• Facebook page managed by SPES (ANIA)
The official AFTER project website is available since the very beginning (by end of 2010) of the project) at http://www.after-fp7.eu/en. The objective of this website is to provide information regarding the project addressed to the public with a special eye to scientific and industrial coomunity. During the project lifetime, website visitors were informed about the projects concept, progress and innovative results. For more detailed information all results (deliverables) accepted by the EU are available for download. The website was created and updated by CIRAD (with support of all participants), and will be maintained and hosted by CIRAD even after the end of the grant agreement. During the 3rd reporting period, 22 additional news have been uploaded (36 in total for the project duration in English and French). Public deliverables, Scientific publications, link to the Posters and press articles have been uploaded. The total number of visits were 8.716 (for a total of 23.826 screen views).
A logo was created to maintain the corporate identity of the project. Templates for Power Point presentations and deliverables were designed to ensure a united presentation to those external to the project.
The project leaflets were designed early in the project. They provide a thorough but simple to understand description of the project’s concept. The leaflets are available in English language, and have been translated into national language from SPES third parties on a voluntary basis (such as Italian and French). The leaflets were distributed at project events, such as workshops, and at other events where consortium members participated. Copies were sent to a large number of stakeholders in the EU. In addition also an official brochure released in English and French was edited by SPES with the support of the partners. This dissemination tool was finalised in order to include the already ongoing RTD results. Therefore it was prepared during the 3rd reporting period.
During important Congresses and for the final conference 44 posters were also produced and used as presentation material.
In order to comply with dissemination objectives, SPES, in close collaboration with all other partners, organized at least 1 workshop per each country (Italy, Spain, France and Portugal), combining these workshops with already existing events such as Food Fairs, open days, Food and Drink Federation Annual events like the National Technology Platform Food For Life events. Moreover in order to enhance scientific aspects of the project, SPES also organized and facilitated, with the active collaboration of R&D partners, the participation of the project partners at scientific congresses taking place in the EU and in African beneficiary countries. In Italy Federalimentare organized a working group session during CIBUS Fair in collaboration with Assafrica & Mediterranean Association to scout future opportunities of business for Italian food companies which are also located in African country. In France Ania organized large number of regional meetings in collaboration with the Food associations where AFTER was presented, discussed and promoted for further exploitation even after the end of project life. SIAL biannual Fair, as well as Alimentaria & Horexpo Lisboa 2013 Fair, were used as events to disseminate the project and distribute dissemination materials. In Portugal Fipa, in collaboration with ESB-UCP, organized a workshop “Revisiting African products for European consumers” where scientific and technical aspects were given to the participants. In Spain Fiab organized during Alimentaria Food Fair in Barcelone a workshop “Presentation of new African products developed from the Project AFTER”. AFTER Congress 1, the first congress organised on the theme of promoting traditional African foods, was a major event in the results dissemination phase. This event co-organised by CIRAD, ESP and AAFEX was held on 11 and 12 November 2014 in the Ngor Diarama hotel in Dakar, Senegal. The Congress had the theme of “Promoting traditional African foods: innovations, quality and market access”. It hosted more than a hundred participants across the two days. The event had an international scope, with more than 10 countries represented in the oral communications, while in total 21 traditional African products were studied, and their research results shared.
The dissemination activities during the third reporting period continued as planned and the relevance and impact of them increased a lot. It is to be considered also that the project released important results which were used to arrange proper dissemination strategy as follows:
Scientific community was approached by the oral presentation of the project during important scientific congresses and conferences; via the preparation of scientific publications in peer-reviewed journals
Food industry network was approached by the partners (mainly AAFEX, CIRAD and SPES third parties) via the organization of specific workshops and working groups targeting the presentation of main opportunities for EU SMEs and African companies coming from the project results. Moreover huge number of public events where AFTER short announcement or slides display were attended by SPES third parties (in Spain, Portugal, Italy and France).
During the project implementation the partnership agreed to use the most common social networks to raise the attention of the wider public dealing with African food & nutrition matters, as well as European food industry stakeholders dealing with recent developments in the food technologies of reformulation of products. At this regard NRI managed the twitter account to provide with general communication on Novel food’s ingredients from AFRICA. While SPES (ANIA) managed to open a Facebook page on the project.
Moreover SPES (ANIA) used budget from dissemination to release a video on the project which was launched by the web channel of ANIA dedicated to research and innovation.
List of Websites:
http://www.after-fp7.eu/en
Planned over 4 years between September 2010 and November 2014, AFTER has revisited traditional African products, knowledge and know-how in the light of new technologies for the benefit of consumers, producers and processors in Africa and Europe. By applying European science and technology to 10 (ten) selected African traditional food products, AFTER turned research into quantifiable and innovative technologies and products that are commercially viable in both European and African markets. The ten traditional food products studied were chosen to represent three families of foods: (1) Fermented cereal-based: Akpan, a yoghurt-like product prepared from maize gruel and Gowé, a homogenous beverage prepared from malted sorghum, millet or maize, are both originating in Benin. Kenkey, fermented dough made from maize is originating in Ghana and Kishk Sa’eedi, made from a combination of wheat and fermented buttermilk, is originating in Egypt. (2) Fermented salted fish and meat: Lanhouin, salted/dried fish spontaneously fermented, is originating in Benin. Kong, traditional smoked fish, is originating in Senegal. Kitoza, salted/dried meat, is originating in Madagascar. (3) Vegetable and fruit based functional foods: the fruit of baobab and Hibiscus sabdariffa are respectively called “bouye” and “bissap” in Senegal. Ziziphus mauritiana, fruit of the jujube tree, is called “jaabi” in Cameroon.
First, comprehensive scientific knowledge of the existing know-how has been obtained about technologies, processes and products in the six African countries of origin of the project’s targeted products, as well as about the sensory quality criteria as perceived by the traditional processors and consumers. Analytical and sampling methods to be used have been specified. Then, improved traditional processes have been proposed according to objective criteria of acceptability of the traditional products by the consumers. The improved products, produced through reengineering and new processing technologies, have been tested for consumer acceptance, safety and nutritional quality. The market and entry requirement for new products had been assessed. Involving EU and African companies in production trials for the improved products helped to translate the results into ready-to-use information for food companies. Finally, and thanks to dissemination activities, AFTER results have been transferred to the private sector represented by SMEs and made widely available: technical guidelines have been created, one for each selected product.
The project has directly contributed to improving the competitiveness of these ten traditional products and facilitated their implementation and uptake by food companies and their marketing on the diverse types of markets for these products. Beyond these direct results, the lessons learnt and the methodologies for the assessment of traditional products and processes have been shared with other countries from both continents in order to disseminate the results among the research community involved in food research in developing countries.
Public website: http://www.after-fp7.eu/en
Contact details: Dominique Pallet, scientific coordinator of the project (CIRAD), dominique.pallet@cirad.fr
Project Context and Objectives:
1.2 Summary description of project context and objectives (max 4pages)
AFTER (African Food Tradition rEvisited by Research) intended to generate and share knowledge on food technology and to support the implementation of a range of ten (10) traditional products in African and EU markets. The project focused on one developing country continent only, Africa. The project involved seven African countries (Benin, Cameroon, Egypt, Madagascar, Senegal, Ghana and South Africa) and four EU countries (France, Portugal, Italy and the UK).
Taking novel traditional foods from viable local markets to high value international markets is attractive because of the potential for income generation, but, outside products sold in small quantities to the African diasporas, few indigenous foods have been sold in any volume outside their countries of origin. The success can be improved by applying an integrated approach with down-stream production issues such as meeting commercial volumes of production whilst over-coming market entry barriers and building partnerships with EU based companies. This complexity has so far limited the extent to which indigenous and traditional foods have penetrated the EU market. A possible hurdle to the successful introduction of traditional products into EU markets is that since 1997, new food products would be considered as ‘novel foods’ by the EU. However, there is the potential for indigenous food products to be 'fast-tracked' by the EU, especially if the food products do not substantially differ from how they are traditionally produced and consumed (http://news.bbc.co.uk/1/hi/uk/7506997.stm).
Consumer acceptance is important in marketing strategies and in product development in the EU and Africa. Along with product development and economic viability, it gives food companies confidence to adopt these products in the EU and Africa. While consumers seek convenient and healthy products, taste is consistently rated as the most important factor that drives consumption and repeat purchase of consumers. However, little is known about how food and drink products that are indigenous to Africa will be accepted in Europe. The project therefore explored the factors that influence consumer acceptance primarily from a taste perspective for the indigenous products but linked this with potential nutritional and health advantages. Consumer acceptance approach is still relatively underexploited in Africa where there are issues of culture, language and low income. Recent work has explored some of these issues; variations in acceptability within populations, with ethnicity, socio-economic factors and age. Rural and urban consumers in Africa appear to readily accept new products with distinctly different sensory characteristics and this is contrary to some views often held. However, the distinct sensory differences can have implications in product development.
Four general objectives had thus been set for the ten selected traditional food: (1) To reach comprehensive scientific knowledge of the existing know-how on technologies, processes and products, (2) To propose improved traditional processes by a reengineering of the unit operations with the aim of improving the safety and nutritional quality while keeping or improving the organoleptic characteristics of traditional products, (3) To reach objective criteria of acceptability of the traditional products by the consumers and to ensure that the products can effectively access the EU markets in view of regulatory and ethical issues while also protecting the intellectual rights of the people in Africa, (4) To present the results into ready-to-use information for food companies including SMEs via guidelines on quality management, food law and regulation and consumer protection and to transfer the results to the stakeholders from Africa and from the EU.
The 10 (ten) products on which the project focused on were organised in three groups: fermented cereal-based (Akpan, Kenkey, Gowé and Kishk Sa’eedi), fermented salted fish (Lanhouin, Kong) and meat (Kitoza), and vegetable and fruit based functional foods (Baobab, Hibiscus sabdariffa and Ziziphus mauritiania). Akpan is a yoghurt-like product prepared from a partially fermented cooked maize gruel, named ogi. It is usually mixed with condensed milk, ice and sugar by street vendors just before consumption. It is the most commonly consumed beverage in Benin. Kenkey is a popular traditional fermented food made from maize and is a staple for most of the peoples in the coastal regions of Ghana. It is a sour tasting cooked stiff porridge of elastic consistency made from fermented whole meal maize dough shaped into balls or cylindrical forms and wrapped in maize husks or plantain leaves. Gowé is a homogenous gelatinised, malted, fermented and cooked paste prepared from sorghum, millet or maize. It is consumed as a beverage after dilution in water and addition of ice, sugar and sometimes milk. It is the preferred beverage of children, pregnant women, sick and old people in Benin. The name 'kishk' refers to a group of popular fermented dairy cereal mix products common to Egypt and the Middle East. The product is made from a combination of wheat with natural local fermented buttermilk in the form of yoghurt or sour milk. On completion of fermentation, the mixture is shaped and sun dried. Lanhouin (cassava fish, Spendotolithus sp.) is a salted/dried fish spontaneously fermented. It is widely used as a condiment in Benin, Togo, and Ghana. Kong (catfish, Arius heudelotii) is traditionally smoked in Senegal for local and export markets. Such smoked fishes are not voluntarily fermented; however, a spontaneous fermentation step often takes place in the process of traditional dried fish. Kitoza is a salted/dried meat. Depending on the process conditions, the fermen¬tation can be spontaneous. Sometimes, it is smoked in order to improve organoleptic and shelf-stability properties. It is a traditional product of Madagascar. It is also known as biltong in Southern Africa. The baobab (Adansonia digitata L.) is a tree that grows wild in all semi-arid and dry sub-humid areas throughout Africa and Madagascar. The fruit of the baobab or monkey bread, called 'buy' in Senegal, is widely consumed in various forms. Dry calyx of Hibiscus sabdariffa, known as bissap, is used in Senegal and other Western African countries for the preparation of beverages and other products with high anthocyanins content. Z. mauritiana is the fruit of the jujube tree, widely spread in the Soudano-Sahelian savannas of Africa, particularly in Cameroon. The fruit is locally used fresh or dried for food purpose. It is consumed as snack food or processed into flour for the preparation of pancakes, or also associated with pastry or drinks. The dried and processed fruit has a pleasant biscuit taste and a plain aromatic flavour.
For each of the three groups of products, the specific objectives were: (1) To improve the nutritional quality and safety of four traditional fermented cereal-based products and to develop new formulations for local markets in Africa and for exports, which meant to improve the technological processes for obtaining a better and more reproducible quality and to develop new formulations of the traditional products adapted to urban consumer demand, (2) To develop new and improved meat and fish products and technological processes in view of quality and safety, which meant to improve the technological characteristics of the African processes in order to formulate products that will meet safety requirements (extended shelf life) and consumer preferences, (3) To develop products derived from extracts of baobab, hibiscus and ziziphus for local and regional export markets, which meant to develop new processes or a combination of processes to produce anthocyanins extracts from calyx of Hibiscus sabdariffa and pulp of Ziziphus mauritiana, and polyphenolic extracts from the pulp of Adansonia digitata and Ziziphus mauritiana, to optimise methods of preparation, microbiological stabilisation of the products and to develop new products from the fruit of Adansonia digitata, dry calyx of Hibiscus sabdariffa and pulp of Z. mauritiana.
The project also applied African traditional processes to European raw materials to develop new alternatives of foodstuffs thus providing new outlets for European raw materials (eg maize, pork). Simultaneously, the aim was to apply new technologies originating in Europe to African traditional production (eg bissap and baobab drink). The global strategy has been to implement the sharing of the African traditional know-how with Europe to develop new technologies and/or new products in Africa and in Europe.
Creating new markets and trade opportunities for improved traditional foods and novel products in Europe and Africa increases economic returns for all stakeholders involved in the production chain, down to the community level. Due consideration has been accorded to regulatory, ethical and IPR issues while also protecting the intellectual rights of Africans.
Project Results:
1.3 Main Scientific and Technical results/foregrounds
THE CHARACTERISATION OF TRADITIONAL PRODUCTS AND KNOW-HOW concerned the ten traditional products from Africa. It aimed to evaluate the existing knowledge and know-how on technologies, process and products variability according to socio-cultural groups, the sensorial quality criteria as perceived by the traditional processors and consumers, the corresponding instrumental quality. All these characteristics were necessary for the process reengineering and consumer and market acceptance. The results obtained are here summarized by products.
GROUP1. Gowé is a traditional fermented product made from sorghum and maize used singly or in combination. Four processes were identified: two using a mixing of malted and non-malted grains, one using only malted grains and one excluding the malting operation. Irrespective of processing, gowé had a sweet taste and was found to be slightly acidic. With a smooth texture, Gowé was recognized to have specific aroma which included 32 compounds. Lactic acid bacteria (LAB) and yeasts were the main technological flora. With regard to pathogenic germs, only Enterobacteriaceae and Echerichia coli were observed in some gowe samples collected from market. However 25% of gowe samples (N=8) were contaminated with aflatoxin and fumonisin at higher than the permissible level.
Akpan is a traditional fermented product made from maize or/and sorghum using four processing techniques: akpan from maize ogi, a wet sieved fermented maize mash, akpan from sorghum ogi, akpan obtained by kneading and fermentation of whole sorghum flour and akpan from “mixed sorghum and maize”. Akpan was recognized to be slightly acid with a low content of sugar. There was a great variability between akpan viscosities. Gelatinization level appeared very diverse for akpan, pointing out that cooking level is a critical point for this process for which gelatinization must not be completed. Akpan had a fermented ogi aroma. 25% and 12% of akpan samples (N=8) were contaminated with aflatoxin and fumonisin respectively at higher than the permissible level. Lactic acid bacteria and yeasts were the main technological flora where as Enterobacteriaceae were observed in some akpan samples.
Kishk Sa’eedi (KS) is made from a combination of parboiled whole locally fresh grown wheat with fermented butter milk from water buffalos and/or cows. Based on quality, two KS were identified: KS produced for home consumption BEITY and KS produced for commercialization SOOKY. With regard to type of fermentation agent, two others KS were reported: KS fermented with skimmed laban zeer and KS fermented with full fat laban zeer. These KS were significantly different in proximate composition. KS was recognized slightly acid, rich in amino acids, minerals (Fe and Zn) and free of mycotoxins. Among the technological flora, lactic acid bacteria were predominant except for some KS samples collected in the first round for which yeasts and moulds were predominant. With regard to pathogenic germs, Escherichia coli, Listeria sp., Clostridium sp., and Salmonella sp. were encountered in some KiskSa’eedi samples.
Kenkey is a popular traditional fermented food made from fermented whole meal maize dough shaped into balls or cylindrical forms, and wrapped in maize husks or plantain leaves. Ga and FantiKenkey were the most common and popular forms. Kenkey prepared from degermed and dehulled maize, were poorer in fiber, ash, and crude. Kenkey had also lower vitamin and essential minerals such as Zn and Fe. Kenkey was slightly acid with a low sugar content and colour differences were noticed between Kenkey process types. Particle size revealed significant differences in the process types Kenkey. Microbial counts were very low in the case of Kenkey samples with lactic acid bacteria as the main technological flora. Kenkey appeared free of pathogens and mycotoxins.
GROUP2. Lanhouin, a traditional fermented fish, is generally processed in rural and informal small scales plants. The methods of processing were developed at home and improvements were based on the observations of actors. What the actors recognize are changes in sensory properties of the product, changes which result from modifications of the process or variation in ingredients used. From the survey, the appreciation of the quality of Lanhouin by the processors, traders and consumers is mainly based on observations through a number of sensory attributes such as colour, texture, aroma, consistency of flesh and the general appearance of the product. Other attributes such as taste, absence of foreign matter were mentioned by some actors. The lack of packaging has also been pointed out by some consumers as a negative aspect for Lanhouin handling. Lanhouin is rich in protein, lipid and acidity index level within acceptable limit. The fatty fish lanhouin were rich on biogenic amines, a potential vector of food poisoning. Lanhouin is exempted of pathogenic bacteria such as Salmonella and Listeria monocytogenes.
Kong, a traditional smoked fish, is processed in traditional way by actors living generally near the coast. From the survey, the appreciation of the quality of wet smoked Kong, and dried smoked Kong by the producers, traders and consumers is mainly based on observations through a number of sensory attributes such as colour, taste, flavour, humidity ratio and calibre of these products. The dried smoked Kong were more rich in polycyclic aromatic hydrocarbons (PAH) with a levels above European standard. It is quite different for wet smoked one. A short smoking time induced a high level of moisture and less phenolics contents in the wet smoked Kong. These characteristics do not allow a long shelf-life when compare to dried smoked Kong. Smoked Kong is exempted of pathogens namely Salmonella, Staphylococcus aureus, Listeria monocytogenes, Bacillus cereus and Vibrio spp.
Kitoza, a traditional salted dried and/or smoked meat product of Madagascar, is generally processed on an artisanal or industrial scale and at family level. Kitoza, pork or beef based product is consumed with rice soup at breakfast or dinner. Kitoza is rich in protein (25.1-47.8%) and lipid (10.5 – 27.1%). From microbiological point of view, no pathogenic germ (Salmonella) was detected neither in beef nor in pork kitoza.
GROUP3. Important informations on processing, marketing system, sensory properties and attributes and therapeutic effects were obtained through the survey for Hibiscus sabdariffa (bissap) and Adansonia digitata (buy) and in Cameroon for Ziziphus mauritiania (Jaabi). In addition the quality has been determined by evaluating the composition of macronutrients, micronutrients and anti-nutritional factors, the microbiological safety and the sensory quality attributes. Buy, baobab pulp, is characterized by its low water activity of water (0.43-0.55). Density is between 0.33 and 0.40. The three products are characterized by their richness in polyphenols (up to 2 %), vitamin C (200 to 500 mg.100 g-1) (buy and jaabi) and anthocyanin (0.5 to 2.0 g.100g-1) (bissap). Baobab fruits and Hibiscus sabdariffa calyx present a good quality about chemical safety parameters. Jaabi fruits appears as safe for chemical quality. For bissap and buy, products showed no presence of pathogens germs. Some samples from jaabi showed non-conformities.
THE PROCESS REENGINEERING OF FERMENTED CEREAL BASED PRODUCTS enabled to improve fermented cereal-based products and their traditional processes with respect to safety and nutritional quality as well as their acceptability by African and European consumers. The specific objectives were: first to obtain products using improved processes that enhance the control of the safety, sensory and nutritional quality, second to obtain new forms of fermented cereal-based traditional products adapted to urban African consumers in accordance with European market and consumer expectations for the identified market segments. The work has been organized in 4 main tasks: (1) Improvement of indigenous starter cultures and selection of the best potential cultures, (2) Re-engineering for new fermented cereal-based products, which means dividing some combined operations, or reversing the order of the sequences of unit operations or adding new unit operations, starting from the traditional process diagram described, (3) Microbiological challenge testing for ensuring safety of products, defining the ability of fermented products to inhibit the growth of spoilage organisms or pathogens, (4) Laboratory scale production where hygienic, nutritional, sensory and service quality (ease of using, shelf life) has been evaluated. The results obtained are here summarized by product.
Akpan was re-engineered for increasing its shelf life and improving its sensory and sanitary qualities. Three steps (precooking-steeping maize, fermentation and cooking) were optimized and pasteurization steps were added. Two other important changes were brought to the process: the formulation step was shifted before the fermentation step and a bottling step was added; the final product is bottled ready to drink akpan that can be stored for 21 days at 4°C. Maize grain precooking-steeping: the use of hot boiling water followed by steeping at 50°C allowed reducing by a quarter the duration of steeping maize grains; it allowed producing high yield and fine wet milled dough. In addition, it significantly reduced the lactic acid bacteria load to 3.5 Log CFU/g versus 8 Log CFU/g for traditional steeping at room temperature (28-32°C). The yeast was also inhibited at this temperature. Fermentation: three Lactobacilli (Lb. brevis, Lb.Casei and Lb. fermentum) were tested for inoculating wet milled dough (ogi). Lb. Casei evidenced an intermediate behaviour in term of growth rate and lactic acid production between the two other strains; it was thus selected as a good compromise and because it can be easily provided as commercial dry active bacteria. Fermentations were achieved for plain ogi and for ogi mixed with milk and sugar (formulated product) at 42°C after inoculation with Lb casei. The fermentation of the formulated products was more rapid (shorter lag time) and final load was higher compared to plain ogi; the pH in the mixed ogi was however higher. Cooking: the temperature and duration of cooking, the ratios of cooked ogi /native ogi and ogi/water were improved to get akpan that meet consumers acceptance. The desirable viscosity by consumers can be obtained with the following pre-cooking conditions: 50% cooked ogi at 90°C for 10 minutes, ratio cooked ogi/water of 2:1 (w/v). Quality of re-engineered Akpan: the physico-chemical characteristics of the re-engineered Akpan were very close to those of the traditional Akpan. Re-engineered Akpan was exempt of pathogenic germs and the yeast count was lower than in the traditional Akpan. Beyond 21 days, the count of moulds was not conforming to the standard (NFV08-59). In addition, challenge test performed by inoculating ogi with spores of Bacillus cereus just at the beginning of the fermentation showed that the re-engineered process for producing Akpan is safe; no B. cereus could be detected at the end of the fermentation step.
The traditional process of gowé was re-engineered in the perspective of improving the reproducibility of the quality of the traditional product and for developing large scale production. For the latter, a drying step was added to the process; the final product will be ready to cook gowé flour. In addition, we focused the re-engineering essentially on the malting and and saccharification/fermentation steps. Malting: the quality criteria for high quality malt are high amylasic activity, low cyanide content and dry matter losses. The optimum conditions for malting were soaking for 15 h followed by germination for 60 h. Saccharification and fermentation: the hydrolysis rate of starch by α-amylase from the malt and effect of pre-cooking conditions on starch hydrolysis rate were modeled. Pre-cooking of sorghum flour up to 80°C increased drastically the rate of hydrolysis of starch. According to the model, a saccharification at 65°C for 2 h gave similar rate of maltose and glucose content as for the traditional saccharification process (30°C for 12h). Prior to fermentation, a pasteurization step was tested to decrease the initial microbial load of malt. Accordingly, the pasteurization at 65°C for 30 to 60 minutes allowed dividing natural microbial flora by 10. In addition, the α-amylase activity was checked to be stable at this temperature. Thus, the saccharification was performed at 65°C for 60 minutes. Additionally, a model was developed for predicting the fermentation, and then used for testing various scenarii of the fermentation of Gowé. In this respect, the inoculation with Lb. casei is particularly interesting for rapidly ferment Gowé. The inoculation of Lb. brevis could be interesting in the context of very small processing unit that cannot control the temperature and the final pH. With regard to yeasts, Kluyveromyces thermotolerans was the best to ferment Gowé since it is relatively thermoresistant with high growth rate at 40°C. It also evidenced a high stability to pH, and produces desired/liked aroma. Kluyveromyces thermotolerans can thus be used to ferment Gowé in combination with Lb casei. Drying: the fermented slurry was dried at 70°C within 5 h. The flour shelf-life was thus more than 6 months, compared to three days for the traditional product. This flour can be reconstituted in Gowé by dilution in tap water (ratio water / flour: 9 / 1) and cooked. Quality of re-engineered Gowé: the acidity of re-engineered Gowé was similar to that of the traditional Gowé. Additionally, the re-engineered Gowé had high level of maltose and glucose and was free pathogenic strains. Lactic acid bacteria and yeast and moulds counts were hundred times lower in the Gowé flour than in the traditional Gowé. In addition, challenge tests performed by inoculating Gowé with spores of Bacillus cereus showed that the re-engineered process for producing Gowé is safe.
Reengineering of kenkey was based on identifying nsiho as the type of kenkey with the best universal appeal and optimizing its processes and improving its appeal and presentation to target non-traditional consumers of kenkey. Thus dehulled rather than whole maize grains were used to produce a less sour, and more whitish coloured kenkey as compared to the standard Ga- and Fanti-kenkey. The pre-processing (steeping and fermentation) and cooking steps for producing white kenkey have been optimized and the product was given a new shape as cylindrical slices instead of the crudely round balls of kenkey. The slices were packaged in cling film or vacuum packed rather than wrapped in banana, maize or other traditional packaging leaves. Vacuum packaging extended the shelf life of kenkey from between 4 – 7 days to 6 months under refrigerated storage. Pre-process variables: steeping and fermentation during white kenkey production were optimized using both a 3 x 3 factorial and a Box-Behnken experimental designs to optimize the pre-process variables, steeping time, steeping temperature and dough fermentation time. The pre-process variables had significant influences on the physico-chemical properties and sensory quality of white kenkey. Long steeping times (over 24 h) of dehulled maize grains were clearly favorable to give finer dough after milling. The ease of milling was not related to water uptake by the dehulled maize grains that was fast during the first 5 h of steeping then levelled off at 10 h, but could be related to some degradation of the components of the grains as evidenced by the loss of water soluble proteins from the grains into the steep water that begins after 8 h. A fermentation process was also evidenced during steeping with an accumulation of lactic acid, acetic acid and ethanol and a lowering of pH. Long steeping and fermentation times as well as steeping at elevated temperatures increased titratable acidity, per cent lactic acid and lowered the pH of the fermented dough, with fermentation time having a stronger influence. Both steeping and fermentation decreased glucose content of the maize dough and white kenkey in the Box-Behnken experiments. However, this was not confirmed in the 3 x 3 factorial experiments. Increasing steeping time and temperature positively influenced acceptability of white kenkey. The optimum pre-process conditions for production of consumer acceptable white kenkey were determined to be steeping time of 30-45 hours at temperatures of 30-35ºC, and fermentation time of 12 hours. Cooking variables: a peculiar process in kenkey production, aflatalization i.e. pre-cooking part of fermented dough (aflata) and mixing it with the remaining uncooked dough before final cooking gives kenkey a characteristic elastic/sticky texture. Aflata: uncooked dough ratio and steaming time had a significant effect on both the hardness and stickiness of white kenkey. Reducing aflata proportion increased both the hardness and stickiness of white kenkey after the aflata:uncooked ratio became less than 2:1. The effect of aflata proportion on the textural characteristics was also dependent on the duration of the final steaming step. Increasing steaming duration from 15 to 30 or 45 minutes increased hardness and stickiness for all ratios of aflata and uncooked dough. The acceptability of re-engineered kenkey was much higher for long steaming time and high proportion of aflata. Consumers indeed look for kenkey with low firmness and stickiness. In addition, the taste of short time steamed kenkey was clearly rejected by the consumers. Quality of re-engineered kenkey: the characteristics of reengineered kenkey were close to those of the traditional white kenkey. It however had higher glucose content, due to a more controlled fermentation step in the re-engineered process. Significant, but low levels (far lower than the limit of acceptability), of some of the pathogenic bacteria were counted in reengineered kenkey. This may be linked to the lower duration of cooking, 30-45 minutes in the re-engineered process. Aflatoxins, the main hazard in kenkey, were not detected in reengineered kenkey. In addition, challenge tests showed that the process was safe.
The process for producing Kishk sa’eedi has been re-engineered. New lactic acid bacteria strains: three hundreds and eleven isolated strains (isolated from good quality traditional Laban Zeer) have been examined for flavor acceptability in reconstituted skim milk powder to select only strains that produce accepted flavor. The strains that produce acceptable flavor have been screened for proteolytic and esterase activities. The selected strains were then screened according to antagonistic system and antibiotic sensitive. At the end of experimental, 15 strains have been selected and used for fermenting butter milk to produce Laban Zeer. Optimization of fermentation of Laban Zeer: three selected strains exhibiting the faster acidification rate and the better aroma were selected as inoculum for KS. A concentration of milk of 15% (wet basis) was selected as an optimum; this concentration evidenced the best flavor and acceptability together with imparting a sufficient kinetic and level of acidification for insuring the microbial safety of the product. Optimization of wheat pre-cooking step: in order to optimize the processing parameters for the production of precooked whole wheat kernels, the effect of steeping as well as boiling temperature and time was tested. The level of starch gelatinization as well as particle size index PSI was measured. A level of gelatinization within the range of ~ 70-80% gives the preferred degree of grittiness. Chemical and microbiological characteristics of re-engineered KS: re-engineered KS had lower moisture content than traditional BEITY KS. Re-engineered KS had higher protein and lower fat contents than Traditional BEITY KS which is usually made using butter milk. Lactic acid was the main organic acid in re-engineered KS, as in the traditional ones, with almost the same level; around 2.5% (dry basis). Maltose was the main free sugar in the re-engineered KS, but with a much higher level (5 fold) than in the traditional KS, thus conferring a more sugary taste to the re-engineered KS. Re-engineered KS contains higher levels (almost doubled values) of some essential amino acids than the traditional KS. The Re-engineered KS had lower level of total bacterial count and Lactic acid bacteria, yeasts and mould when compared with Traditional BEITY KS. Re-engineered KS was free from pathogens and challenge tests showed that pathogens were completely eliminated due to the acidity of the fermented product. However, when the contamination occurs just before drying, pathogens can remain in the dried product for several months. New snack inspired by the traditional KS: a novel cereal-based snack inspired from KS and adapted to the preferences of the modern consumer and to the demands of modernity was developed. The new KS snack was made from a dough containing salt, cumin, mixture of butter milk and full fat milk, and either parboiled whole wheat or soaked then parboiled whole wheat. After fermentation, the dough was shaped into chips, breadsticks and mini biscuits. The novel KS snack is good source of dietary fiber and minerals besides being a way for youth to become engaged with their traditions, culture, and health through food.
THE PROCESS REENGINEERING OF MEAT AND FISH PRODUCTS brought the forces of seven partners, to secure and optimize the Kong, the Lanhouin and the Kitoza. This collective work had two goals for which we had to deal with constraints: 1) for the local market, improvements are oriented on sanitary and toxicological qualities of products to ensure, as a priority, the safety and health of consumers. All improvements have been reflected in the respect of traditional knowledge. The main obstacles to the optimization of the products were the quality of raw materials, lack of structure and specific equipment, including the conservation of products. 2) For the European market, the aim was also in priority the safety of products, whether produced locally or in Europe for the diaspora or the European consumers. The compliance of products regarding the EU regulation was an obligation. The manufacture of products by European companies rather offers an advantage to achieve quality objectives because of available equipment as cold chain. Conversely, the local manufacturing for export is a challenge because the gap between means and objective is real. The work of reengineering has expanded the product range, by acting on the final form of products (as lanhouin in powder and cubes), on organoleptic qualities (as Kitoza with a smoke flavor less intense) or yet on the storage modalities (such as packaging film or mosquito cage for kong). For the purpose of rationalization or innovation of products and processes, this work is built on a strong investment on the characterization of traditional know-how by long studies following a methodological plan. The acquisition of data on the evolution of the characteristics of the meat and fish products at key stages of the traditional process fully contributes to the success of the process reengineering.
Critical analysis of manufacture diagram of kong, lanhouin and kitoza
Reengineering activities were built with strict methodology and consistent for the three products from group 2. First, a Standard Operating Procedure (SOP) was established for the critical analysis of processes. Using this SOP, the team has thus achieved a structured and detailed survey work nearby nine local producers. The UCAD has audited 2 production sites of Kong around Dakar: Seuty Ndiaré producing wet smoked Kong and Yarakh producing dry smoked Kong. The UAC met 4 processors of Lanhouin in Grand Popo municipality, two at Ativicondji and 2 at Adovlocondji (beach and district), where the fermentation process applied is aerobic or semi-aerobic. The study of the Kitoza manufacturing process performed by the UT was held in Antananarivo with 2 producers of salted / smoked beef Kitoza, one in the Ivandry area and the other one in Behoririka area, and 1 producer of salted / smoked pork Kitoza located at Fiadanamanga. Each process flow diagram has been detailed to the scale of the unit operation (7 or 8 UO by diagram for the kong and lanhouin, 3 to 6 UO for Kitoza). This qualitative (description of inputs / outgoing, materials, human resources, arduous tasks ...) and quantitative analysis (yields, time, temperature, cost ...) of traditional diagrams manufacturing constitute an important database never acquired before. Similarly, the sampling of products at each key stage has allowed assessing the evolution of physico-chemical, toxicological, microbiological and nutritional qualities of fish and meat products.
In the case of smoked products (Kong and Kitoza), the step of smoking is critical as generating PAH compounds resulting in high levels of Benzo(a)pyrene in products consumed and greater than the threshold of the EU regulation (2μg/kg). Eating such smoked products is therefore health hazardous (risk of cancer). The length of this smoking step and the nature of the fuel have been pointed out. The quality of the raw material used by the Kong producers appears also poor, characterized by high levels of biogenic amines. On this criterion, the washing and draining catfish proved to be negative.
Finally, microbiological qualities of all products are not always satisfactory and are a priority for reengineering. The inventory of the technological flora and pathogens during process validated the impact of unit operations. For Kitoza, E. coli is present in the raw material of all producers. During the drying step, all micro-organisms concentrations increase. It is worth to mention that the drying step lasts from 45 minutes to 1 hour at 70-150°C, this allows microorganisms development, especially lactic bacteria. Conversely, the load of these germs decreases after salt addition. For Lanhouin, the total viable counts of all the samples whatever the process were under the acceptable limits. The enterobacteriaceae loads were found low in the intermediate products and final Lanhouin. No Salmonella and Listeria monocytogenes were found in any sample. Nevertheless, the lack of good hygiene and good manufacturing practices were observed with the four processors, so corrective actions to secure lanhouin had been proposed. For Kong, the total flora loads decrease in the end-products (wet and dried kong). Yeasts, lactic bacteria and coagulase negative Staphylococci are present until the end-product. No Staphylococcus aureus nor coagulase positive Staphylococci were observed during all process.
Re-enginering activities (diagram simplification, local and European improvements)
The operation of all these data from analysis of the impact of unit operations on the qualities of Group 2 products was based on common methodologies as SOP for local reengineering or in order to export or manufacture in Europe. The objective was to prioritize emergencies, imagine the different solutions but retaining only those whose application was technically and economically feasible.
Initially, simple adjustments of manufacturing diagrams have reduced the risk of PAHs in Kong and Kitoza. The traditional smoking step was split into a cooking/drying and a smoking unit operation. The objective is to reduce the water content of products, lower the water activity and reduce the duration of smoking to significantly reduce the accumulation of PAHs in products. For Kong as for Kitoza, the choice of fuel was optimized: the use of wood sawdust (for smoking) and charcoal (for cooking/drying) reduces the risk of carcinogenesis associated with PAH and B(a)P. Smoking with sawdust (30 min., 100 °C) followed by cooking with charcoal (2h, 100 °C) allows to reduce B(a)P content in the Kitoza below 2μg/kg. For Kong, 3 hours of drying and 1 hour of smoking also achieves PAH reduction, with particular interest recorded for coconut husks from the sawdust as fuel.
In the case of Lanhouin the ripening and salting operations were combined to prevent microbiological degradation, final drying was optimized by the use of a shell dryer (GERES/GRET) before sun drying (duration 18h) to reduce the contact with insects. At the end of the process, a washing step of fish fillets in a mixed solution of lemon juice (8%) and garlic extract (8%) followed by a packaging in plastic bag and a storage at 4°C have significant effect on the microbiological and physico-chemical changes since the conditions allow to reach a shelf-life of 90 days. The reengineering of Lanhouin was also adapted to the European market by 3 strategies: i) introduce marinating during the ripening step to avoid high microbial proliferation and to limit the generation of biogenic amines, ii) improve the fermentation conditions by adding commercial starter culture of Lactobacillus plantarum and strain of Staphylococcus xylosus obtained from INRA as biopreservative organisms, and iii) improve the storage and shelf life by using different packaging. The improved Lanhouin presented in forms of powder or cube, packaged in a plastic bag (Type B Walovac 90) can be stored at ambient temperature (30 ± 2°C) up to 90 days without microbial problem.
In the case of smoked Kong, technological alternatives proposed by CIRAD and UCAD in the traditional process took into account the local and European marketing with a priority for improvement sanitary qualities of products. Biopreservation strategy by inoculation of fish with Lactobacillus plantarum starter cultures is efficient to increase the shelf life from 8 to 14 days of smoked Kong only if final products are stored in paper film at ambient temperature (traditional way). No benefit is observed with storage at 4°C under vacuum. Other strategies have been tested by acting on the traditional unit operations (the intermediate washing, smoking, storage and distribution) and new unit operations have been proposed (salting, acidification). Washing the kong in bacteriostatic solutions was tested after evisceration, either bleach solution (4 water plugs bleach/30 L water/30 kg of fish) at least 5 minutes, although this condemns fish at the local market (prohibition of treatment for the EU), or in solutions with 20% of plant extracts (ginger, garlic, moringa) for 30 minutes, while constraints remain (impact on taste, costs, water consumption ...). The effectiveness of these treatments should be checked in representative conditions of local producers (raw material with high total flora). Salting is an effective strategy to reduce the microbiological risk. A 6% salt impregnation has a significant lowering effect on the water activity of the finished product which reduces the growth of pathogenic and spoilage bacteria and which results in a shelf-life increased over 3 days at 30°C and further 6 days at 4°C. The addition of an acidification step by immersion of the fish for 5 minutes in a 0.5N solution of lactic acid at 25°C, until a pH of 5.75 is also effective against microbiological risk (conservation increases further 6 days at 30°C and not more than 3 days at 4°C). However, the impact on the texture of the filets is negative (rejection by consumers). Finally, the packaging is a key step to optimize storage of smoked Kong. But the packaging by portion in trays under film causes maximum growth of the total flora at the high ambient temperature. It is therefore to be avoided or to recommend only with a chilled or frozen distribution. The “mosquito cage” tested in the project is used in southern countries and perfectly suited to the traditional local market to limit product contamination by insects and the many manipulations of customers. Coliform decrease as well as pathogens. For optimization of smoking, the use of liquid smoke is an option offered by modern technologies in Europe. A Senegalese company (Marepêche) plans to develop a smoking line for the export markets in 2015. The products are completely free of carcinogenic PAH, due to the purity of the liquid smoke used.
Reengineering of Kitoza conducted by ADIV for the European market aimed to secure products in the toxicological (reduction of PAH) and microbiological point of view (FCD criteria consistent). The initial operation of washing the raw material was suppressed in the context where cold chain is maintained. The salting and seasoning step has been optimized for the taste of European consumers. The smoking program was optimized at 60°C using specific equipment (smoke cell CCF 1001 by ARCOS, France). For beef, the sequences of the drying (30 min) and smoking (15 min) are renewed once at during 10 min by step. With pork, the program integrates three drying and smoking cycles. The biopreservation of meat by using a commercial starter (BCL77 by CHR-Hansen) is an effective strategy because combined with vacuum packaging and storage at 4°C, the shelf-life of Kitoza is 35 days minimum. The packaging under modified atmosphere confers no advantage as kitoza meat exudes on the packaging, a reason of consumer reject.
Conclusion - Most of the traditional productions of Kong, Lanhouin and Kitoza are based on very archaic and insecure workshops, with very limited financial means. The presence of pathogens and spoilage bacteria in high quantities reveals defiance of basic hygienic practices and post-production cross-contamination. Reengineering can only be done in parallel of the implementation of compliance of workshops, with the rules of good hygiene practices issued by the competent authorities. This compliance is mandatory for export (required approval) and could be progressively obtained for the local market. The product and process improvements proposed in the AFTER project are the first alternative solutions to reduce microbiological and toxicological risk. The packaging is a key element to secure the distribution of products. For modern markets, individual packages sealed in plastic film under chilled and frozen mode are to consider. For the traditional local market, without cold chain, packaged products under plastic would rapidly decay. Solution as “mosquito cage” is an affordable and available alternative.
THE PROCESS REENGINEERING OF TRADITIONAL FUNCTIONAL FOOD enabled to set up combined processes applied to traditional fruits (Adansonia digitata, Ziziphus mauritiana) and calyxes (Hibiscus sabdariffa), in order to produce ingredients and beverages with improved functional and nutritional qualities. The process of achieving these objectives involved several stages, performed over 4 years. These stages were: literature review on the relevant products, characterization investigation of raw materials, diagnostic of the processing of the end products from these raw materials, optimization and development of new products, and implementation of several sensory and consumer tests.
The literature review provides a better background knowledge of the products. The quality of the baobab fruit, bissap calyx and Ziziphus fruit was determined by evaluating the composition of macronutrients, micronutrients and antinutritional factors, the microbiological safety and the sensory quality attributes.
In order to provide good knowledge of the different products concerned, a survey was conducted in Senegal for Hibiscus sabdariffa (bissap) and Adansonia digitata (baobab), and in Cameroon for Jujuphis mauritiania (Jaabi). We carried out a lot of information gathering, such as on processing, marketing systems, sensory properties and attributes, and therapeutic effects.
After sampling various raw materials across the main production areas of the countries concerned (bissap and baobab in Senegal; jaabi in Cameroon), a complete characterization was performed. Prior laboratory standard operating protocols were optimized and validated by the various project research teams. A variety of results were obtained. For baobab chemical analysis, significant differences were observed both between geographical areas and varieties. In the case of bissap calyx, four varieties of Hibiscus sabdariffa and five production zones were chosen. In each zone, 6 samples were analysed. Significant differences were observed both between varieties of the same geographical area and between geographical areas. For Jaabi, two varieties of jaabi and four production zones were chosen. The effects of two processing techniques were also evaluated. Significant differences were observed both between varieties of the same geographical area and between geographical areas. Chemical safety results: Hibiscus sabdariffa calyxes, and fruits of Adansonia digitata and Ziziphus mauritiana in general exhibit good quality chemical safety parameters (aflatoxins and ochratoxin A). In the case of jaabi, one sample exhibits high aflatoxin and ochratoxin levels. We think that the presence of aflatoxins is due to the long storage time before analysis. Inventory of the technological flora and pathogenic germs: for all the Group 3 products (raw materials and raw material based products), the total flora, technological flora and pathogenic germs were investigated. For bissap and baobab, the products exhibited no presence of pathogenic germs. Conversely, some jaabi samples exhibit non-compliances. Results of the biochemical and nutritional quality: for all the group 3 products, biochemical and nutritional analyses of the products were conducted with regard to functional components. Analysis of the results shows significant differences, which were observed both between varieties of the same geographical area and between geographical areas. In the case of jaabi, the processing has also a strong effect on the biochemical and nutritional quality. The three products are characterized by their richness in polyphenols (up to 2 %), vitamin C (200 to 500 mg/100 g) (baobab and jaabi) and anthocyanins (0.5 to 2.0 g/100g) (bissap). This translates into high antioxidant capacity values.
Diagnostic of the processing of the end products aimed at: 1) to study the effects of local processing practices on the functional properties of products, and 2) to identify the processing limits of these practices, with regard to quality and stability of products. Report on the influence of local processing on quality: for each product, the local processing techniques were identified and validated. The influence of local processing conditions (form of utilisation, temperature, storage conditions, etc.) on their quality, with regard to functional components (anthocyanins, polyphenols and vitamins), was analysed. In the case of baobab, the results showed that the storage conditions (temperature, packaging) significantly affect the nutritional and functional compounds. Losses of 70-90% and 50-70% were noted respectively for vitamin C and total polyphenols. For bissap, the result showed that the storage conditions (temperature, packaging) significantly affect the functional compounds (anthocyanins). Losses of 40 to 70 % were observed. The form of utilisation (whole calyx, shredded calyx) also has an impact on the anthocyanins content. The drying method seems to have a strong effect on the quality. So we plan to conduct a comparative study between drying methods during the next fresh calyx season. The results for jaabi seem to indicate no significant differences between Jaabi samples, whatever the variety and origin. Conversely, the chemical analyses show chemical and nutritional differences between Jaabi grains and the resulting Yaabande depending on the processing method used. In addition, since steaming is the major processing method applied, a study of the conditions of this processing method on the quality and functionality of Jaabi is ongoing. Identification of processing limits: analysis of the diagnostic results, combined with interviews, enabled to highlight the critical stages to improve in the different manufacturing processes. It proved that reengineering work is needed to improve traditional product quality. In the case of the baobab and bissap products, the aqueous extraction and stabilization stages were considered first. While for Yabande (jaabi product), the formulation and cooking stages were considered. Characterisation of traditional products: samples collected for diagnostics were analysed using the standards operating protocols. Very clearly, the report shows that for the same product, the quality is heterogeneous, and varies according to several criteria such as the producer, the origin of raw materials, and the processes used.
OPTIMIZATION PHASE. In Senegal, this work was done in close collaboration with four companies (2 in Dakar, 1 in Thies and 1 in Kaolack) manufacturing products from Hibiscus sabdariffa and Adansonia digitata. The processing of jaabi into Yaabande was studied in northern Cameroon. So, for jaabi, the processing analysis indicates that steaming is more common and has more potential. Analysis of the critical process parameters indicates that the flour sieving operation after grinding and the steaming time are likely to have an influence on the final product quality. The analysis of these parameters shows that the fineness of jaabi flour leads to a stronger texture of Yaabande cake. Moreover, the biological properties (antioxidant properties) of the product are conserved during steaming. In Senegal, the results show that baobab and bissap products (beverages, syrups) are generally processed on a small and semi-industrial scale, with a lack of technical tools for quality control. The work was able to highlight the constraints (quality of raw material, extraction procedure, filtration, heat treatment, storage conditions, etc.). So, to improve product quality, ensure consistent quality between production batches, a reengineering stage was carried out. New improved processing protocols for bissap and baobab products (beverages, syrups) ensuring high and constant quality were proposed, and are already being applied by some companies. It is within this framework that the extraction, filtration and thermal stabilization stages were optimized. These improvements were immediately adopted by the companies. The organization of the harvesting system (production of baobab powder and crushed bissap calyx of good quality, proper packaging and good storage conditions of raw materials, traceability, etc.) would be a considerable asset. Similarly, the availability of glass and/or heat resistant plastic packaging would be a great help.
DEVELOPMENT OF NEW PRODUCTS. The literature review and survey results showed that jaabi (Ziziphus mauritiana) was traditionally processed into flour by grinding, and baked into small round cakes locally known as Yaabande. Consumer testing showed that the product texture is among the main quality attributes considered by consumers. So, with local processors, processing techniques were improved, consisting in the introduction of milling and sieving in the jaabi flour production. The proposed result is Yaabande exhibiting a fine texture which is highly appreciated by consumers. Processors in Garoua have adopted the practice. Flour of particle size 250 µm>Ø>125 µm appears to be the most appropriate selection, in view of local sieve availability. In addition, the intense aroma of jaabi raises an opportunity for its added-value use in biscuit making. Proposition of composite flour biscuit, made of wheat - jaabi (60 - 40) or maize – jaabi (70 – 30) appears to be a potential new functional product for market development of local Ziziphus. In Senegal, the literature review and survey results showed that traditional bissap and baobab products (beverages, syrups) are generally processed on a small and semi-industrial scale, with a lack of technical tools for quality control. The previous diagnostic studies were able to highlight the constraints (quality of raw material, extraction procedure, filtration, heat treatment, storage conditions, etc.). So, the reengineering stage led to many innovations which were introduced in the various processes. In the case of bissap, we developed new products such as syrups, concentrates and atomized powder, while with baobab fruit products such as powders and syrups were optimized. These products were characterized by high levels of vitamin C, acidity, polyphenols and antioxidant capacity. These new products have a high potential for use as functional foods. These products represent good opportunities with applications in various sectors, such as food & beverages, cosmetics and pharmaceuticals. The new and improved products were well accepted by consumers.
More sensory and consumer tests were conducted during the four years of the project. These tests allowed us to characterize the different products in sensory terms, and to assess the impact of operating conditions on product quality. The view of consumers was taken into account by the consumer organization tests. The Senegal and Cameroon AFTER project team conducted for the first time in their country sensory and consumer testing, following a rigorous scientific methodology. Thanks to the AFTER project, a sensory analysis team was set up in these countries. No doubt this team will be a precursor of the future first sensory analysis laboratory in Senegal and Cameroon.
CONSUMER AND MARKET ACCEPTANCE studies ensured that the products developed are acceptable to consumers in the African and Europeans markets and that issues of market access are understood in order for the products to maximise the likelihood of success. Sensory evaluation and consumer acceptance studies of the baseline products in Africa and the EU showed that in general they had higher acceptance in the African countries than in the EU, especially when the product was one that EU consumers were not familiar with such as the fermented maize products (Kenkey, Akpan and Gowe). It should be noted that not all of the baseline products were tested in the due to either regularity issues that prevented importation (meat and fish products) or sanitary issues (Kishk Sa’eedi). For the reengineered products, acceptance varied in both the EU and Africa but it should be noted that some improvements were more food safety and processing related rather than sensory one. In the EU, consumers reported mixed views with moderate to high acceptance for Kitoza made from pork, kong made with liquid smoke, bissap and baobab. Low acceptance was reported for fermented products (Akpan, Kenkey and Kishk Sa’eedi) while Gowe and Jaabi were not tested due to aflatoxin contamination and lower quality than the traditional one respectively. Similarly, African consumers also reported mixed views regarding the reengineered products. Some reengineered products were found to be more acceptable (Gowe and Akpan in Benin, white Kenkey in Ghana, liquid-smoked Kong and Lanhouin in Senegal, Bissap and Baobab in Senegal), some of similar acceptance (Kitoza in Madagascar) and some were less acceptable (Kishk Sa’eedi in Egypt and Jaabi in Cameroon). This has implications concerning the marketing and regulatory aspects. In the African markets the main issues were related to the need for standardized products of consistent quality and safety aspects which this project has met and the selection of the sector that the reengineered product would succeed in (informal, formal, supermarket, snack, tourist industry etc.). In EU markets, the issues were that for some products the size of the markets was small (e.g. reengineered akpan, gowe, kenkey) and crowded market space (kong, baobab) while bissap and kitoza appear to have potential. In all products, in the EU market, while there were no serious impediments to market access complying with private standards or certification will require high costs. The process of achieving these objectives involved several stages, performed over 4 years. These stages were: studies of the regulatory, marketing and economical aspects in the selected EU and African countries; defining the sensory properties and consumer acceptance of the initial products in the selected EU countries; defining the sensory properties and consumer acceptance of the initial products in the selected African countries; assessing the sensory properties and consumer acceptance of the improved products in the EU and assessing the sensory properties and consumer acceptance of the improved products in Africa.
Studies of the regulatory, marketing and economical aspects in the selected EU and African countries - In Africa, regulatory and market analysis and training in value chain analysis have been provided to all African partners. The training was located in Senegal, Ghana and Madagascar. The training covered value chain analysis, value chain upgrading and economics and market GAP analysis. For Group 1 products, market gap analysis identified potential market spaces in each African country that the re-engineered AFTER products could occupy. For Akpan and Gowe, the new products require standardisation and an extended shelf-life and could be introduced in the formal market place whereas for Kenkey Ghana’s fast growing supermarket sector had the greatest potential for a re-engineered product and that the products should be white Kenkey. In the case of Kishk Sa’eedi, the tourist industry and local supermarkets held the most potential for an improved traditional product. For Group 2 a new standardised Lanhouin in Benin can compete in the formal sector with existing food condiments such as ‘Maggie Cubes’ but would require investment. For a higher value Kitoza product in Madagascar, new market opportunities in the snack market were promising. Kong in Senegal has potential in the ready-to-eat products after safety and quality issues have been addressed. For Group 3 products, several opportunities were identified for baobab in Senegal (instant powders, functional ingredient, and beverages). A standardised bissap has a market gap in the growing domestic beverage market. Jaabi would seem to be for an instant food ingredient in the small-scale bakery sector in Cameroon. In the EU, surveys were carried out of the reengineered products in 2014 in the UK, France and Portugal. The market for reengineered AFTER products in the EU can be broadly divided in to two sub-markets: the African diaspora and mainstream, food markets. For Group 1, for Akpan and Gowe a re-engineered yoghurt type drink would be popular but the market size is relatively small (specialist health food stores). For Kishk Sa’eedi, links to the exciting trend for Mediterranean cuisine show great potential for niche marketing of a well-presented food safe product. For Kenkey, a survey did not see a market opportunity for this product in the UK even with the Ghanaian diaspora. For Group 2, Lanhouin has potential as a gourmet seasoning product and for reengineered Kong the product will probably not out-compete other similar, but easier to eat, smoked fish offerings. For Group 3 reengineered products, both Baobab and Bissap have potential as ingredients for different food and beverage products in all markets but Jaabi biscuits did not. There were no serious impediment exists to market access for this group of products but concerns exist with respect to these products complying with private standards or certification due to the high costs involved.
Defining the sensory properties and consumer acceptance of the initial products in the selected EU countries - Sensory and consumer acceptance studies were undertaken in the UK, France and Portugal of the AFTER products before reengineering from each group. Considering group 1 products, acceptance of gowe in France and Kenkey in the UK was low and the majority (64 %) of consumers would not buy them. Akpan had higher acceptance. No group 2 products were tested. For group 3 products, sensory profile was fully described by trained assessors’ panel using QDA methodology in Portugal. In terms of consumer acceptance, bissap was tested in the UK, France and Portugal to obtain inter-cultural comparisons. Acceptance of the drink was high and Portuguese consumers differed from UK and French ones two clusters: the first one composed by Portugal and the second by France and the UK. The Portuguese consumers preferred an instant drink followed by hot extraction drinks whereas in the UK and France consumers preferred a cold extracted bissap followed by instant drink. Besides the overall liking a new methodology, CATA was applied to improve the gathered information. Concerning Baobab the studies were conducted in Portugal. The complete sensory profile of four samples were evaluated by a trained assessors’ panel using QDA methodology and consumer studies included score their overall liking and a CATA questionnaire. Results showed that all of the drinks were on the acceptable range but product needs reengineering to be adapted to the Portuguese market, especially regarding to the texture and aroma attributes.
Defining the sensory properties and consumer acceptance of the initial products in the selected African countries - A workshop was held in Ghana in May 2011. SOP’s for sensory and consumer testing in Africa and Europe was developed and these working documents evolved during the course of the project, particularly with the introduction of the CATA methodology. In addition, in the African countries, both African and EU consumers were interviewed in order to compare them. Considering group 1, for akpan, African and non-African consumers behaved differently with respect to acceptability; Europeans had lower acceptability compared to Africans. This was probably due to the fact that most Europeans were not familiar with the product. Regarding Kenkey, African and non-African consumers differed markedly in acceptance. Non-African consumers mostly preferred the white kenkey which was less acidic. Regarding Gowe, acceptance depended on whether it was made from sorghum or maize, but no significant difference was noted with sugar was added. Consumer acceptance of Kishk Sa’eedi (KS) indicated that Egyptian consumers preferred KS with strong sour taste and spicy flavour whereas most non Egyptian consumers liked KS with off-white to light creamy colour, mild sour taste, pleasant typical KS aroma and crunchy texture. For Group 2 traditional Lanhouin was sensorially different and three classes of consumers’ behaviour were identified. Consumers’ acceptance was significantly associated with size of fish, whitish colour, dried fish odour and ammoniacal odour. Lanhouin from king fish with semi aerobic fermentation and Lanhouin from cassava fish (except for aerobic fermentation) were more accepted and could be interesting for reengineering. For Kong, four samples were compared. Most of the Kong products were on average acceptance but moist kong had a better acceptability than dried samples submitted to the same processes of smoking. For Kitoza in Madagascar, there was a clear difference between sensory profile of pork and beef samples. Pork Kitoza were more associated to fatty, salty, wet and smoked sensory characteristics. Beef Kitoza were associated to fibrous, darker, harder, roasted and elastic or, depending of the process, to spicy and sweet sensory characteristics. Four smoked Kitoza products met a good acceptance with both European and Malagasy consumers, with a slightly preference for Pork Kitoza, even if the frequency of consumption was low for both. Four groups of consumers were identified. Sensory evaluation and consumer testing of group 3 products - Hibiscus, Baobab and Jaabi was undertaken with African and EU consumers in Senegal and Cameroon. For bissap, the tested products had different sensory perceptions. Three classes of behaviour from the consumers were identified. The liking by African and EU consumers was similar but European consumers were more likely to prefer syrup. African consumers were more likely to prefer juice, consume bissap more frequently and purchase it in sachets. The sensory profile of seven samples of baobab drinks (syrup and juice) was evaluated in Senegal. The acceptability of the drink was tested and three classes of behaviour from the consumers were identified. The reengineering approach appears to have two options being products suited to milk taste or taste and odour characteristic of baobab. Sensory profile and consumer acceptability was undertaken for Jaabi, in the Cameroon. All samples tested were acceptable. The main option of reengineering approach is based on standardisation of process procedures in order to guarantee the taste of the products. Inclusion of therapeutic aspects of the products may be coupled to this option for market development.
Assessing the sensory properties and consumer acceptance of the improved products in the EU - After the AFTER products had been reengineered, they were tested by sensory panellists and consumers in France, the UK and Portugal. Not all products were tested by consumers due to either the reengineered products not being as acceptable as the traditional product (e.g. Lanhouin and Jaabi) or due to technical issues (e.g. Gowe).
Sensory Evaluation. Considering Group 1 products, the sensory properties of reengineered products of Akpan and Kenkey did not differ significantly from traditional ones, however the opposite was observed for the new Kishk Saa’edi compared to the traditional one. Gowe was not tested due technical issues as it contained aflatoxin. Concerning the group 2 products it was decided to test only Kong and Kitoza, since Lanhouin demonstrated the lowest interest in EU market. In the case of Kong, four samples were tested: The studied samples were traditionally smoked Kong, Reengineered smoked and salted Kong, Reengineered smoked, salted and garlic flavoured Kong, Reengineered smoked Kong with liquid smoke. The complete descriptive study of sensory profile was not performed. Kitoza samples were analysed in Portugal for sensory tests included two different types of reengineering products: Kitoza beef (KB) and Kitoza pork (KP) which had distinct sensory differences. For group 3 products, due to restrictions of Jaabi product only Bissap and Baobab was studied in Europe, since jaabi demonstrated low interest in EU market. Baobab samples were assessed by a Portuguese trained panel. Four different samples were included. Sensory profiling showed similar results between the four samples, however samples produced from similar raw material, Baobab powder or fruit showed to be closer in particular concerning colour hue and turbidity. The attribute that was highlighted in all samples was sweetness and all samples were considered very sweet. Concerning Bissap assessed by a Portuguese trained panel, using three hibiscus drinks, an hibiscus infusion prepared freshly from dried calyces according to Senegalese recipe for baseline comparison and two new hibiscus drinks developed under as reengineered products – an ultra-vacuum concentrate and improved syrup. The reengineered product was similar to the traditional one. The results demonstrate diverse sensory characteristics for each sample, and some identified attributes and intensities that together with consumer study provided recommendation of some improvements to facilitate increased penetration in African and European markets.
Consumer acceptance. Considering group 1 products, Kishk Sa’eedi samples were generally disliked by Portuguese consumers who were unlikely to buy or consume it; Portuguese consumers are not familiar with fermented foods based cereal and milk which could help to explain the results obtained in this study. Similarly, reengineered Akpan products, although more accepted than the traditional version, did not have high acceptance by French consumers and few would likely buy it. Reengineered white Kenkey had improved acceptance compared to traditional form, but was not high enough to be readily marketed in the UK. Gowé was not tested by consumers owing to contamination of the raw material with aflatoxins. Concerning group 2 acceptance in EU, it was decided to test only Kong and Kitoza, since Lanhouin demonstrated the lowest interest for the EU market. Reengineered pork and beef Kitoza, was tested by Portuguese consumers and the pork version was most appreciated, especially if the slices were large. Additionally, the Madagascar origin was perceived as positive. Kong was tested by French consumers. No difference was observed among the reengineered products regarding their overall acceptability (like slightly-like moderately), but the traditional one was liked less. The most liked Kong product was the one made with liquid smoke. Of the group 3 reengineered products, only Bissap and Baobab were tested by EU consumers as previously explained. Of four baobab drinks tested by Portuguese consumers, all were liked and found to be acceptable. For the two reengineered bissap drinks (ultra-vacuum concentrate and a syrup), these were tested by consumers in France, Portugal and the UK. All of the hibiscus drinks evaluated were positively appreciated by consumers and the reengineered one was more liked. Similar preference profiles were observed across EU countries although French participants gave slightly higher acceptance.
Assessing the sensory properties and consumer acceptance of the improved products in Africa. - After the AFTER products had been reengineered, they were tested by sensory panellists and then by consumers in each African country (Benin, Cameroon, Ghana, Senegal, Egypt and Madagascar). Changes and simplifications in sensory evaluation methodology have also led to modifications in the approach. Firstly, new more powerful methodologies have recently been developed (CATA) which enabled the use of consumers to estimate the sensory characteristics instead of using a separate sensory panel using the QDA method and secondly, since the sensory methodology is independent of the where the samples being tested, when test samples were common to both consumers in the EU and in Africa, there was only the need for one sensory test in either the EU or Africa instead of the need to do it in both. Hence, a single sensory evaluation result could be used in the calculations for relating sensory parameters to hedonic outputs by consumers
Sensory evaluation testing. Concerning reengineered Akpan from Benin, the sensory evaluation was undertaken in Montpellier, France. Reengineering of Akpan has focused primarily on improvement of sanitary properties of the product to enable increased production by SMEs in Africa. Sensory evaluation of the Akpan products was carried out using CATA and JAR techniques that have been developed for use with consumers instead of a trained panel. Three Akpan products were tested which had similar sensory attributes. Gowe from Benin was not tested using sensory evaluation samples provided for the French sensory panel contained a concentration of aflatoxin that was slightly higher than the minimum EU allowable limit. The sensory evaluation of Kenkey in Ghana was of a white type that has increasing popularity among urban consumers and requires larger scale production with consistent quality. Testing was conducted to determine the sensory profile of white reengineered kenkey made using the optimum pre-process conditions of steeping time, temperature and dough fermentation time. The sensory profile of white kenkey was dependent on pre-processing variables. Soft and sticky texture in white kenkey was highly appreciated. Sensory evaluation of Kishk Sa’eedi (KS) was undertaken in Egypt. Three KS samples were profiled. The re-engineered KS sample perceived as less sour and less salty, easy to fracture, and scored higher for grittiness compared to traditional ones. It was rated lower than the traditional ones with regard to Kishk taste and fermented odour. The present study showed that substantial differences in sensory character were noted between the traditional and re-engineered KS in particular, differences in colour, fresh odour, KS taste, fracutability and mouth coating. Considering Group 2 of the three products, sensory evaluation of only Kitoza was undertaken. For both Lanhouin and Kong it was not conducted because this product was only tested using a consumer panel. The reason for not testing using a sensory panel is because the product is used as a taste enhancer and hence the sensory properties were strongly influenced by the accompanying product. This makes the sensory evaluation much more complicated. Considering Kitoza, the sensory profile of the beef and pork reengineered Kitoza, was compared with 7 locally produced samples. The results of the descriptive analyses showed that the new reengineered products were not significantly different compared the traditional ones (but pork differed from beef) but offered new market potential because of improvements in safety and quality. Considering group 3 products, bissap and baobab had different sensory properties, which indicate differing consumer perceptions which may or may not improve market penetration in Africa and EU. The re-engineering of the bissap drinks was conducted with the main objectives of improving the eco-efficiency of the production process, the preservation of nutritional quality and colour of the products, while diminishing the production costs. The sensory study conducted in Portugal, the results confirmed that the new processing of bissap resulting in a beneficial softening of some of the strongest attributes present in traditional infusion, such as bitterness, acidity and astringency, while the reengineered infusion, traditionally a well appreciated drink among Senegalese consumers maintained most of the sensory characteristics of the traditional product. In the case of baobab, the reengineered juices tested in Portugal had different sensory characteristics to syrups. The attribute that was more distinguished for all samples it was sweetness. In the case of Jaabi, this was not tested by a sensory panel because the reengineered product had inferior properties to the baseline one and hence would not have a viable market.
Consumer testing. The reengineered products relating to groups 1 to 3 were tested by consumers in Africa in order to test whether the acceptance meets consumer needs. These products were widely different and tested in differing cultures and situations. A common feature, however, is that all products are already commonly consumed by the communities and accepted, particularly with respect to the baseline products. Some reengineered products were found to be more acceptable (Gowe and Akpan in Benin, white Kenkey in Ghana, liquid-smoked Kong and Lanhouin in Senegal, Bissap and Baobab in Senegal), some of similar acceptance (Kitoza in Madagascar) and some were less acceptable (Kishk Sa’eedi in Egypt and Jaabi in Cameroon). These acceptance tests indicate the challenges is reengineering products that are very different from each other and are consumed by consumers who may be familiar with them (as in Africa) or not (as in the EU). The market in the EU is very crowded and presents particular challenges to these products while in the African market, the markets are rapidly evolving as consumers start to experiment with new foods.
THE DEMONSTRATION OF THE IMPROVED PROCESSES AND TECHNOLOGIES enabled to transfer the scientific results to the private sector represented by SMEs. The process of achieving this objective involved several stages performed once the results were available, from September 2013 to the end of the project. Five pilot products were selected during the AFTER Porto meeting in June 2013. The consortium selected among the ten products the five with highest potential to be treated at pilot scale, using a spreadsheet to compare each product. Taking into account the amount of activities which remain to implement for each product, the five for those we already achieved identifiable scientific and technological results were listed: Bissap, Baobab, Kong, Gowé and Akpan. Demonstrations have been organized for all of them, including a “report on test results”. For the other five products (Kitoza, Lanhouin, Kenkey, Jaabi and Kishk) the results have been brought together and shown into the form of “showcases”: the content is not as formalised as for the demonstrations.
Successful pilot tests in African SMEs food companies
The methodology of the results demonstration used has been described in a milestone, which gives logistical & communication tools to maximize AFTER project impacts and leads into the dissemination phase. The pilot product demonstrations have been organized by the five product champions concerned, in collaboration with their Team, CIRAD and AAAFEX partners between September 2013 and May 2014.
The demonstration of Bissap & Baobab transformation (23d of September 2013 in Dakar, Senegal) focused on the improvement of traditional processes. It was divided in two phases. First, pilot tests were organized in a technical center as a global presentation of results (i.e. in ideal conditions). The research findings were then shared with each company involved (i.e. in real-life working conditions). Workshops and discussions were focused on the particular stages improved thanks to what we have learned from the research: manual or mechanical grinding, aqueous extraction, filtration, pasteurization scale and rapid cooling system (detailed in D6.1.2 and D6.1.3). The pilot tests conducted to make natural products, without aroma (like strawberry or ananas, traditionally added to the recipe). Although it requires investments in terms of equipment, the companies also showed a strong interest for the bissap concentrate, as a solution to standardize their production of drink or syrup.
A participative workshop has been organized on the 30th of November 2013 at the modern-type GIE “Seuti Ndiaré” (Dakar, Senegal) to share AFTER process improvement with local kong producers. These improvements are partly on sanitary aspects, for example by the introduction of a dipping operation into salted water for a reduction of the microbial flora and water loss prior to smoking. Moreover, the separation of the unit operations of drying and smoking, combined with the use of clean fuels, was introduced (results detailed in the D6.1.4). The workshop counted twelve participants (without counting AAFEX, UCAD and CIRAD representatives for the AFTER project).
The results obtained for Akpan and Gowe have been presented to 14 Beninese SMEs on Wednesday the 14th of May 2014 in Cotonou. With limited premises, the day was organized at the scientific library of the UAC. The main results obtained have been oraly presented before being illustrated by a mixing and bottling workshop for Akpan and a reconstitution workshop for Gowé (from Gowé flour). This event has been a really good occasion to stress the interests that private sector (SMEs) and research have in common. The richness of the discussions which took place in the meeting and debates all testify of the movement begun and invites to think about a more structured collaboration between all the actors of food processing field.
The wealth of the exchanges been born within the framework of these demonstrations of the research results testifies of the interest of companies for this type of initiative. The participants had the possibility to ask a lot of questions and the discussions offered to every participant the possibility to voice his opinion or concern. The contacts formalized on this occasion were shared to make this work bear fruit: towards a future and even richer collaboration! Good hygiene practices were also reminded and included in all the guidelines for the industry. These workshops were a good occasion to take pictures during food processing to illustrate communication tools, and also to collect data to assess the processes environment impacts.
Impact of the technologies on environment, energy and water consumption known
A parallel task was to verify whether the selected processes reduce the impact on the environment and ensure a cleaner and more sustainable production. For this, a simplified version of the Life Cycle Assessment (LCA) has been applied. As it has been done to characterize traditional processes, parameters had been recorded for reengineered processes on three or more essays. After data collection, LCI data was entered in Simapro software (Pré Consultant) to model the production processes and calculate the environmental impacts. When available, generic processes (e.g. sugar, salt, electricity…) were taken from the Ecoinvent database. Some of these processes were used as proxies, for instance wood chips available in Ecoinvent were considered equivalent to the sawdust actually used for some of the tests. These approximations were necessary to compensate for the lack of data on the environmental impacts of several of the inputs to the processes. Consequently the system boundaries were limited to the processing phase of the life cycle of the products, including the sourcing and use of the various inputs (ingredients, energy, water), but excluding the farming stage (agricultural production of Bissap, baobab, etc.) and transportation to the factory. The consumption phase was also not included in the system boundaries. Hence the study applies LCI tools to assess the environmental impacts of the target production processes, but does not constitute a full life cycle assessment as defined by the ISO14040-44 norm. The environmental impacts enable to compare conventional and reengineered processes, but the values do not represent the actual impacts. The functional unit (FU) was defined as 1 kg of product, for all the products. The same methodology was used for 5 products (Kong, Bissap, Baobab, Akpan and Gowé).
Conclusions are that Kong and Akpan revisited processes have better environmental performance comparing to traditional processes. That is mainly due to more efficient water used and cleaner energy used. So, for the limited differences between traditional and revisited Bissap and Baobab processes, those points constitute opportunities optimizing and improvement way for reengineered those products, in term of environmental performance.
Potential Impact:
1.4 Potential impact, main dissemination activities and exploitation of results
1.4.1. IMPACT
The main immediate and direct impacts of the project are the production of traditional food products with improved quality and safety and the commercialisation of new food products and additives.
AFTER has had a direct impact on the production of the ten selected traditional food products from Africa by improving their safety and their organoleptic & nutritional quality. The process reengineering of fermented cereal based products has helped to improve their safety thanks to better control of fermentation parameters. Three Lactobacilli (Lb. brevis, Lb.Casei and Lb. fermentum) were tested for inoculating wet milled dough (ogi) to produce gowé. Lb. Casei has been selected as a good compromise and because it can be easily provided as commercial dry active bacteria. A model was developed for predicting the fermentation, and then used for testing various scenarii of the fermentation of Gowé. In this respect, the inoculation with Lb. casei demonstrated his efficiency to rapidly ferment Gowé. The inoculation of Lb. brevis could be interesting in the context of very small processing unit that cannot control the temperature and the final pH. In order to improve Kishk Sa’eedi process, three hundreds and eleven isolated strains (isolated from good quality traditional Laban Zeer) have been examined for flavor acceptability in reconstituted skim milk powder to select only strains that produce accepted flavor. At the end of experimental, 15 strains have been selected and used for fermenting butter milk to produce Laban Zeer. The optimised processes also lead to improvements in end use quality (shelf-life, packaging, ease of preparation). As a result, the gowé flour shelf-life is more than 6 months, compared to three days for the traditional product. This flour can easily be reconstituted in Gowé by dilution in tap water and small time of cooking. The pre-processing (steeping and fermentation) and cooking steps for producing white kenkey have been optimized and the product was given a new shape as cylindrical slices instead of the crudely round balls of kenkey. The slices are packaged in cling film or vacuum packed rather than wrapped in banana, maize or other traditional packaging leaves. Vacuum packaging extends the shelf life of kenkey from between 4 and 7 days to 6 months under refrigerated storage.
The process reengineering of meat and fish products contributed to improvements in products safety and quality through the optimization of existing processes, through the introduction of new operations such as biopreservation or impregnation and through the utilisation of new ingredients. Simple adjustments of manufacturing diagrams have reduced the risk of PAHs in Kong and Kitoza, splitting the traditional smoking step into a cooking/drying and a smoking unit operation. For Kong as for Kitoza, the choice of fuel was optimized: the use of wood sawdust (for smoking) and charcoal (for cooking/drying) reduces the risk of carcinogenesis associated with PAH and B(a)P. In the case of Lanhouin the ripening and salting operations were combined to prevent microbiological degradation, final drying was optimized by the use of a shell dryer before sun drying to reduce the contact with insects. At the end of the process, a washing step of fish fillets in a mixed solution of lemon juice and garlic extract followed by a packaging in plastic bag and a storage at 4°C have significant effect on the microbiological and physico-chemical changes since the conditions allow to reach a shelf-life of 90 days. Reengineering can only be done in parallel of the implementation of compliance of workshops with the rules of good hygiene practices issued by the competent authorities. This compliance is mandatory for export (required approval) and could be progressively obtained for the local market. The product and process improvements proposed in the AFTER project are the first alternative solutions to reduce microbiological and toxicological risk. The packaging is a key element to secure the distribution of products. For modern markets, individual packages sealed in plastic film under chilled and frozen mode are to consider. For the traditional local market, without cold chain, packaged products under plastic would rapidly decay. Solution as “mosquito cage” is an affordable and available alternative.
The process reengineering of traditional functional food contributed to improvements in the nutritional value, the quality, the stability and the safety of the traditional food products made from hibiscus, baobab and jujube extracts. For jaabi, the processing analysis indicates that steaming is more common and has more potential, preserving the antioxidant properties. In Senegal, new improved processing protocols for bissap and baobab products (beverages, syrups) ensuring high and constant quality were proposed, and are already being applied by some companies: extraction, filtration and thermal stabilization stages were optimized.
The modifications of process practices that have been proposed respect local traditions and take into account sustainable environmental and economic criteria. The participation of organisations specialised in technology transfer (ACTIA) and of two major associations of food companies (SPES in the EU and AAFEX in Africa) helps to maximise the impact for the industry. The importance accorded to consumer acceptance from an early stage of the project also ensured a rapid uptake of the results by the industry.
Besides the improvement of existing products, AFTER also lead to the introduction and the commercialization of new food products. Results from process reengineering of fermented cereal based products could interest European cereal and milk processors for developing new products with high nutritional values and health claim (fermented vegetable yogurt-like products like Akpan and Gowé for example). A novel cereal-based snack inspired from Kishk Sa’eedi (KS) and adapted to the preferences of the modern consumer and to the demands of modernity was developed. The novel KS snack is a good source of dietary fiber and minerals besides being a way for youth to become engaged with their traditions, culture, and health through food. Results from process reengineering of meat and fish products should interest European meat producers. As a result, reengineering of Kitoza conducted by ADIV for the European market can help manufacturers to find new ways of transformation running the processes developed in this project. AFTER results also enables manufacturers to supplement their traditional dried product line using pig and bovine raw material with exotic products developed during the project. The formulation of new products from the calyx of Hibiscus sabdariffa as concentrate or instant powder opens new opportunities for the industry. The characterisation of jujube functionality and its valorisation contribute to propose new foods rich in natural antioxidants.
The expected medium-term impacts of the project are an increased competitiveness of African companies, an increase of the trade opportunities for African food companies, more opportunities for the European food industry, mutual knowledge generation and enhanced collaboration between different scientific disciplines and stakeholders, capability-building for European and international cooperation partner countries (ICPC) companies, a positive economic impact on both the EU and the targeted region, and contribution to meeting the EU’s commitment towards the United Nations Millennium Development Goals.
The implementation of the technologies studied in the project is helping food companies to improve their competitiveness. The active knowledge and know-how transfer, thanks to pilot tests, guidelines for the industry and the other dissemination activities (detailed below) directly benefits the food industry and should lead to a more competitive food industry.
As mentioned before, compliance of workshops with the rules of good hygiene practices issued by the competent authorities is mandatory for export (required approval). The demonstration and dissemination work done during the AFTER project contributed to introduce or remind good hygiene practices, also formalized in the ten guidelines for the industry.
Besides technology improvements, the project also improves knowledge and marketing ability. While consumer acceptance studies are common in the EU, this approach was still relatively underexploited in Africa where there are issues of culture, language and low income. AFTER project African teams conducted for the first time in their country sensory and consumer testing, following a rigorous scientific methodology. A sensory analysis team was set up in the six countries concerned. For successful implementation, the impact of the quality and safety improvements for each product has been evaluated and the acceptability of final products in EU and African markets has been assessed. The consumer testing studies, along with price and economic viability, bring food companies confidence to adopt these products in the EU and Africa.
AFTER helped to increase exports of traditional products to the EU by African companies. In the case of smoked Kong, technological alternatives proposed by CIRAD and UCAD in the traditional process took into account the local and European marketing. For optimization of smoking, the use of liquid smoke is an option offered by modern technologies in Europe. A Senegalese company (Marepêche) plans to develop a smoking line for the export markets in 2015. The products are completely free of carcinogenic PAH, due to the purity of the liquid smoke used. The reengineering of Lanhouin was also adapted to the European market by 3 strategies: 1) introduce marinating during the ripening step to avoid high microbial proliferation and to limit the generation of biogenic amines, 2) improve the fermentation conditions by adding commercial starter culture as biopreservative organisms, and 3) improve the storage and shelf life by using different packaging. The improved Lanhouin presented in forms of powder or cube, packaged in a plastic bag can be stored at ambient temperature up to 90 days without microbial problem.
The marketing mix for each product was determined by understanding the product, the pricing and economics, promotion branding and placement or channel by which each selected product is sold. It has been used to start developing a strategy for implementing the new improved products. An integral component of this is the implementation of consumer acceptance studies in the EU. The expertise from the consortium (NRI in particular) in regulatory and marketing issues also assists in overcoming potential hurdles to the successful introduction of these products into EU markets. Regional food products, although considered as ‘novel products’ by the EU have the potential to be 'fast-tracked' by the EU, especially if the food products do not differ from how they are traditionally produced and consumed.
European food companies are concerned with European competing market and are looking for new trade opportunities to improve their portfolio or create new food segments to expand their business. The integration of traditional food products and new functional foods with improved quality and safety is of great interest for European SMEs. The partners from France (ACTIA and CIRAD), Portugal (ESB) and UK (NRI) are transferring the results to food companies from their countries. The company RACINE, the most important importer of African food in France involved in the project as an advisor had already encouraged the development of the new smoking line in Senegal (using liquid smoke).
AFTER combines knowledge from both Europe and Africa to provide findings relevant to the food industry. The project has strengthened scientific exchange between scientists and also promoted industry-academia cooperation between the EU and Africa. The methodologies developed for assessing consumer acceptance and market potential as well as the improved technologies contributes to the development of bi-regional standards that will promote market penetration and generate new trade opportunities.
The impact will be important for the 12 research organisations involved. AFTER helped to exchange knowledge and know-how in several disciplines: food science, consumer acceptance, food regulations, intellectual property management etc. As a concrete result, AFTER Congress 1, the first congress organised on the theme of promoting traditional African foods was an international event co-organised by CIRAD, ESP and AAFEX on 11 and 12 November 2014 in Dakar, Senegal, with the theme “Promoting traditional African foods: innovations, quality and market access”. More than a hundred participants were hosted across the two days, with more than 10 countries represented in the oral communications, while in total 21 traditional African products were studied, and their research results shared.
AFTER contributes to the sustainable development of African rural areas by increasing the value of local products. The exploitation of the results provides new commercial opportunities for local communities in Africa. The commercialization of improved processed food products contributes to the economic growth of all stakeholders (food companies, farmers, equipment providers, exporters etc.).
Finally, AFTER contributes to meet the EU’s commitment towards the United Nations Millennium Development Goals (MDGs). For Africa, revalorization of the traditional food heritage and preserving the dietary diversity of traditional food systems have been identified as an important resource in strategies conceived to combat hunger and malnutrition and current soaring food prices (FAO Food Summit Action Plan, 2008). The project contributes to more than one of the eight targets set out in the UN Millennium Development Goals:
• Poverty alleviation through income generation and economic empowerment of women, who are the principal producers of traditional foods in most of the African countries, will also enhance gender equality.
• Improved mother and child health and nutrition as a result of improved standards of living can in turn reduce child malnutrition and susceptibility to infections, and result in increased educational outcomes and in eventual reduction in child mortality.
• Higher incomes will contribute to reduced school leaving rates for both girls and boys.
The above listed developmental impacts satisfy targets under MDGs 1 to 6. Ensuring environmental sustainability (MDG 7) is addressed by the project by minimizing the environmental impact of the processing technologies designed for production of the 'engineered' novel products, which maintains as far as possible the low energy consumption and environmental friendliness characteristic of the original indigenous techniques used in traditional food production. The long-term impact of poverty reduction on environmental degradation can be expected if improved living conditions are sustained. Mobilisation of resources – financial as well as technical – from donor countries (the EU) in support of the realization of the above listed expected Project outcomes satisfies targets under MDG.
1.4.2. DISSEMINATION
Dissemination and management of IPR were addressed all along the project life, in order to exploit results in concrete ways, affordable for both EU and African food companies and industrial stakeholders. This included a series of industrial property and technology transfer guidelines. Special attention was given to the rules regarding the exploitation of the generated know-how in industrial practice. Main objectives for the project duration were the following: production of traditional food products with improved quality and safety, modifications of process practices in respect to local traditions and taking into account sustainable environmental and economic criteria, enable technology transfer via the participation of organisations specialised in such methodologies (ACTIA) and via two major associations of food companies (SPES in the EU and AAFEX in Africa), maximise the impact for the industry (ensuring a rapid uptake of the results by the industry), disseminate research results to achieve increased competitiveness of African companies and trade opportunities for African food companies and for the European food industry.
Public dissemination of the project results occurred not only through publication in high-quality peer-reviewed scientific journals, but also through press releases, scientific and industrial platform meetings (posters, talks, working group) and through the web via the project website (see below). The new processing protocols and methods for the 10 products have been made available to the food industry through the publications and dissemination of 10 guidelines and articles in specialised magazines. Furthermore the involvement of SPES and AAFEX ensured wide “industry oriented” dissemination to their network at national level but also abroad, taking advantage from their several activities organised also in external countries and from the management, at country level, of the most important international food Fairs (such as SIAL in Paris, CIBUS in Parma, Alimentaria in Barcelone and Lisone).
According to the dissemination plan written by SPES with contributions from all partners, AFTER set out during its lifetime various dissemination activities aimed at promoting its research and at reaching the widest and varied audience possible.
Information sent to policy makers
• 10 technical guidelines
• Knowledge of African Traditional Food Products (throughout scientific outputs) was enhanced and awareness on the diversity of the African products on which the research is based on (i.e. Akpan, Kenkey, Gowé, Kishk Sa’eedi, Lanhouin –cassava fish, Kitoza, Kongin, Adansonia digitata, Hibiscus sabdariffa, Ziziphus mauritiana) was promoted. The support to the conservation of plant and cultural diversity was increased. At this regard the marketing regulartory reports released under WP5 were of interest to let them aware of the concrete possibilities and main constraints. Moreover concepts of health promoting foods were appreciated during the project events.
Information shared with the scientific community
• 61 events where specific focus of the project given by the Coordinator during scientific congresses or Symposium
• 13 scientific publications in peer-rewied journals
• 44 Posters during congresses (EFFOST and SAFFOST)
Dissemination to the general public
• 179 events where at least a project slide was given within national public events
• Briefs of the project regularly published via partners’ electronic newsletters
• 17 articles generalist papers (such as quartely review, newsletter, magazines)
Informations and tools provided to communities in Africa
• Specific tools for the technology transfer like brochure
• Food Fair (targeting agrofood companies and farmers associations)
• 5 Demonstrations of technical results at pilot scale
• 10 technical guidelines
• Final Conference in Saly
General communication
• Content and items in the official website regularly updated
• Preparation of dissemination material (flyers and leaflets also in national languages)
• Finalisation of the Brochure (English and French), paper and electronic version
• Video link created by SPES (ANIA)
• Twitter account managed by NRI
• Facebook page managed by SPES (ANIA)
The official AFTER project website is available since the very beginning (by end of 2010) of the project) at http://www.after-fp7.eu/en. The objective of this website is to provide information regarding the project addressed to the public with a special eye to scientific and industrial coomunity. During the project lifetime, website visitors were informed about the projects concept, progress and innovative results. For more detailed information all results (deliverables) accepted by the EU are available for download. The website was created and updated by CIRAD (with support of all participants), and will be maintained and hosted by CIRAD even after the end of the grant agreement. During the 3rd reporting period, 22 additional news have been uploaded (36 in total for the project duration in English and French). Public deliverables, Scientific publications, link to the Posters and press articles have been uploaded. The total number of visits were 8.716 (for a total of 23.826 screen views).
A logo was created to maintain the corporate identity of the project. Templates for Power Point presentations and deliverables were designed to ensure a united presentation to those external to the project.
The project leaflets were designed early in the project. They provide a thorough but simple to understand description of the project’s concept. The leaflets are available in English language, and have been translated into national language from SPES third parties on a voluntary basis (such as Italian and French). The leaflets were distributed at project events, such as workshops, and at other events where consortium members participated. Copies were sent to a large number of stakeholders in the EU. In addition also an official brochure released in English and French was edited by SPES with the support of the partners. This dissemination tool was finalised in order to include the already ongoing RTD results. Therefore it was prepared during the 3rd reporting period.
During important Congresses and for the final conference 44 posters were also produced and used as presentation material.
In order to comply with dissemination objectives, SPES, in close collaboration with all other partners, organized at least 1 workshop per each country (Italy, Spain, France and Portugal), combining these workshops with already existing events such as Food Fairs, open days, Food and Drink Federation Annual events like the National Technology Platform Food For Life events. Moreover in order to enhance scientific aspects of the project, SPES also organized and facilitated, with the active collaboration of R&D partners, the participation of the project partners at scientific congresses taking place in the EU and in African beneficiary countries. In Italy Federalimentare organized a working group session during CIBUS Fair in collaboration with Assafrica & Mediterranean Association to scout future opportunities of business for Italian food companies which are also located in African country. In France Ania organized large number of regional meetings in collaboration with the Food associations where AFTER was presented, discussed and promoted for further exploitation even after the end of project life. SIAL biannual Fair, as well as Alimentaria & Horexpo Lisboa 2013 Fair, were used as events to disseminate the project and distribute dissemination materials. In Portugal Fipa, in collaboration with ESB-UCP, organized a workshop “Revisiting African products for European consumers” where scientific and technical aspects were given to the participants. In Spain Fiab organized during Alimentaria Food Fair in Barcelone a workshop “Presentation of new African products developed from the Project AFTER”. AFTER Congress 1, the first congress organised on the theme of promoting traditional African foods, was a major event in the results dissemination phase. This event co-organised by CIRAD, ESP and AAFEX was held on 11 and 12 November 2014 in the Ngor Diarama hotel in Dakar, Senegal. The Congress had the theme of “Promoting traditional African foods: innovations, quality and market access”. It hosted more than a hundred participants across the two days. The event had an international scope, with more than 10 countries represented in the oral communications, while in total 21 traditional African products were studied, and their research results shared.
The dissemination activities during the third reporting period continued as planned and the relevance and impact of them increased a lot. It is to be considered also that the project released important results which were used to arrange proper dissemination strategy as follows:
Scientific community was approached by the oral presentation of the project during important scientific congresses and conferences; via the preparation of scientific publications in peer-reviewed journals
Food industry network was approached by the partners (mainly AAFEX, CIRAD and SPES third parties) via the organization of specific workshops and working groups targeting the presentation of main opportunities for EU SMEs and African companies coming from the project results. Moreover huge number of public events where AFTER short announcement or slides display were attended by SPES third parties (in Spain, Portugal, Italy and France).
During the project implementation the partnership agreed to use the most common social networks to raise the attention of the wider public dealing with African food & nutrition matters, as well as European food industry stakeholders dealing with recent developments in the food technologies of reformulation of products. At this regard NRI managed the twitter account to provide with general communication on Novel food’s ingredients from AFRICA. While SPES (ANIA) managed to open a Facebook page on the project.
Moreover SPES (ANIA) used budget from dissemination to release a video on the project which was launched by the web channel of ANIA dedicated to research and innovation.
List of Websites:
http://www.after-fp7.eu/en