Grudgingly, agro-processing companies in most sub-Saharan countries have accepted power outages (sometimes called load-shedding) as a reality they must learn to live with. For discerning companies, however, this presents an opportunity to adopt innovative alternatives to the current methods. Twin-screen extrusion technology, for example, could help producers mitigate the migration effects and limitations of single-screw extruders.
By Sibonelo Magagula
The changing operating atmosphere is adversely affecting the bottom-line of the African agro-processing industry. This is a clarion call for players to seek practical ways of reducing operating costs and improving efficiency.
One of the sure-fire ways they could achieve this is by embracing innovative technologies. So far, twin-screw extrusion technology is a tried-and-tested option within their grasp.
The scale of the risk of rising operating costs for agro-processing businesses underlines compelling grounds for the adoption of twin screw extrusion.
Rising operating costs
Agro-processing companies in most Saharan African countries are facing rising inflation. As a result, raw materials are becoming prohibitively expensive.
Compounding matters, intermittent power outages result in costly disruptions to production schedules and product losses due to quality issues. In most cases, companies are forced to use diesel generators, incurring unplanned expenditures.
These two factors are increasing operating costs and reducing profitability. Without a doubt, this is a worrying situation for business.
Massive opportunity in the challenge
However, while tackling rising operating costs is a challenge, it could also be a massive business opportunity for discerning players.
A World Bank report (Africa Can End Poverty, published in 2022) paints the scale of the problem of food security in Africa: “Eastern and Southern Africa— home to over 656 million people, many of whom are poor and face significant challenges accessing adequate, safe, and nutritious food every day—has some of the most vulnerable food systems in the world.”
Besides the World Bank, the Food and Agriculture Organisation (FAO) has consistently warned that sub-Saharan African countries face a food security crisis. Other agencies, like OXFAM, have echoed this sentiment.
Without a doubt, this situation calls for the industry to rise to the occasion and increase production to meet the demand for food. Producers must adopt methods with an output a notch higher than what they currently use.
Twin-screw extrusion
Among the options available on the market, twin-screw extrusion technology emerges as a low-hanging fruit. The food producers could use the advantages this method offers in their favour.
Basically, extrusion food manufacturing technology involves mixing, forming, texturing, and cooking to develop a desired food product. In the process, screws push feed through small slots; the feed is then cooked at high pressure and temperature before being transferred to a vessel. The levels of pressure and temperature depend on the desired outcome.
Besides, twin-screw extrusion, single-screw is another option. Fundamentally, the former uses two screws screw while the latter one screw.
Single screw extruders
The convenience of single-screw extruders is without question; they are fit for purpose when power is reliable, and there is no urgency for high output. This is in a situation where it is business as usual.
However, single-screw extruders would not suffice when food producers are overwhelmed by the challenge of high operating costs, and at the same time, there is an urgent and huge demand for food products.
Comparison
A comparison between the two provides clarity on why twin-screw technology would be a convenient option, specifically in the following areas:
- Output
Single-screw extruders rely on the flow and speed of one functioning screw. Due to this limitation, they can only mix a small amount of material with a limited output. On the other hand, developing food within a short time gives twin-screw extruders a high output.
- Energy efficiency
Load shedding significantly affects the availability of single-screw extruders in food production when they are most needed. Unfortunately, this happens when productivity is at its peak.
In contrast, the short time to produce output makes twin-screw extruders an energy-efficient option. This offsets the limitations of single-screw extruders when it comes to energy efficiency.
- Versatility
Another feature of twin-screw extruders worth highlighting is their versatility. Twin-screw extruders can handle various processing functions involving a wide range of mixed formulas, raw materials, and recipes.
More benefits
Over and above, twin-screw extruders could offer more benefits than conventional food-producing methods:
- Reduction of microbial contamination
Over and above, as a high-temperature short-time (HTST) extrusion cooking method with less moisture, twin-screw extruders inactivate enzymes and reduce microbial contamination.
- Higher nutrient retention
Compared with conventional cooking methods and other processes, the method has higher nutrient retention. This is much needed in African countries, where people lack access to vital nutrients.
- Minimal equipment footprint
Setting up conventional equipment is time-consuming and expensive. Besides, it requires more space. In contrast, with a smaller footprint, the twin-screw extruders can be up and running in no time.
Automatic choice, perfect fit
Clearly, twin-screw extruders offset the limitations of single-screw food extruders and other methods, giving them the edge. This makes them an automatic choice and a perfect fit for agro-processing companies, filling the gap in food supply demand and ensuring that their operations are sustainable.
All the more, there is no better endorsement of the technology’s efficacy than extensive usage in the development of snacks, pasta, breakfast cereals, and other textured foods globally.
