INSTANT POUNDED YAM FLOUR PRODUCTION TECHNOLOGY
INTRODUCTION
Pounded yam is a staple food, which is consumed by almost every tribe in Nigeria. The indigenous process of production is very laborious. It requires physical pounding by two or more men or women, depending on the quantity, in mortars with pistols. Instant Pounded Yam Flour (IPYF) brings succour to pounded yam lovers as the drudgery of pounding is eliminated.
Production Process
The production process consists of simple operations, which have been mechanized. The unit operations are:
Yam selection and weighing
Wholesome suitable varieties are selected for IPYF production. The wholesome tubers are then weighed.
Washing
The selected tubers are washed properly to remove adhering sand.
Peeling and slicing
The washed tubers are carefully peeled manually with stainless steel knives. The peeled tubers are then mechanically sliced to desirable thickness in a slicing machine made of stainless steel blades.
Parboiling
The yam slices are blanched in boiling water (parboiled) for some minutes, depending on the thickness of the slices.
Drying
The blanched yam slices are dried in a dryer at specified drying temperature for few hours. The dried yam chips are stored in airtight containers.
Milling
The dried yam chips are pulverized (milled) directly into flour of uniform particle size distribution.
Packaging
The yam flour is packed into airtight, moisture- proof packaging materials.
Flow diagram for instant pounded yam flour
Yam
Selection and weighing
Washing
Peeling
Slicing
Parboiling
Drying
Milling
Packaging
Labour Requirement : Six workers are required for the factory operations. Five as operators, and one as supervisor. Also casual labourers will be needed for peeling the yam tubers.
Machinery and Equipment
The necessary processing machinery and equipment can be fabricated locally. The list is as follows:
i Slicer
ii Parboiler
iii Dryer
iv Hammer mill
v Sealing machine
vi Weighing scale
Other accessories include: knives, plastic containers, scoops, wood paddles.
The plant capacity is 400kg/8 hours.
Space Requirement
The factory space required is about 15m x 12m. This will house all the machineries and equipment. Additional space needs be provided for raw material storage and end product stock storage.
Proposed Production Programme
No. of hours/days 16hrs.
“ “ days/week 5days
“ “ days/year 250days
“ " Shift/day 2
“ “ hours/shift 8
The input/output ratio 3:1
Cost of yam tuber/tonne N35,500.00
Volume of production 400kg/8hr
Estimated Capital
Requirements N
The total equipment cost 1,380,000.00
Estimated Fixed Capital 7,483,000.00
Estimated Working Capital 2,236,260.00
Total Capital requirement 9,719,260.00
Profitability
1.Sales revenue from 100 tonnes @ N250/kg - 25,000,000.00
2.Total production cost - 21,520,420.00
3. Profit before tax - 3,479.580.00
4. Tax @ 30% - 1,043.870.00
5. Net Profit - 2,435.710.00
SERVICES AVAILABLE AT FIIRO
1.Training in IPYF production
2. Supply of equipment
3. Preparation of detailed feasibility reports
4. Quality control analysis.
Technical Assistance Services (including Machine and Equipment installation, commissioning and personnel training on installed machines) and Consultancy Services