PACKAGING TECHNIQUES

TO IMPROVE SOY FOOD

SHELF LIFE
Presented by:
USAID Feed the Future Innovation Lab for Soybean Value Chain Research
 Webinar Agenda
11am: Introductory Remarks by Maggie Cornelius, SIL Human Nutrition Program Manager
11:10: Overview of Preservation and Packaging Options for Soy Dairies by Hart Jansson, Vice President of
Malnutrition Matters
11:15: SIL Soy Dairy Entrepreneur Flora Amagloh in Tamale, Ghana
11:20: SIL Soy Diary Entrepreneur Frank Peget in Accra, Ghana
11:25: SIL Soy Dairy Entrepreneur Dr. Joseph Osei in Agona, Ghana
11:30: SIL Soy Dairy Entrepreneur Edison Rwodzi in Namaacha, Mozambique
11:35: SIL Soy Dairy Entrepreneur Dr. Asa Maria Tham in Mocuba, Mozambique
11:40: Lucas Mujuju, Managing Director of So Soja in Chimoio, Mozambique
11:45: Presentation of SIL research on mechanized bottling systems and
price analyses of packaging methods
11:50: Q & A
12:00pm: Conclusion
 Soybean Innovation Lab
Soy Dairy Entrepreneur Network
• SIL funded the installation of 5 soy dairies in Ghana and Mozambique.
• Network was founded in 2015

• Soy Dairy Entrepreneurs produce soy milk, soy yogurt, tofu, and okara.
• Sell their products to schools, hospitals, groceries, and on-site.
• Also administer local nutrition trainings

• The Entrepreneurs collect data on their operation costs and production rates.

• SIL provides technical support for each dairy.

• Resources for improving operation, increasing production,
and developing business plans
Soy Dairy Entrepreneur Network Services
• Webinars and Networking
• On-site technical training
• New Product Development
• Packaging Designs
• Branding and Marketing Plans
• Food Labeling and Certification
• Food Safety and Sanitation Training
• Business Development
• Capacity Building
• Soy Cooking and Utilization Training
• Access to Credit
• Storage Designs
• Integration into School Feeding
Programs
• Other Institution Feed Programs
 State of Packaging Among SIL Soy Dairies
• Plastic and glass bottles are used
• Cans and plastic bags have also been tried, but entrepreneurs settled on bottles.

• All bottling is done by hand

• But entrepreneurs use a variety of bottling methods.
• SIL research demonstrates the impracticality of a mechanized full pasteurization/bottling
system.

• Ice chests filled with ice/ice packs are a popular method for transporting soy food.
• Attached to bicycles or put in cars

• Shelf life ranges from 24 hours to 3+ months.

• Some entrepreneurs’ milk can only be refrigerated.
• Others can keep their milk on a shelf.
Speaking: Hart Jansson
Vice President of Malnutrition Matters
 Preservation and Packaging
for Small-Scale Soy Dairy
Preservation Technique Overview

1) Bulk Milk Distribution & Consumer Vessel Use

2) Plastic Bag Filling and Cooling
3) Plastic Bottle Filling and Cooling
4) “Hot Filling” Glass or Plastic Bottles and Jars
5) Pasteurization (Partial Sterilization)
6) Sterilization for Long Life Without Refrigeration
 Speaking: Flora Amagloh
Managing Director of Soy Plus Natural Soymilk
Savannah Agricultural Research Institute, Tamale, Ghana

http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif Photo Credits: Flora Amagloh and Krystal Montesdeoca

Speaking: Frank Peget
SIL Soy Dairy Managing Assistant of En Soy Milk
CSIR-Food Research Institute in Accra, Ghana

http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif Photo Credits: Frank Peget and Dr. Marilyn Nash

Speaking: Professor Joseph Kwame Osei
Managing Director of AA Pure Soya Milk
Agona Ashanti, Ghana

http://www.ezilon.com/maps/images/africa/Ghana-physical-map.gif

Photo Credits: Dr. Joseph Osei

 Speaking: Edison Rwodzi
Plant Manager of Associaçao Pala Wassokot
Namaacha, Mozambique

Image Credit: http://www.bizbilla.com/country-maps/maps/mozambique-map.jpg Photo Credits: Edison Rwodzi and Dr. Marilyn Nash
Speaking: Dr. Asa Maria Tham
Managing Director of Winnua Ltd.
Mocuba, Mozambique

Photo Credits: Dr. Marilyn Nash and Krystal Montesdeoca

 Drawbacks of a mechanized
full pasteurization & bottle system
Research conducted by SIL in Mozambique shows that these systems are impractical
for the following reasons:

1) process control and assuring food safety along the cold chain would be difficult;
2) costs of filling equipment and bottles would be expensive
3) maintenance of equipment would be difficult and parts availability would be limited
4) a full ultra-high temperature system would be cost prohibitive given the scale and
price point for soy foods. This is a barrier to producing soy foods that are acceptable,
affordable, and nutritious to low income populations.
 SIL Soy Dairy Packaging Costs
• Packaging is a large expense for a small-scale soy dairy.
• Packaging Costs range from 20-50% of operation costs
SIL Soy Dairy in Mozambique: Components of Production Costs: Month 1

capital depreciation
transportation
16%
21%
working capital
other inputs
2%
4%
personnel
5%

ingredients
12%

packaging
40%
 Packing Materials used by
SIL Soy Dairies and their costs
• Material costs vary by location, urban v. rural, etc.
• Glass Bottles are more expensive than plastic bottles

Northern Ghana Northern Ghana Accra, Ghana Southern

Mozambique

Type of packaging Recycled glass bottles HDPE Plastic bottles PET Plastic bottles HDPE Plastic bottles

Packaging capacity 300ml 330ml 300ml 350ml

Price of bottle 0.5 GH 0.4 GH 0.28 GH 1.1 MT

$0.13 USD $0.10 USD $0.07 USD $0.01 USD
 Glass Bottle v. Plastic Bottle Price Analysis
• Both SIL Dairies have similar soymilk outputs but different
packaging methods.
• The glass bottler pays more for glass bottles and uses more gas.
Average Production Day Glass Bottle/Double Boil Plastic/Normal Fill
Soymilk Production 39L milk 39L milk

Number of bottles used: 130 bottles (300ml) 118 bottles (330 ml)
Price per bottle: 0.5 GH 0.4 GH
Total bottle expenditure: 65 GH 47 GH
Daily Electricity expenditure 25 GH 32 GH

Daily Gas expenditure 26 GH 4 GH

Shelf life 1-3 months on shelf Can’t last on shelf

3+ months in fridge 24 hours in fridge

Glass Bottle v. Plastic Bottle Price Analysis
• Changing to glass bottles would mean a 28% increase in
bottle expenditure for the entrepreneur currently using plastic
bottles.

• Double boiling the milk, as well as boiling the bottles for 30mn
after filling, would entail paying 8 times more for gas.

• Using glass bottles and the boiling methods can increase

shelf life by 30-90 days.
 THANK YOU!
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