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Objectives:

Strategies developed and promoted which improve food security of poor households through increased availability and improved quality of cereal, pulse and oilseed foods and better access to markets.

Background:

Communal women farmers consider the slow manual aspect of peanut butter production to be a constraint to generating household income through the sale of peanut butter in local markets.

In a survey carried out by Price Waterhouse in 1994, women's groups involved in peanut butter production produced between 120-340kg annually for sale. Figures quoted by these farmers indicated that peanut butter marketing can be a profitable business for households involved in its production.

Powered processing equipment speeds up the process, providing the potential for increased income generation. In 1996, the Development Technology Centre (DTC) of the University of Zimbabwe (UZ), with assistance from Compatable Technology Inc. (USA), developed the OMEGA peanut butter grinder, which has a throughput of about 10-12kg/hr when driven manually, and about 150kg/hr when driven by a 2hp motor. The OMEGA grinder (then priced at Z$3,500.00) was expensive for households and small groups, and therefore smaller, manually-operated grinders, Corona (Colombia) and the Porket (Czechoslovakia) were introduced.

At present, there are many groups and households with these grinders (estimate of 200). Forty OMEGA grinders and fifty Coronas have been supplied to groups or individuals spread throughout the country, by DTC. Two NGOs, ITDG and ZOPP, are also involved in the dissemination of peanut butter grinders.

The reaction of the users has been varied, and the following issues have been raised:

* the productivity is low because in some cases the peanut butter has to be ground three or four times, in order to achieve a fine consistency.

* operator perception varies between cast steel, carborundum, and machined steel as the preferred material for grinding burrs.

* the parameters affecting grinding efficiency such as groundnut variety, time for roasting, moisture content, and material for grinding burrs is unknown.

In some instances some users achieve excellent results, while others complain of poor performance of grinders. Additionally, peanut butter producers have highlighted the fact that oil tends to separate in locally-produced peanut butter, leading to a certain consumer resistance to the product.

Traditionally produced peanut butter is largely marketed informally, because most formal outlets insist on the product meeting high quality standards. The issues of hygiene, aflatoxin and storage life are very important, and there are knowledge gaps on these issues among most rural entrepreneurs.

Intended Outputs:

A social-economic assessment of the viability of peanut butter processing incorporating market analysis, ergonomics and gender roles. Lessons will be drawn from enterprises which have succeeded or failed.

An assessment of the risk of mycotoxin contamination in groundnuts used in the rural processing of peanut butter (food safety).

Detailed methods for producing peanut butter using simple grinding machines, including technical recommendations on optimal conditions for storing groundnuts after harvesting, processing, storage and packaging conditions for peanut butter.

Identification of the physio-chemical, shelf life, and food safety characteristics of peanut butter produced under different processing conditions.

Documented guidelines and simple business plans for setting up and running viable small scale peanut butter enterprises to be presented at a national workshop.

Progress and Impact:

The surveys revealed that current food laws form the basis which formal outlets, especially supermarkets, accept products on their shelves. The market analysis showed that the current supply does not meet demand and that there are exporting opportunities. The key to accessing these markets was to meet the food laws and Standards Association of Zimbabwe certification.

Health risk assessment studies revealed that aflatoxins were a threat in rural and large scale processed peanut butter. The rural processed peanut showed the highest percentage of samples which had no Aflatoxin detected in them. This is largely due to the careful sorting before and after roasting and also that quantities processed at any one time were small therefore sorting is easy. However the rural processed peanut butter especially the manual and motorised machines showed higher levels of E-coli and Salmonella than the large scale suggesting that hygiene has to be improved. Rural processors have to take due care on the cleanliness of processing equipment.

The machinery research determined the optimum conditions for good performance of grinders. Moisture of nuts has effect on the quality of the peanut butter. Ideally the moisture content has to be below 1%. This is achieved by roasting nuts for long periods (30 minutes) at a moderately high temperature (3500C). The actual temperature of the nuts should not exceed 1600C. The feed rate of the auger into the grinding plates and speed of plates had effect on the quality of the end product. A metering device was developed to match the feed rate with speed of burrs so as to have a smooth butter in one pass. So far there are more than 40 machines in the field.

The ergonomics study showed that manual operation of grinders was heavy. The heart beat rate exceeded those recommended by FAO. The option of introducing a metering device worked well but has cost implications if productivity is not high. The study revealed that using the traditional stone was even more labour intensive than grinders.

These research findings were shared with researchers, extensionists, Standards Association of Zimbabwe, Harare City Health department, machinery manufacturers, and rural processors. Guidelines for the manufacture and operation of machines and food quality and safety aspects of peanut butter were developed. Currently these are being tested with other processors.

Additional funding has been provided by CPHP which will assist in:
*Conducting socio-economic survey.
*Publishing the guidelines.
*Producing a dissemination video and publications.

Project Conclusions:

The project has made immense contribution to DFID's developmental goal. The research activities have generated knowledge which enhanced the design and operation of peanut butter grinders. Rural families will benefit from the improved productivity and quality of the peanut butter. There has been a tremendous growth in the rural peanut butter processing in Zimbabwe as a result of the project. The positive aspect is that so far one group has Standards Association of Zimbabwe certification and some more groups have shown interest in attaining certification. The NGOs have been highly instrumental in the success of the dissemination process. The survey carried out in Zambia has shown that there is potential of establishing viable rural peanut butter enterprises. Groundnuts are in abundance and yet the country is importing peanut butter. The key to success is to ensure that the peanut butter is affordable to all classes of the society. Research on the quality and safety aspects has helped to enlighten entrepreneurs, institutions, and NGOs disseminating technologies on the importance of areas especially as a tool of accessing formal markets. The research process and workshops was greatly fostered by all the important stakeholders. The Standards Association of Zimbabwe, City Health department, equipment manufacturers, private and public extension agents, private sector and the rural entrepreneurs all made contributions. This has created an avenue to disseminate the technology. Of special mention is the willingness of Standards Association of Zimbabwe to assist rural entrepreneurs to attain their licence and certification. So far one group has achieved this and more are keen to follow suit. There is a big growth in peanut butter enterprises in rural and urban areas. The follow up which is required is to educate the processors on how to produce a safe and high quality product. The issue of concern at the moment is that most entrepreneurs do not know good operation and maintenance procedures for their grinders. There is need to develop simple manuals on grinder assembly and operation. Regular cleaning of machines is necessary in order to avoid microbial contamination. Future work should focus at the critical control points for controlling aflatoxins. The study was not able to determine this. Given the high level of adoption of peanut butter technologies in Zimbabwe there is a possibility that the knowledge gains are made to benefit neighbouring countries. At the moment additional funding has been given by the Crop Post-Harvest Programme which will help to disseminate the research findings. Pamphlets and a video on peanut butter processing will be produced.

Publications:

Rukuni T and Mutungamiri A (2000). Making peanuts pay in Zimbabwe. pp 14-15. In: Groundup. Volume 1 No 3. Mbozi P (ed). Pelum Association, Harare, Zimbabwe



MHAZO, N., NYAKUDYA, E., NAZARE, R. and MVUMI, B. (in press) Ergonomic evaluation of manually operated peanut butter mills.



RUKUNI, T. and MUTUNGAMIRI, A. (2001) Zimbabwean farmers benefit from peanuts processing. Post Harvest Bulletin. Issue Number 1, April - June 2001.



MUPANDA, K. and GUVEYA, E. (2001) The socio-economic analysis of the viability of mechanized small-scale peanut butter processing in Zimbabwe. 24 pp.



MUPANDA, K. and MHAZO, N. (2001) Socio-economic survey of Zambia: Assessing the possibility of establishing rural peanut butter processing. 19 pp.



RUKUNI, T. and MUTUNGAMIRI, A. (2001) Baseline survey to establish current markets, imports, food legislation processing methods and packaging for rural and commercial peanut butter products. University of Zimbabwe. 26 pp.

Associated References:

R6674