Project Title: Copra Cake Meal Enhancement

PROJECT TITLE: COPRA CAKE MEAL ENHANCEMENT

PROBLEMS OF COPRA MEAL:

• Low protein content, dark brown, yellow color, no good odor
• Occurrence of aflatoxin
• Rigid structure, low digestion values for monogastric animals.

BIOTREATMENT OF COPRA MEAL

The Bio treated Copra Meal (BTCM) has the following improved qualities:

• Protein increases from 21.60% to 48.30%, light yellow color and good odor.
• Zero aflatoxin content.
• Increase of essential amino acid content.

The raw material copra meal is bio-treated with the micro-organism called Aspergillus Oryzae through fermentation to enhance protein content of the meal, which may be substituted with imported Soya meal. The aflatoxin level is degraded making it to be more attractive to European markets.

PROCESS

Step 1: Micro-organism propagation, chemical medium for fermentation or solid state fermentation, pasteurization of solution, and pasteurization of copra meal.

Step 2: Mechanical mixing of all pasteurized components: copra meal, micro-organism and fermentation medium.

Step 3: Fermentation of the mixture with sanitized trays for 2 days at ambient temperature.

Step 4: Mechanical drying of fermented meal up to 12% moisture using hot air sourced from excess surface heat loss from carbonizer, or coco shell gasifier.

Step 5: Mechanical Shredding / grinding of the bio treated copra meal.

Step 6: Packaging of the bio treated copra meal in bags.

COST:

Based on 15 MT Feedstock Capacity – 16MTD output bio treated copra meal (BTCM), updated January 2008, Philippine market and currency.

Cost per day / Peso cost per kilo output, BTCM
Chemicals / P 29, 265.20 / 1.81
Utilities / P 29, 978.50 / 1.85
Labor / P11, 200.00 / 0.69
Equipment Depreciation – 10 years / P 7, 966.00 / 0.49
Total Cost / P 78, 409.70 / 4.84

Product Cost:

Based on current copra meal cost at P 6.00 / kg.

BTCM cost / kg. = (P 78, 409.7) + P 6.00 x 15, 000 kgs)) / 16, 200 kg.

= P 10.40 / kg. or about € 0.16 / kg

Estimated Plant and Equipment cost:

Based on 15 MTD feedstock capacity / pilot plant

Pasteurizer boiler / P 1, 500,000.00
Mixing tank / 1, 000,000.00
Mixer / 200, 000.00
Fermentation structure / rack / 5, 600, 000.00
Microorganism culture room / 1, 000 ,000.00
Tray / 600, 000.00
Drier system / 3, 000, 000.00
Grinder / shredder / 60, 000.00
Forklift / 1, 300, 000.00
Solid state fermentation system / 4, 000, 000.00
Screw conveyors / 1, 000, 000.00
Boiler motors / 55, 000.00
Mixer motors / 250, 000.00
Grinder motors / 45, 000.00
Screw conveyor motors / 250, 000.00
Blower motors / 55, 000.00
Sub - total / 19, 915,000.00
Allowance :20% / 3, 983, 000.00
Total / P 23, 898,000.00

Annual Net Income:

Basis: Plant capacity – 15 MTD copra meal input

Product cost – P 10.40 / kg.

BTCM – 40% protein selling price - P 15.50 / kg.

Soya bean meal – 48 % protein price - P 18.00 / kg

Tax, 35%

Annual production = 16.2 MTD x 300 days / year

= 4, 860 MT / year

Gross income = 4, 860 Mt / year x (P 15.50 – 10.40)/ kg x 1000 kg / MT

= P 24, 768, 000.00 / year

Net income = P 24, 786, 000.00 / year x (1- 0.35)

= P 16, 110, 900.00 / year

Ratio:

Return on Investment = P 16, 110, 900.00 x 100

P 23, 898, 000.00

= 67.4%

Payback period = P 23, 898, 000.00

P 16, 110, 900.00

= 1.48 years

Analysis of raw copra meal compared to the bio treated copra meal

Component / Raw Copra Meal (dry basis, %) / Bio treated copra meal, (dry basis, %)
Crude protein / 21,60 / 43.30
Crude fiber / 11.27 / 7.58
Crude fat / 7.10 / 8.42
Ash / 7.30 / 8.01
Carbohydrate / 64.00 / 39.17
Aflatoxin , ppb / 126 / Not detected

• average of several trials

Amino Acid Profile of fermented copra meal

Composition / Raw Copra Meal / Bio treated copra meal, BTCM
A. Protein / 18.85 / 39.80
Amino Acid, mg / g protein
Alanine / 653.34 / 365.76
Asparagine / 1136.09 / 382.88
Cystine / 333.27 / 177.91
Glutamic Acid / 4160.95 / 6227.90
Glycine / 821.86 / 2699.63
Proline / 585.48 / 393.22
Serine / 740.24 / 1840.75
Tyrosine / 131.95 / 350.64
Arginine / 2435.23 / 3357.93
Histidine / 442.41 / 2147.21
Isoleucine / 755.70 / 2854.06
Leucine / 1195.28 / 4255.42
Methionine / 793.96 / 2752.17
Phenylalanine / 364.56 / 528.15
Valine / 750.80 / 2004.33
Threonine / 1131.38 / 3560.11
Trytophan / 689.91 / 2276.63
Lysine / 47.13 / 151.64

RESULTS OF FEEDING TRIALS

Feeding trials were done in cooperation with animal farms in Batangas province. Fish feeding trials for tilapia and bangus are fresh water fish ponds.

1. Feeding trials in Swine

Treatment Description of Biotreated Copra Meal Feeding (BTCM) Trial in Swine

Treatment No. / Description
I / Control ( fed with 0% soybean substituted by BTCM
II / Fed with 18.6% soybean substituted by BTCM
III / Fed with 30%soybean substituted by BTCM
!V / Fed with 50% soybean by BTCM

Management and data collected

Body weight - Average daily weight gain

Feed conversion ratio - Feed conversion

Production performance of pigs fed with diets with varying levels of BTCM

Parameters / I / II / III / !V
Initial weight, kg / 18.92 / 20.04 / 19.44 / 16.0
Final weight, kg. / 88.4 / 92.0 / 84.4 / 77.0
Days on test, d / 100.0 / 99.0 / 100.0 / 103.0
Average weight gain, kg / 69.48 / 71.96 / 64.96 / 61.0
Average daily gain, kg / day / 0.6948 / 0.729 / 0.6498 / 0.5922
Average total feed consumption, kg / 240.1 / 235.9 / 186.5 / 180.5
Average feed conversion ratio,FCR kg/kg / 3.473 / 3.2782 / 2.8710 / 3.004

Swine Meat Evaluation

Swine Carcass Characteristics

Measurements / I / II / III / IV
Slaughter weight,kg / 88.0 / 93.0 / 92.0 / 83.0
Carcass weight, kg / 69.0 / 75.0 / 70.0 / 60.0
Body length, cm / 121.95 / 114.33 / 110.52 / 108.10
Average back fat thickness, cm / 1.7 / 1.9 / 1.8 / 1.8
Dressing percentage,% / 78.409 / 80.645 / 76. 087 / 72.289

Physical analysis of the carcass

Treatment / Tenderness, lbs/sq. inch / Firmness, mm
Control (o%soybean meal substitution) / 1.35 / 8.84
Treatment III (30% soybean substituted by BTCM) / 1.57 / 8.39

B. Feeding Trials in Tilapia

Treatment Description of BTCM Feeding in Tilapia

Treatment / Description
I / Control (commercial feed)
II / 50% soybean meal substitution by BTCM
III / 100% soybean meal substitution by BTCM

Production Performance of Tilapia fed with Varying Levels of BTCM

Parameters / I / II / III
Initial weight, g / 8.6 / 12.19 / 10.5
Final weight, g / 357.14 / 384.61 / 416.67
Fish length, cm / 28.0 / 29.5 / 30.0
Weight gain / day, g / day / 3.058 / 3.416 / 3.659
Days of culture, d / 114 / 109 / 111
Total Feed Consumption, kg / 5, 734 / 6, 205 / 5, 944
Total Biomass, kg / 2, 162 / 2, 737 / 2, 852
FCR,% / 2.652 / 2.267 / 2.084

Fish Recovery and Survival Rate in Tilapia

Treatment No. / Total Biomass / Survival Rate,%
I / 2, 162 / 60.54
II / 2, 737 / 88.96
III / 2. 852 / 85.56

Sensory Evaluation of Tilapia

Evaluation Treatment No.
I / II / III
Color / Moderately desirable(3.55) / Desirable(3.95) / Desirable(3.95)
Flavor / Desirable( 3.5) / Desirable (3.75) / Desirable (3.8)
Aroma / Perceptible (3.65) / Perceptible (3.65) / Perceptible (3.75)
Juiciness / Neither juicy nor tough (3.6) / Neither juicy nor tough (3.85) / Juicy (4.1)
Tenderness / Neither tender not tough
(3.6) / Neither tender nor tough (3.8) / Tender (4.1)
General Acceptability / Moderately Desirable (3.85) / Desirable (4.0) / Desirable (4.0)

1. Feeding Trials in Bangus

Treatment Description of BTCM Feeding Trials in Bangus

Treatment No. / Description
I / Control (commercial feed)
II / 50% Soybean meal substitution by BTCM
III / 100% soybean meal substitution by BTCM

Production Performance of Bangus fed with Varying Levels of BTCM

Parameters / I / II / III
Initial weight, g / 11.50 / 11.50 / 11.50
Final weight, g / 459.40 / 476.54 / 726.22
Fish length, cm / 35.95 / 38.10 / 48.18
Weight gain / day, g /day / 3.378 / 3.938 / 4.297
Days of culture, d / 136 / 121 / 169
Total feed consumption, kg / 5, 552 / 5, 824 / 6, 003
Total biomass, kg / 1, 970 / 2, 700 / 2, 189
Average feed conversion ratio(FCR),% / 2 .818 / 2. 157 / 2. 742

Fish Recovery and survival Rate of Bangus

Treatment No. / Stocking Density at Starter / Fish Recovery, kg / Survival Rate,%
I / 6, 000 / 1, 970 / 71.34
II / 6, 000 / 2, 700 / 94.43
III / 4, 000 / 2, 189 / 75.38

Sensory Evaluation of Bangus Meat

Evaluation Treatment No.
I / II / III
Color / Desirable (4.0) / Desirable (4.0) / Desirable(4.0)
Flavor / Moderate Full Flavor characteristics(4.0) / Moderate full flavor characteristics(4.0) / Moderately full flavor characteristics(4.0)
Aroma / Moderately Perceptible (3.8) / Perceptible(4.0) / Perceptible(4.0)
Juiciness / Neither juicy nor dry (3.0) / Juicy (4.0) / Juicy (4.0)
Tenderness / Tender(4.0) / Tender(4.0) / Tender(4.0)
General Acceptability / Desirable (4.0) / Desirable (4.0) / Desirable(4.0)

Recommendation:

1. The technology of copra meal proteinenhancement was done to upgrade copra cake quality and to make it more competitive in the world market.

1. The BTCM can be used as soy bean meal replacement. It will help reduce the country’s importation of soy bean meal, and in turn will support the Philippine economy.

1. Increased copra cake market will greatly help the Philippine coconut industry and will

help alleviate the lives of themillions of coconut farmers in the Philippines.

1. The technology of the biotreated copra is done in a research laboratory in Luzon. It is wise to revalidate the process in one of the oil mills in Mindanao, to do online with the coco shell gasifier (carbonizer) project for the utilization of the excess heat from the charcoal production forthe drying of BTCM to 12% moisture.

5. For 2009, the project partners are targeting aminimum production of copra meal at

175,000 MT annually.