Ghana: Fruit Juice Manufacturing Plant Operational Improvement Study

A European company commenced a green field project in partnership with Ghanaian shareholders to convert 55 acres of agricultural land into a state-of-the-art citrus processing facility capable of processing pineapples and oranges into Frozen Concentrate (FC) and aseptic Not For Concentrate (NFC) juice. Pinora, Pineapple and Oranges, is based in Asamankese, 85km northwest of Ghana’s capital Accra. The facility uses the most up-to-date technology and is capable of processing 500 tonnes of oranges and 200 tonnes of pineapples per day.

While the plant was demonstrating output of world-class quality juice products, its efficiencies were in question and profitability not at the anticipated levels. In particular, production restrictions did not reflect the availability of fresh fruit inputs, and sporadic shutdowns during the dry season were impacting the ability to meet expected quotas and resultant revenues.

Pinora engaged Cakum to undertake an operational improvement study to investigate:

• Opportunities for better coordination with farmers and transport workers for delivery of fruit.
• Options for reducing or negating the dry season shutdown problem.
• Volume restrictions at each stage of the process.
• Opportunities for efficiencies in the packaging process.
• Opportunities for efficiencies in storage.
• Opportunities for better coordination with export authorities and transport workers collection of pallets of product and delivery to the port in Accra.

Cakum delivered a detailed report that included accurate drawings of all grounds and facilities, details of dimensions of plant and equipment and maximum throughput volumes per item of plant/equipment.

We also provided significant information about all elements of the operation, including personnel management, governmental requirements, age and general serviceability of all plant/equipment and focal points for areas that were highlighted by staff during the visit.

Of particular note, the main production facility had a huge near-flat roof that, during the wet season, did not collect any rainfall. Thus, one key recommendation included options for collection, storage, filtration and use of rainwater in times of sparse rains or lack of availability of bore water.

One item of plant had a maximum throughput that was significantly smaller than any other items of plant, thus restricting total throughput to this one choke point. The restriction prevented maximization of receipt of fresh fruit from farmers and restricted final juice product output.

Off the back of the Ghana project, the European owners requested Cakum to undertake studies of options for establishing similar operations in Angola and Mozambique in conjunction with the latters’ governments.