COCOA PRODUCTS (ILE-OLUJI) LIMITED
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Incorporated asCOCOA PRODUCTS (ILE-OLUJI) LIMITED on 1st of April 1980 and started operation on the May 31, 1984. One of the three first generation Cocoa Processing companies in Nigeria.
Designed And Installed Capacity: 30,000 tons of raw beans per annum (based on a projected 100 tons of cocoa beans per 24 hour day of 300-day year) to produce;
- 7,000 tons of Cocoa Liquor
- 8,000 tons of Cocoa Butter
- 2,000 tons of Cocoa Cake
- 7,200 tons Cocoa Powder
Factory Information :
The factory is located on about 23.6 hectare of land, a very large percentage of which is yet to be developed. The factory comprises of the following:-
- Weigh bridge (50 tonnes)
- Ware house for raw materials
- Production floor sub – divided into:
- Beans in take, cleaning and Nibs production
- Refinery and pot processing
- Cocoa powder plant
- Butter and liquor packing
- Finished products warehouse
Power Station and Utilities comprising:-
- Boiler House
- Diesel Generator House
- Transformer Station
- Hv. And Lv. Switch rooms
- Potable Water Tank
- Storage tanks for fuel [175m3 for AGO + 330m3 for LPFO]
- Cooling Water tower
- Fire fighting water pump
- Workshops: auto, electrical and mechanical
- Spare parts store
- Social Building comprising:-2 Administrative buildings
- Medical/first aid station(clinic)
- Cloak room
- Gate keeper house
All floors are of reinforced concrete adequately set to withstand all installed loads. All main concrete strengths are selected between grades C. 20, C. 25 and C. 30 with C. 5 for lean concrete. All floor level is ± 0.00. The walls are of filling concrete block with concrete column and beams inll – shutter finish. Elevated floor walls are of translucent PVC sheeting and aluminum rap wall cladding.
All roofs except the cold storage store are of single shell aluminum trapezoid roof sheetings. Cold store warehousing are of steel column plus 22.5cm concrete block walls with 5cm thick thermal insulation and aluminum profile wall cladding while the roof is of double shell aluminum trapezoid profile sheetings with 5cm thick thermal insulation. Drive ways are of high grade bitumen, reinforced to withstand load of heavy trucks.
The initial designed and installed capacity (for complete product range) was 30,000 tonnes of raw beans per annum based on a projected 100 tonnes of cocoa beans per 24 hour day of 300 – day year to produce (a) 8,000 tonnes of cocoa butter (b) 7,000 tonnes of cocoa liquor (c) 7,200 tonnes cocoa powder (d) 2,000 tonnes of cocoa cake.
Cocoa beans are received at the factory where they are check-weighed and tested to determine the grade, moisture content, mouldiness, slatey, insect infestation and other quality parameters to ensure minimum acceptable quality of beans intake that will guarantee optimum product yield from such consignment of beans. Apart from the above quality parameters, the product yield is also dependent on the beans count of the cocoa fed into the process line. Principally the factory is designed to process the accepted cocoa beans into cocoa liquor, cocoa butter, cocoa cake/powder. The factory is divided into the following sub-sections:
Cocoa beans (withdrawn from beans store) are fed from bags into the acceptance hoper where the beans are transported via batch weighting machine through cleaning machine and destoner before being passed into the beans silos.
PRE-DRYING OF BEANS
The cleaned beans withdrawn from the beans silo are fed into the Micronizers where their initial moisture content of about 8% is reduced to 5% thereby expanding the shell for effective separation of the nibs from the shell. The high temperature also reduces the original bacterial content on the surface of the shells, thereby reducing the risk of nibs contamination.
COCOA BEANS WINNOWING:
The micronized cocoa beans in their expanded shells are fed into the crushing chamber where they are softly broken into pieces and separated in the different compartments into nibs and shells. The separated cocoa shells are further crushed in a shell crushing unit before being pneumatically conveyed into the shell silo from where they are withdrawn and burnt into ashes which is used in soap making or used as additives in animal feed production.