July 2002 USA PHILIPPINES Department of Food Science and Technology University of Georgia Griffin, Georgia USA Department of Food Science and Nutrition University of the Philippines Diliman, Quezon City Philippines Food Development Center National Food Authority Taguig, Metro Manila Philippines Department of Agricultural Chemistry and Food Science Leyte State University Leyte Philippines No. 8 United States Agency for International Development Peanut Collaborative Research Support Program MONOGRAPH SERIES Impact assessment of PEANUT-crsp projects in the philippines - part 1 United States Agency for International Development Peanut Collaborative Research Support Program Project 04 (USA and Philippines) MONOGRAPH SERIES No. 8 Department of Food Science and Technology University of Georgia 1109 Experiment St. Griffin, Georgia 30223-1797 USA Department of Sociology and Anthropology North Carolina State University Raleigh, North Carolina 27695 USA Food Development Center National Food Authority Department of Agriculture FTI Complex, Taguig 1632 Metro Manila, Philippines Department of Food Science and Nutrition College of Home Economics University of the Philippines Diliman 1101 Quezon City, Philippines Department of Food Science and Technology Leyte State University Visca, Baybay, Leyte 6521-A Philippines 2 IMPACT ASSESSMENT OF PEANUT-CRSP PROJECTS IN THE PHILIPPINES Part 1 Alicia O. Lustre1 Lutgarda S. Palomar2 Ma. Leonora dL. Francisco3 Robert L. Moxley4 and Anna V.A. Resurreccion 5 1 Co-Principal Investigator USAID Peanut-CRSP; Director, Food Development Center 1632, Philippines 2 Professor, Leyte State University 6521-A, Philippines 3 Assistant Professor, College of Home Economics, U.P. Diliman 1101, Philippines 4 Professor, North Carolina State University, Raleigh, NC 27695, USA 5 Principal Investigator USAID Peanut-CRSP; Professor, University of Georgia, Griffin, Georgia 30223-1797, USA July 2002 3 4 ACKNOWLEDGEMENT The authors acknowledge the Peanut Collaborative Research Support Program (Peanut-CRSP) of the United States Agency for International Development (USAID) for providing research funds through Grant No. LAG-G-00096-00013-00. We would also like to thank Dr. Tim Williams, Program Director of Peanut-CRSP for his support of our research activities; Dr. Anna V. A. Resurreccion, for her leadership as principal investigator of this Peanut-CRSP project, Dr. Robert L. Moxley, for his leadership as Project Director of this Peanut-CRSP Impact Studies, and Dr. William B. Clifford, for his contributions to the research and training activities. Our gratitude is extended to Mr. Ramon Pua of Newborn Food Products and to Mr. Kim Lapus of Marigold Commodities Corporation, for collaborating with us on these projects. We are grateful to the respondents who provided the necessary data for the completion of the survey part of the project, and all the interviewers for their efforts in data collection. The support of Ms. Marina Escaño, Division Chief, Food Development Center (FDC) Support Services, for assistance in monitoring and reporting expenses is greatly appreciated. We thank Ms. Lotis dL. Francisco for editing the manuscript and Ms. Jocelyn M. Sales for making all arrangements for its printing, and Ms. Gertrude Agustin, Ms. Edith San Juan and Ms. Sue Ellen McCullough for their technical support in the preparation of this monograph. 5 6 TABLE OF CONTENTS IMPACT ASSESSMENT OF PEANUT-CRSP PROJECTS IN THE PHILIPPINES - Part 1 Page ACKNOWLEDGEMENT 5 Chapter 1 Monitoring Impact of Completed Projects in the Market 16 Alicia O. Lustre, Alberto R. Cariso Jr., Robert Nestor B. Buan, Gertrude M. Agustin, and Anna V.A. Resureccion I. ABSTRACT 17 II. INTRODUCTION 18 III. OBJECTIVES 18 IV. METHODS 18 A. Preparation of a Checklist for Use in the Measurement of the Sales Production, Production and Socio- Economic Impact 18 B. Collection and Verification of Data 19 C. Collection and Analysis of Samples 19 V. RESULTS 19 A. Monitoring the Impact of Project 3.2.7A: Technology for Vitamin A Fortification of Peanut Butter 19 1. Monitoring the Production Volume, Sales Performance and Socio-Economic Benefits as a Measure of Impact 19 2. Monitoring the Vitamin A Content in Fortified Peanut Butter 21 3. Verification of the Possible Cause of Low Vitamin A Contents in Fortified Peanut Butter 26 4. Stability of Vitamin A Palmitate During Storage 28 B. Monitoring the Impact of Project 3.2.8A: Sorting Technology for Aflatoxin Control 29 1. Monitoring the Aflatoxin Content in Kare-Kare Mix 29 2. Monitoring the Sales Performance, Production and Socio-Economic Benefits 29 VI. CONCLUSIONS 31 7 Chapter 2 Impact Assessment on the Use of Sorting in the Production of Peanut-Based Products 34 Ma. Leonora dL. Francisco, Flor Crisanta F. Galvez,, Lutgarda S. Palomar, Robert L. Moxley and Anna V.A. Resurreccion I. ABSTRACT 35 II. INTRODUCTION 35 III. OBJECTIVES 38 IV. METHODS 38 V. RESULTS A. Negative Impacts Encountered Upon Initial Adoption B. Impact on Employment, Facilities and Raw Material 1. Manufacturing Facilities 2. Employment 3. Employees 4. Raw Material C. Impact on Business 1. Production Impacts on Kare-kare with Peanuts 2. Production Impacts on Kare-kare without Peanuts 3. International Marketing 4. Research and Development D. Impact on Product Quality E. Impact on Consumers 39 39 40 40 40 40 40 41 41 45 45 49 49 50 VI. CONCLUSIONS 58 VII. REFERENCES 59 VIII. APPENDIX Appendix A Questionnaire Used in the Consumer Survey 60 Chapter 3 Impact Assessment on the Technology of Vitamin A Fortified Peanut Butter 73 Alicia O. Lustre, Alberto R. Cariso Jr., Gertrude M. Agustin,, Robert L. Moxley, and Anna V. A. Resurreccion I. ABSTRACT 74 II. INTRODUCTION 75 III. OBJECTIVES 75 8 IV. METHODS A. Preparation of Questionnaires B. Gathering of Data 75 76 76 V. RESULTS A. Responses to questionnaires 1. Effect on Product Sales 2. Effect on the Marketing System and Volume 3. Effect on the Product Quality 4. Effect on the Production Cost 5. Effect on the Employment and Workers’ Attitude 76 76 76 78 79 79 80 VI. CONCLUSIONS 82 VII. REFERENCES 83 Chapter 4 Impact Assessment of Vitamin A Fortification of Peanut Butter on Filipino Families and Consumers 84 Ma. Leonora dL. Francisco, Flor Crisanta F. Galvez, Lutgarda S. Palomar, Robert L. Moxley, and Anna V. A. Resurreccion I. ABSTRACT 85 II. INTRODUCTION A. Consumer Research B. Food Preferences C. Peanut and Peanut Products D. The Need for Vitamin A Fortification 86 86 86 87 87 III. OBJECCTIVES 88 IV. METHODS A. Questionnaire Development B. Data Collection and Processing 88 88 88 V. RESULTS A. Demographic Findings B. Socio-Economic Information C. Consumer Attitudes, Knowledge and Behavior 89 89 90 92 VI. CONCLUSIONS 101 VII. REFERENCES 103 VIII. APPENDICES 105 Appendix A Total Population, Household Population and Number of Households in the Barangay Area Surveyed in Metro Manila 105 9 Appendix B List of Areas and Outlets Selling Lily’s Peanut Butter 107 Appendix C Total Population, Household Population and Number of Households in the City/ Town Area Surveyed Outside Metro Manila 110 10 LIST OF TABLES Chapter 1 Monitoring Impact of Completed Projects in the Market Table No. Title Page Table 1.1 Production volume and percent increase/decrease in sales volume of fortified peanut butter before and after technology adoption. 22 Table 1.2 Vitamin A content in samples of fortified peanut butter for the period covering March 1999 to February 2001. 25 Table 1.3 Comparison of levels of vitamin A in fortified peanut butter, peanut butter premix, and vitamin A palmitate using the recommended procedures in adding and mixing of the fortificant. 27 Table 1.4 Total production volume of Kare-kare mix (with peanuts added), volume for export and volume produced for the U.S. market. 32 Table 1.5 Aflatoxin content in samples of Kare-kare mix (with peanuts added) taken from supermarkets in Metro manila, provinces and Marigold plant. 33 Chapter 2 Impact Assessment on the Use of Sorting in the Production of Peanut-Based Products Table No. Title Page Table 2.1 Maximum allowable level of total aflatoxin (ppb) for commodities for human and animal consumption. 36 Table 2.2 Aflatoxin content of dry blanched peanut samples obtained during the development of the sorting process. 39 Table 2.3 Countries where peanut-based products are currently being exported (Kare-Kare mix and Java sauce). 45 Table 2.4 Total production volume of Java sauce, volume for domestic and volume for export. 49 Chapter 3 Impact Assessment on the Technology of Vitamin A Fortified Peanut Butter Table No. Title Page Table 3.1 Questions and responses relevant to the effect on product sales. 77 Table 3.2 Volume of production of fortified peanut butter and raw material usage before (Year 1999) and after (Years 2000 and 2002) technology adoption. 78 11 Table 3.3 Questions and responses relevant to effect on the marketing system and volume. 78 Table 3.4 Questions and responses relevant to the effect on product quality. 79 Table 3.5 Questions and responses relevant to the effect on production cost. 80 Table 3.6 Questions and responses relevant to the effect on employment and workers' attitude. 80 Chapter 4 Impact Assessment of Vitamin A Fortification of Peanut Butter on Filipino Families and Consumers Table No. Title Page Table 4.1 Sample distribution: major sampling area and gross monthly income for families with children living at home (N=361) 90 12 LIST OF FIGURES Chapter 1 Monitoring Impact of Completed Projects in the Market Fig. No. Title Page Fig. 1.1 Percentage increase/decrease in sales of vitamin A fortified peanut butter, CY 1999, 2000 & 2001. 20 Fig. 1.2 Monthly levels of vitamin A (Retinol) in fortified peanut butter, CY 1999-2000. 24 Fig. 1.3 Selected monthly total production volume, total volume for export and total for the U.S. Market, July-Dec. 2000 and Jan-Mar 2001. 30 Chapter 2 Impact Assessment on the Use of Sorting in the Production of Peanut-Based Products Fig. No. Title Page Fig. 2.1 Flow diagram of the developed manual sorting procedure for raw peanuts. 37 Fig. 2.2 Total production volume of Kare-kare mix with peanuts, volume for domestic and volume for export from January to October. 42 Fig. 2.3 Percent market share of domestic, export and U.S. sales of Kare-kare mix with peanuts from January to October. 43 Fig. 2.4 Percent USA market share of Kare-kare mix with peanuts from January to October. 44 Fig. 2.5 Total volume sales (as number of cases) of Kare-kare mix with peanuts. KRM57g = Kare-Kare Mix, 57 g variant; KRM100g = Kare-Kare Mix, 100 g variant. 46 Fig. 2.6 Total production volume of Kare-Kare mix without peanuts, volume for domestic and volume for export from January to December. 47 Fig. 2.7 Percent market share of domestic, export and US sales on Kare-Kare mix without peanuts from January to December. 48 Fig. 2.8 Number of respondents in different regions who buys Kare-Kare mix. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 51 13 Fig. 2.9 Frequency of Kare-Kare mix purchased by Filipino consumers in different regions. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 52 Fig. 2.10 Type of Kare-kare mix usually purchased by Filipino consumers in different regions. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 53 Fig. 2.11 Basis of choice for Kare-kare mix p urchase of Filipino consumers in different regions. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 54 Fig. 2.12 Brand of Kare-kare mix usually purchased by Filipino consumers in different regions. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 55 Fig. 2.13 Response of Filipino consumers in different regions regarding their knowledge on aflatoxin. (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively; M. Mla stands for Metro Manila; LI stands for low income and MI stands for middle income). 56 Fig. 2.14 Percentage of Filipino consumers in different regions who will buy aflatoxin-free Kare-Kare mix 57 Chapter 4 Impact Assessment of Vitamin A Fortification of Peanut Butter on Filipino Families and Consumers Fig. No. Title Page Fig. 4.1 Amount in peso (PhP) spent by Filipino consumers in different regions on food per week (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively, M. Mla stands for Metro Manila and MI and LI stands for middle income and low income, respectively) 91 Fig. 4.2 Number of Filipino respondents in different regions who buys peanut butter (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively, M. Mla stands for Metro Manila and MI and LI stands for middle income and low income, respectively) 94 Fig. 4.3 Basis of choice for peanut butter purchase of Filipino consumers in different regions (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively, M. Mla stands for Metro Manila and MI and LI stands for middle income and low income, respectively) 95 14 Fig. 4.4 Response of Filipino consumers in different regions on their awareness regarding vitamin A fortified peanut butter available in the market (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively, M. Mla stands for Metro Manila and MI and LI stands for middle income and low income, respectively). 97 Fig. 4.5 Number of Filipino consumers in different regions who bought vitamin A fortified peanut butter (N. Luzon and S. Luzon stands for Northern and Southern Luzon, respectively, M. Mla stands for Metro Manila and MI and LI stands for middle income and low income, respectively) 98 Fig. 4.6 Peanut butter consumption of children (in tablespoon) in low income households per week (Male <21, Female <18; 1 serving = 1 tablespoon) 99 Fig. 4.7 Peanut butter consumption of children (in tablespoon) in middle income households per week (Male <21, Female <18; 1 serving = 1 tablespoon) 100 15 CHAPTER 1 MONITORING IMPACT OF COMPLETED PROJECTS Alicia O. Lustre1 Alberto R. Cariso, Jr2 Robert Nestor B. Buan 3 Gertrude M. Agustin4 and Anna V. A. Resurreccion5 1 Co-Principal Investigator USAID Peanut-CRSP; Director, Food Development Center 1632, Philippines 2 Division Chief, Food Development Center 1632, Philippines 3 Former Senior Research Specialist, Food Development Center 1632, Philippines 4 Acting Division Chief, Food Development Center 1632, Philippines 5 Principal Investigator USAID Peanut-CRSP; Professor, University of Georgia 30223-1797, U.S.A. 16 ABSTRACT Impacts of two technologies developed in the project are discussed. The impact of the vitamin A fortification of peanut butter and of the sorting technology for aflatoxin control on the sales performance, production volumes and socio-economic benefits was determined through interviews with the collaborating company’s representatives and monitoring of the vitamin A and aflatoxin content of peanut butter in the market. The collaborator promoted the vitamin A fortified peanut butter through: (1) a sticker on the label panel which bears the information “Fortified with Vitamin A” and the percentage vitamin A content on the Nutrition Facts Panel, (2) advertisements aired over the radio in January 2000 and on television in February 2000, and (3) nationwide distribution of 2,500 posters of the product. Production volume was affected by the sales performance of the vitamin A fortified peanut butter. The volume decreased when sales were down, especially during the first few months after launch of the labeled vitamin A fortified peanut butter in December 1999 to March 2000. The volume was increased by the company in anticipation of the peak months of sales. Data shows that the sales performance dictates the production volume for succeeding months except when sales for the succeeding months are anticipated to increase. The adoption of the fortification technology necessitated the hiring of additional personnel, three women who were assigned to the Research and Development, Quality Control and Production Sections. In addition, two men from the Production Section were assigned full-time to the mixing step to ensure that recommended procedures for addition and mixing of the fortificant and premix were followed. Samples of vitamin A fortified peanut butter from area supermarkets were analyzed for vitamin A content to evaluate the efficacy of the premix technology. The data showed that the vitamin A in 10 of 22 samples, vitamin A content met the target RENI of 4.38 μg retinol/g peanut butter. Verification of the possible causes of low vitamin A contents in the product was conducted. Results showed that the production personnel followed the recommended procedure in the addition and mixing of the fortificant. A storage study of the fortificant was conducted and showed that the initial content of the fortificant was found to be only 33% of the declared value and further decreased after one week of storage at refrigeration temperatures. This showed that a rate of loss after one week in storage was 2.49%. The low vitamin A content in fortified peanut butter samples was attributed to the low concentration of vitamin A in the batch of fortificant used. These findings were used as basis for advising the collaborator to discontinue the use of that particular batch of fortificant until a new supplier of the fortificant was available. Adoption of the sorting technology for removal of aflatoxin contaminated peanut kernels enabled the collaborating company to export Kare-kare mix with peanuts in the US, Middle East and Hong Kong, whereas sales performance of the Kare-kare mix with peanuts, before the introduction of the sorting technology, was zero. The addition of peanuts to Kare-kare sauce mix with peanuts not only improved the product but also contributed to an increase in sales. After adoption of the sorting technology, the collaborating company experienced increase in sales and production volume, and sometimes could not fill some orders, for both domestic and export markets as a result of the high demand and limited production situation. The adoption of the two technologies created confidence in the collaborating companies regarding the superiority of their products over their competitors, giving them a competitive advantage. 17 INTRODUCTION The project aims to evaluate the sustainability of Peanut-CRSP completed projects by monitoring perceptible social and economic benefits experienced by industry collaborators resulting in the adoption of the new technologies developed. Two completed projects namely: (1) Technology for Vitamin A Fortification of Peanut Butter, and (2) Sorting Technology for Aflatoxin Control, were monitored to assess the impact of the projects after adoption of the technology by the industry partners collaborating on the project. The formal turnover of above technologies to their respective collaborators took place in a signing ceremony held in June 1999. Present were industry collaborators from Newborn Food Products Corporation headed by Mr. Ramon Pua and Marigold Commodities Corporation headed by Mr. Kim Lapuz and Peanut-CRSP Principal Investigators headed by Dr. Anna V.A. Resurreccion of the University of Georgia, Dr. Alicia O. Lustre of the Food Development Center, Dean Angelita Dizon and Dr. Flor Crisanta F. Galvez of the University of the Philippines in Diliman. In July 1999, samples of Vitamin A Fortified Peanut Butter and of aflatoxin-free Kare-kare Mix, were part of a food exhibit which was showcased during the Launching of Proper Food Handling Program “Epektibo at Responsableng Asal sa Pagkain” held at the Food Development Center. This event marked the first introduction of vitamin A fortified peanut butter and aflatoxin-free Kare-kare Mix in the local market as the two industry collaborators joined other food companies in participating in the food tasting and product selling activities. OBJECTIVES Our objective was to monitor perceptible social and economic benefits of completed projects and to evaluate their sustainability. Specifically, we evaluated the impact of aflatoxin control technology on the acceptance/expansion of export shipments for “Kare-kare” mix to the U.S., of vitamin A fortification of peanut butter and of aflatoxin control on the sales of relevant products by Marigold and Newborn, of technology adoption by both industry collaborators on product quality at the market and other socio￾economic benefits provided by the technologies transferred. METHODS Preparation of a Checklist for Use in the Measurement of the Sales Performance, Production and Socio-Economic Impact A questionnaire was prepared and was used as guide in gathering data on the sales performance of the product, monthly changes in the production volumes, employment opportunities and promotion of women welfare. The questionnaire was initially provided to the collaborators who took them several months to complete and return the accomplished forms. The first questionnaire was personally handed to 18 the collaborators in February 2000 but the completed forms were received by the Food Development Center (FDC) only in June 2000. Collection and Verification of Data Quarterly interviews with the collaborators were conducted at least once for the period to gather and/or verify information supplied on production volume, sales volume, promotional activities and number of additional hired labor. Collection and Analysis of Samples Samples of Kare-kare mix and fortified peanut butter were obtained from Metro Manila stores and/or supermarkets on a monthly basis for aflatoxin and vitamin A analysis, respectively. Samples collected came from production batches with the highest production for the month, which were supplied by the industry collaborator. Thirteen packs of Kare-kare mix and two bottles of fortified peanut butter were either purchased in supermarkets and public markets or taken directly from the industry collaborator’s plant. In addition to the above, six shipments of Kare-kare mix (with peanuts added) intended for the U.S. market were analyzed prior to shipment to ensure that the product will not encounter any detention due to presence of aflatoxin. Samples obtained were submitted to the FDC, Chemistry Section for analysis. RESULTS Monitoring the Impact of Project 3.2.7A Technology for Vitamin A Fortification of Peanut Butter Monitoring the Production Volume, Sales Performance and Socio-Economic Benefits as a Measure of Impact Production Volume. Table 1.1 shows the production volume of vitamin A fortified peanut butter before and after technology adoption. The technology was actually adopted by the collaborator in July 1999 but the market launch of the labeled vitamin A fortified peanut butter did not occur until December 1999. The production volume gathered in 1999 represents the pre-technology adoption period, whereas the production volume gathered in 2000 represents the post technology adoption period. The total production for year 1999 was 507 metric tons while for year 2000, it was 534 metric tons or a production increase of 5.3%. There was an increase in production every quarter in 2000 compared to 1999 except in the third quarter (July – September) of 2000. This decrease in production in the 3rd quarter of 2000 was purposely implemented by the collaborating company’s management, in anticipation of decreasing sales after the beginning of the school year in June. Conversely, when sales were anticipated to increase in the 4th quarter (September - December) production volume was increased. The first quarter of the year showed the lowest levels of production. This was expected as this period was just after the Christmas season when the purchasing activities of the Filipinos were also lowest. In year 2000, the highest production volumes achieved by the collaborator were in the 2nd and 4th quarters of the year. The specific months of highest production were in June and December. June is the start of school year and December is the start of Christmas season. 19 Although the total increase in production volume in year 2000, after technology adoption, was relatively small compared to year 1999, before technology adoption, this was considered by the collaborator as a positive event in sustaining their competitiveness during these difficult economic periods in the Philippines. During these years, the Philippines experienced the devaluation of peso and many factories closed down. This was particularly a difficult time for peanut processors as peanuts raw materials were imported, and thus the cost was high but could not increase the price of the finished product as consumers might not buy it. Launching Percenta ge J FMAM J J ASOND J FMAM J J ASOND J FM 1999 2000 2001 Production Month Fig. 1.1 Monthly sales comparison of vitamin A fortified peanut butter in 1999, 2000 & 2001. Sales Performance. The sales performance (Fig. 1.1) for vitamin A fortified peanut butter was monitored from December 1999 to April 2001 after the collaborating company introduced the labeled Vitamin A fortified peanut butter product in the market in December 1999. According to the industry collaborator, one of the causes for the delay in market launch was because it took the company several months (∼4 months) to obtain the Bureau of Food and Drug’s (BFAD) approval for the product registration of its fortified peanut butter, which was considered a new product. There was also a need to prepare for technology adoption, by hiring and training additional workforce, purchasing and installation of equipment, which took approximately four months to complete. One of the first promotional strategies undertaken by the collaborator was to place a sticker bearing the information “Fortified with Vitamin A” and % vitamin A content on the Nutrition Facts Panel, declaring that the peanut butter has been fortified with vitamin A. This was followed with advertisements about the product, aired over the radio in January 2000 and on television in February 2000. Finally, 2,500 posters of the vitamin A fortified peanut butter were distributed nationwide. 20 21 Table 1.1 also shows the percentage increase/decrease in sales volume of vitamin A fortified peanut butter before and after technology adoption. The basis of percentage computation in increase/decrease in sales was the comparison of the sales of the particular month to the same month of the previous year. Eight of twelve months in 2000, after technology adoption, showed an increase or equivalent sales was realized compared to 1999. However, there were only six of twelve months of increased or equal sales in 1999, before technology adoption compared to the previous year (1998). The first quarter of 2001 also showed sales increases in two of three months. In addition, Fig 1.1 shows that when the decreased sales observed yearly, in January and February, after the Christmas season, there were only three months of ten in 2002 that sales were lower compared to the same period in 1999. The increasing sales in 2000 and 2001, demonstrated above, helped the collaborating company to survive the otherwise catastrophic effect of the economic downturn experienced by the country in 1999 and early 2000 as discussed previously. Socio-economic Impact. According to the collaborator, the adoption of the fortification technology in their peanut butter necessitated the hiring of three women workers and the reassignment of two males to the production section. The newly hired workers were assigned to the Research and Development and Quality Control and Production functions. A female full-time R&D/QC Head, was hired to oversee the research and development as well as quality control operations of the company. Two other females were hired, one as a Quality Control worker and the other as production head. Preparation of the fortificant, i.e. weighing of fortificant during the weekly transfer to smaller containers and its addition during premix preparation, was closely supervised by the R&D Head together with the QC worker who was tasked to supervise the preparation of the premix and fortified peanut butter. The female hired as production head supervised the company’s production operations. In addition to the above, the two males in the Production Section were assigned full-time to the mixing step to ensure that recommended procedures for addition and mixing of the fortificant and premix were followed. Monitoring the Vitamin A Content in Fortified Peanut Butter The effectiveness of the premix technology for the vitamin A fortification of peanut butter developed for Newborn Food Products Corporation was evaluated by collecting market samples of fortified peanut butter from local supermarkets and the industry collaborator’s plant. The information on the highest production codes produced during the month was taken from the industry collaborator to serve as basis for sample collection. In some instances, samples were obtained directly from the industry collaborator’s plant, particularly during the time when an FDC personnel conducted an observation of the addition and mixing process during a commercial production run to verify possible causes of low vitamin A content in fortified peanut butter. Samples from supermarkets consisted of two jars of fortified peanut butter while samples taken from the industry collaborator’s plant, consisted of three samples taken at the start, middle and end of the filling line. Samples collected were then analyzed compositely. 22 Table 1.1 Production volume and percent increase/decrease in sales volume of fortified peanut butter before and after technology adoption. Month Production Volume (Kg)1 Sales Percentage Increase/Decrease2 1999 2000 2001 1999 2000 2001 1st Q (Before Technology Adoption) Jan 32,000 33,760 32,000 Decreased (-12.0) Decreased (-20.0) Equal to 2000 sales Feb 38,000 41,800 45,000 Decreased (-13.0) Decreased (-20.0) Increased (+2.0) Mar 49,000 46,158 46,000 Increased (+10.0) Decreased (-3.0) Increased (+9.0) Sub-Total 119,000 121,718 123,000 Decreased (-15.0) Decreased (-43.0) Increased (+11.0) 2nd Q (After Technology Adoption) Apr 46,000 47,794 - Decreased (-10.0) Increased (+2.0) - May 37,000 38,998 - Decreased (-5.0) Increased (+2.0) - Jun 46,000 58,420 - Equal to 1998 sales Increased (+6.0) - Sub-Total 129,000 145,212 Decreased (-15.0) Increased (+10.0) - 3rd Q Jul 46,000 39,100 - Equal to 1998 sales Decreased (-15.0) - Aug 46,000 44,128 - Equal to 1998 sales Equal to 1999 sales - Sep 40,000 41,000 - Decreased (-5.0) Increased (+6.9) - Sub-Total 132,000 124,228 Decreased (-5.0) Decreased (-8.1) - 4th Q Oct 40,000 46,000 - Equal to 1998 Increased (+5.0) - Nov 41,000 48,000 - Increased (+2.5) Increased (+5.0) - Dec 46,000 49,000 - Decreased (-20.0) Increased (+26.0) - Sub-Total 127,000 143,000 - Decreased (-17.5) Increased (+36.0) - TOTAL 507,000 534,158 - Decreased (-52.5) Decreased (-5.1) - 11999 was used as baseline production volume before the product launch in December 1999; production figures are contained in a report submitted to FDC by Ms. Arlene Hilao dated October 11, 2000. 2Basis of percentage computation is sales volume compared to the same month of the previous year. Note: Technology adoption started in July 1999 but 100% of peanut butter in the market was fortified in December 1999 The collection and analysis of samples of fortified peanut butter from supermarkets and industry collaborator’s plant started in July 1999 immediately after the signing ceremony in June 1999 which marked the formal turn-over of the premix technology for the vitamin A fortification of Lily’s brand peanut butter. Commercial production of vitamin A fortified peanut butter did not occur until December 1999. Table 1.2 shows the level of vitamin A content in samples of fortified peanut butter obtained in supermarkets and industry collaborator’s plant covering production dates from March 1999 to February 2001. A graphical presentation of the above data is presented in Fig. 1.3. Serving as benchmark data was a sample of unfortified peanut butter purchased in Sorsogon, which was produced in March 1999. As expected, the vitamin A content of the peanut butter from Sorsogon had zero mcg retinol/g peanut butter. The vitamin A content in fortified peanut butter (Fig. 1.3) from various sources indicated varying levels of vitamin A which ranged from 2.23 - 11.51 μg retinol/g peanut butter. The data showed that the vitamin A in 10 of 22 samples, vitamin A content met the target RENI of 4.38 μg retinol/g. An initial verification of the possible cause of low vitamin A contents in fortified peanut butter was conducted in December 1999 by validating the fortification procedure recommended to the industry collaborator. The process was evaluated by observing plant personnel involved in the actual addition and mixing of the fortificant and/or premix during a commercial production of the premix and of the final fortified product. Result of actual observation indicated that the FDC recommended procedure for vitamin A fortification was not strictly followed by plant personnel. In two instances, e.g. in the months of January 2000 and May 2000, were highest (10.79 – 11.51 μg retinol/g) The high levels of vitamin A in the January 2000 production date were attributed to an FDC staff members being physically present to observe the actual addition and mixing of the fortificant, thus the proper addition of the fortificant was implemented. The sample processed in May 2000 did not have an FDC staff members present. Based on the above findings, the industry collaborator was advised to strictly follow the FDC recommended procedure for the addition and mixing of the fortificant, to achieve the target level of fortification of 1/3 RENI. Since the fortificant used by the industry collaborator takes about 2 - 3 months to consume, evaluation of results was made on a quarterly basis. From July - December 1999, relatively low vitamin A content was observed in the fortified peanut butter, which ranged from 2.23 - 4.01 μg retinol/g peanut butter. The samples obtained in July to December 1999 had vitamin A when launching was only in December 1999 because the collaborator started to adopt the fortification technology as early as July 1999 but it was only in December 19999 that the collaborator started to label their product with vitamin A. A validation of the procedure was conducted by FDC to verify the possible cause of the low levels of vitamin A in the final product. Results of the verification study showed that the recommended procedure for the addition and mixing of the fortificant was not strictly followed by plant personnel in-charge. Based on the above findings, the industry collaborator was advised to strictly follow the FDC recommended procedure for the addition and mixing of the fortificant, to achieve the target level of fortification of 1/3 RENI. 23 0 2 4 6 8 10 12 14 Mar Jul Sep Oct Dec Jan1 Jan2 Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec1 Dec2 Jan Jan Feb 1999 2000 2001 P ro d u c tio n M o n th mcg Retinol / g Peanut Butter 4.38 Fig. 1.2 Monthly levels of vitamin A (Retinol) in fortified peanut butter, CY 1999-2000. 24 Table 1.2 Vitamin A content in samples of fortified peanut butter for the period covering March 1999 to February 2001. Production Date Collection Site Date Analyzed Vitamin A content (μg/g) Remarks 1999 Mar ‘99 Sorsogon Public Market September 1, 1999 0.00 Sample not fortified. Jul Newborn Plant September 1, 1999 2.23 Sep Newborn Plant September 14, 1999 3.19 Oct SM Megamall October 27, 1999 4.01 Dec Newborn Plant December 23, 1999 3.88 2000 Jan’00 Newborn Plant January 14, 2000 11.51 Jan Alabang Public Market April 3, 2000 4.67 Feb Alabang Public Market April 4, 2000 4.43 Mar SM Makati, Makati City May 12, 2000 4.02 Apr 7-11 Alabang July 25, 2000 3.06 May SM Makati, Makati City August 2, 2000 10.79 Jun Ever Gotesco, Quezon City July 25, 2000 3.42 Jul SM Megamall, Mandaluyong City October 17,2000 2.90 Aug SM Megamall, Mandaluyong City October 18, 2000 2.91 Sep SM Megamall, Mandaluyong City October 4, 2000 3.54 Oct SM Makati, Makati City December 5, 2000 7.23 Nov Landmark Supermarket, Makati City December 7, 2000 5.71 Dec Newborn Plant December 12, 2000 5.28 Dec Newborn Plant December 12, 2000 5.45 Sample obtained during the 1st verification study. Dec‘00 Zamboanga City March 2, 2001 5.93 Provincial sample 2001 Jan’01 Newborn Plant January 30, 2001 2.47 Sample obtained during the 2nd verification study Feb SM Makati February 28, 2001 3.00 25 After market launch in December 1999, in January - April 2000, the vitamin A content of fortified peanut butter was relatively higher (3.06 – 11.51 μg retinol/g peanut butter) than those obtained before launch in July - December 1999. The values obtained except for the March and April, 2000 samples were found to be within the target fortification level of 1/3 RENI, which corresponds to 4.38 μg retinol/g peanut butter. Over the four-month monitoring period, a decreasing level of vitamin A was likewise observed which resulted in an increase in the rates of vitamin A loss. The lowest reported level of 3.06 μg retinol/g peanut butter was noted to have been produced in April 2000 while the highest reported level of 4.67 μg retinol/g peanut butter was produced in January 2000. The monthly rates of vitamin A loss during the period covered was an increasing 5.13%, 9.26% and 23.88%. One of the possible reasons for the low levels of vitamin A in the fortified product was the use of a fortificant, which had an initial assay lower than the declared concentration of 1 Million IU/g. It is important that the fortificant used provides the stated concentration on its label, as this would affect the level of vitamin A in the final product if it does not. The decreasing level of vitamin A over the four-month monitoring period, may be attributed to the possible degradation of the opened fortificant during its shelf-life, until it was used up. Since the 5 Kg fortificant used by the industry collaborator takes about 2 - 3 months to consume, the weekly transfer of the fortificant into smaller containers may have caused the degradation of vitamin A. Weekly transfer of the fortificant to smaller containers, needed for one day’s production was necessary to prevent the entire 5 Kg of fortificant from being exposed daily to light and oxygen, with each production run. However, as vitamin A is sensitive to light and oxygen, it is possible that the weekly transfer of the fortificant to smaller containers has affected the efficacy of the vitamin A palmitate. From June - September 2000, the vitamin A content of product samples during the period covered, were very low ranging from 2.90 - 3.54 μg retinol/g peanut butter. The values obtained did not meet both the results of pilot trials as well as the target fortification level of 4.38 μg retinol/g peanut butter. From October - December 2000, the vitamin A content in samples of fortified peanut butter were found to be relatively higher than previous months, as it ranged from 5.28 - 7.23 μg retinol/g peanut butter. Vitamin A contents were high on the months of January 2000, May to June 2000, and on October 2000. The high amount of vitamin A in the products could be due to high levels of vitamin A in the newly opened 5 Kg containers of the fortificant. According to the collaborator, a 5 Kg container of the fortificant is consumed within 2 to 3 months of production. However, decreases in Vitamin A followed a four month cycle. If one assumes that high levels of vitamin A on the months of May and October could be due to newly opened containers of the fortificant. The above findings showed that vitamin A inproduct samples decreased with longer time of storage or the vitamin A concentration of the fortificant decreased with longer time of use during this monitoring period. Verification of the Possible Cause of Low Vitamin A Contents in Fortified Peanut Butter As a result of the low vitamin A content in fortified peanut butter obtained in supermarkets in Metro Manila, a verification of its possible cause was conducted in December 2000 – January 2001. For every verification tests, an actual observation of the addition and mixing process by plant personnel was made after which samples of fortified peanut butter were taken for analysis of vitamin A content. The following were the results of the verification conducted. 1st verification In December 2000, an announced inspection of an actual commercial production was conducted by FDC to determine the cause of the low vitamin A contents in samples of fortified peanut butter taken in supermarkets. Two sets of product samples were taken and submitted at the FDC Chemistry 26 Laboratory for vitamin A analysis, i.e. samples taken in a production batch where FDC personnel observed the actual mixing of the premix to plain peanut butter and in a production batch where no FDC personnel was present during production. Production of the premix was not observed at this time because the premix was already prepared when the team arrived. Result of observation of the mixing process showed that the personnel in charge of mixing followed the recommended procedure in the addition and mixing of the fortificant. This is probably the reason why the level of vitamin A in samples taken in the presence and absence of FDC personnel did not show any significant difference, as shown in the results of analysis which indicated a vitamin A content of 5.28 and 5.45 μg retinol/g peanut butter, respectively. The values obtained were 20 - 23% higher than the declared value of 1/3 RENI which corresponds to 4.4 mcg retinol/g peanut butter because an overage was added. The low vitamin A content in fortified peanut butter was attributed to the low concentration of vitamin A palmitate used in fortifying which according to the industry collaborator had been opened more than a month ago. Considering the above finding, a second verification was recommended wherein actual observation of the premix preparation and weighing of fortificant was conducted. 2nd verification In January 2001, a second verification was conducted. Production was observed starting from the weighing of the fortificant to the production of the premix to the production of fortified peanut butter. Samples of the fortificant, premix and fortified peanut butter were taken from the production line for vitamin A analysis. According to the industry collaborator, the fortificant used was manufactured by Roche and was purchased from Vitachem, a local distributor of Roche products. At the time the 2nd verification was made, the fortificant had been opened and stored at refrigerated temperature for about two weeks. Result of actual observation showed that the recommended procedures for the addition and mixing of the fortificant during the production of premix and fortified peanut butter were strictly followed by the industry collaborator. Despite this observation, it was noted that low levels of vitamin A content in both the premix and fortified peanut butter were obtained (Table 1.3). Following are the results of vitamin A analysis versus target levels: Table 1.3 Comparison of levels of vitamin A in fortified peanut butter, peanut butter premix, and vitamin A palmitate using the recommended procedures in adding and mixing of the fortificant Product Analyzed Vitamin A content Obtained (μg Retinol/g) Vitamin A content expected (μg Retinol/g) Fortified Peanut Butter 2.47 4.38 (1/3 of RENI) Peanut Butter Premix 159.68 252.68 - 282.42 Vitamin A palmitate 64,033.00 300,000 - 333,333 27 The low vitamin A content in the peanut butter premix and fortified peanut butter were attributed to the low content of the vitamin A palmitate used to fortify the peanut butter as this was found to be only 21% of the declared value of 1 Million I.U. (or 300,000 μg Retinol/g). This confirms earlier hypothesis made in the 2nd verification that the possible cause of low vitamin A content in the final product was probably due to the low content of vitamin A in the fortificant used. Considering the above findings, the industry collaborator was advised to inform its supplier about the low assay of the vitamin A palmitate and to request for a certificate of product analysis every delivery to ensure that the fortificant delivered meets the specifications. Information was likewise requested from Roche on studies undertaken by their company on the shelf life of vitamin A palmitate in both open and unopened conditions. The shelf life of vitamin A palmitate in the opened condition was deemed necessary because the smallest packaging available for a vitamin A palmitate is 5 Kg, which takes about 2.5 months for Newborn to consume. According to Ms. Corazon Garalde of Roche, they do not have any data on the stability of vitamin A palmitate after it has been opened. Since no information on the stability of vitamin A palmitate after opening the container provided by Roche, it was recommended that a study to determine the stability of the fortificant at the target shelf life of 2.3 months be conducted. This is to ensure that the concentration of the fortificant is still within acceptable levels at the end of the target shelf life. A proposal to determine the stability of vitamin A palmitate at the target shelf life was prepared, with the fortificant being subjected to the existing handling and storage conditions practiced by the collaborator. Stability of Vitamin A Palmitate During Storage A study to determine the stability of vitamin A palmitate under existing conditions of handling and storage practiced by Newborn Food Products was conducted. The study involved the collection of vitamin A palmitate from Newborn Food Products, for the conduct of assay on the fortificant. Collection of samples was done immediately upon opening of the 5-Kg container then weekly thereafter until all of the contents are fully used up. Throughout the study, the fortificant simulated the existing handling and storage conditions practiced by the industry collaborator as follows: Initially, the 5 Kg vitamin A palmitate packed in aluminum container was divided into two separate containers of 5 Kg capacity. One of the containers was immediately stored at refrigerated temperatures for use after contents of the other container has been fully used up. Fortificant intended for one-week production was then taken from the other container by transferring ∼ 85 g of vitamin A palmitate in five 100 ml capacity aluminum containers. After every transfer in smaller containers, the fortificant was stored at refrigerated temperatures (2-8°C) until its intended use. Above procedure was to be repeated until the contents of both containers were used up. For this study, a 5-Kg container of vitamin A palmitate obtained by Newborn Food Products, Inc. from Vitachem, a local distributor of Roche products, was used. Result of initial assay after opening indicate that the fortificant had a low vitamin A content of 99,758.95 μg retinol/g (or 332,529.83 IU/g) as this was found to be only 33% of the declared value of 300,000 μg retinol/g (or 1 Million I.U./g). After one week of storage at refrigerated temperature (2-8°C), the assay of the vitamin A palmitate dropped to 97,277.78 μg retinol/g peanut butter (or 324.259.27 IU/g). The rate of loss after one week in storage was 2.49% which is considered low. Above findings confirm previous hypothesis that the cause of the low vitamin A content in the fortified peanut butter was due to the low concentration of vitamin A in the fortificant used after opening. Considering however, the low assay of the fortificant, it was recommended that the on-going stability study of the vitamin A palmitate from Roche, be discontinued. The need to continue the study was found unnecessary because the vitamin A content of the fortificant did not meet the declared value of 28 1M IU/g, which was the concentration, needed to arrive at the target fortification level of 1/3 RENI. The collaborator was likewise advised to discontinue use of the entire container unless the amount of fortificant added is increased to meet the target level of fortification. As of this writing, a new supplier was being tapped by the R&D Head to supply the company with vitamin A palmitate. The study on the stability of the fortificant will resume soon as the new supplier delivers the fortificant. The need to conduct a study on the stability of the vitamin A palmitate with an assay of 1 Million IU/g at the target shelf life of 2.5 months was deemed necessary to determine the rate of vitamin A loss in the fortificant at the existing handling and storage conditions practiced by the collaborator. Knowledge of the level of vitamin A in the fortificant during the target storage period will be useful in establishing recommendations as to the amount of fortificant to be added after prolonged storage. Monitoring the Impact of Project 3.2.8A Sorting Technology for Aflatoxin Control Monitoring the Aflatoxin Content in Kare-kare Mix For the period March 1999 to January 2001, a total of 21 samples were obtained from the supermarkets and the collaborator’s plant. All samples tested negative for aflatoxin content (Table 1.4). Likewise, samples taken from six shipments to the U.S. tested negative of aflatoxin contamination. According to the industry collaborator, it has not received any reports of detention due to aflatoxin contamination. The above findings indicate the effectiveness of the sorting technology in controlling aflatoxin in Kare-kare Mix. Monitoring the Sales Performance, Production and Socio-Economic Benefits A total of five quarterly interviews were conducted and in attendance were, Mr. Kim Lapus, General Manager, Mr. Juan Bernad, the Management Trainee for Domestic Sales, Mr. Frank Aguba, Deputy Director for Sales and Marketing, Ms. Oteyza Peñero, R & D Head and Ms. Evangeline Tayag, Production Supervisor. The following information was gathered during the meeting: Sales Performance. Before the introduction of the sorting technology for aflatoxin control, the product sold by the industry collaborator to the U.S. market was a type of Kare-kare mix without peanuts, to prevent the product from being detained at the port of entry to the U.S. due to aflatoxin contamination. Consumers using the product were required to add peanuts or peanut butter during the preparation of the sauce for Kare-kare to enhance its peanut flavor, which is a characteristic of the product. After the collaborator adopted the technology, they tried shipping Kare-kare mix with peanuts to the U.S. initially in small quantities starting in June 1999. Since no reports of detention problems were received from its distributor in the United States, the industry collaborator after building confidence started accepting orders. The biggest shipment of the product made to the U.S. was reported in January 2001 at 1,040 Kg. (Table 1.5). During the monitoring period covered, the collaborator did not provide any figures of their sales. Only production volumes were provided. Since the collaborator claimed that all products produced for export are based on orders they received, it was then assumed that volume of sales for export are the volume produced for the given period. In an interview conducted last December 6, 2000, Mr. Frank Aguba, Deputy Director for Sales and Marketing, mentioned that the company sometimes had to deny some orders both in the domestic and export market because of the high demand and limited production situation. Promotional activities were reportedly conducted by the collaborator in the U.S. in November 2000 in the Los Angeles, California area where Filipino population is high. Almost at the same time, an intensified promotion of aflatoxin-free Kare-kare mix with peanuts was conducted in the local market 29 through the “Pistang Mama Sita”. The Pistang Mama Sita is a promotional activity where cooking demonstrations and free tasting activities were held in supermarkets and groceries. Production Volume. The collaborator claimed that they have no production data for the period April 1999 to June 2000 except for the volume shipped to the U.S. market during the period June-October 1999 where they claimed to have produced and exported a total of 246.24 kg. of the product (Fig. 1.4). The collaborator however, cannot identify how much was produced and exported on a monthly basis. A comparison of production for the period January to March 2001 showed an increase of more than 30.0% from the total production of the same months in 1999 (Table 1.4). Table 1.4 shows that the total production for the export market was 246.24 Kg, however, the total production for the US Market was only 82.08 Kg. Almost two-thirds of the production volume went to other markets such as the Middle East and Hongkong, according to the collaborator. A total of 1,766.24 kg of Mama Sita’s Kare Kare Mix was exported during the first three months of year 2001 comprising 12.1% of total production while the volume produced for the U.S. market comprised 7.7% of total production and 63.5% of the total export. All exports to the U.S. market have not been tested by the U.S. Food and Drug (USFDA). This mean that the aflatoxin content of the product is acceptable. 0 1000 2000 3000 4000 5000 6000 7000 Jul Aug Sep Oct Nov Dec Jan Feb M ar P ro d u ctio n M o n th Kilogram of Product T o tal P ro d . T o tal E xp o rt T o tal fo r U .S . Fig. 1.3 Selected monthly total production volume, total volume for export and total for U.S. market, July-December 2000 & January-March 2001. The fluctuations in the total monthly production levels from July 2000 to March 2001 is not based on sales forecasts but on the availability of the supply of good quality shelled peanuts. Socio-economic Benefits. With the adoption of the sorting technology for aflatoxin control, the collaborator reportedly hired five additional male workers to perform the sorting operation. The male workers were preferred because unlike its female counterparts, the male workers are able to carry the sack-loads of peanuts to the sorting table without any help. 30 31 CONCLUSIONS Initial Impact Vitamin A Fortified Peanut Butter The collaborator, Newborn Foods Corp., is the first peanut butter processor in the Philippines to market vitamin A fortified peanut butter. The vitamin A fortification technology for peanut butter is often referred to by the industry collaborator as the main reason for their increased sales. Sorting Technology for Aflatoxin Control The adoption of the sorting technology enabled the collaborator, Marigold Commodities Corp., to export their Kare-kare mix with peanuts not only to the U.S. but also to Middle East and Hong Kong. Before the adoption of the technology, Kare-kare mix with peanuts could not be exported to these countries. The aflatoxin content of 0 ppb constantly obtained in samples of products obtained during the monitoring period, has built a high degree of confidence on the part of the collaborator, resulting in the development of additional peanut products including “Java” sauce, which incorporates the sorting technology as a major step in its production. The improved product i.e. with added peanuts, has contributed to the increase in sales. Continuing Impact The continuing impact created by the two technologies to their respective collaborators is the increased confidence in the superiority of their products over their competitors. The projects also achieved the objective of increase peanut consumption in the country. Table 1.4 Total production volume of kare-kare mix (with peanuts added), volume for export and volume produced for the U.S. market. Production Date (Month) Total Production (Kg) Total Production For the Export Market (Kg) Total Production for the U.S. Market (Kg) 1999 2000 2001 1999 2000 2001 1999 2000 2001 January 3,920.00 - 3,120.00 - - 1,520.00 - - 1,040.00 February 3,880.00 - 5,760.00 - - - - - - March 3,440.00 - 5,760.00 - - 246.24 - - 82.08 April - - - - - - - - - May - - - - - - - - - June - - - - - - - - - July - 6,240.00 - - 171.36 - - 171.36 - August - 4,240.00 - - 492.48 - - 492.48 - September - 4,880.00 - - 41.04 - - 41.04 - October 246.24 3,600.00 - 246.24 1,680.00 - 246.241 143.64 - November - 5,920.00 - - 1,160.00 - - 53.35 - December - 4,720.00 - - 1,760.00 - - 880.00 - Total 11,486.24 29,600.00 14,640.00 246.24 5,304.88 1,766.24 246.24 1,781.87 1,122.08 Source: Monthly Report submitted to FDC by Marigold Commodities Corp. 1The amount represents all shipments made to the U.S. from June to October 1999. 32 33 Production Date Place Bought Date Analyzed Aflatoxin content (ppb) Remarks Feb. 1999 EDSA Central Public Market Aug. 31, 1999 0 Initial sample before sorting was introduced. Jul. 1999 Rustan’s Supermarket, Mandaluyong Aug.31, 1999 0 3 months after introduction of the sorting process. Sept. 1999 SM Megamall Oct. 26, 1999 0 Oct. 1999 Marigold plant Dec. 29, 1999 0 1st shipment to the U.S. January Marigold Plant January 9, 2000 0 2nd shipment to the U.S. January Rustan’s Mandaluyong May 11, 2000 0 Shipping to the US & Middle East at 300 cases/month average. February Marigold Plant February 28, 2000 0 3rd shipment to the U.S. February SM Makati City May 11, 2000 0 Experienced no detention problems in the U. S. March Rustan’s Mandaluyong May 11, 2000 0 April Sunshine Mall Taguig July 13, 2000 0 May Sunshine Mall Taguig July 13, 2000 0 June SM Megamall August 8, 2000 0 July Makro, Sucat August 4, 2000 0 August Rustan’s Mandaluyong May 22, 2000 0 September Rustan’s Supermarket November 20, 2000 0 October Landmark Supermarket, Makati City December 5, 2000 0 November Landmark Supermarket, Makati City December 5, 2000 0 December Agoo Supermarket, Agoo, La Union December 12, 2000 0 Provincial sample. Marigold Plant December 12, 2000 0 Produced for the U.S. market. 4th monitoring batch Jan. 2001 Marigold Plant January 18, 2001 0 Produced for the U.S. market. 5th monitoring batch Marigold Plant January 28, 2001 0 Produced for the U.S. market. 6th monitoring batch Table 1.5 Aflatoxin content in samples of kare-kare mix (with peanuts added) taken from supermarkets in Metro Manila, provinces and Marigold Plant. CHAPTER 2 IMPACT ASSESSMENT ON THE USE OF SORTING IN THE PRODUCTION OF PEANUT-BASED PRODUCTS Ma. Leonora dL. Francisco1 Flor Crisanta F. Galvez, Ph.D.2 Lutgarda S. Palomar, Ph.D.3 Robert L. Moxley, Ph.D.4 and Anna V.A. Resurreccion, Ph.D.5 1 Assistant Professor, College of Home Economics, UP Diliman 1101, Philippines 2 Professor, College of Home Economics, UP Diliman 1101, Philippines 3 Professor, Leyte State University 6521-A, Philippines 4 Sociologist, North Carolina State University, Raleigh, NC 27695, USA 5 Principal Investigator USAID Peanut-CRSP; Professor, University of Georgia, Griffin, Georgia 30223-1797, USA 34 ABSTRACT While aflatoxins are known to be carcinogens, they also have additional toxic effects. A previous research and development project resulted in a procedure designed to eliminate aflatoxin-contaminated kernels in raw peanuts through a new treatment and sorting process. The collaborative project was carried out by the University of Georgia, the Food Development Center/National Food Authority, and the University of the Philippines at Diliman and was funded by the Peanut Collaborative Research Support Program (supported by U.S. Agency for International Development). A private company agreed to adopt the procedure for the peanut content in one of its products. This is a report on the process of technology transfer and assessment of the socioeconomic impacts of this new aflatoxin elimination process on that company. Among other impacts, it was found that despite some increase in costs and labor (positive impacts on the Philippine economy) the adoption of the sorting technology enabled the company to significantly improve the quality of their production and subsequently their sales. For example, this process helped account for an increase in the total export market for all countries for Kare-Kare mixes (with peanuts) and 100% of the increase in these exports to the United States. Also, new products have since been developed with other peanut-based products for export mostly due to aflatoxin reduction. Another major impact is that this company is now providing the Philippine consumer with the aflatoxin-free product. The company also indicates that their adoption of the sorting process led to an improvement in product quality in other ways, such as increased shelf life. A survey of consumers included questions concerning awareness and knowledge about aflatoxin among Filipino consumer and suggests very low familiarity with issues concerning food safety and hazards, especially aflatoxin. The indicated support of consumers (in the survey) in buying aflatoxin-free peanut products should encourage the collaborating company and others to look into the possibility of adding an “aflatoxin-free” statement on their labels of aflatoxin-free peanut-based products such as their Kare-Kare mix and Java sauce and adding aflatoxin-free messages to their advertising. This study also suggests that, while the sorting technology is labor intensive, it is feasible under the appropriate conditions and should be considered by other companies. 35 INTRODUCTION Mycotoxins, such as aflatoxin, are chemical substances produced as secondary metabolites by fungi, especially molds. It is commonly produced by particular strains of Aspergillus flavus and Aspergillus parasiticus and is widely found in many agricultural products. These mycotoxins are widely studied due to their biological effect to animals and humans as well as their economic implications. Examples of agricultural commodities implicated with aflatoxin are groundnuts, corn, barley, beans, cottonseed, rice, wheat, copra, cassava and peas. The first aflatoxins identified were designated as aflatoxin B1, B2, G1 and G2 on the basis of their color, either blue (B) or green (G), at which they fluoresce under ultraviolet (UV) light. Aflatoxin B1 is the most potent carcinogen among all natural compounds and is also acutely toxic at high levels of contamination (IARC, 1993). Even at low concentration, aflatoxin is believed to pose a risk to human health due to its extreme toxicity. Furthermore, since they are considered ‘unavoidable contaminants’ of major plant commodities, aflatoxin is considered a consumer food safety issue. Because of its carcinogenic properties, high levels of aflatoxin in agricultural products are not permitted by government food agencies such as the Bureau of Food and Drug in the Philippines and U.S. Food and Drug Administration in the USA. The maximum allowable level of total aflatoxin for commodities for human and animal consumption in different countries is shown in Table 2.1. However, aflatoxin exposure in many high mortality developing countries makes it probable that such exposure negatively influences many health factors (including HIV) that account for 40% of the burden of diseases in these countries (Williams et al, 2004). Table 2.1. Maximum allowable level of total aflatoxin (ppb) for commodities for human and animal consumption. U.S. FDA United Kingdom Asia3 Philippines 20 ppb1 4 ppb2 20-30 ppb1 15 ppb 1 Flach, 1987, 2 MAFF, 1996, 3 China, India, Malaysia and Thailand The presence of aflatoxin in agricultural products can be detoxified in various ways. Physical destruction such as treating with heat and irradiation has been used but none of which was entirely effective. Chemical degradation of aflatoxins can be carried out by adding various chlorinating, oxidizing and hydrolytic agents. The use of bacteria, fungi and algae can remove or degrade aflatoxin in foods and feeds. And last, infected kernels or grains can be physically removed using the electronic color sorting equipment, water-flotation method, hydrogen peroxide blanching process and manually sorting for damaged kernels or grains. One of the problems of the peanut industry in the Philippines is aflatoxin contamination of raw and processed peanuts due to difficulty in controlling the temperature and relative humidity during storage. Norhayati, et. al. (1999) reported that in the Philippines, roasted shelled peanuts and fried peanuts had aflatoxin content of 117 and 375 ppb, respectively. Peanut products exported from the Philippines have suffered detention problems because of high levels of aflatoxin. Consumer demand and the world export market for commodities susceptible to aflatoxin contamination are even pushing towards zero tolerance for aflatoxin. From the methods mentioned on aflatoxin detoxification, peanut manufacturers in the Philippines can use manual sorting of raw peanuts to separate kernels that are not fit for human consumption. A manual sorting procedure to eliminate aflatoxin-contaminated kernels in raw peanuts has been developed through a tripartite collaboration between the University of Georgia, the Food 36 Development Center under the National Food Authority and the College of Home Economics of the University of the Philippines (Galvez, Francisco, Lustre and Resurreccion, 2002). From the methods mentioned on aflatoxin detoxification, peanut manufacturers in the Philippines can use the manual sorting of raw peanuts to separate out kernels that are not fit for human consumption. The research and development was funded by the Peanut Collaborative Research Support Program (Peanut-CRSP) of the United States Agency for International Development (USAID). The technology involves a dry blanching procedure where raw peanuts are roasted for 45 to 55 minutes and then aflatoxin-contaminated peanuts are manually sorted out from the batch of peanuts (Fig. 2.1). The newly developed procedure for sorting peanuts at commercial scale is as follows: Weigh 50 kg of raw peanuts Feed peanuts into the roaster Blanch for 45-55 minutes Cool peanuts Remove the skins using a de-skinner/blancher Sort for aflatoxin-contaminated, discolored and damaged kernels Store clean, sound peanuts until use Fig. 2.1 Flow diagram of the developed manual sorting procedure for raw peanut. The manual containing guidelines for sorting aflatoxin-contaminated, discolored and damaged kernels were introduced to a peanut product manufacturer. The sorting procedure resulted in a number of changes in the previous procedure that was being followed by the collaborator on roasting of raw peanuts prior to production of peanut-based products. The company now has to follow a 2-stage roasting process, the first stage of which is the blanching process to facilitate sorting of the aflatoxin-contaminated peanut kernels. The assessment of the process of transferring the technology and the factors affecting it are important for assessing the value of the technology transfer. In this study, the impact of the addition of the sorting procedure in the production of peanut-based products was assessed in terms of such factors as the quality of the product, sales and marketing, and changes in employment. This knowledge can inform and enhance the transfer of similar technology to other food industries engaged in producing peanut products. 37 OBJECTIVES This study was undertaken to assess the overall impacts of sorting of peanuts in the production of peanut-based products specifically Kare-Kare mix. As there will be multiple impacts, the study expressly seeks to (1) assess the impact of sorting technology on the business and socio-economic status of the collaborating agency; (2) assess the impact of sorting technology on the employees directly affected by the technology and (3) assess consumer awareness of the negative effects of aflatoxin in peanuts. METHODS Chronology of Technology Transfer and Production Impacts The sorting technology was developed by the research team from the University of Georgia, University of the Philippines and the Food Development Center (FDC) (Galvez et al, 2002). Activities related to the transfer, adoption and commercialization of the sorting technology are given in Table 2.2. In January of 1998, the research team became a technology transfer team. For example, management had to be satisfied with regard to potential changes and costs of adoption of the technology, and middle managers directly responsible for production had to be trained on the steps of the sorting technology. Finally, new workspace had to be allocated and remodeled and workers trained to do the sorting. The company does not process peanuts regularly. The normal practice is for the company to blanch peanuts in bulk, and then store them until orders for Kare-Kare mix have been made. Once the orders have been placed, blanched peanuts are processed into Kare-Kare mix. The company also has a marketing distribution group, separate from the company that handles shipment of Kare-Kare mix outside the Metro Manila area. All of the above, plus the company’s concern for privacy and subsequent reluctance for revealing the monetary value of data reported, made the impact assessment less quantitative and precise. However, one basis of comparison is the data supplied by the company for Table 2.2. The January through March 1999 total production of Kare-Kare mix with peanuts (11,486.24 kg and 14,640 kg for the same period in 2001) shows an increase of 3,154 kg (about 28%). The total amount produced for the U.S. export market between July 2000 and March 2001 is 15,762 kg. The total amount of Kare￾Kare mix with peanuts produced during this period is 44,240 kg, making the U.S. 35.6% of the market for this product during this period. Later figures in this report on the analysis of impacts on business give greater detail on the comparison of the domestic and export market. It is important to recognize that none of the Kare-Kare mix with peanuts could have been exported to the U.S. before the adoption of the sorting technology. After a number of qualitative open-ended interviews with the company owner and personnel in charge of the peanut sorting process, a set of questionnaires were prepared to be used as interview guides in gathering data on the impact of sorting technology. The questionnaires were designed to incorporate relevant questions regarding business and socio-economic status of the company. A questionnaire was submitted to the General Manager of the company. Interviews with the General Manager and the Production Manager were likewise conducted for gathering further data and verification of information. 38 Table 2.2. Calendar of events on collaboration with a peanut manufacturing company on the adoption of sorting technology (Galvez et al, 2002). Date Activities January 1998 December 1998 April 1999 June 1999 January – March 1999, October 1999 July – December 2000 January – March 2001 Start of collaboration with peanut processors Use of technology in production line of the collaborating company Trial shipment of aflatoxin-free Kare-Kare mix to the USA Formal turn-over of sorting technology to industry collaborator Signing ceremony 1st shipment of aflatoxin-free Kare-Kare mix to the USA Total production of Kare-Kare mix with peanuts, 11,486.24 kg Total production produced for the US market, 264.24 kg Total production of Kare-Kare mix with peanuts, 29,600.00 kg Total production produced for the US market, 14,640.00 kg Total production of Kare-Kare mix with peanuts, 14,640.00 kg Total production produced for the US market, 1,122.08 kg To assess the aflatoxin awareness of consumers, interviews were conducted with 361 household respondents in 10 areas of Manila and communities North and South of Manila and in Visayas Islands of the Philippines using a structured questionnaire (Appendix A). The barangays (communities) in these areas were randomly selected from a list of 127 stores selling vitamin A fortified peanut butter. The survey was part of an impact assessment of a vitamin A fortification technology transfer project to a peanut butter manufacturer (Galvez et al, 2003). Respondents were chosen based on the following criteria: (1) respondent is the one who determines what foods will be bought for the household; (2) respondent’s household has children and; (3) respondent’s family eats peanut and/or peanut-based products. RESULTS Negative Impacts Encountered Upon Initial Adoption The sorting procedure, which involves at least six steps, was added to the production flow diagram of the company. The initial problems perceived by the company were the following: 1. Inavailability of space to accommodate manual sorting of peanuts. 2. Additional personnel to manually sort the blanched peanuts. 3. Training of personnel for proper sorting of damaged peanuts. 4. Increase in production cost due to an additional processing step. 5. Increase in time needed to prepare the peanuts for processing. 39 Impact on Employment, Facilities and Raw Material Manufacturing Facilities The manufacture of the Kare-Kare mix is maintained in one of the company’s food plants and the design of the food plant was modified to allow flexibility and continuity in the production. A total of 25 square meter area was provided as an additional area for the manual sorting of peanuts. Additional utensils and/or equipment were purchased such as stainless tabletop trays and scoops to be used for sorting. The company has recently transferred to a bigger manufacturing facility. Operations for peanut￾based products started during the first quarter of 2003. A sorting area was included in the new plant, and the company also purchased a new, larger, continuous roaster to be used for blanching and roasting the peanuts. The Research and Development (R&D) Group of the company had to modify the sorting procedure that was originally given to them as a result of using the new roaster for their peanuts. New parameters, temperature and blanching time were established to conduct proper sorting of peanuts. Employment During bulk processing of peanuts, at least four to eight employees are assigned to conduct the sorting. The company hired two additional personnel to join the production team. The company assigns two regular employees as part of the team while the rest are temporary casual employees (employed for five months only). The sorting of kernels requires a high degree of familiarization of aflatoxin￾contaminated kernels. A total of 30 hours of training and orientation was given by the R&D group to production personnel involved in sorting. The Production Manager and two other assistants closely monitor the sorting of peanuts during the day. A few regular employees are included in the team, to serve as ‘leaders’ of the group. In this way, these regular employees are being asked to carry the responsibilities of the management. When an order must be filled, the workers always extend the normal 8-hr workday by two to five hours to finish the processing of peanuts. This results in additional overtime pay. Employees The sorting of peanuts for aflatoxin-contaminated and damaged kernels is not an easy task. The Production Manager indicated that they try to minimize the number of employees in the production. Therefore, workers have many tasks assigned to them such as sorting, weighing, and packing, among others. A maximum of eight employees have been identified to do the sorting of peanuts. The usual complaints by the sorters are eyestrain and also, extension of working hours due to sorting. As a response, the management decided to rotate the sorters in the production area to reduce eyestrain. At the conclusion of four hours of sorting, workers are transferred to do another task to rest their eyes. And after a few hours, they are rotated back and resume sorting. Raw Material Since the company had not previously sorted for damaged nuts, an increase in raw material loss was noted, between 15 to 25%. This figure was found to be quite high. This reflects either raw peanuts being used are not of good quality or sorting for aflatoxin-contaminated peanuts is being overly done. When asked to verify this figure, the Production Manager said that sorters do not only look for aflatoxin￾contaminated and damaged nuts, but also, they have included off-colored peanuts in their sorting. The discoloration of peanuts was later found to be due to uncontrolled heating of peanuts while blanching. The fabricated roaster that the company is using does not have adequate temperature controls, and so, the roasting of peanuts was likely overdone, causing the discoloration of some peanuts. When the study by the research team on the development of the blanching procedure began, it was found that overheating 40 results in the development of more intense color on peanuts, which might be mistaken for damaged or aflatoxin-contaminated. This can, therefore, increase raw material loss in the batch of peanuts. As the company has already built a new plant and acquired new equipment including a better roaster, the problem of overheating was solved. As a result, raw material loss dramatically decreased from 15-25% to 1-3%. Impact on Business Production Impacts of Kare-Kare with Peanuts Production data from 1999 up to 2002 was obtained from the company for their Kare-Kare mix with peanuts. The data included yearly production reports for domestic, export and U.S. markets, where values are in unspecified “weight units” to maintain the company’s privacy. A summary of the total production volume of Kare-Kare mix with peanuts from January to October is shown in Fig. 2.2. The company indicated a growth of 30% in volume of domestic and exports sales after the sorting technology was adopted. Total production increased from 1999 to 2002 except for year 2001 where there was a drop in production volume both for domestic and export. Sourcing of raw materials and price of peanuts in the market contributed to the slight drop in production. A comparison of the total production for the period of January to October from 1999 to 2002 revealed an increase of almost 60% from the total production of the same months in 1999. Covering the same period, the domestic market increased by 48%, while the export market increased (in gross weight units) from 3,100 to 6,900 which would not have been possible without aflatoxin-free peanut. As shown in Fig. 2.3, the majority of the Kare-Kare mix sales are for domestic consumption, with an average of 83.74%, while Kare-Kare mix for export sales is an average of 16.26%. The export market share sales gradually increased from 1999 to 2002 (a 39% increase). Looking at the production data for export (Fig. 2.4), an increase in export production volume from 1999 to 2002 can be seen. None of this production could have gone to the U.S. without the aflatoxin elimination technology, and the market share increased even after the first year of exports. The average U.S. market share for the next three years (2000 to 2002) increased an average of 26.7 % over 1999. The average U.S. market share of 45.37% was obtained in 2001. 41 Fig. 2.2 Total production volume of Kare-Kare mix with peanuts, volume for domestic and volume for export from January to October. 0 10 20 30 40 50 60 1999 2000 2001 2002 Year Total Volume '000 (weight units) Total Production Total Domestic Total Export 42 Fig. 2.3 Percent market share of domestic, export and US sales of Kare-Kare mix with peanuts from January to October. 0 10 20 30 40 50 60 70 80 90 100 1999 2000 2001 2002 Year Percent Domestic Export USA 43 0 10 20 30 40 50 60 70 1999 2000 2001 2002 Year Percent Fig. 2.4 Percent USA market share of Kare-Kare mix with peanuts from January to October. 44 An updated sales report was provided to the research team showing worldwide volume sales from 2000 to 2004 (Fig. 2.5). The figures were reported in terms of number of cases sold for two sizes of Kare-Kare mix, the 57 g and 100 g sizes. Total sales volume increased from 2000 to 2004 for both sizes of Kare-Kare sauce mix. Highest percentage increase of 39.7% and 9.4% was obtained from 2002 to 2003 for the 57 g and 100 g variants, respectively. Increases in dollar amounts were again not made available for both variants. Production Impacts of Kare-Kare Mix without Peanuts Despite the increase in total exports of Kare-kare sauce mix with peanuts, this has not diminished total exports of Kare-kare mix without peanuts to the US. Production data for the Kare-Kare mix without peanuts were also obtained from 1999 to 2002. Total production of the mix without peanuts increased from 1999 to 2002 by 8% as shown in Fig. 2.6, while a decrease was noted for the years 2000 and 2001. Sourcing of raw materials and price of peanuts in the market contributed to the slight drop in production as claimed by the company. Total export increased by 7% from 1999 to 2002. Almost 60% of the Kare-Kare mix without peanuts was produced for export as shown in Fig. 2.7. The percent market share for export, including the U.S., remained stable, even with the introduction of Kare-Kare mix with peanuts. The biggest export market is still the U.S., with at least one-third of the total volume for export produced. This is remarkable in that it suggests that all the Kare-Kare mix with peanuts exported to the U.S. resulted in new additional sales with introduction of the new product. International Marketing Table 2.7 shows the countries where Kare-Kare mix is currently being exported. New markets established for the Kare-Kare mix with aflatoxin-free peanuts include the U.S., Hong Kong and Middle East. The company indicated that the U.S. and the Middle East are their biggest exporting countries for the Kare-Kare mix with peanuts. The inclusion of these countries in their market list improved positive growth and expansion for their Kare-Kare mix with peanuts. Although there was growth in the production of Kare-Kare mix with peanuts, the management indicated that their sales for Kare-Kare mix without peanuts remained unaffected by these improvements. Marketing activities conducted by the company included advertisements in the newspapers, consumer tasting in supermarkets and participation in trade fairs. Accompanying the display of their different products is a note that highlights the zero-aflatoxin content of their peanut-based products. The advantage that their product is the first peanut-based mix in the country to be proven aflatoxin-free was highlighted in their official website and product brochures. Table 2.3. Countries where peanut-based products are currently being Exported (Kare-Kare mix and Java sauce). USA Canada Hong Kong Singapore France Spain Italy Qatar Belgium Germany Kuwait United Arab Emirates Commonwealth of Northern Marianas Islands Japan Oman Bahrain 45 Fig. 2.5 Total volume sales (as number of cases) of Kare-Kare mix with peanuts. (KRM57g = Kare-Kare Mix, 57 g variant; KRM100g = Kare-Kare Mix, 100 g variant.) 0 2000 4000 6000 8000 10000 12000 14000 16000 2000 2001 2002 2003 2004 Year No. of Cases KRM57g KRM100g 46 Fig. 2.6 Total production volume of Kare-Kare mix without peanuts, volume for domestic and volume for export from January to December. 0 5 10 15 20 25 30 1999 2000 2001 2002 Year Number of cases '000 Total Production Total Export Total Domestic 47 0 10 20 30 40 50 60 70 80 1999 2000 2001 2002 Year Percent Domestic Export USA Fig 2.7 Percent market share of domestic, export and US sales on Kare-Kare mix without peanuts from January to December. 48 Research and Development of Peanut-Based Products The assurance that peanut-based products will pass the aflatoxin requirement encouraged the company to export Kare-Kare mix with added peanuts to the U.S. market. The success of the product in penetrating the U.S. market gave them the company confidence to develop other peanut-based products. The newest product that has been released and exported in other countries, including the U.S. is the Java sauce, which was released during the last quarter of year 2001. As shown in Table 2.8, the company started exporting Java sauce to the U.S. only in 2002 and almost 50% of the total export was targeted for the U.S. market. The collaborator also indicated that they have two additional peanut-based products currently under development. Table 2.4. Total production volume of Java sauce, volume for domestic and volume for export. Year Total Production (weight units) Total Domestic (weight units) Total Export (weight units) Total U.S. (weight units) 20011 101.44 87.38 14.06 0.00 20022 296.46 216.26 57.16 23.04 1 From October to December 2 From January to December Impact on Product Quality Upon the adoption of the technology and subsequently exporting Kare-Kare mix with peanuts to the U.S., the Food Development Center (FDC) monitored the aflatoxin contents of shipments made to the U.S. from October 1999 to January 2001. A total of six analyses were done, each of which resulted in zero level of aflatoxin. As for its shipments made to other countries, the company indicates that they have not received any product detentions from its distributors outside the Philippines. Management indicated that the inclusion of peanut sorting and aflatoxin testing increased production cost by 30%. This increase affected the price of Kare-Kare mix in the market. The company used to test their products for aflatoxin every month. At present, the company tests their products for aflatoxin every quarter, indicating great confidence that peanut sorting is successful in eliminating aflatoxin for their products. When the company adopted the sorting procedure, several product improvements were observed. The company claimed that Kare-Kare mix increased its shelf life from the normal six months to one year. They claim to have products that lasted for two years, without turning rancid. The research and development and production groups of the company regularly conduct sensory tasting of their products, and they noted that Kare-Kare mix had a better taste profile and acceptability. Since peanuts are rigorously sorted for aflatoxin-contaminated, as well as, damaged and discolored peanuts before processing, the Kare-Kare mix was improved in several ways. Products returns reported were 1.2%, mainly due to macro contamination rather than product deterioration. The exact figures cannot be quantified since the common practice is that the distributor accumulates all rejects for a certain period of time, before traveling to Manila to save on cost. These rejects are normally found to occur in small groceries or ‘sari-sari’ stores in the provinces. 49 Impact on Consumers A total of 361 households were interviewed in the Luzon and the Visayas Islands. Respondents were chosen based on three criteria: (1) respondents are the ones who decide what food to buy; (2) respondents and their families eat peanut-based products and; (3) the household has children. Of the 361 households, 176 respondents belong to the middle-income group (with monthly income >PhP10,000.00) while 185 respondents belong to the low-income group (with monthly income PhP1 10,000.00) Low income (Php3000 Metro Manila North Luzon South Luzon Visayas Fig. 4.1 Amount in Philippine peso (PhP) spent by Filipino consumers in different regions on food per week (MI and LI stands for middle income and low income, respectively). 91 Consumer Attitudes, Knowledge and Behavior Family Activities Based on Lyman’s (1989) statement that family influences food preference, there was a need to establish a clear picture of how strongly the parents and other family members influence the food preferences of the children. This can be achieved by finding out the activities the family do together most often. Results of the survey showed that the most common activity done together by family members was eating dinner (80% for both middle and low-income groups), followed by birthday parties for children (70% for MI and 52% for LI), birthday for parents (60% for MI and 36% for LI) and going on picnics (56% for MI and 47% for LI). Further analysis revealed that these activities have one thing in common – these all involve food purchase and consumption. This gives evidence that family indeed would have a substantial influence on children’s food preferences. These family members may not necessarily be the parents but other adult members of the household as well. Family Decision-Making Family decision-making was included in this study to determine the dynamics of decision-making in a typical Filipino household and whether this would have a significant influence on the decision to purchase and consume vitamin A fortified peanut butter. Previously, it was found that the women in the household were often the ones responsible for deciding on food purchases. The answers to these set of questions further strengthened the idea that women in the family were in fact responsible for decisions based on food consumption and purchases. More than 90% of respondents for both income groups were female and mostly the mothers and/or wives. Thus, it would be safe to infer that the main decision￾makers regarding what food to eat for dinner and what groceries to buy were the mothers and/or wives. It can also be seen that there was a very few percentage of children who were part of the decision￾making activities. Furthermore, most of these activities were related to going out to movies and inviting people to dinner. The adults in the family, as expected, had the final say with respect to what food to eat and what groceries to purchase. This suggests that adult decisions prevail and so information dissemination with regard to nutrition should target the adult members of the family. They are the ones who would eventually have to make an evaluation of the nutritional value of foods and its importance on the children or the younger members of the family. Nutrition Knowledge The variable, nutrition knowledge, was measured by first asking the respondents whether the 13 food items enumerated in the survey had some nutritive value or none. Based on the total correct answers the level of knowledge was divided into three categories: level 1 (scores equal to or below 7 points), level 2 (scores of 8-10) and level 3 (scores of 11-13). Seventy-seven percent of MI and 68.7% of LI are in level 3. Knowledge of the respondents on the nutritive values of certain foods shows that both groups are able to correctly identify from the given list what foods are nutritious. Respondents from both MI and LI are also correct in saying what effects good and poor nutrition have on the body. Based on the results, it seems that both groups are about equal in level of knowledge capabilities. The nutrition questions included in the survey may not be sufficient to accurately gauge the extent of knowledge each group possesses especially, more complex health implications. For example, it is notable that the lowest correct response on the effects of good nutrition was the effect on good eyesight (MI = 22.2%; LI = 15.7%). Since this would include vitamin A’s positive contribution, additional nutrition education is, apparently, still needed. 92 Moxley (1981) cites numerous studies that provide evidence for a relationship between nutrition knowledge and a number of appropriate food and vitamin choices. Analyzing a U.S. sample (North Carolina families) he also found that family income and mother’s education were related to “mother’s nutrition knowledge”. Consumption of Peanut Butter Among the peanut products available in the market, peanut butter got the highest percentage (91.5% for MI and 93% for LI). It shows that it is still the most popular peanut product among Filipinos and an excellent medium through which to get vitamin A into the diet of the Philippine population. Fig. 4.2 shows the number of respondents in the different regions who buys peanut butter. Peanut butter consumption patterns of Filipino families vary in terms of frequency of purchase, basis of choice and in the way it is eaten. This is not surprising because most of the respondents’ (both middle and low income groups) top three bases of choice for peanut butter were taste, brand, and price across all regions visited (Fig. 4.3). The survey revealed that the most common period of purchase is once a month. It would be difficult to judge, however, from the frequency of purchase alone to compare amounts of household consumption because the packaging size that each household buys varies. Comparison of peanut butter purchases between income groups showed that MI families (23.9% once a week) buy peanut butter more frequently than LI households (17.8% once a week). Only about 8% of households never buy peanut butter. A certain sense of brand loyalty is evident but this could perhaps be attributed to the taste of peanut butter the respondents were used to. Filipinos are known to have a liking for sweet taste as evidenced by the products catering to the so-called Filipino palate such as the sweet-blend catsup, Filipino-style spaghetti sauce (which is also slightly sweet) and sweet chili sauces. This could partly be the reason why there was a high percentage of respondents who bought Lily’s and Lady’s Choice peanut butter. Filipino households seem to also be price-conscious as supported by the relatively high percentage of respondents who answered price (74% for MI and 65% for LI) as determinant of peanut butter choice. When asked if they are willing to buy another brand, if the particular brand they like is not available, 51.1% of MI and 51.9% of LI families said “no”. This shows that the respondents have brand loyalty. This could be attributed to the taste respondents are used to having. Lily’s and Lady’s Choice are the most popular alternative brands. Among MI households 11.4% choose Lady’s Choice and 8.5% choose Lily’s, whenever the preferred brand is unavailable. For LI households, 10.3% choose Lady’s Choice and 9.2% choose Lily’s as an alternative. Until all peanut butter is fortified with vitamin A, brand loyalty is a problem, if it prevents consumers from switching to vitamin A fortified peanut butter. 93 0 20 40 60 80 100 120 MI LI MI LI MI LI MI LI Region Percent Yes No Metro Manila North Luzon South Luzon Visayas Fig. 4.2 Number of Filipino respondents in different regions who buys peanut butter (MI and LI stands for middle income and low income, respectively). 94 Fig. 4.3 Basis of choice for peanut butter purchase of Filipino consumers in different regions (MI and LI stands for middle income and low income, respectively). 0 10 20 30 40 50 60 70 80 90 MI LI MI LI MI LI MI LI Region Percent Brand Price Availability Taste Color Texture Others Metro Manila North Luzon South Luzon Visayas 95 Consumption of Vitamin A Fortified Peanut Butter Results reveal that a large percentage of respondents (71.0% for MI and 84.3% for LI) say they do not consume vitamin A fortified peanut butter. However, when asked if they were willing to purchase vitamin A fortified peanut butter, 96.0% of MI and 94.6% of LI respondents responded positively. Only 26.1% of MI families and 15.7% of LI families conveyed that they have eaten vitamin A fortified peanut butter (Fig. 4.4). Just 34.7% of MI and 26.0% of LI respondents have heard of or seen vitamin A fortified peanut butter (Fig. 4.5). Willingness to buy vitamin A peanut butter is supported by previous studies by Galvez et al. (2002) on Filipino consumer preferences for peanut butter. The results indicated that 98% of MI respondents and 96% of LI respondents were willing to purchase vitamin A fortified peanut butter. However, if the price was higher, they might not buy it. Lady’s Choice and Lily’s are the most frequently purchased peanut butter brands. Therefore, nearly half of households (51.1% of MI and 47.0% of LI) purchase and eat peanut brands that are labeled “fortified with vitamin A” (Lady’s Choice and Lily’s). These are the only brands labeled “fortified with vitamin A.” However, Lady’s Choice was not so labeled when Lily’s first sold fortified peanut butter and unlike Lily’s, the technology transfer team did not test Lady’s Choice for amounts of vitamin A content. Actual peanut butter consumption (by number of servings) of children in LI and MI households shows that the age range with the highest amount of servings consumed per week (31-40 tablespoons) was 13-20 years old for LI and 7-12 years old for MI. Across all age ranges above 2 yrs for both income groups, the most frequent amount of servings consumed per week is 0.5-10 tablespoons. The highest is 63.6% for LI children 7 to 12 (Fig. 4.6 and 4.7). According to the United States National Institute of Health (US/NIH), the daily recommended intake (RDI) of vitamin A for children ages 2-6 is approximately 350 mcg (micrograms), equivalent to that contained in two tablespoons of Lily’s vitamin A fortified peanut butter. For children ages 7-12, the recommended daily intake (RDI) is roughly 550 mcg (just over three tablespoons of Lily’s vitamin A fortified peanut butter). For persons ages 13-20, this number is 900 mcg (between five and five and a half tablespoons). The United States Institute of Health’s recommended daily intake numbers for vitamin A are provided here since the Philippine RENI’s are only available for adults. Vitamin A deficiency (VAD) at present is most prevalent among children age 6 months to 6 years old. The responses in this study were obtained from children ages 2 to 6, which is the most vulnerable age group among these categories. Even if all peanut butter were as fortified as Lily’s, 11.4% of LI and 6.8% of MI children ages 2 to 6 would certainly be consuming enough to receive the RDI. Some LI and MI in the categories of 11-20 servings per week would as well. The results show the highest consumption is among older children 7 to 12 years of age (about 64% of LI and about 58% MI eat 0.5 to 10 servings per week). However, since only those consuming 3 tablespoons per day of vitamin A fortified peanut butter (according to US/NIH) get the full RDI, most of the children do not consume sufficient quantities to get the full RDI. If all peanut butters were fortified, a large percentage of the vulnerable groups’ age 2 to 6 would be able to obtain a higher percent of the target RENI for fortified foods with vitamin A. Additional variants of peanut butter (e. g. chocolate-flavored or strawberry-flavored peanut butter) could also be fortified with vitamin A. Consumer research should be carried out to see what would most effectively increase consumption of vitamin A by younger children. 96 0 10 20 30 40 50 60 70 80 90 100 MI LI MI LI MI LI MI LI Region Percent Yes No No answer Metro Manila North Luzon South Luzon Visayas Fig. 4.4 Response of Filipino consumers in different regions on their awareness regarding vitamin A fortified peanut butter available in the market (MI and LI stands for middle income and low income, respectively). 97 Fig. 4.5 Number of Filipino consumers in different regions who bought vitamin A fortified peanut butter (MI and LI stands for middle income and low income, respectively). 0 20 40 60 80 100 120 MI LI MI LI MI LI MI LI Region Percent Metro Manila North Luzon South Luzon Visayas 98 0 5 10 15 20 25 <2 2 to 6 7 to 12 13 to 20 Age (Years) Average Weekly Consumption (Percent) 0 0.5 to 10 11 to 20 21 to 30 31 to 40 41 to 50 In tablespoons Fig. 4.6 Peanut butter consumption of children in low income households per week (Male < 21, Female < 18; 1 serving = 1 tablespoon). 99 0 5 10 15 20 25 <2 2 to 6 7 to 12 13 to 20 Age (Years) Average Weekly Consumption (Percent) 0 0.5 to 10 11 to 20 21 to 30 31 to 40 41 to 50 In tablespoons Fig. 4.7 Peanut butter consumption of children (in tablespoon) in middle income households per week (Male < 21, Female < 18, 1 serving = 1 tablespoon). 100 CONCLUSIONS This study of the impacts of vitamin A fortification of Lily’s Peanut Butter on consumers is based on a sample of 361 households with 150 distributed in 10 barangays (communities) in Metro Manila, 50 each from Northern Luzon and Southern Luzon and 110 from Cebu, the second largest City in the Philippines. There are 900 children in these households, 468 in lower-income (LI) households and 432 in middle-income (MI) households. On average, there are 2.49 children in each household. Of the 361 households, 71 indicate Lily's is the brand they buy (the second most purchased peanut butter in the Philippines). At 2.49 children per household the estimate would be that 177 (19.7%) are living in households with Lily's vitamin A fortified peanut butter available. However, since response patterns indicate that 76 percent of children eat peanut butter weekly, the number actually consuming Lily's peanut butter on a regular basis would be closer to 135 (15.0%). There are 185 LI households in this sample. Of these, 42 indicate regularly purchasing Lily's Peanut Butter. LI households have an average of 2.53 children per household, which means about 106 (22.6%) of LI children live in households with Lily's vitamin A fortified peanut butter available. Of the 176 MI households in the sample, 29 purchase Lilly's Peanut Butter. MI households average 2.45 children per household, which means about 71 (16.4%) of MI children live in households with Lily's vitamin A fortified peanut butter available. While the samples in this study are not large enough to be scientifically representative and, therefore, we cannot provide statistical probabilities of accuracy, we are able to obtain some basic demographic data for the 10 sample barangays (communities) where stores selling the Lily's product in the Metro Manila area are located (Appendix A). These 10 store locations (in 10 barangays) range from 999 to 11,016 households for a total of 33,673 households. If one assumes that, as in the study sample, 92% of households would meet the screening criteria, the total would be 30,979 households (with children) in which peanut butter is consumed. If, as in the sample, 20% of these purchase the Lily's product, this would be about 6,196 households using the vitamin A fortified Lily's brand. While population estimates for them are not available, there are 127 locations in and around the Metro Manila area containing stores selling Lily's vitamin A fortified Peanut butter (Appendix B). Also, the barangay level population data are not available for the areas sampled in Northern Luzon, Southern Luzon and Cebu. The cities in which these stores are located have a total of 280,645 households (see Appendix C for details). The potential for increasing the intake of vitamin A through peanut butter fortification appears substantial. Peanut butter is by far the number one choice among peanut products (92.2% of respondents). Only 30.2% of respondents have seen or even heard of vitamin A fortified peanut butter. However, after being informed of its importance, 95.3% indicate they will buy vitamin A fortified peanut butter in the future. This suggests that considerable gains could be made through effective education and advertising. Since 90% of respondents were female and about 74% of them are mothers who make the decisions on what foods to buy, women are the logical target audience. Another avenue to increase vitamin A intake is to convince the other peanut butter producers to add vitamin A. One competitor has recently done so (Lady’s Choice) and is the first choice of survey participants among all brands (34.7% of MI and 24.3% of LI). Together, vitamin A fortified labeled peanut butter brands (Lily’s and Lady’s Choice) are purchased by 47.0% of LI and 51.1% of MI households. (Lady’s Choice was not tested for actual vitamin A content.) 101 If 57.1% of MI and 47.0% of LI households in the survey areas are consuming vitamin A fortified brands, this amounts to a substantial contribution. Providing thousands of Filipinos with this additional source of vitamin A will help augment total vitamin A and diminish deficiencies and its debilitating effects. The sample population on which this study is based is mainly urban and suburban (72.3% from Manila and Cebu, the second largest city). Forty-nine percent of respondents had obtained some education or skill training beyond high school. Over 60% of the mostly female respondents are employed at least part-time. While all LI families made less than PhP 10,000 per month, 45% spent more than PhP 1,000 per week (PhP 4,000 per month) on food. By comparison MI families make more than PhP 10,000 per month and 70% spend more than PhP 1,000 per week on food. The findings regarding peanut butter consumption and vitamin A in this study are more likely to apply to other urban and suburban populations of the Philippines with the characteristics described here. Even with a relatively urban and educated population, like the one represented in this study, the knowledge of vitamin A and food sources containing it are not very well known. Four years after the industry collaborators’ launch of vitamin A fortified peanut butter in the market, there still seems to be a lack of awareness about this product. The lowest percent correct response on the nutrition knowledge test in this survey was the detrimental effect of vitamin A deficiency on eyesight. Consumers need to be made more aware of the importance of obtaining the required vitamin A from their diet and the severity of the adverse effects from its deficiency. The results point to a need for more aggressive marketing of the fortified peanut butter by the company and a more extensive vitamin A information dissemination campaign on the part of the government. NOTES 1. The research and development technology being assessed here resulted in a serving of vitamin A fortified peanut butter that is 65 percent of the Philippine Recommended Daily Allowance (RENI) for an adult male and is equivalent to 525 mcg RE. The actual vitamin A content was 8.50 to 8.60 mcg retinol per gram peanut butter. The serving size was 2 tablespoons (or 40g) 2. The U.S. RENI for vitamin A is 1,000 retinol equivalents per day for adults and children over 4 yrs. A good food source of vitamin A contains at least 10 percent of U.S. RENI “in a selected serving size or a unit of measure considered easy for the consumer to use” (Hopkins Technology, 2003). 3. At the end of the data collection day, each questionnaire was reviewed to assure completeness and accuracy. The actual interview period was from June to October 2002. Three types of interviews were conducted to pre-test the questionnaire: (1) actual interview practice with project staff members; (2) actual interview with households in nearby residential area and (3) actual interview on one of the sampling sites. Interviewers were asked to read the questions verbatim. For every actual survey conducted, interviewers were asked for feedback on their experiences and problems encountered. Necessary revisions were done on the questionnaire based on the results of the pre-test. Upon completion of the survey, questionnaires were coded and data were entered in the database. Data entry was 100% verified. Statistical Analysis System v.8 (SAS Inc., 2001) was used for all statistical analyses. 4. Random sampling of households began in the city blocks surrounding each store and continued in the next until the target N was reached. Proximity to stores which sold Lily’s peanut butter was considered important to insure that households had a reasonable opportunity to have access to it. Zero purchases would eliminate the dependent variable. 102 5. A serving is one tablespoon, which is 32.5% of the Philippine Recommended Daily Allowance for an adult male (see note number one). 6. The latest recommendations for the daily intake for vitamin A (updated October 6, 2003) provided in the Dietary Reference Intakes developed by the Institute of Medicine are: 300 mcg for children ages 1-3, 400 mcg for children ages 4-8, 600 mcg for children 9-13, 900 mcg and 750 mcg for males and females ages 14-18, respectively, and 900 mcg and 770 mcg for males and females over the age of 19, respectively (Clinical Nutrition Service, Warren Grant Magnuson Clinical Center, 2003) REFERENCES Abdullah, A., Malundo, T.M., Resurreccion, A.V.A. and Beuchat, L.R. 1993. 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The AVI Publishing Co., Inc., Westport, Connecticut. 104 APPENDIX A TOTAL POPULATION, HOUSEHOLD POPULATION AND NUMBER OF HOUSEHOLDS IN THE BARANGAY AREA SURVEYED IN METRO MANILA 105 TOTAL POPULATION, HOUSEHOLD POPULATION AND NUMBER OF HOUSEHOLDS1 IN THE BARANGAY AREA SURVEYED IN METRO MANILA Store Location Total Population Household Population Number of Households Glorimart San Francisco del Monte, Q.C. 35,923 35,782 8,300 Welcome Rotonda, Q.C. 4,292 4,292 1,011 New Life Delta, Q.C. 12,600 12,505 3,236 EPC Munoz, Q.C. 9,265 9,254 2,131 TDC Novaliches, Q.C. 12,078 12,038 2,731 Value Point Binondo, Manila 5,384 5,373 1,121 Admiral Blumentritt, Manila 8,038 8,030 1,664 Trident Paco, Manila 5,395 5,381 999 All Nation Las Pinas City 6,377 6,377 1,464 Big C Bicutan, Taguig 48,865 48,689 11,016 1 as of May 1, 2000 Sources (Personal Communication): Mr. Ramon Dolor, Sec 1, NSO, Household Statistics Department Ms. Gloria Barcebal, Community Office, Manila City Hall Ms. Nimfa Maranan, Community Affairs Officer V, Manila Barangay Bureau 106 APPENDIX B LIST OF AREAS AND OUTLETS SELLING LILY’S PEANUT BUTTER 107 LIST OF METRO MANILA AREAS AND OUTLETS SELLING LILY’S PEANUT BUTTER Quezon City Manila Store Location Store Location Eunilane Supermarket Visayas Ave. Glorimart Laon-laan Eunilane Supermarket Kalayaan Intermassive Paco Paco G.L. Delmonte Del Monte Manel’s Mart Singalong, Malate Glorimart Tandang Sora SSG Sta. Ana Sta. Ana Glorimart Del Monte SK Port Area Port Area Glorimart Kamias Corona Foodmart Binondo Glorimart Project 8 Masagana Supermarket Kalaw Glorimart Project 4 Manel’s Mart Malate Glorimart Visayas Ave. Value Point Binondo Parco Supermarket Quezon Ave. Fairmart Sta. Cruz Parco Supermarket EDSA Trident Paco ALW Quirino Quirino Masangkay Sta. Cruz Fernando’s Supermarket Sta. Mesa Subway Sta. Cruz Daily Supermarket Cubao Admiral Grocery Blumentrit Anson Aurora Phil. Commercial San Andres UC Plaza Kamuning St. Joseph Supermarket Gagalangin Purity Supermarket Cordillera Imart Sampaloc Shopper’s Delight Project 8 Imart Paco Welcome Supermarket Rotonda Imart Sta. Mesa UP Cooperative UP Diliman Imart Tayuman Home Sweet Home Roosevelt, SFDM Imart Vito G. Cruz New Life Delta Imart V. Mapa Tropical Panay Imart P. Campa EPC Munoz Munoz Imart Onyx Imart Kamuning Imart Hidalgo Imart QC Hope Well Foundation Sta. Cruz Imart Banawe Kings Foodmart Sta. Cruz Imart Katipunan Fargo Quiapo Imart Dahlia Shoppersmart Sta. Cruz Imart Vicas Plaza Fair Manila Kids & Mom Pandacan Imart Shorthorn Kids & Mom Faura Imart Mayon Kids & Mom Maypajo Liana’s Supermarket Rotonda Western Supermarket Escolta Plaza Fair Cubao Remson Carriedo Grocer’s Foodarama Cubao Cesar’s Balintawak A. Bonifacio, Balintawak 108 List of Metro Manila Areas and Outlets Selling Lily’s Peanut Butter (continued) Quezon City Paranaque Store Location Store Location Super Nova Novaliches Sucat Foodmart Sucat TDC Bayan, Novaliches Better Living Paranaque Glorimart Novaliches Chessy Sucat Edd Tess Novaliches V.M. Baclaran Nova Gold Bayan, Novaliches Big C Bicutan EPC Novaliches Novaliches Mega Mart Bicutan San Roque Supermarket Novaliches Tropical Bicutan Nova Deal Novaliches Imart Paranaque Imart Novaliches Imart Baclaran I Plaza Claire Sauyo Imart Baclaran II Imart Lagro Gracewill Lagro Meadows Regalado Valenzuela Shortstop B.F. Fairview Store Location CVC Supermarket Malinta Mandaluyong Home Sweet Home Dalandanan Royal Mall Malinta Exit Store Location Fast n’ Shop Valenzuela EPC Kalentong Kalentong Richmarsh Kalentong Imart Kalentong Pasay Imart Parklea Store Location Masagana Pasay Rizal Alphabeta Taft Avenue Imart Taft Store Location Publix Mart Taft Imart Taytay Tropical Taytay Tropical Cainta Antipolo CVC Supermarket Cainta Home Sweet Home Masinag, Rizal Store Location Rempson Taytay Taytay Imart San Mateo Rempson Masinag Imart Antipolo 2 Gems Supermarket Antipolo Imart Antipolo Eastmart Antipolo Imart Parang Rejoice Antipolo Super Palengke Antipolo Ultramega Antipolo 109 APPENDIX C TOTAL POPULATION, HOUSEHOLD POPULATION AND NUMBER OF HOUSEHOLDS IN THE CITY/TOWN AREA SURVEYED OUTSIDE METRO MANILA 110 TOTAL POPULATION, HOUSEHOLD POPULATION AND NUMBER OF HOUSEHOLDS1 IN THE CITY/TOWN AREA SURVEYED OUTSIDE METRO MANILA Province City/Town Total Population Household Population Number of Households Laguna Calamba City 281,146 280,529 58,466 Los Banos 82,027 80,830 17,030 Tarlac Tarlac City 262,481 262,015 51,703 Cebu Cebu City 718,821 714,388 147,600 Source: 1 www.census.gov.ph/census, 2000, 111