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WhatIF is a specialised food production company, using bamnut processing in a sustainable way to create innovative, plant-based solutions across a range of food products.

We were tasked with supporting in the design of a self-powering facility in Ghana. Planned to be fully operational by 2030, the site will oversee the processing of bamnut beans while also converting feedstock into biochar and using this sustainably within energy requirement processes.

Scoping Workshop

Beginning with a Scoping Workshop, we determined that the site needed to deliver over 35,000 mt of bamnut beans per year, while 30,000 mt of biochar would also be produced for use within self-powering processes. At this stage of the process, we took into account how the facility would impact the local area, as well as the wider community. This included where the employees would travel from and what their needs would be.

Storage, ventilation and energy demands were some additional points that were raised, alongside more infrastructure-based topics, including transport reliability. We also focused on warehousing and distribution requirements
and how seasonal changes can be accommodated.

Feasibility Phase

We used this key phase to test theories and analyse how potential processes would (or wouldn’t) work. Using practices such as FMEA (Failure Mode Effect Analysis) Workshop Sessions, we assessed the issues each process may have faced, while also using the opportunity to build team relationships between WhatIF and our engineers. We were able to work collaboratively to solve upcoming problems in each process, while thought-provoking debates took place over counter-measures and solutions.

Before moving onto the next phase of requirements specification, we reviewed each step of the process, reducing the role of those that could be shortened and removing those that were deemed ineffective.
During the Feasibility stage, we also created a factory flow diagram that showcased the different approaches and criteria the site would need for successful operation. These included a phased construction approach, design and equipment considerations and construction requirements.

Concept Analysis

During Concept Analysis stage, we added more to the process, bringing detail to both the input of mass and the output of energy, assessing the balance across the processes. As well as designing such factors as electricity hubs, harvest storage bins and facilities including offices and car parks, we also designed the warehousing capacities and a community hub that features a kitchen and playing fields. During this phase we broke down the process into individual stages and produced numbers for equipment and personnel for the project.

This stage involved particular challenges, including keeping all facilities on-site and recycling everything at our disposal.

Detailed Design

Our plan is now to move onto the next phase of the project: Detailed Design & Definition, where we would visit the existing site and meet the team, getting a full understanding of the idiosyncrasies of the environment.

During this phase we would also schedule several supplier visits, to inspect the quality of the equipment and assess whether any improvements could be made. The number of employees for each phase of the project can also be ascertained at this stage, helping with the recruitment drive, while site ground inspections and supplier selection all take place.

We are delighted to be working with WhatIF on this project and playing our part in a sustainable food production facility.

Project Director Stuart Turnbull:

“This is an incredibly exciting project. We’re really proud of how we’ve approached this challenge as, not only have we used considered, alternative thinking, we have innovated the project approach through detailed calculations and theories that have fed directly into the factory design itself.”

External URL: https://www.feg-global.com/