From Ground to Grain: The Making of Nigerian Garri at Zerack Nigeria Ltd

Introduction to Garri Production at Zerack Nigeria Ltd.

Garri is a popular West African food staple made from cassava tubers. It is a versatile product that can be eaten dry, soaked in water, or used to make a dough called Eba when hot water is added. Zerack Nigeria Ltd. has perfected the art of garri production by utilizing a blend of traditional methods and modern technology. This article delves into the detailed process of making Nigerian garri, from the selection of raw cassava to the final product ready for consumption.

Step 1: Selection and Harvesting of Cassava

The journey to making garri begins with the selection of high-quality cassava tubers. Zerack Nigeria Ltd. sources its cassava from trusted local farmers, ensuring that the roots are properly matured and disease-free. The cassava is harvested manually by farm laborers, using simple tools like cutlasses and hoes to unearth the tubers from the ground. The company prioritizes sustainability by rotating crops and allowing the soil to regenerate, thus continuously producing robust cassava yields for garri processing.

Step 2: Peeling and Washing

Upon arrival at the Zerack processing facility, the cassava tubers are thoroughly washed to remove dirt and any foreign particles. Next, the tubers are peeled to discard the outer brown layer, uncovering the white flesh of the cassava. This is a crucial step since the peels contain substances that can affect the quality and safety of the final product. Peeling is done either manually or with the help of mechanical peelers to enhance efficiency.

Step 3: Grating the Cassava

After washing and peeling, the white cassava flesh is grated into a fine pulp. Zerack Nigeria Ltd. uses industrial graters that are capable of processing large volumes of cassava at a time, ensuring a uniform texture. The grated cassava is a wet mash at this stage, and it requires further processing to become the dry grain known as garri.

Step 4: Fermentation

• Bagging the grated cassava mash into large sacks made of permeable fabric.
• The bags are then stacked in a fermentation room with controlled temperature and humidity.
• Fermentation occurs over a period of 1 to 3 days, depending on the desired sourness of the garri.
• During fermentation, the cassava mash undergoes biochemical changes, enhancing the flavor and reducing potentially harmful substances.

Step 5: Pressing and Dewatering

Once fermentation is complete, the bags containing the cassava mash are subjected to a mechanical press. This process squeezes out excess water, further concentrating the cassava and allowing for a more manageable material to process into garri. The dewatering process is essential in preventing spoilage and improving the quality of the finished product.

Step 6: Sieving

After pressing, the semi-dry cassava mash is broken up and sieved to achieve a consistent, fine particle size. Sieving is done using a high-capacity industrial sieve or manually through woven baskets, depending on the quantity being processed. Consistency in particle size is vital for even frying in the subsequent step.

Step 7: Roasting or Frying

• The cassava mash is spread on large frying trays or inside rotary fryers.
• Expert operators at Zerack Nigeria Ltd. oversee the frying process to ensure even heat distribution.
• The mash is continuously stirred to avoid clumping and achieve uniform dryness.
• Roasting transforms the cassava into a dry, granular form—garri—with a significantly reduced moisture content, making it shelf-stable.

Step 8: Cooling

The freshly fried garri is very hot and requires cooling before it can be handled further. Zerack Nigeria Ltd facilitates this step by spreading the garri in a thin layer on large trays, allowing the product to cool naturally in well-ventilated areas. This gradual cooling helps in preventing condensation and moisture buildup, which could otherwise compromise the quality of the garri.

Step 9: Quality Control Checks

Quality control is integral at Zerack Nigeria Ltd., with trained personnel conducting several checks to ensure that the garri meets stringent standards. Parameters such as moisture content, granule size, acidity, and absence of foreign matter are rigorously tested. Any batch that doesn't meet the company's high standards is reprocessed or appropriately handled to prevent any possibility of inferior product reaching the market.

Step 10: Packaging

Once the garri has passed all quality checks, it is packaged for distribution. Packaging is done using materials that protect the garri from moisture, pests, and contamination. Zerack Nigeria Ltd. uses branded, food-grade packaging that comes in various sizes to cater to different market needs, from small bags suitable for individual households to large sacks for wholesalers.

Step 11: Distribution

The packaged garri is stored in a cool, dry place until it is distributed to retailers and end consumers. Zerack Nigeria Ltd. collaborates with a vast network of distributors to ensure that their garri is available across Nigeria and even in international markets. The company prides itself on timely delivery and maintaining a reliable supply chain to meet the ever-present demand for this nutritious staple.

Conclusion of The Garri Making Process at Zerack Nigeria Ltd.

The making of Nigerian garri at Zerack Nigeria Ltd. is a meticulous process that requires attention to detail and adherence to traditional practices, enhanced by modern technology. From the selection of high-quality cassava roots to the packaging of the final product, each step is carried out with precision and care to ensure that only the best garri reaches consumers' tables. Zerack Nigeria Ltd. stands as a testament to the successful integration of agricultural practices with industrial production, contributing significantly to food security and economic growth in Nigeria.