Modelling and Optimisation of the Fanti Kenkey Production Process

Abstract

This study focused on developing and optimising the production process of Fanti kenkey, a traditional fermented maize product widely consumed in Ghana, with the goal of reducing the variability in quality due to non-standardized processing methods. The research was carried out in two phases. In the first phase, a structured survey was administered to 138 Fanti kenkey processors across the Central and Eastern regions of Ghana, covering towns such as Abura, Anomabo, Nyanyano, Kade, and Koforidua. The results showed that 99% of the respondents were females with aged between ranges from 28 to 54 years. 20 individuals or 14.5%, reported skipping some operations. Of these, 7 respondents or 5.1% skipped fermenting, 11 respondents or 8% skipped soaking, and 1 respondent or 0.7% skipped grinding. The majority, 118 respondents or 85.5%, did not skip any operations. The survey gathered information on traditional methods, key processing challenges, and common practices used by processors to maintain product quality and efficiency. The second phase consisted of experimental trials designed to measure the effects of critical processing parameters—steeping time, mixing ratio, and cooking time—on the texture and pH of Fanti kenkey. A total of 30 experimental runs were conducted with two replications per condition. Texture analysis was performed using a texture analyser, measuring properties such as adhesion, cohesion, springiness, and hardness, while pH was assessed using a pH meter. The statistical analysis, using response surface methodology and correlation studies, revealed that mixing ratio significantly affected all measured texture properties, while pH showed no significant correlation with texture variables or processing factors. Descriptive statistics indicated a high degree of consistency across most quality metrics, such as pH, springiness, and cohesion, but identified variability in steeping time, hardness, and adhesion, which reflected diverse traditional practices. The results emphasize the cultural and socioeconomic importance of Fanti kenkey production, which not only provides a staple food for a large segment of the Ghanaian population but also supports local economies by offering job opportunities in maize processing and street vending. The findings underscore the potential benefits of optimising critical unit operations to improve the consistency and quality of Fanti kenkey. By verifying that the final textural characteristics and pH of the product are significantly and predictably impacted by the standard processing steps of steeping time, aflata to raw dough ratio, and cooking time. Response Surface Methodology was successfully applied to accomplish the main goal of this thesis. The following ideal parameters can be used to dependably manufacture the most desired Fanti kenkey, which has high springiness (18.827 mm), high cohesion (0.673), low adhesion (11.647 mJ), and moderate hardness (175 g), according to numerical optimisation.