Indicator framework for large-scale cacao (Theobroma cacao L.) in vitro plant production planning and controlling

Somatic embryogenesis (SE) is considered the most suitable and integrated biotechnology for the large-scale production of clonal cacao plants compared to conventional methods. Hence, the scale-up of relevant technologies must be interfaced with effective and efficient management of productive processes at an industrial scale like biofactories. Production facilities like biofactories serve to transform plant resources into products like plantlets. This technology constitutes an essential innovative variant since it allows obtaining high multiplication coefficients in short periods. Currently, there is no reference to carrying out adequate planning of the entire production process; for this reason, it is not used for the maximum production capacity of the facilities, and there is a high level of uncertainty. With the aid of production planning and controlling (PPC) systems, inputs can be planned to achieve a determined output of products. Therefore, this work proposes a production planning and controlling (PPC) system for SE cacao plantlet multiplication through the pilot large-scale. This paper presents input and output information considering the leading indicators of the production process, like materials, labor, quality, and performance. Emphasis is placed on technical details on the production process of 100.000 plantlets in batches from the CCN51 genotype. Through the model analysis, challenges and requirements for PPC system have been defined as a basis for future works and will have successfully managed the production process. Keywords: Commercial-scale propagation, cost of production, indicators, somatic embryo, vegetative propagation.

Cost Analysis of Cacao (Theobroma cacao L.) Plant Propagation through the Somatic Embryogenesis Method

In vitro cacao (Theobroma cacao L.) production via somatic embryogenesis (SE) is being implemented to mass propagate clonal plant material with the donor material’s prominent characteristics. Though it is an advanced technology, it is con-sidered expensive compared to other propagation techniques. This work focused on identifying the critical financial feasi-bility factors for the SE productive process. The process's costs were estimated, identifying factors influencing each la-boratory's standardized ES process. A Monte Carlo Simulation (MCS) was performed to evaluate different variables upon increasing productive scale in a biofactory (commercial-scale production). The projected lot volume was 100,000 plantlets in solid media, considering the process flow from in vitro introduction to acclimation. A biofactory operational model was projected, establishing time and operator movements and identifying direct and indirect costs. Costs were defined by the standardized or integral method, with estimated and budgeted calculations to set the cost per plantlet. The identified cost components were culture medium (CM), indirect manufacturing costs (IMC), labor (direct and indirect) and operating expenses. Labor had the most significant share of the costs, at 53%, followed by operating expenses, at 30%, CM, at 12%, and IMC, at 5%. The MCS helped define that the variables with the highest impact on unit price were the embryos’ response in the germination-acclimation stage and the proliferation coefficient during the maturation stage. This projection yielded a figure of US $0.73 per plantlet. However, strategies to reduce this cost have been proposed. These strategies are mainly conducive to optimizing labor and implementing practices that increase multiplication. Keywords. Plant Tissue culture, Cost analysis, Large-scale production, Biofactory, Monte Carlo Simulation (MCS)