Maize (Zea mays) is an important staple food crop produced by the majority of smallholder farmers that provides household food security through direct consumption and income generation. However, postharvest grain losses caused by insect pests during storage pose a major constraint to household food security. Hermetic storage technology is an alternative method that minimises postharvest losses by depleting oxygen and increasing carbon dioxide levels within the storage container through metabolic respiration of the grains, insects, and microorganism. Maize grain was stored for 180 days in hermetic bags or open-weave polypropylene bags to compare quality preservation when subject to initial grain moisture contents of 12, 14, 16, and 18 percent and infestation by Sitophilus zeamais. The moisture content of grain in hermetic bags remained unchanged while in polypropylene bags decreased. Dry grains (12% moisture content) stored well in hermetic bags and suffered 1.2% weight loss while for equivalent grains in polypropylene bags the weight loss was 35.8%. Moist grains (18% moisture content) recorded the lowest insect density (7 adults/kg grain) in hermetic bags while polypropylene bags had the highest (1273 adults/kg grain). Hermetic and polypropylene bags recorded the lowest (0–4 adults/kg grain) and highest (16–41 adults/kg grain) Prostephanus truncatus population, respectively. Discoloured grains were 4, 6, and 12 times more in grains at 14, 16, and 18 than 12 percent moisture content in hermetic bags. Grains at 18% moisture content recorded significantly lower oxygen (10.2%) and higher carbon dioxide (18.9%) levels. Holes made by P. truncatus in the hermetic bags were observed. In conclusion, storage of moist grains (14–18% moisture content) in hermetic bags may pose health risk due to grain discolouration caused by fungal growth that produces mycotoxins if the grains enter the food chain. The study was on only one site which was hot and dry and further investigation under cool, hot, and humid conditions is required.

The performance of six grain storage technologies for the control of insect pests in maize was evaluated over a 36-week (9-month) storage period. The six technologies used were: two ZeroFly® hermetic bag brands (laminated and non-laminated); Purdue Improved Crop Storage (PICS) bag; non-hermetic ZeroFly® bag; woven polypropylene (PP) bag containing maize grain treated with Actellic Gold® Dust (pirimiphos-methyl 1.6% + thiamethoxam 0.3%) and woven PP bag containing untreated grain. Each bag was filled with 50 kg maize grain and four replicates of each were set up. With the exception of the non-hermetic ZeroFly® bag, 50 live adults of the larger grain borer Prostephanus truncatus and of the maize weevil Sitophilus zeamais, were introduced into all the bags. Insects were not introduced into the non-hermetic ZeroFly® bag to assess its effectiveness in repelling infestation from outside. Parameters recorded were gas composition (oxygen and carbon dioxide) levels inside the bags; weight of flour generated by insect feeding activities; grain moisture level; live adult insect counts; grain damage and weight loss; grain germination rate and aflatoxin level. At termination, the plastic liners of the hermetic bags were examined for perforations. Results show that oxygen depletion and carbon dioxide evolution were faster in ZeroFly® hermetic compared to PICS bags. Throughout the 36-week storage trial, grain damage remained below 4% and weight loss below 3% in all the treatments except in the untreated PP bags in which it increased to 81.1 and 25.5%, respectively. The hermetic PICS, ZeroFly® and Actellic Gold dust-treated PP bags maintained grain germination at 60%, which was lower than the initial 90%, while in untreated control, it reduced to 4.7%. The mean aflatoxin levels fluctuated between 0.39 and 3.56 parts per billion (ppb) during 24 weeks of storage in all the technologies tested, which is below the acceptable maximum level of 10 ppb in maize. Based on the evaluation results, it can be concluded that hermetic PICS and ZeroFly® bags and woven PP bag with Actellic Gold dust-treated grain effectively protected stored maize grain from insect attack and weight losses. Appropriate strategies and mechanisms for the effective and efficient adoption of hermetic storage bag technology at scale would contribute towards global food security.

Hermetic technologies are being promoted in Africa as safer and more effective methods of grain storage on smallholder farms. However, farmers and policy makers lack knowledge of their efficacy in controlling major stored grain pests. An on-station study was conducted to evaluate the triple layer Purdue Improved Crop Storage (PICS) airtight bags against two major storage insect pests. Two sets each of PICS, jute and polypropylene bags were filled with 50 kg maize grain per bag. Each set was replicated four times. One set of PICS bags was each infested with 50 insects each of the larger grain borer P. truncatus and the maize weevil S. zeamais; while the other set was not. One set of jute and polypropylene woven bags was treated with a cocktail of 1.6% Pirimiphos methyl and 0.3% Permethrin, serving as positive controls; while the remaining sets with untreated maize grain formed negative controls. Gas analysis in the PICS bags followed the expected trend with oxygen levels falling sharply below 10% and carbon dioxide increasing to almost 10% after 12 weeks hence resulting in insect death. After 16 weeks, increase in oxygen levels may be attributed to perforation of the bags from outside by the P. truncatus. Results showed that PICS bags were significantly (P < 0.05) superior to treated and untreated controls of polypropylene and jute bags in suppressing insect development, maize grain damage and weight loss during storage. Weight loss in polypropylene and jute bags reached 40% and 41%, respectively, at 24 weeks after storage compared to PICS (2.4–2.9%). These results demonstrate that PICS bags can be used to store maize against P. truncatus and S. zeamais attack.

On-farm trial with a total of 32 farmers in eight villages of Naivasha and Nakuru areas of Kenya was conducted between December 2013 and September 2014 to evaluate hermetic grain storage technologies under farmers’ management conditions. The storage technologies evaluated were metal silo and SuperGrain IV-R bag alongside the standard woven polypropylene bag with or without Actellic super dust. Moisture content, insect population, grain discoloration, and weight loss were analyzed 90, 180, and 270 d after storage. Grain moisture content remained stable over the storage period. Both metal silo and SuperGrain IV-R bag suppressed insect population, prevented grain loss and cross-infestation of insects from the surrounding environment. On the contrary, polypropylene bags allowed rapid build up of insect population and re-infestation from the surrounding environment. Grain weight losses were 1.5% in the metal silo and 1.8% in the SuperGrain IV-R bags compared to 32% in the polypropylene bags without Actellic Super dust, 270 d after storage. The present study, therefore, demonstrates that storing grains either in metal silo or SuperGrain IV-R bags would benefit farmers in reducing grain losses and improving quality. The study was of great interest to the farmers, grain storage scientists, and food security experts.

Sitophilus zeamais causes significant losses to maize produce worldwide. The use of biodegradable and environmentally friendly botanicals as an alternative to synthetic pesticides is increasingly becoming important. Therefore, we sought to determine the use of plant extract formulations to manage S. zeamais during storage. Crude Zanthroxylum usambarense and Warburgia ugandensis stembark extracts were used for contact toxicity and repellent bioassays against S. zeamais. The formulations that exhibited the highest repellence and mortality were tested for insecticidal activity during storage for six months. Phytochemical profiles of the extracts were determined using GC-MS, and molecular docking of active compounds against insect target proteins was done. Mortality analyses revealed LD₅₀ values of 114.89 µg/mL and 197.19 µg/mL for Z. usambarense’s hexane and methanol organic extracts, respectively. Warburgia ugandensis extracts had LD₅₀ values of 69.25 µg/mL and 163.52 µg/mL, respectively. Extract formulations achieved weevil perforation index values of <50.00 in all treatments. The docking analysis showed the pesticidal potential of several compounds, and mortality could be attributed to Eugenol (19.28%), 1,8-cineole (5.78%) and Linalool (21.42%). The tested botanicals have demonstrated their ability to suppress S. zeamais development in stored maize and could be utilized to protect maize grains during storage.