Funded by the Ministry of Agriculture, Forestry and Fisheries of Japan

Feasibility Survey on Local Production for
Local Consumption (Chisan-Chisho)
Activity and Extension in Africa
Final Report –Second Year-

March 2018

Japan Association for International
Collaboration of Agriculture and Forestry

Japan Association for International
Collaboration of Agriculture and Forestry
AKASAKA KSA BLDG. 3F
8-10- 39, AKASAKA, MINATO-KU
Tel: + 81- 3-5772- 7880
Fax: +81- 3-5772- 7680
ISBN: 978-4-908563-32-4 print
ISBN: 978-4-908563-33-1 pdf
Printed in Japan by Shokou Insatsu Ltd.

Preface
In August 2016, The Sixth Tokyo International Conference on African Development(TICAD VI) was held in Nairobi, Kenya. At the conference, we were expected to linkproducers and consumers and develop new markets for contribution to economic
diversification and industrialization by supporting agriculture and other industries. In
Japan, we successfully vitalized local production for local consumption and produced newmarkets. We made such achievements as increasing local income, creating employment
opportunities, and vitalizing regions. We think our past experiences are applicable todevelopment in Africa. Moreover, we will support local production for local consumption
by considering actual situations in Africa and promote shift from self-sufficient
agriculture to commercial agriculture for increasing agricultural income.
Under such circumstances, our association has been implementing cereal
popping technology in rural areas of Kenya and investigating the feasibility of diffusion
since fiscal 2016. We have been promoting local production for local consumption byconsidering actual situations in Africa, with subsidies from the Ministry of Agriculture,
Forestry and Fisheries (MAFF). In this fiscal year, we first expanded the sales of local
pressure popping machines modeled from Japanese pressure popping machines andstrengthened dissemination and enlightenment activities at agricultural fairs. We
conducted trainings on those who purchased pressure popping machines. We urged themto master Japanese technologies about the production, processing, and sales of popped
cereals. We also kept monitoring farmer organizations that implemented pressure
popping machines to extract future issues. Meanwhile, we found successful cases where
the utilization of pressure popping machine improved income greatly. This allow us to
expect future activity expansion.
This report outlines the above activities and summarizes the achievements. We
hope that the project achievements will be utilized among Japanese private companies
and parties of international collaboration while contributing to local activities of local
production for local consumption.
About project planning and evaluation, we received guidance and counselingseparately from members of the evaluation committee set up within the secretariat. We
also received cooperation in local specialist activities from the Kenya Office of Japan
International Cooperation Agency (JICA), Dr. Morimoto, researcher at the International
Plant Genetic Resources Institute in the Consultative Group on International
Agricultural Research (CGIAR), and Dr. Kanda at CDC International. We would like toexpress our deepest gratitude for their cooperation.
iLastly, this report was created under the responsibility of our association anddoes not represent opinions of MAFF or the Japanese Government.
March 2018
Eiji Matsubara, President
Japan Association forInternational Collaboration ofAgriculture and ForestryiiFeasibility Survey on Local Production for Local Consumption (Chisan-Chisho)
Activity and Extension in Africa – Final Report – Second Year –― Table of Contents ―Chapter 1 Overview of the project ..................................................................................... 1
1. Period of activities ...................................................................................................... 1
2. Contents of activities .................................................................................................. 1
Chapter 2 Result of the activities ...................................................................................... 3
1. Strengthening the mass production and sales of Kenyan-made popping cereal
machines .................................................................................................................... 3
2. Strengthening the dissemination and sales of and enlightenment about popped
cereal products........................................................................................................... 9
3. Results of the activities by the group and incidental survey .................................. 24
4. Training in Japan ..................................................................................................... 48
5. Proposal of new popped cereal processing techniques ............................................ 63
Chapter 3 Direction of Future Activity Deployment ...................................................... 72
1. Result of the project activity .................................................................................... 72
2. Direction of future activity deployment ................................................................... 73

Appendix
1. Final Workshop Report............................................................................................. 77
2. Operation and Processing Manual ......................................................................... 101

iii

Project Activity Map
Main Activity County is marked red color (Javis, A., et al., 2008).

iv

Project Photos
Dissemination of popped cereal product

Migori member introducing popping process tojunior high school students in Kisii

Migori member introducing popped cereal toelementary school students in Kisii

Production and sales of popped cereal

Mr. Gichangi’s Factory of Kashate (molded
popped cereal) in Embu

Packaging of kashata
Factory in Embu

Selling kashata in market day of Embu

Men who are surprised by kashata

v

in

Mr.

Gichangi’sProcessing kashata in Kitui

Processing rice ball (molded popped cereal) in
Migori

Making popped cereal in Migori

Cutting kashata in Bomet group

Motorcycle taxi drivers like kashata.

Children who eat kashata for the first timeviTraining in Japan

Leaning how to use popping cereal machine

Leaning how to make kashata

Packaging process of new flavor of kashata

Appealing new flavor kashata at the sales
office near the factory

WorkshopParticipants shared the results and challengesof each group and set new goals.

Participants shared the skills acquired in the
training in Japan.

vii

Abbreviations List
Abbreviation
ASK
JAICAF
JICA
JKUAT
KEBS
KIRDI
MSEA
MOA
NEMA
SACCOS
TICAD
UGITF

Standard name
Agricultural Society of Kenya
Japan Association for International Collaboration of Agriculture and Forestry
Japan International Cooperation Agency
Jomo Kenyatta University of Agriculture and Technology
Kenya Bureau of Standards
Kenya Industrial Research & Development InstituteMicro & Small Enterprises Authority
Ministry of Agriculture
National Environment Management Authority
Saving and Credit Co-operative Societies
Tokyo International Conference for African Development
Uganda International Trade Fair

Kenya Shillings：
1 JPY = 0.94959 Ksh(http://www.exchange-rates.org/converter/JPY/KES/1/Y, access 2018/03/14)

viii

Summary
1. Purpose of ProjectIn August 2016, The Sixth Tokyo International Conference on African Development(TICAD VI) was held in Nairobi, Kenya. The declaration at the Conference states "tocontribute in sustainable manner to economic diversification and industrialization byhelping to accelerate the growth of industries including agriculture. From thisperspective, the declaration states "We will create new markets by linking consumers,
producers, farmers and economies through region-wide development."
In Japan, we promoted agricultural product processing as an integration projectplan based on the Act Concerning Promotion of New Business Creation by Agricultural,
Forestry and Fishery Workers Utilizing Local Resources, and Use of Local Agricultural,
Forestry and Fishery Product (Law No. 67 in 2010). These efforts created new markets,raised incomes in rural areas, created employment opportunities, and vitalized local
areas.
In this project, we study efforts complying with the actual situations of local
production for local consumption in Africa by utilizing our findings in Japan. The
purpose of this project is to raise the incomes of African farmers by promoting shift fromself-sufficient agriculture to commercial agriculture in Africa through demonstration
tests.
2. Contents of ProjectThis project follows that of fiscal 2016 as efforts complying with the actual situations oflocal production for local consumption in Africa. With exclusive focus on original local
agricultural products, we mainly implemented popped cereal technology as foodprocessing technology to add high values to local agricultural products, diversify the usesof such products, and generate incomes in rural areas.
As in the previous fiscal year, this project was mainly targeted at Kenya. We
manufactured experimental pressure popping machines on site and evaluated theprocesses from production & sales to merchandise development and dissemination byleasing or selling the machines to farmer groups and entrepreneurs. As a survey
incidental to local production for local consumption, we also surveyed governmental andother support measures to disseminate local production for local consumption andregulations concerning sales, such as agricultural product processing. As a model
demonstration survey about local production for local consumption, we demonstrated amodel contributing to the improvement of local incomes in several areas of Kenya byix

utilizing local agricultural products. At the same time, we studied measures of diffusing
the model to other areas.
In the current fiscal year, we conducted a training at a popped cereal
manufacturer in Japan to improve the technology of producing, processing, and selling
popped cereals. We also conducted follow-up activities in Kenya to check the skill levelof the trainees.
As part of our achievement diffusion activities, we held a workshop by gathering
farmer groups and entrepreneurs who have been producing and selling popped cereals,
with government officials. We studied the future possibilities of activity expansion by
sharing business experiences and networks.
3．Summary of Results
One of the achievements by activities in this project is the expansion of pressure popping
machine production. A trial Kenyan machine modeled from a Japanese machine trial
could be manufactured successfully in the last fiscal year. We also organized issues
identified by field activities and worked out their solutions to establish a new technology
for mass machine production. As a result, we have manufactured and sold five machines
in total and are now more machines by expecting orders. We have received orders fromsemi-governmental organs and Japanese private companies, as well as local agriculturalgroups. Technical inquiries are not only from within the country but also fromneighboring countries. They indicate strong interest in and concerns about this project.
Another achievement is the dissemination and sales of popped cereals, including
the strengthening of their enlightenment. To raise of the social awareness of popped
cereals, we made demonstrations using pressure popping machines at agricultural showsin various places and widely conducted diffusion and enlightenment activities.
Consequently, we conducted activities a total of 25 times at agricultural shows in thisproject. Popped cereals were highly evaluated and awarded 37 prizes. Particularly at an
agricultural show held in September 2017, President Uhuru Kenyatta came to our boothand tasted popped cereals. Many visitors to agricultural shows had interest and concerns.
We received about 50 to 100 inquiries at each agricultural show. The activities were notlimited to Kenya but also conducted in neighboring Uganda and Burundi.
The number of farmer organizations and entrepreneurs who implemented
pressure popping machines increased one to four in total in this fiscal year. The activities
were scaled down in Kitui County and Migori County because of such group issues as amoney problem but are continuing. Difficulty in securing a sales network is also an issue.
In Migori County, kiosks and other stores were secured as targets of sales. Our activitiesx

in this fiscal year were affected particularly by the prohibition of plastic bags that started
in August 2017. The purchasers of cereal popping machines were expected to change
their means of packaging. An entrepreneur in Embu County solved this issue well andpromoted sales by using not only paper packages and containers but also plastic cups
and containers. The entrepreneur in Embu County is turning the cycle of kashata (called"okoshi" in Japan) production, processing, and sales very efficiently. Since the averagemonthly sales in a 10-month period became about 47,000 Ksh, the machine charge could
be paid back in about 5 months. The entrepreneur is very enthusiastic about mastering
techniques and active in sales activities. This may be the reason for the success.
We conducted a training in Japan to help trainees master Japanese technologies
of producing, processing, and selling popped cereals. The trainees were entrepreneurs ofseemingly high business mind from Embu County and Bomet County. The training washeld at Ieda Seika, one of the major manufacturers of popped cereal in Japan. The
trainees learned through sanitation management at food processing factory, anappropriate method of using a pressure popping machine, seasoning and molding as
processing technologies, and sales activities at direct sales stores. We also developed newmerchandise by using baobab and other African tastes, with an emphasis on kashataseasoning and molding technologies important for adding values to popped cereals. We
confirmed that the entrepreneurs in Embu County and Bomet County mastered
technologies acquired in the training by follow-up survey after the training. Particularly
the entrepreneur in Embu County was found producing kashata rather efficiently.
During the follow-up survey, the entrepreneur made efforts to add high values tomerchandise also by developing new flavors.
In the last phase of this project, we developed puff-cracker machine as new
agricultural product processing technology replacing pressure popping machine. Puffcracker machine was verified expectable as a means of solving several issues at theimplementation of pressure popping machine.

xi

xii

Chapter 1 Overview of the Project
1. Period of activities
The project conducted for eleven months from May11, 2017 (determination of subsidy)
until March 31, 2018.
2. Contents of activities
In this project, we use popped cereal technology as food processing technology to process
and add new values to local grains, beans, and nuts, and sell them as local brandproducts. The purpose of this project is to raise the incomes of farmers by promoting the
local industry and increasing consumption. In the first fiscal year (2016), we
manufactured Kenyan-made cereal popping machines experimentally and produced
popped cereals from various local agricultural products. We proposed new ways of eatingand evaluated marketability (JAICAF, 2017).
In the current fiscal year (2017), we continued the project of the previous fiscal
year. We focused ourselves on three activities. The first activity was to improve cereal
popping machines and establish a mass production system. The second activity was topromote dissemination of and enlightenment about popped cereals at agricultural
exhibitions. The third activity was to develop original products, highly local and healthoriented. For merchandise development, we received cooperation from Ikeda Seika, aJapanese popped cereal manufacturer. Two Kenyan trainees attended a training inJapan and the merchandise development staff of Ikeda Seika visited Kenya formerchandise development and manufacturing skill training.
Business operators may be interested in purchasing pressure popping machines
but hesitating to purchase expensive machines by considering worker employment andinsufficient business experiences. For such business operators, we took up two
processing technologies for hand-grilled cracker processing and puff cracker processing
as startup technologies. These technologies allow business startup by small amounts ofinitial investment and business management investment, less than half the amount for
implementing a pressure popping machine. We experimentally manufactured machines
and products on site.
The following three activities were conducted:(1) Strengthening the mass production and sales of Kenyan-made cereal popping
machines(2) Strengthening the dissemination and sales of and enlightenment about popped cereal
products
1

-Demonstration sales and presentations at agricultural exhibitions and workshops
studying value addition to local agricultural products and sales of health foods-Business expansion in neighboring countries-Providing voluntary entrepreneurs (individual and organization) with information
about the handling of pressure popping machines, the acquisition of food sanitation
certificates, and nutrition analysis, and with technologies by training guidance
about manufacturing, sales, labeling, and packaging(3) Developing local products under the leadership of farmers, training Kenyan people
on production processing, merchandise development, and sales in Japan, anddeveloping new merchandise and training people on development and manufacturing
skills by Ikeda Seika staff visiting Kenya.
As demonstration incidental survey, we surveyed production & sales support systems fortarget farmer organizations, including business analysis, evaluation, and expansion, andpartner identification for dissemination in succession to the last fiscal year. By thissurvey, we verified whether these food processing technologies of Japan are applicable
the activities complying with the actual situations of local production for local
consumption in Africa.
As demonstration incidental surveys, we conducted three surveys.


Popped cereal product development and sales efforts, business analysis and issue
identification, and efforts by agricultural organizations for solutionsoSyokinili Self Help Groupo

Okonyo Migori GroupoGichangi Cereals and SpicesoKoech Family (from this fiscal year)Support systems for business expansionPartner identification for diffusion

Study of new startup technologies, trial manufacture of machines for handgrilled cracker processing and puff cracker processing machines, anddevelopment of products by local production for local consumption

2Chapter 2 Results of Activities
1. Strengthening the mass production and sales of Kenyan-made pressure popping
machines
By activities in the last fiscal year (2016), we developed a machine modeled with highfidelity from a Japanese issho-type (1800 cc) pressure popping machine of the Yoshimura
type and completed a trial machine. In the current fiscal year, we organized machine
problems identified during on-site operation so far, reported them to an engineer incharge, and studied improvements. We also supported the establishment of newtechnology for machine production. We witnessed machine test operation and extracted
and solved issues with focus on quality maintenance and improvement and engineer
rearing.
As a result, we solve a total of five machines by the end of February 2018. We
are now manufacturing two more machines by expecting further sales (Table 1). The
sales price of the machine is 100,000 Ksh. The purchasers are not only local agriculturalorganizations but also semi-governmental Kenya Industrial Research and Development
Institute (KIRDI) and Japanese private company. We also receive many technicalinquiries about the machine from domestic individual entrepreneurs and neighboring
countries but have not received orders yet. The inquiries are from Ethiopia National Rice
Research and Training Center (Ethio-Rice) for Strengthening Project, Kikkoman Corp.
(activities in Tanzania), United Nations Human Settlements Programme (UNHABITAT), CARE (international NGO conducting humanitarian aid activities in Kenya),and Su-Re Coffee (environmental NGO devoted to the development of sustainableagriculture adapted to climate change in Bali, Indonesia, Bali. The inquiries show greatinterest in this project. DK Engineering is expanding sales activities by making the mostof their web site1 and unique network and continuing activities for dissemination of thisproject and enlightenment about the achievements.

8

Table 1 Organizations that DK Engineering has delivered machines since November 2016
Organization
As of end-February 2018
Syo kinili Women Group, Kitui
Delivered
Migori Okonyo, Migori
Delivered
Gichangi Cereals and Spices, Embu
Delivered
Tenri, Embu
DeliveredJohn Koech, Bomet
DeliveredJKUAT/Nissin Co. Ltd, Nairobi
Delivered
Kenya Industrial Research and Development Institute (KIRDI) Delivered
Bukula, Kakamega County (Women rep.)
KERDI Kisii, Kisii County (Women rep.)
Delivered

9
10

TBD
TBD

1
2
3
4
5
6
7

1

Under production
Under production

http://dkengineering.co.ke/index.php/2014-07-19-11-37-30/cereal-pop-machine3

Now DK Engineering can manufacture one or two units a month. However, there is somebusiness management problem because they are short of skilled engineers and morethan one job must be done at a time. According to a report, they had to collect and repair
a machine from a customer where the machine was found defective. The project staff
always witnesses testing before machine delivery to find defects and maintain andimprove quality in cooperation with engineers from DK Engineering. After the end of the
project, however, DK Engineering needs to secure skilled workers by their own businessefforts, improve processing technology by training workers, and strengthen their mass
production system. DK Engineering thinks the dissemination of popped cereals will
increase machine orders and help establishing, improving, and strengthening a machine
production system.
DK Engineering also feels it necessary to support business using their machines
while maintaining and improving machine quality. We are expected to provide
continuous technical follow-up, such as the training of customer staff from management
to manufacturing and sales.

Photo 1, 2 Manufacturing process in mass-production system (Left) and cylinder manufacturing(Right)4

Photo 3 Testing with DK Engineering

Photo 4 Internal view of the DK Engineering(2) Identification of Issues and Improvement of Machine
In the last fiscal year, three rural organizations implemented pressure popping machines.
Their use has been clarifying fragile sections, parts requiring maintenance, andrepairing costs. DK Engineering is focused on identifying issues, improving defective
parts, and solving some issues free of charge (Table 2). They are strengthening partmaterials and studying screw positions and materials to unify and make common parts
between different devices and between right and left sides. They are promoting further
improvements to establish a mass-production system and meet increasing orders.

Photo 5 Name of each parts of pressure popping machine5

Table 2 Main identified issues and solutions
Issue
Stand
1
Size and diameter of bolt and nut
different between machines

2

Fatigue fracture of frame welded
point

Stove
3
Mixing of smoke and charcoal

4

Deformatation and distortion
particularly at the front

5
Damper damage
Mesh cage
6
Rupture of mesh cage

Cylinder7
Pressure gauge damage

8

9
10
11
12
13
14

Peg and mount deformation anddamage.
Air pressure leakage from coverandTeflonseal
ring
deformation。
Fatigue fracture of cover andcenter bolt attachment partCenter bolt deformation andscrew thread damage
Bearing damage and center shaft
deformation
Shaft pin damage
Handle attachment position andhandle attachment bolt damage
Electric motor position

Cause

Solution / Improvement

Issues at manufacturing
processes.
Using common parts andunifying right and left
sides
Handling
atmachineinstallation

Unification of parts andadoption of common parts toimprove maintainability

Use of firewood

Use of gas burner

Direct contact of themount with the front part,
General deformation bystrong shock at striking.
Strong shock at striking

Damper replacement andperiodic inspection, andreinforcement by welding

Cheapmaterialorinadequate attachment

Change to durable material.
Change of cage shape(rectangle). Adoption ofcloth back.

Strong shock at striking

Adoption of coupler joint.
Improvementtoallowpressure gauge removal at
striking.
Adoption of En9 (toughenedmaterial).
Changetodimensions similar to thoseof the original machine.

Bad material not strong
enoughBad material not strong
enoughDamper insertion failure
or attachment error
Bad material not resistantagainst heat
Strong shock at striking
Attachment error
User needs

6

Reinforcement,
andstrengtheningof
explanation about handlingDamper replacement

Reinforcement and periodic
inspection
Damper replacement andperiodic inspection
Replacement and periodic
inspection
Pin groove re-machining
Determinationof
attachment place
Adoption
under
consideration

Photo 6, 7, 8 The handle attachment pin comes off and the cylinder is slid forward (left andcenter). Since the shaft pin could not be repaired, the part was welded directly (Left). DKEngineering deepened the pin grooved so that the pin would not come off.

Photo 9, 10 Thread-crushed handle attachment part (Left) and Z bearing of handle completely
broken by heat and shock (Right).

7

Photo 11, 12 Thread-crushed U shaped part (Left) and broken peg of low strength (Right)

Photo 13, 14 Broken cage (Left) and frame bent by strong shock at striking (Right)

Photo 15, 16 Pressure gauge with coupler joint, broken by strong shock at striking (Left) andpressure gauge removable at striking not to receive shock (Right)

8

2. Strengthening the dissemination and sales of and enlightenment about popped cereal
products
Demonstration sales and presentations at agricultural exhibitions andworkshops to add values to agricultural products and study the sales of healthfoods(1) Dissemination and enlightenment activity in Kenya
According to the survey of the last fiscal year, many people did not know about popped
cereals. Some people mistook popped rice products as large grains of rice. Therefore, we
strengthened demonstration sales using pressure popping machine at agricultural showsand seminars in this fiscal year to raise the social awareness of popped cereal productsin this fiscal year. We conducted dissemination and enlightenment activities widely togovernmental organizations and private companies as well as the general public. We
showed the production processes directly to consumers by expecting the effect of
expanding the awareness of popped cereals. We participated in agricultural shows andother events and organized two expert sales teams from eight members fordemonstration sales. At the same time, the project members worked in cooperation withrural organizations also to support the three groups (Syokinili women group, Okonyo
Migori group, Gichangi Cereals and Spices) that we trained in the last fiscal year. We
participated in agricultural shows with the cooperation of such partners as the Microand Small Enterprise Authority (MSEA), the Ministry of Agriculture (MOA), and the
Jomo Kenyatta University Agriculture and Technology (JKUAT). We borrowed spaces
within their exhibition booths to reduce expenses and also worked together as theirmembers for enlightenment.
As a result, we made presentations at agricultural shows and seminars anddemonstration sales a total of 25 times during the period of about 10 months from May
2017 until late February 2018. We conducted dissemination and enlightenment activities
on people exceeding 20,000 in total (Table 3). According to a trial calculation, the numberof visitors per exhibition was about 15,000 to 25,000 and about 10% of them, about 1,500
to 2,000 people, dropped by at the booths of this project. Thus, we were awarded 37 prizes
in total at agricultural shows. We won the first prize 26 times, the second prize 9 times,
and the third prize twice. We were awarded most the prizes of Best innovation andinvention stand and Best small trade stand, commercial and industrial stand. We won
each prize at five different agricultural shows (Table 4). Since about 100 to 150
organizations participate in each agricultural show, many awards that we won may
indicate great interests and concerns about this project. Since we exhibited products
within the booths of our partners, we cannot say that our activities contributed 100% to9awarding. Considering other exhibits (Table 5), however, we are sure that our efforts inthis project contributed to the acquisition of such prizes as innovation. At the Nyeri
Agricultural Show held in September 2017, President Uhuru Kenyatta visited the venue
and tasted popped cereals made from pearl millet. JKUAT that hosted the show received
the Presisdent Prize (Photo 17). MSEA endorsed contribution of this project by declaring
booth charge reduction at participation in the next fiscal year to acknowledge ourachievement and support project continuation.
At demonstration sales, merchandise of about 20 Ksh were very popular (Table6) and the main customer bracket was children not aged higher than 20. Therefore, sales
increased remarkably on days when schools participated. Processed foods sold atexhibitions and popular among children were ice creams, candies, and biscuits.
Compared with general merchandise, popped cereals were not known well and tasting
was often requested. After tasting or purchase, however, not a small number of children
brought their friends. Thus, we could confirm great demand. We made the greatest sales
at the Meru Agricultural Show among the agricultural shows where we participated. By
4-day demonstration sales, we achieved the total sales of 207,135 Ksh (about 27,000 yen).
We also confirmed it necessary to vary flavor and processing form and further devise
package and label designs. Children did not have particularly favorite products(merchandise) but tended to prefer sugar, honey, and other sweet tastes. To the contrary,salty seasoning was not popular. Rice ball (balling up rice popped cereal by suger),kashata (solidifying popped cereal by syrup) and other products made by the secondary
processing of popped cereals ranked high also because they are easy to use, sell, and buy(Table 7). As to differences between grains, adults strongly prefer millet and sorghum
while children prefer sweet seasoning. We could confirm people's tendency of preferring
low-price products rather than specific grains.
Agricultural shows were also participated in by many participants who wereinterested in the machine structure, the principle of pressure processing, purchasers,
and prices. We received 50 to 100 inquiries per participation in an agricultural show. We
also received many inquiries about expiration date. We heard various ideas aboutmachine improvements and packages. As to the purchase of machine, many people said
it difficult to make decision now (wait and see) because popped cereals are not wellknown, and the marketability is not clear. A few individuals or organizations seriously
considered purchase at each exhibition. We could identify potential customers contacting
each other.

10Table 3 Schedule of agricultural shows and seminars participated in by the project1

Type
Agricultural show

Schedule
May 25 to 27

Nyanyuki

Place

Subject
General public

Demonstrator
Sales (Ksh)Award
Project team, Embu Group 12,900
First prize in three fields
First prize in three fields

2Agricultural show

June 7 to 10

Meru

General public

Project team, Embu Group 27,135

3School event

12-JunEmbu-ACK St Josephcollege Manyatta

4

Agricultural show

June15 to 17

Kakamega

Secondfields

prize

in

three

Third prize in one field

General public

Embu Group

4,300

Project team, Migori
Group

9,430

5

Agricultural show

June 28 to July 1

Machakos

General public

Project team, Kitui Group 12,300

6

WorkshopJune 10 and 12

Kilifi, Kware

participants

Project team

7

Agricultural show

July 4 to 8

NakuruGeneral public

Project team, Embu Group 23,730

8

Kisumu workshop by
Australian Centre forJuly 3 to 7
International Agricultural
Research (ACIAR)

Kisumu / Busia

Governmentalorganization,
NGO,
andGovernment

9

Agricultural show

July 13 to 15

Kisii

General public

10

Agricultural show

July 20 to 22

Kabarnet

General public
General public

11

Agricultural show

July 20 to 22

Kitui

12

Local event

July 28 to 29

Nyeri Wambugu farm

13

Agricultural show

July 25 to 29

Kisumu14

Local event

24-AugManyatta stakeholders
forum (mashf) kairuri,
Embu

15

Agricultural show

September 14 to 17

Nyeri National show

16-SepNairobi

22-Sep

Bonanza School Embu

October 3 to 10

Kampara, UGANDA

General public

General public

Project team, MigoriGroup
Project team, MigoriGroup

14,030First prize in three fields

9,440First prize in four fields
Second prize in two fields

Kitui Group

10,490First prize in one field

Embu Group

22,000

Project team, Kitui Group 18,840

Embu Group

2,000

Embu Group

20,1501718Agricultural show

19

Agricultural show

October 12 to 14

Migori

General public

20

WorkshopNovember 21 and 22

National Agri-Nutrition
Conference, Nairobi

Participants and US-AID
Project team
staff

21

Fureai Festivel by theJapanese Association

9-Dec

Japanese Embassy Nairobi Participants

Project team

22

Agricultural show

December 3 to 10

Bujumbura, BURUNDI

Migori Group

23

Workshop

23-Jan24

Community seminar

21-Feb

25

Exhibition

March 7 and 8

Japnese Association and
Project teamJapanese school staff
Embu GroupDK engineers, Project
General publicteam, Embu Group

General public

6,000

3
4
5
6
7
8
9
10
11
12

No sell
No sell

Final Workshop of
Project staff (inc. general
Project team
JAICAF-Bioversity project public)
Itumbu Community, Vihiga
Local participants
Project teamCountyKenya National Nutrition
General public
Project team
Week (5-11 March)

Ra nk in g, a nd P la ce o f A gr ic ul tu ra l Sh ow
First
SecondThird
Total prizes 26
92
Nyanyuki 、 Kakamega 、 Kisii 、NakuruBest innovation and invention standNieri、Meru
Machakos 、 Meru 、 Kisii 、Best small trade stand, commercial and industrial
Nakuru、Kisumu
Best regulatory authority and cooperation stand, Best
organization/association in community projects/services Nyanyuki、Machakos、Kabarnet
standBest agricultural based statutory board standMeru、Kabarnet、Nieri
Best show theme interpretation
Kisii、Kabarnet、Nieri
Best local manufacturing stand, Non-consumables
NyanukiNakuruKisumuBest youth activities empowerment capacity building
Kakamega
KisumuBest stand demonstrating the application of environmental
Kabarnet
quality standards
Best stand exhibiting agricultural and Erath moving
Nieri
equipment

13
14
15
16
17
18
19

Best government ministry stand (Baringo county)
Kabarnet
Best Traditional foods stand (Kitui County)
Kitui
President Award the best university trophy
Nieri
Best local stand in strategic of international trade andexports
Best stand that promote national cohesion and integration
development
The best government social functions standThe most striking display (demonstration of locallymanufactured products
Best stand research and development
The most striking display (promotion of local manufactured
products)
The best agro-processing stand

11

Partnership with JKUATFirst prize in five fields
Second prize in threefieldsAt the request of PTA of
Japense school

Migori GroupFi el d o f Co mm en da ti on

1

First prize in one field
Second prize in one field
Third prize in one field

820

Table 4 Fields of commendation and places of agricultural show

2

First prize in one field
Second prize in one field
Third prize in one field

CGIAR,
Project teamAustralianInteraction festival by
Japanese school
School event

16

First prize in three fields
Second prize in two fields
First prize in two fields
Second prize in one field

Meru
MachakosKabarnet
Kabarnet
Nieri
Nieri
Nieri

At the request of theJapanese
Association,
Kenya
With the support of Migori
CountyBioversity

Table 5 Main agricultural processed foods exibited at the Kitui County Agricultural Show
Food
Pilaf
ChapatiFeature of Merchandise
Using sorghum instead of rice
Mixing wheat powder with millet, mung bean, carrot, sweet potato,
and pumpkin
Mixing wheat powder with sweet potato and cassava
Using banana and yam
Basil
Mango, papaya, pineapple, and lemon peeling
Omena, tilapia, and catfish
Passion fruit, mango, and pineapple
Insect powder
Cake containing soybean and cake containing rice powder
TomatoHome-madePopcorn machine
Home-roasted
Health food

Mandazi (Doughnut)
Chips
Dried vegetable
Dried fruit
Dried or smoked fish
Juice
Fish bait
Cake
Tomato sauce
YoghurtPopcorn
CoffeeChia seed

Table 6 Bagged popped cereal products manufactured by Gichangi Cereals and Spices and sold at
the Nyanyuki Agricultural Show
Merchandise

Weight (g)Price (Ksh)

Maize
Sorghum
Pearl millet
Wheat
Maize
Sorghum
Pearl millet
Wheat

25
25
25
25
50
50
50
50

20
20
20
20
40
40
40
40

Manufactured
Quantity
123
418
418
217
23
33
50
20

Sold Quantity
75
147
169
188
8
13
27
20

Table 7 Merchandise sold most at different events
Agricultural Show Site
Nyanyuki
Maru
Kakamega
Machakos
Kisii
NakuruKabarnet
KisumuFirst
Maize
Pearl millet
Rice (Ball)
Sorghum
Rice(Ball)
Sorghum
Sorghum
Rice(Ball)

Ranking and Merchandise Name
SecondThird
Pearl millet
Sorghum
Sorghum
Maize
Maize
Wheat
Maize
Rice (Kashata)
Sorghum
SoybeanPearl millet
Wheat
Rice
Pearl millet
Sorghum
Maize

12

FourthMaize
Wheat
SoybeanPearl millet
Maize
Maize
Maize
SoybeanPhoto 17 Mr. Gichangi (Representative of Gichangi Cereal and Spices) (rightmost end) explaining
popped cereal products made from pearl millet to Mr. Uhuru Kenyatta, President of Kenya (Source:
http://www.jkuat.ac.ke; 16 September 2017). Considering agriculture as the most important
industry, the Kenya Government supports development in the agricultural business field bydeveloping agricultural technologies. In particular, the government launched the strengtheningof support particularly on small-scale farmers, women, and young people.

Photo 18, 19 Mr. Charles, Representative of the Okonyo Migori Group that won five prizes at
the Kakamega Agricultural Show held from June 20 to 22, 2017 (Left)
Ms. Peniennah and Ms. Dorocy from the Syokinili Women Group showing trophies awarded at the
Machakos Agricultural Show held from July 4 to 8, 2017 (Right)

13

Photo 20, 21 Member of the Syokinili Women group selling popped cereals to children who
visited the Machakos Agricultural Show (July 4 to 8) by school trip (Left)
Member of the Syokinili Women Group explaining the handling of a cereal popping machine tomembers of the evaluation committee (Right)

Photo 22, 23 Mr. Francis Oundo introducing activities in this project to participants at aninternational workshop hosted by the Australian Center for International Agricultural. Research(ACIAR) (July 3 to 7, 2017) (Left and right)

Photo 24, 25 Demonstration of popped cereals at Busia County Mundika High School (Left) andthe Agricultural Training Center (Right) (July 7, 2017). Demonstration to 480 students at
Mundika High School (Left)14

(2) Dissemination and Enlightenment Activities in Surrounding Countries
The demonstration survey in this project was not limited to Kenya but expanded toneighboring countries.
(a) Tanzania
Participation in the international commercial festival Saba Saba held in Dodoma,Tanzania held on July 7, 2017 was planned for popped cereal demonstration sales. Since
Kenyan presidential election result was also to be announced on the day, however, thisplan was abandoned because of concerns about insecurity and border blockade.
Meanwhile, Kikkoman Corp. is considering the implementation of pressure popping
machine in cooperation with Matoborwa Ltd. 2 based in Dodoma County, Tanzania.
Kikkoman Corp. is considering merchandise development through test marketing with
Yoshimura-type pressure popping machine, and survey on favorite flavors of residents.
If this starts turning a business cycle, we will disseminate pop processing for social
contribution, such as business launch and promotion of using traditional foods in local
areas by using profits distributed to the company as funds. From the technicalperspective, we are now developing a trial popped soybean snack. It is difficult to season
the snack because the surface is smoother than those of grains. Since the snack should
also be crunchy, we need to overcome a technical hurdle in commercializing the snack.
As to processing, we are now considering cooperation with Ikeda Seika based in Aichi
Prefecture, Japan.
In addition, we received inquiries about the implementation of Kenyan-madecereal popping machine from several NGOs based in Tanzania organization. Purchase is
now under consideration by visiting DK Engineering.
(b) Uganda
With the cooperation of Gichangi Cereals and Spices and DK Engineering, the project
team participated in the Uganda International Trade Fair (UGITF) held in Kampala,
Uganda for popped cereal demonstration sales from October 3 to 10, 2017. DKEngineering exhibited many in-house juicing machines as well as cereal popping
machines.
This trade fair was participated in not only by the team of this project but also
Crystal Field Investment Ltd. (Zimbabwe capital) selling popped cereal products
2

Matoborwa Ltd.: Local company manufacturing and selling dried potatoes and fruits in Tanzania(http://57631919.at.webry.info/201511/article_2.html)

15

(Maputi). The company has a large 6 kg cereal popping machine made in China and is
now manufacturing products mainly from Ugandan maize. The seasonings were red
pepper and honey coating. In Nairobi, Yalika Ltd. used to manufacture and sell maize
products (Business Daily 2014). However, the Zimbabwe-capitalized popped cereal
manufacturer withdrew from the market about 2015. Relationships between Crystal
Field Investment Ltd. and Yalika Ltd. are unknown. However, the companies are very
similar to each other because they are both Zimbabwe-capitalized and manufacture andsell maize-only products.
At other processed food fairs, banana powder, banana biscuits, and nutritionadjusted porridge mixes using soybean powder and banana powder were exhibited underthe Banana Industrial Development Project supported by the Ugandan Government.
The exhibits included dried bamboo shoots, amaranths cereal bars and biscuits, andnutrition-adjusted porridge mixes manufactured and sold by Natural Limited under thesupervision of the Makerere University. The Islamic University exhibited hibiscus juice,tamarind juice, soursop juice, and date jam and syrup. Participants from neighboring
Rwanda were Africa Improved Foods Ltd. and Sosoma Industries Ltd. Africa Improved
Foods Ltd. exhibited nutrition-adjusted porridge mixes and cassava powder. Sosoma
Industries Ltd. exhibited soybean powder, organically grown coffee and tea, and otherproducts, including passion fruit juice and banana wine. They featured many products
processed from local agricultural products and nutrition-considered processed products.

Photo 26 Processed product in UGITF

Photo 27 Popped cereal was displayed in UGITF

Many participants in the field of food processing machines were agencies importing andselling products made in China and India. Their exhibits were grain mills, vegetables,
fruit juicers & mixers, vegetable and fruit peelers, waffle irons, and pancake machines.
Judging from these exhibits, the cereal popping machines and processed products
16manufactured from sorghum and millet under this project were considered unique andattracted participants.

Photo 28 Processing machine in UGITF

Photo 29 Pressure popping machine in UGITF

In October 2016, a meeting was held with agricultural staff at the Ugandan Office of
JICA. At the meeting, a rice producing area in the east was taken up as a candidate forthe implementation of cereal popping machine. In Uganda, JICA specialists from Japan
implemented one Yoshimura-type pressure popping machine made in Japan. A local
newspaper introduced activities of local cooperation staff by using this machine.
According to the newspaper, however, the activities are limited to demonstrations bycooperation staff at events because there are no human resources or parts for repairing
available in Uganda and import will cost very high.
(c) Burundi
The 18th East Africa Jua Kari/Nguvu Kazi Expo was held in Bujumbura, the capital of
Burundi, from December 3 to 10, 2017. Mr. Charles Mogeni from the Okonyo Migori
Group participated in this exposition and demonstrated a pressure popping machine andsold popped cereals. This exposition is held once a year, in five East African countries byturns. Burundi was not included in the target countries of this project in the fiscal year.
However, Burundi was included at the request of Enterprise Development Support
Personnel of the Kusumu County Government (Kusumu County, Siaya County, and Kisii
County) and governmental organization Micro & Small Enterprise Authority and tosupport participation by the Okonyo Migori Group totally. JUAKARI is a word coinedfrom "jua" meaning the sun and "kali" meaning sharp in Swahili. This refers to the
manufacturing business (tinsmith, blacksmith, woodworking, sewing, printing, etc.) or
repairing business (repairing electric products, bicycles, shoes, etc.) belonging to an
17

informal sector and requiring technology and skills.
(d) Ethiopia
A JICA specialist at the Project for Functional Enhancement of the National Rice
Research and Training Center (EthioRice) made an inquiry about pressure popping
machine for value addition to rice. They seem to be considering the implementation of
Kenyan-made cereal popping machines also because part procurement and technicaltraining are easy.
(e) Cambodia・Indonesia
Su-Re Coffee Ltd. based in Bali, Indonesia is directly devoted to sustainable development
and environment-resilient activities. Mr. Takeshi Takama, president of the company,
studied the project activities and visited DK Engineering. By taking these opportunities,
Su-Re Coffee Ltd. started manufacturing an experimental cereal popping machine basedon a design drawing provided from Bioversity. The company worked out a project toimprove the agricultural income and cultivate human resources by implementing
Kenyan-made cereal popping machines. At the same time, they created a written
proposal to improve the agricultural income of Bali with DK Engineering and Stockholm
Environment Institute by using DK Engineering developed technology. With this
proposal, they made an application to the Small Grants Programme of the Global
Environment Facility (GEF) for funding.

Photo 30 Mr. Takeshi Takama, representative of Su-Re Coffee Ltd. inIndonesia and Mr. Daniel Kirori from DK Engineering(f) International organizations
In the latter half of the last fiscal year, UN-HABITAT was considering the18

implementation of pressure popping machine as measures of assisting residents at a
refugee camp in Turkana County located in the north of Kenya. However, no substantial
progress was made in this fiscal year. Meanwhile, WFP is also considering theimplementation of cereal popping machine and specific coordination in activities in
Makueni County located in the east of Kenya. Our continuous enlightenment activities
by demonstration sales at many shows listed in Table 3 seem to be making pressure
popping machines and popped products known to domestic and international partners
organizations visiting the shows.
(g) Japanese school
We made popped cereal demonstration sales at "Fureai Festival" held on September 16,
2017 under the auspices of the Japanese Association Nairobi. With the cooperation of
PTA of the Japanese school in Nairobi, we devised original products by applying various
seasonings to sorghum-based cereals. On the day, we sold nine kinds of products of eightflavor types. The basic flavor was sugar (plain) and the other flavors were curry, sauce,cocoa, green tea milk, sweet soy sauce glaze (sugar, soy sauce, and mixture of seven
spices), chocolate coating (Right-hand photo: white and black chocolate), and kashata(kashata: syrup and roasted soybean flour). We received cooperation from PTA andchildren and donated the profit to the PTA of the Japanese school.

Photo 31, 32 Popped cereal demonstration sales by PTA of Japanese school (September 16)(3) Provision of Training
In this fiscal year, we held two-day trainings by visiting individual and organizational
entrepreneurs and business operators who voluntarily purchased pressure popping
machines. Through the trainings, we provided information and technology acquired
through the project activities.
So far, we have conducted the training on three organizations as detailed inTable 8.
19

Table 8．Places and periods of training and purchasing organization names
1

Place
Bomet

2

Nairobi

3

BukuraPeriodSeptember 25 to27
December 6 and13
February 23 and24

Purchasing Organization
John Koech

Attribute
Individual
entrepreneur
Company

Nissin Foods Group
Affective Action, Women Represent office,Kakamega County.

Localgovernmentalorganization

We explained the background and purpose of this project, the section names of cereal
popping machines, and the handling, management, material preparation, andadjustment methods. We also explained the processing, seasoning, labeling, packaging,and sales methods, including the acquisition of food sanitation certificate and nutrition
analysis result.
We could verify the great effect of providing a training at the same as machinepurchase because of high awareness of the purchasers. From participants, we receive agreat many inquiries about continuous training after the project, about troubleshooting
or support concerning parts, operation, and management, and the like. They expect us
to keep providing trainings. Therefore, Bioversity International is planning continuous
support (information provision) about machine repairing, management, and cereal
popping even after the project, in cooperation with DK Engineering. If part procurement
or on-site repairing is not possible, the machine needs to be taken to DK Engineeringand an extra charge becomes necessary for personnel dispatch.
In cooperation with KIRDI, the Government is promoting the implementationof food processing machines for peanut butter, sunflower oil, and mango juice to promote
the local industries and support rural organizations. DK Engineering manufactures
various food processing machines to meet such governmental demands, but their support
is not enough about post-implementation management and demonstration sales using
the machines. Since KIRDI engineers do not necessarily have enough knowledge about
each machine, they cannot make full use of the machines. There were found many
machines not used or even tested by actual running in the KIRDI warehouse. Continuous
training on machine purchasers is important also for progress of this project.
Formanagement,

continuous

training

activities

operation,

management,(machine

poppedcerealmanufacturing,

quality

manufacturing,productmanagement, etc.), it is considered good to establish a local corporation or NGO by using
local human resources cultivated in this project, nurture local expert trainers, and makethe dispatch service independent. However, further verification may be necessary about
20

sustainability.

Photo 33, 34 Peanut butter making machine provided by DK Engineering at the request of Kagamega
County Government (Left) Staff from DK Engineering is explaining the handling of a sunflower
oil machine to representatives of local organizations in Kagamega County, government officialsof the county, and KIRDI staff. It is necessary to continue training about the method of using
and managing an implemented machine and about processes from production to sales.

Photo 35, 36 Training on a rural organization in Bulura Village, Kagamega County located in thewest of Kenya. Project team explaining the handling of a cereal popping machine to therepresentative of rural organization and local government officials (Left). Demonstration of
kashata processing and tasting (Right). Continuous follow-up activities are expected.

21

Photo 37, 38 Training on the family of Mr. John Koech, an individual investor in Bomet County(Left), Mr. and Mrs. Koech (Right). Mr. Koech is public servant working for Kisii County. He
decided to purchase a cereal popping machines for a new business after retirement. He knew theexistence of cereal popping machine at the agricultural shows held in Nakuru County and Kabarnet
County.

Photo 39, 40 Demonstration to employees of Nissin Foods Co., Ltd., including machine training(4) Issues about Organizational Activities
Last year, this project was started with three business operators. Among them, theindividual entrepreneur Gichangi Cereals and Spices increased income steadily by
expanding business. This was sharp contrast with the other two business operators,
Syokinili Women Group and Okonyo Migori Group, who tackled the business byorganizational activities. Thus, several issues were highlighted about organizational
activities. The issues affected even exhibition activities at agricultural shows.
・Business experiences are not sufficient. They cannot handle many customers becauseof their unfamiliarity with customer attendance. However, they are showing signs ofimprovement.
・There is not enough merchandise and preparation is not satisfactory. They are not22

proficient in money management, and lacking in the habit of booking, transparency,
and leadership. Under a complete role sharing system, the specialties andresponsibilities of individual members are respected but they cannot do work assigned
to other members. In addition, they do not share work possibly because they respectindividual roles each other, do not have enough experiences, and are lacking inexperiences of cooperation. Therefore, if one member cannot participate in group
activities, the entire work stops. There are not many people who can do all the work.
・They have limited skills and inadequate experiences. Labels and packages are not
improved. Bags are torn, and merchandise is not uniform because of eyeballing oreyeballing with a cup.
・Merchandise cannot be developed. They do not have confidence in tastes and selleven merchandise not finished well.
・Flavors are not selected well. Products of salty favor to not sell to children.
・They do not have enough business experiences. This explains everything.
・Unlike merry-go-round or table bank, this business requires experiences in fundmanagement and operation. Without transparency, the group will lose reliance andcollapse because of stagnant group activities.
(5) Governmental and other support systems to diffuse local production for local
consumption
About subsidies and financing systems available for farmer groups to promote
implementation by purchase, we already conducted a survey in Kitui County in the last
fiscal year. In the case of Kitui, several banks were investigated for financing about 1,000
dollars. Based on the Youth Enterprise Development Fund by the Kenyan Government,
various packages are provided for the financial support and individuals andorganizations and for agri-business support 3 . Since the maximum amount andcharacteristics of support differ between the packages, an optimum package can beselected according to the characteristics and purpose of business operator.
However, since the interest rate of bank financing is as high as 15% and fundaccess is complicated, many organizations feel it more effective and easier to use tablebanking and other personal loans or to raise funds among rural group members.
In addition, local governments have sections supporting Affirmative Action andwomen organization activities. They are promoting active machine implementation as
measures of increasing income in rural areas and promote the use of local resources.

3

http://www.youthfund.go.ke/

23

(6) Creation of Various Snacks by Using Popped Grains
On June 13, Mr. Gichangi visited Kenya Fruit Solutions and held a meeting with Mr.
Yamamoto and Mr. Jeseph (production manager). The following merchandise can be sold.
-Pineapple grade B-Mango grade B-Coconut grade B and C
The water contents of the merchandise can be adjusted to 5% or less for shredding or
milling to mix into popped cereals. The proposed price was 150Ksh per 250 g. This is not
bad for testing at the initial stage of implementation. However, high cost may makesustainable use impossible. The remaining issue was how nonstandard products of highquality, but low merchandise value could be procured.
We hear that Fruit Solutions disposes of mango peels. We will appreciate it if
we can have opportunities of developing new merchandise by drying the disposed peels
into chips or by using other means.
Mr. Gichangi et. al. visited macadamia nut and cashew nut processing
companies and investigated materials available as flavors. However, they foundmerchandise for products too expensive to use. They found crushed dregs but were toldthat the dregs are for feedstuff and cannot be sold as foods. It will be important to acquirematerials for mixing into popped cereals. Therefore, we should keep investigating goodmerchandise and vendors.
Cereal popping not only raises the agricultural income but also vitalizes rural
areas by increasing employment opportunities. According to a survey, this processing
also reduces the cooking time and does not change nutrients. Therefore, contribution to
nutrition improvement can also expected from popped cereals. Even grains that fail toswell are milled and used as porridges selling as popular merchandise. We can contributeto sustainable agricultural production and the conservation of Satoyama environment
by increasing the demand for the conventional agricultural produces and developing a
new market. Popped cereals will also improve nutrition (the main consumer bracket ischildren in the local areas) and contribute to the conservation of local agricultural
resources and production environment (Satoyama) and the restoration of traditional foodculture.
3. Results of the activities by the group and incidental survey(1) Syokinili Group of Kitsui County
 The Syokinili Group split in March 2017. Since the split, the popped cereal production24activities have been stagnant as they overlap with the busy farming season.
 The Group had an opportunity to participate in the Machakos and Cabalnet
Agricultural Shows that were held in June and July, 2017 respectively. The Groupexhibited and sold popped cereals made of rice, maize, sorghum, and pearl millet,
achieving the sales amounting to 22,310 Ksh in total at two venues.
 The Group was requested to display and sell traditional cuisines and popped cereals
from the County Government and African Harvest (NGO) that participated in the
Kitui Agricultural Show at the end of July in 2017. In response to this invitation, theGroup prepared a total of 1505 bags of popped cereals made of rice, maize, sorghum,
and pearl millet.
 The participation in the agricultural show triggered revitalization of the activities of
the Group. However at that time, on the second day of the Kitui Agricultural Show, acholera pandemic occurred in Nairobi and Kisumu County, and seven other counties,
and the Ministry of Health prohibited the sales of foods on the streets. At the sametime, they prohibited the sales of foods even in the hall of the agricultural show,
resulting in that two thirds of the 1505 bags, which is 981 bags, of popped cereals thatwere prepared were left unsold.
 The unsold products were divided and stored in the home of each group member andwere sold slowly in the areas around the houses of the members. However, only around10 bags were sold per day.
 At the beginning of August, when two young members (male) of the Group werearranging the leftover products in small plastic bags on a stall in the Kato Rani regularmarket, they were arrested by an official of NEMA (National Environment
Management Authority) and a government official of the County Office for selling
products by using plastic bags.
 In February 2017, prohibition of the use, manufacturing, and importing of plastic bags
was notified. Although it was widely known that the notice would be effective from
August, which is six months from the date of the notice, no one expected the degree ofthe strictness of the control response.
 One of the members who were arrested was released as a result of the negotiation andinformed the situation to the leader of the Group immediately. The leader immediately
visited the office and started the negotiation. The other member was released bypaying a penalty of 3,000 Ksh, although it was 30,000 Ksh officially.
 The amount of 3,000 Ksh was a significant expenditure for the Group, causing a
trauma within the Group. Discouraged members could not devise an alternative
packaging method to the plastic bags and the activity became stagnant.
 None of the popped cereals were produced for the period from September to thebeginning of December due to the external factors such as the pandemic of cholera andthe prohibition of the use of plastic bags.
 When we visited the Group at the beginning of December, the members asked us about
the popped cereal packaging method. We introduced to the members of the Group the25packaging method and the sales method that were being applied by Mr. Gichangi of
Embu County.

Photo 42 Printed A4 paper

Photo 41 Packed in funnel shape

Photo 44 Plastic cups and containers

Photo 43 Paper and paper bags for wrappingkashatas

 Kashatas are stored in a transparent plastic bucket to make them visible to customers
and are sold to customers by wrapping them with paper (Photo 41, 42). For a customer
who buys five or more kashatas, they are put in a paper bag (Photo 43). Kashatas were
initially produced by the Syokinili Group and the members re-recognized thatkashatas can be sold without using plastic bags. Then they noticed that the products
can be sold with a simple method by using a packaging material that can be obtained
locally and as a result, the activities were resumed.

Photo 45 Preparing the paper for wrapping

Photo 46 Kashata wrapped by paper

kashatas26 This concludes the monitoring. We heard that the machine broke afterward. However,
it is not known whether they repaired the machine by themselves.
(2) Okonyo Group of Migori County
 Since March 2017, the number of members who are engaged in the popped cereal
production has become two in the Okonyo Group. They managed to continue theirsmall activities in the unstable condition while securing labor forces temporarily at
the production stage only.
 Under such circumstances, the Group had opportunities for participating in the
Kakamega, Kishii, and Kitsui Agricultural Shows over the period from June to July.
They exhibited and sold maize, sorghum, rice (ball), and soybeans, and sales amounted
to 42,300 Ksh across the three venues.
 When the activities were beginning to become vitalized as a result of the participationin the Agricultural Shows, the campaigns for the Presidency started heating up
towards the election on August 8. In Migori County, near Kisumu, which was the baseof Mr. Odinga, who was a Presidential candidate in the opposition alliance, the publicorder started to become unstable. During this time, the members halted production of
popped cereals as it produced a loud noise.
 After the defeat of Mr. Odinga became clear as a result of the election results, Mr.
Odinga lodged a protest to the High Court for possible fraud in the counting operation.
On September 1, the High Court approved the protest from NASA, invalidated theelection result, and ordered re-election within 60 days.
 Given this situation, participation in the Agricultural Show that was to be held at
Migori in August 23 was requested from the County Government, and the Group
produced popped cereals from 5 kg of maize, 9 kg of rice, and 1 kg of sorghum. During
this process, the pressure gauge started to have a problem, so the maize and sorghum
could not be processed properly and the maize and sorghum were sold before theAgricultural Show. Consequently, only the rice was exhibited and sold at theAgricultural Show. Although products amounting to 10,275 Ksh were prepared, about
only a half, that is products amounting to 5,475 Ksh, were actually sold.
 Even after having sold all the products that were left unsold at the Agricultural show,
they avoided any production that produced a loud noise.
 Although the re-election date was determined to be on October 26, in Migori, which isone of the support bases for the opposition alliance, violent protest activities were
frequent up to the re-election. With the deterioration of the public order, popped cereal
production activities became difficult under the increased number of police for the
maintenance of public order. Although the voting rate of the re-election was low dueto the boycott by the NASA camp, Mr. Kenyatta, the current President, won gaining
98% for the percentage of votes obtained and was formally appointed as the President27

on November 28. After all, the turmoil of the political situation started to become morestable.
 The corporate development officer of the County Government indicated participationof the Group, representing Migori, in the “East Africa JUAKALI/NGUVU KAZIExhibition Bujumbura Burundi”, which was held in Burundi for the period from
December 3 to 10. In response to this request, the leader of the Okonyo Group preparedpopped cereals from 4 kg of rice, 4 kg of sorghum, 5 kg of maize, and 2 kg of soybeans
and shipped them through a truck that was prepared by MSEA together with raw
grains, 25 kg, 40 kg, 6 kg, and 2 kg respectively and also 1 kg of wheat as well as apressure popping machine. At the venue, the Group demonstrated the pressure
popping process for 2 kg of rice, 2 kg of sorghum, and 2 kg of soybeans over 3 days.
The sales of the products were poor and only snacks equivalent to 1400 Ksh were soldthroughout the period.
 While the political situation has become comparatively stable, future activities of the
Okonyo Group were anticipated. However, since they were not as enthusiastic as they
were for participation in these events, we decided to listen to the customers’ opinions.
 The leader of the Okonyo Group has been conducting a small business by selling soy
drink (powder), roasted soybean flower, tea, and spice at a kiosk at kiosks by packing
them in small bags since before he started the pressure popping process business.
Through the business that has been continued by the leader, the Group has alreadyestablished the method of selling the products to customers such as kiosks, mini supermarkets, and shops within the markets, thereby establishing a sales network.
 This time, we had a chance to listen to the shop owners by visiting a total of 41 kiosks
and mini super-markets and recognized again the size of this network and thesignificance of the popped cereal market.
 No popped cereals were left in any of the shops that we visited this time and all the
shop owners were hoping for the next delivery of the products. In all the shops, they
asked, “When can you deliver the products?” and even said, “We will lose the customers
unless the products are made available soon.” In Migori, since the sales network that was built by the leader of the Okonyo Group isalready established, the only remaining task is efficient production and no concern isnecessary regarding the sales method.

28

Photo 47 Owner of the kiosk

Photo 48 Owner of the mini super-market(3) Gichangi Cereals and Spices in Embu County
 Of the 12 months from February 2017, the monthly sales over 9 months by Mr.
Gichangi were about 48,000 Ksh, excluding the sales of August, for which sales records
were unavailable, and the sales of October, during which Mr. Gichangi visited Uganda
and Japan. Based on this result, both the production/processing and sales are assumed
to be operating well. August was the month of the Presidency election and theintroduction of the prohibition of plastic bags.
 As the countermeasure for the prohibition of the use of plastic bags, Mr. Gichangi
created containers by wrapping A4 paper into a funnel shape (Photo 41). Paper of adifferent color is used for each grain and after the paper is formed as a container, theprinted letters are placed at the front (Photo 42). For the cost for the paper container,
the printing of one sheet costs 3 Ksh, a white paper including printing (for wheat) costs
3.8 Ksh/sheet, a colored paper (for sorghum and millet) costs 4 Ksh/sheet. Currently,
the products that use the paper containers are sold for 20 Ksh. Since snacks of 25 g ina container were sold at 20 Ksh, the volume was reduced by 5 g (20%), which means
the consumer bears the cost of the paper container of about 4 Ksh. For a container of
500 ml plastic cup (container fee 6 Ksh) and a 1000 ml plastic container (container fee
13.5 Ksh/container), the container fees are borne by the customer based on the pricesetting.
 Mr. Gichangi participated in the training program in Japan that was implemented by
Ieda Seika Corporation for the period from October 21 to November 1, 2017. He
introduced, in the production site in Kenya, many of the production methods of a snack
called Okoshi (kashata in Kenya), machine management, and hygiene management of
the processing factory that he learned during the training.
(a) For the kashata production, he used the recipes of Ieda Seika without change andalso introduced an originality by using baobab, honey, soy sauce, cinnamon, ginger,
turmeric, and red pepper.
(b) For the molding process also, he created a mold frame of the same size and changed
the size that allows the making of 216 (average 11 g/piece) kashata each time. The
29

production cost per piece was 3.4 Ksh. He sells this product at 10 Ksh per piece.
However, the sales cost and machine depreciation were not included in the
production cost.

Photo

49

Kashatamolding

processing

Photo 50 Cutting kashata(levelling)(c) The pressure popping machine was improved by connecting the main unit and thepressure gauge with a coupler socket to allow disconnection of the pressure gauge
at decompression in order to reduce the load to the pressure gauge at decompression
by instantly opening the cover of the pressure popping machine.

Photo 51 The pressure gauge is connected

Photo 52 The pressure gauge is removed

30

Photo 53 Uniform in the processing factory

Photo 54 The heat source is changed fromfirewood to a gas stove(d) The hygiene management in the processing factory has also been improved. Eachworker wears rubber boots, a coat, and a hat (Photo 53). When touching a product,a worker uses disposable gloves.
(e) The heat source of the pressure popping machine was changed from firewood to agas stove (Photo 54). Although the gas stove was purchased during his visit to Japanfor training, Mr. Gichangi improved and installed it immediately after returning
home. The cost of the gas required for one popped cereal production is 3.4 Ksh. Since
the firewood costed 5 Ksh per time, the introduction of the gas stove is more effective
in terms of cost as well as the elimination of smoke.
 Since kashatas over a large varieties of flavors are produced, they cannot be
discriminated simply by color coding. Therefore, Mr. Gichangi colors the face of the
kashata for identification by placing thinly roasted soybean flour or powder of driedstinging nettle leaves on the table when producing kashata (Photo 55 and 56).
 The current problem for Mr. Gichangi is humidity. In Japan, a dryer is used and silica
gel is also placed in a bag. Although Mr. Gichangi searched for silica gel within Kenya,
he found out that silica gel is not available and he is currently searching for somealternative. We informed him that, in Japan, limestone (calcium oxide) is used as afood drying agent as well as silica gel. Since limestone may be available in Kenya also,
we hope that he will try it soon.

31

Photo 55 Kashata colored with roasted soybean

Photo 56 Kashata colored with Nettleflour(4) Koech Family of Bomet County
 The popped cereal business that was started by Mr. John involves four young malemembers comprising his son and relatives. Mr. John and the members received
training from the project team, operated for 7 days for the period of about 50 days from
October 16 to December 4, and produced popped cereals of honey flavor from the grains
including 58 kg of maize, 18 kg of rice, 15 kg of sorghum, and 5 kg of wheat. The sales
amount for this period was 24,980 Ksh.
 The reason that the production volume of maize was far higher stems from thetraditional popcorn that is made with hot charcoal in mound of a burnt field called
Mugero, and maize is the most familiar product for the local consumers.
 Although Mr. John purchased all the tools, ingredients, and equipment for producing
kashata as he had learned in Japan, he had not practiced the production until wevisited for monitoring on December 12, as if he was not confident to teach the othermembers by himself.
 On the day when we visited, all the tools, equipment, pressure popped rice as the main
ingredient and supplementary ingredients such as starch syrup and sugar wereprepared (Photo 57). Initially, the size of a single kashata was decided to be 3 cm x 7
cm and the scales were marked on the table (Photo 58) according to the mold of 63 cm
x 63 cm. One hundred eighty-nine kashatas can be produced at one production run
based on the calculation.

32

Photo 57 Supplementary ingredients for kashata

Photo 58 Tools and marking the scale Young members were in charge of the pressure popping process and sought advice on
the problem of many losses such as burnt finish of rice and the failure of puffing
properly. At the checking of the production site, initially, we noticed that the fire was
not strong enough, so we provided advice to add more firewood. Since the machine wasalso rotated extremely quickly, we advised to rotate at 40 to 70 revolutions per minute.
If the machine is rotated too quickly, only the cylinder rotates and the grains remains
in the one place, resulting in firing only some section of the ingredients. The machinemust be rotated slowly to spread the grains inside of the cylinder. The main cause of a
failure of popping rice grains is the water content of the rice grains. If the rice grains
are too dry, a suitable amount of water must be added to make a proper water content,
which is around 15%, and then the rice must be left to stand overnight. This advice
was also provided to Koech and other members.
 For the flavoring of kashata, brown sugar flavor and a soya sauce flavor were applied
according to the request from Mr. John. Although the proper temperature of toffee was
supposed to be 120C, the temperature did not rise easily from around 110C due tothe high altitude of the site. Therefore, the toffee was removed from the fire when thetemperature reached 115C and it was mixed with the ingredients. It then became
coagulated without any serious problem.
 With this, Mr. John and the other four members seem to have mastered the basic
operations for producing popped cereals and kashatas.
 Koech family produced kashatas by operating for the period of 4 days during a onemonth period from December 12 to January 14. Kashatas were stored in transparent
buckets and were sold by explaining the products face to face while moving around themarket. Although kashatas of popped cereals are not well known in this region, thesales for the period amounted to 28,700 Ksh.
(5) Result of customer survey
 This survey was conducted to understand the age groups of the consumers and theconsumer trend towards popped cereals.
 At the Embu, Runyejes, and Kabati markets, the products were exhibited when themarkets were held and surveys were conducted while selling the products. At the33

Embu market, basically, products were sold at a street stall and at Runyejes andKabati markets, mobile sales were also used for several hours in the afternoon. The
mobile sales produced more sales results as the method gave more opportunities for
direct contact with customers. At the Embu market, the survey over 6 days for theperiod of 8 days was outsourced to Mr. Gichangi.
 Bomet is a region of Mungungo location, where tea plantations are found and thesurvey was conducted during the mobile sales. The survey was outsourced to the sales
staff.
(a) Customer genders
 As shown in the table below, at the Embu and Kabati market, there are no significant
differences between consumer genders. However, in both markets, the numbers offemale customers are slightly higher. This seems to be based on the fact that most of
the shoppers are females and this factor is shown in the result.
 The assumed reason for the higher number of male customers in the Runyejes market
is that drivers of motorbike taxis purchased many kashatas during the mobile roadsales.
 At the survey site of Bomet, the reason for a higher proportion of males seems to be
the reflection of the male to female ratio of the workers at the farms.
(b) Customer age group
 For the Embu, Runyejes, and Kabati markets, the high proportion of the young
generation and the middle age group who use the markets seemed to have been
directly reflected in the result.
 For the Runyejes market, the proportion of the young generation was comparatively
high as many drivers of motorbike taxis purchased the products.
 In Bomet, many children who were picking tea leaves purchased the products and thisseems to the reason for the high proportion of children.
(c) Products that were purchased by the customers
 As kashata had not been produced at that time, it is not yet possible to provide acomparison yet. However, based on the result of other three markets, consumers seemto be overwhelmingly in favor of kashata over popped cereals. According to the tablebelow, popped cereals are accepted by all the age groups.
 In terms of grain type, since the overwhelming popularity of kashata is accepted,
naturally the proportion of rice, which is the main ingredient of kashata, is high.
 According to the figures that are shown in the table below, sales of pearl millet andsorghum, which are also cereals, have not necessarily become stagnant. Kashata,
which is made of rice, gained more customers and in the actual situation, the numberof customers of popped cereals that are made of pearl millet and sorghum still remains
34

high.
 Mr. Gichangi uses a low-priced ground rice for kashata instead of actual rice. Recently,
he has produced kashata by mixing popped rice and pearl millet in the ratio of 8:2.
 Some customers started to request a specific flavor although the number of customers
is still low. This seems to be a sign of the increasing awareness towards the products.
As shown in the table below, seeing that in the Embu market, about 10% of customers
purchased the products over multiple flavors, the offering of a variety of flavors seems
to lead to an increase of consumption.
 For the quantity of products purchased per customer, the result of the surveys at four
locations indicates that almost 60% of customers purchased only one piece.
 In the Embu market, nearly 40% of the customers purchased several pieces.
Customers of the age group older than the middle age and late middle age groups
purchased the products as the souvenirs for the family (children).
 In the Embu market, 23 customers purchased 24 kashatas or more although theproportion is only 2.5%. While the price of one kashata is 10 Ksh, a pack containing 24
kashatas is sold at 180 Ksh. A set of 10 packs is sold at 1700 Ksh, which is even lower
per pack. Recently, the owners of kiosks and hawkers conducting mobile road sales
purchase the products in packs and sell them individually. This situation is increasing.
An increase of such cases is the proof of the increase of acceptance of popped cereals
by customers.
 During this survey, two wholesalers purchased 10 packs each.

35

Table 9 Results of customer survey
Location
CountyBomet (around tea
Kabati Market
plantations)
Kitwii
Bomet
December 6, 2017 to
December 12 and 13,
December 7, 2017
December 21, 2017
January 16, 20182017
(1 day)(1 day)(8 days)(2 days)(Persons)(%)(Persons)(%)(Persons)(%)(Persons)
(%)
397
43.7
148
63.0
39
67.2
74
43.0
511
56.3
87
37.0
19
32.8
98
57.0
908
100.0
235
100.0
58
100.0
172
100.0
Embu market
Embu

Date of survey

Male
FemaleTotal
4 to 12 years
Childof age13 to 19
Juvenileyears of age
Customer
20 to 34
Youthage group
years of age
Mature 35 to 49
years of age
adult
Middle50 years ofage
age or older
Total
Kashata
PoppedcerealType
BothCustomergenderRunyejes Market
Embu

29

3.2

15

6.4

16

27.6

15

8.7

76

8.4

30

12.8

7

12.1

28

16.3

204

22.5

81

34.5

15

25.9

44

25.6

520

57.3

93

39.6

14

24.1

66

38.4

79

8.7

16

6.8

6

10.3

19

11.0

908
759

100.0
83.6

235
199

100.0
84.7

58
0

100.0
0.0

172
120

100.0
69.8

134

14.8

32

13.6

58

100.0

49

28.5

15

4

0
26
0
2
0
20

0.0
100.0
44.8
0.0
3.4
0.0
34.5

3

199
29
0
0
0

1.7
100.0
84.7
12.3
0.0
0.0
0.0

120
38
9
0
1

1.7
100.0
69.8
22.1
5.2
0.0
0.6

7

3.0

10

17.2

4

2.3

199
32

100.0
84.7
13.6

Rice
MilletSorghum
Wheat
Maize
2 types or
more

759
97
31
1
0

1.7
100.0
83.6
10.7
3.4
0.1
0.0

20

2.2

BaobabHoney
Soy sauce
CinnamonGingerTurmeric
Red pepper
Brown sugar
Brown sugar+ baobab
Salt
Multiple

307
229
51
45
116
11
54

100.0
33.8
25.2
5.6
5.0
12.8
1.2
5.9

1 piece2 to 5 pieces
6 to 10piecesQuantity
11 to 23
pieces
24 pieces or
more

Grains

Productspurchasedby thecustomers
Flavors

100.0
58

100.0

100.0
48

27.9

106

61.6

14

8.1

1
3

195
33

1.7
100.0
83.0
14.0

34
23

100.0
58.6
39.7

140
32

0.6
1.7
100.0
81.4
18.6

2.4

0

0.0

1

1.7

0

0.0

2

0.2

0

0.0

0

0.0

0

0.0

23

2.5

7

3.0

0

0.0

0

0.0

908

100.0

235

100.0

58

100.0

172

100.0

95
537
324

10.5
100.0
59.1
35.7

22

4

36

(6) Results of incidental survey(a) Matters to be surveyed as governments supports to diffuse local production for local
consumption(i) Support of training on local production for local consumption
From the government of Kitui County, we have already acquired information about
assistance to the Self Help Group. Independence support to youth and female groups isa nation-level priority issue. Since the activities are consistent, we also surveyed othercounties.
(ii) Introduction of local production for local consumption at agricultural exhibitions andother events
We have ever participated in agricultural shows which Agricultural Society of Kenya(ASK) hosted in 10 areas. We exhibited popped cereals, demonstrated manufacturing,and made sales at the booths of MSEA and MOA. What is noteworthy is that the
Syokinili Group of Kitui was invited by the Ministry of Culture, Youth, Sports, Genderand Social Services and the Africa Harvest (NGO to diffuse improved seeds of pearl
millet and sorghum) to an agricultural show hosted by Kitui County and exhibited andsold popped cereals and porridges at their booths. Tables 10, 11, and 12 show past
participations in agricultural shows. The booths of MSEA and MOA booths won various
prizes in many areas as shown in Table 11. It is a fact patent to the public that thisproject contributed to these commendations.
Table 10
Schedule

Participations in agricultural shows hosted by ASK

Place

Paticipant Team

March 2 to 4, 2017

Embu

Gichangi Cereals and Spices (Embu)

May 25 to 27, 2017
June 6 to 10, 2017

Nanyuki
Meru

Gichangi Cereals and Spices (Embu)
Gichangi Cereals and Spices (Embu)

June 15 to 17, 2017

Kagamega

Okonyo Group (Migori)

June 28 to July 1, 2017

Machakos

Syokinili Group (Kitui)

Commendation

Sales
(Ksh)
15,040First prize in three fields
First prize in three fields
Second prize in three fields
Third prize in one field
First prize in three fields
Second prize in two fields
First prize in two fields

14,00027,1359,430
12,300

Second prize in one field
July 4 to 8 2017
July 13 to 15, 2017
July 20 to 22, 2017

Nakuru
Kisii
Kabarnet

Gichangi Cereals and Spices (Embu)
Okonyo Group (Migori)
Syokinili Group (Kitui)First prize in three fields

26,00014,0309,500

July 20 to 22, 2017

Kitui *

Syokinili Group (Kitui)First prize を in one field

10,490July 25 to 29, 2017

KusumuOkonyo Group (Migori)37

Table 11

Commendations of MSEA and MOA booths at agricultural shows hosted ASK

Field of Commendation

Ranking
First

Best Innovation and Invention Stand

Nanyuki
Kisii

Best Local Manufacturing Stand, Non-

Kagamega

Kisii

SecondThird

Kagamega

Meru

Meru

NanyukiKagamega

consumables

Meru

Best Regulatory Authority andNanyuki

Machakos

Best Regulatory Authority Stand

Kagamega

Meru

Meru

Best Youth Activities and Empowerment

Kagamega

Meru

Kagamega

Cooperation Stand

Capacity Building
Best Agricultural Based Statutory Board

Meru

Stand
Best Small Trade Stand, Commercial andMachakos

Industrial

Kisii

Best Show Theme Interpretation

Kisii

Kisii

Best Local Stand in Strategies of

Meru

International Trade and Exports
Best Stand that Promote National

Machakos

Cohesion and Integration Development
Traditional Foods *Kitui

Table 12 Grain popularity ranking by agricultural show site
Agricultural Show Site

Ranking
First

SecondThird

FourthNanyuki Meru

Wheat millet*

Millet*, sorghum

Sorghum, maize

Maize, wheat

Kagamega

Rice (ball)

Maize

Wheat

SoybeanMachakosSorghum

Maize

Rice (kashata)

Millet*

Kisii

Rice (ball)Sorghum

Soybean

Maize*Pearl millet

38

(iii) Aid or financing system for implementing processing materials and equipment
Loans from major banks have already been surveyed. We will acquire information fromMSEA about Microfinance, SACCOS (Saving and Credit Co-operative Societies),
Cooperative Society, and governmental funds like Youth Enterprise Fund, Woman
Enterprise Fund, and Uwezo Fund.

Photo 59 Awards at Kagamega Agricultural Show Photo 60 Awards at Machakos Agricultural Show

Photo 61 Explanation of manufacturing at Kisii Agricultural Show, Photo 62 Sales at Kisii
Agricultural Show(b) Matters to be surveyed about regulations concerning agricultural product processing
and sales(i) Regulations concerning food sanitation
The popped cereals meet the food standards of KEBS (Kenya Bureau of Standards), butmanufacturing staff must receive medical certificates from the public health office of thecounty. However, only Mr. Gichangi from Embu has this certificate. Manufacturing
facilities require a sanitary certificate from the county.

39

(ii) Regulations concerning food quality
Since the food standards of KEBS are satisfied as mentioned above, quality can be
guaranteed if only business operators acquire a certificate about their products. Mr.
Gichangi from Embu already has a certificate. The Okonyo Group in Migori(manufacturing within KIRDI) is also making preparation for application. At this survey,
we visited the KEBS office in Isebania and confirmed the application proceedings.
(iii) Regulations concerning food processing
Because of a KEBS certificate from Embu, there is no problem about the popped cereal
processing technology.
(iv) Regulations concerning food packaging and labeling
For sales at major markets, products must bear a KEBS mark, a table of ingredients,
and a barcode and be registered for Electricity Tax Register. There are no packaging orlabeling standards for sales at kiosks or in markets. However, the products are labeled
as shown in Photo 63-65. Meanwhile, the littering of plastic bags is impairing thetownscape. Also for environmental protection, the use of plastic bags may be prohibitedin future.

Photo 63-65 Commodity labels (Okonyo Group, Syokinili Group, and Gichangi Cereals and Spices
from left)(v) Regulations concerning the sales of agricultural product processing machines
DK Engineering producing pressure popping machines is taking procedures for KEBS
certification themselves.
(vi) About business license
Mr. Gichangi from Embu has a business permit for his store in the market. According tohim, people are supposed to pay a trading tax to the municipality when doing sales in a40

market or mobile sales. The trading tax is 50 shilling per day for a city or 30 shilling per
day for a town.
(c) Other matters to be surveyed(i) Organization or individual capable of implementing local production for local
consumption
One large-scale rice mill in Mwea is interested in popped cereal manufacturing. Thesedays, many primary school students visit the rice mill by field trip. The milling company
expects to introduce grain processing for value addition as part of the activities. At thesame time, they will sell popped cereals. Since the activities lead to dietary education
about local production for local consumption, we will conduct activities including a
training once machine implementation has been determined.
(d) Outline of entities operating local production for local consumption(i) Kitui County
Since a money problem broke human relations, the Syokinili Group split in March thisyear. The group suspended their activities during the farming season after the split, but
10 members (used to be 23 members) restarted activities by taking an opportunity ofparticipating in an agricultural show. The main raw materials are maize, sorghum, rice,and pearl millet. The female leader of the group has strong connection to the county
government and the group activities are highly evaluated by the county government. The
group may have been invited in the current fiscal year because of great achievements at
the agricultural show of the last fiscal year hosted by the county government. The
Syokinili Group is now indispensable for enlightenment about and restoration of the foodculture.
(ii) Migori County
The Okonyo Group was initiated by seven members from the Table Banking Group whostarted popped cereal production. Then the group members decreased to four. Despite
brisk activities, however, two members left due to a money problem. Since late March
this year, the remaining two members have been continuing production & sales by
employing a few part-time workers on days of activities. Their main products are riceball, soy & nut, and maize. This group features a route established for transactions withnine kiosks as shown in Table 13 attached.

41

Table 13 Sales by the Okonyo Group at kiosks by using customers (as of July 2017)
Store

1

Place

Mavela Market

Weekly Del.i very Frequency

Twice(Thu & Sun)

Delivery Quantity /Cost / Dozen

Sales

Dozen / Week

(Shilling)(Shilling)

Merchandise

Rice ball4

100

Soy & peanut

2

100

400
200

2

Mavela Market

Twice(Thu & Sun)

Maize

4

100

400

3

Mavela Market

Twice(Thu & Sun)

Rice ball

2

100

200

Maize

2

100

200
400

4

Mavela Market

Twice(Thu & Sun)

Maize

4

100

5

Mavela Market

Twice(Thu & Sun)

Soy & peanut

2

100

200

6

Midoti Center

Twice

Rice ball

2

100

200

7

Angolo

Once

Maize

2

50

100

Soy & peanut

2

100

200

Soy & peanut

1

100

100

Maize

2

50

100
100

8

Migori Marke

Twice

Maize

1

100

9

Migori Juakali

Once

Soy & peanut

3

100

300

Maize

1

100

100

Total

3200

(iii) Embu County
An entrepreneur selling grains and spices started popped cereal production as a new
business. His venture business was to handle soybean drinks and roasted soybean flour.
A harmful rumor about an increase cancer incidence rate that eating soybeans raises thecancer incidence rate caused a decline in soybean product sales. He says now he mainly
handles popped cereals made from pearl millet, sorghum, maize, and wheat. The
entrepreneur participates in fair and events and hawks merchandise in a unique stylewith bundles of merchandise hanging from the neck as shown in Photo 68. The uniquesales method attracted the attention of a newspaper reporter and the Daily Nation
posted an article about popped cereals on March 11 and 18. He was also introduced by alocal radio station.

Photo 66, 67 Booths and exhibition at an agricultural show hosted by Kitui County

42

Photo 68 Mr. Gichangi in his store

Photo 69 Embu Market open(e) Matters to be grasped and checked by demonstration(i) Project soundness of Kitui County
As shown in Table 14, the group did not make any activities from one in March until
participation in an agricultural show in June. Therefore, it is difficult to judge thedependency and sustainability of management. Judging from their activities in July, theroles of members became clear because the organization became compact. This seems tohave smoothened the processes from raw material preparation to production, seasoning,(molding), and bagging. Continuing these activities seems to establish independent
management.
Table 14 Production by the Syokinili GroupMonth

Production

Production Amount (Raw Materials in

Frequencykg)(Number of

Rice

Days)

Maize / Millet* /Total

Sorghum

Sales

PorridEvent

ge

Shillin
g

March

1

0

5

2

2

9

2,814

June

2

10

10

4

13

37

9,690

2,610

July

4

15

19

12

14

60

13,7205,250

Machakos
Agricultural Show
Kabarnet Agricultural
Show
Kitui Agricultural
Show

Total

7

25

34

18

29

*Pearl millet

43

106

26,224

7,860

(ii) Issues concerning sales and income expansion of Kitui County
The group has a weak point that they are lacking in human resources of great sales
power. At the visit this time, we introduced the case of Embu (fair traveling sales in Table15) and the case of Migori (establishment of sales network linking kiosks as customers).
He made a call early after that. He seemed to have confidence about sales at fairs. We
hope this continuation will make him confident. The prices of pearl millet and othergrains are soaring, as well as brown sugar. Therefore, price setting based on costcalculation and volume adjustment per bag are necessary.
The efforts shown in Figure 1 are necessary for price-focused marketingtargeted at students. For example, it is necessary to reduce the amount per bag andimprove lower-priced merchandise quickly.
Table 15 Sales by Gichangi Cereals and Spices
MonthJanuary
February

Place

Event

CountyEmbu Market

Fair, demonstration

Embu

Manyata Market
Ishiara Market
Kiritiri Market
Mwea Market

Fair
Fair
Fair
Fair

March

Waboga Farm
Kiajokoma Market
Embu Market
Kisumu Market
Manyata Market
Siacago Market
Chuka Market

Farmers festival
Fair
Fair
Farmers festival
Fair
Fair
Fair

April

Embu Market
Kianjukuma Market
Gitari Market
Leneges Market
Manyata Market
Siacago Market
Kiritiri Market
Kagumo Market
Kagio Market

Fair
Fair
Daily
Fair
Fair
Fair
Fair
Fair
Farmers festival, FairMay

Embu Market
Leneges Market
Nyeri Market
Kagio Market
Manyata Market

Fair
Fair
Fair
Fair
Fair

June

Leneges Market
Embu Market
Manyata Market
Kagio Market
Meru Market

Fair
Fair
Fair
Fair
Fair

July

Ishiara Market
Embu Market
Manyata Market
Leneges Market
Kabutyri College
Waboga Farm

Fair
Fair
Fair
Fair
Farmers festival
Farmers festival

Embu
Embu
Embu
Kirinyaga
Total
Nyeri
Embu
Embu
Embu
Embu
Embu
Thakanis
Total
Embu
Embu
Kiambu
Embu
Embu
Embu
Embu
Kirinyaga
Kirinyaga
Total
Embu
Embu
Nyeri
Kirinyaga
Embu
Total
Embu
Embu
Embu
Kirinyaga
Meru
Total
Embu
Embu
Embu
Embu
Embu
Nyeri
Total

44

Number ofdays(Sales shilling)
15

54,113

1
1
1
1
19
1
1
5
1
1
2
1
12
3
1
3
2
1
2
1
1
2
16
7
1
1
1
1
11
3
2
1
1
1
8
1
3
1
1
1
2
9

3,950
2,200
2,245
2,470
64,978
9,065
4,880
16,9554,965
3,700
12,3703,950
55,885
9,590
4,060
9,430
16,000
3,000
6,000
3,200
4,250
8,970
64,50024,960
4,000
3,000
2,700
2,350
37,010
8,110
2,895
1,800
2,645
3,630
19,080
2,200
4,600
3,470
2,430
4,000
22,00038,700Figure 1

Value zone and market expansion strategy(iii) Use of local food materials, and new products of Kitui County
The group produces popped cereals from local maize, sorghum, and pearl millet as major
raw materials. They manufacture products meeting the preferences of local residents bygrinding these raw materials with millstones. They also make traditional foods, such as
porridges. They developed a new tasty product by mixing popped sorghum with sour milk
and adding sugar or honey according to preferences of people likes. This way of eating
utilizing local tastes will produce local dishes that have new values.
(iv) Project soundness of Migori County
As Table 16 shows, production twice or more has been continued despite a member
decrease or machine faults. More frequent production will enable shift to sustainable
management permitting machine depreciation and maintenance cost raising. Since thebusiness is based on part-time worker employment, there is a concern about thesettlement of manufacturing technology and stable production.

45

Table 16Month

Production

Production Amount (Raw Material in kg)

Frequency(Number ofDays)

Production by the Okonyo Group

Rice

Maize

SoybeanFebruary

1

10

2.5

1

March

4

49

13

6

April

2

17.5

4

2

May

3

12

8

5

June

3

36

11

6

July

1

15

6

3

Total

14

139.5

44.5

23

Wheat

Peanut3

Sorghum

Total

Brought-in Raw Materials (kg)

Ksh

13.5

1,500

2

73

12,875

0.25

23.75

5,440

25

7,240

3

60

14,6907

31

14,03010226.2555,775

4

7

Sales

2.25

Rice

Maize

Income Ksh

3

2.5

180

3

90

5

8

150

5.5

420

*The center bearing broke on May 24 and was replaced at Juakali. (Bearing charge: 350 Ksh, wage:
600 Ksh, transportation expenses: 130 Ksh)
*The center bearing broke again on May 31 and was replaced with a bearing one size smaller. Then
there has been no problem.

(v) Issues concerning sales and income expansion
We could judge that close telephone communications with kiosks as important customers
would promote sales. Although the group leader was at an agricultural show this time,
we surveyed three kiosks making transactions with the group. Merchandise was sold out
at all the three kiosks (Photo 70). They say that merchandise may be sold out on the dayof arrival.
Also for Migori, it seems an urgent matter to improve packaging for pricefocused marketing shown in Figure 1, with a single bag or piece priced at about 5 shilling.
It is also necessary to create merchandise meeting consumer needs.

Photo 70, 71 Kiosk in the Mavela Market (The merchandise shown in the left-hand photo is hungin the store for sales.)46

(vi) Use of local food materials, and new products
Migori is a soybean producing center where soybean popped products are being
manufactured. Seasoning is not more than coating with a small amount of salt. The
products have a plain taste that contrasts soybean sweetness. The soybeans were
finished soft and moist without losing their original shapes. Soybean finishing is said todiffer between varieties. They say that Squire variety shows the best finishing.
(vii) Project soundness of Embu County
As Table 17 shows, the income by sales at fairs amounted to 215,998 shilling in the six
months from February, the next month after the start of production, until July. If the
profit rate is 54%, the net income is 116,639 Ksh. Even if the interest on the loan is added,
the machines charge (100,000 Ksh) can be repaid in six months. If the income atagricultural shows is added, repayment can be completed in not longer than four months.
The venture business started by an entrepreneur can become independent in terms ofmanagement.
Table 17 Production by Gichangi Cereals and Spices
MonthProduction

Production Amount (Raw Materials in kg)

Frequency(Number of

Mille

Mai

Sorgh

Whe

Brown

Soy

Days)

t*

ze

um

at

Rice

bean

Sales

Brought-in Raw Materials (kg)No. of

Total

Periodic ①

Sales

AgriculturDays

al Show

Total

February

6

39

38

10

14

12

2

115

22,823

7

22,823

March

7

40

29

24

25

5

0

123

55,885

12

April

5

60

35

19

18

0

0

132

64,500

16

May

1

21

0

21

15

0

0

57

37,01011

14,00051,010

June

3

60

11

24

34

0

0

129

19,0808

27,135

46,215

July

1

24

0

0

0

0

0

24

16,7007

26,00042,700

Total

22

244

113

98

106

17

2

580

215,998

61

82,175

298,173

15,04070,92564,500*Pearl millet(viii) Issues concerning sales and income expansion of Embu County
Merchandise of about 20 g per bag is sold at 10 Ksh in Migori and Kitui but 25 g per bag
in Embu. As mentioned above, Gichangi Cereals and Spices has a KEBS certificate. For
market expansion, merchandise development shown in Figure 1 will be necessary for
quality-focused marketing targeted at customers aware of safety, security, and health.

47

(ix) Use of local food materials, and new products of Embu County
Since the price of brown rice soared, production is now suspended. Local maize, sorghum,
and pearl millet are used for production. Although new products have not been developed
yet, the current products seem to have been devised by adding cinnamon to seasoning.
4. Training in Japan(1) Purpose of the training
The purpose is to contribute to the improvement of the quality and diversification of the
products by providing skill training for the members who started their own businesses.
For this purpose, the training that satisfies the following three themes is implemented.
Theme 1: The trainees from Kenya understand the approach of Ieda Seika Corporation
towards production and sales of popped cereals and master the new cooking andflavoring skills and techniques before they return home.
Theme 2: The trainees from Kenya have a deeper understanding regarding the local
production for local consumption in the country and can improve the awareness towards
dissemination of this business within Kenya.
Theme 3: By using these training activities as the trigger, the results that leads to the
profit of Ieda Seika Corporation are produced.
(2) Trainees
Two entrepreneurs were selected as trainees from the 4 regions that were targeted bythis project. This time, priority was given to the applicants with a higher awarenesstowards business such as entrepreneurs for the selection rather than the members ofgroups who were participating in group activities.
Mr. Mahinda Elizaphan Gichangi (Embu County)
Mr. Koech John Joseph Kimutai (Bomet County)(3) Training schedule
Table 18 Training schedule
Schedule

Date

Training details

Location

Day 1

October 21

14:05

Depart from Nairobi Airport

Day 2

October 22

13:55

Arrive at Chubu International Airport

15:20

Airport→Toyooka, Minamichita-cho (transfer)

16:30

Orientation and fitting uniform and shoes

19:00

Reception (home of Ieda)

Office of Ieda
Seika

08:20

Morning greeting and factory visit

Main factory

Day 3

October 23

13:00 to 13:40

Visit the direct sales store “Pon Café”.

14:00 to 15:00

Courtesy visit to Minamichita-cho town48

Pon Café

Schedule

Date

Training details
mayor
15:30 to 18:00

Day 4

Day 5

Day 6

Day 7

Day 8

October 24

October 25

October 26

October 27

October 28

Popped cereal production

Location
Minamichitacho town office

19:00

Procurement of the disk type kashata mold andruler

New factory

08:30

Production of disk type kashatas mold andruler

Main factory

10:00

Popped cereal production

New factory

13:00

Popped cereal production and kashata
production (sugar flavor and sweet and salty
soy sauce flavor)

New factory

08:30

Popped cereal production and shredding dry
fruitsNew factory

13:00

Production of kashatas of baobab flavor withdry fruits and peanut-containing kashatas ofbrown sugar flavor, and Chunichi Shimbunpress interview

New factory

08:30

Production of popped rice of baobab flavor andpopped rice of baobab and honey flavor

New factory

13:00

Production of kashata of curry flavor with black
sesameNew factory

18:30

Discussion of packaging labels

Office

08:30

Maintenance of popped cereals and greasing
the bearing

New factory

13:00

Transfer of products from the new factory to themain factory, attaching labels, and packing

Main factory

9:00

Preparation of the venue for the event “4thFlower and Food Marche” and direct sales store“Pon Café”, sales, demonstration, and Chunichi
Shimbun press interview

Toyohan Yanashi
factory

New factory andoffice

15:00

Cleanup

19:00

Farewell party (Gyo Gyo)

21:00

Toyooka Minamichita→Handa city (transfer)

Pon Cafe

Day 9

October 29

Handa City→Nagoya station→Shimbaba (transfer)Day 10

October 30

11:00

Courtesy visit to the Embassy of the Republic of
Kenya

Embassy of the
Republic of
Kenya

14:00

Nihon Nogyo Shimbun press interview

Super Hotel
Technofront
Morikasaki (2companies), andothersDay 11

October 31

13:00

Visit to the innovation sites of small andmedium-sized businesses in Ota-ku

Day 12

November 1

12:00

Shinagawa→Narita airport (transfer)Day 13

November 2

14:30

Check in

17:30

Depart from Narita Airport

13:05

Arrive at Nairobi Airport49

(4) Instructors for the training
Mr. Tamotsu Ieda (President and founder):Instruction on the production andprocessing techniques that have been inherited from the time of the company foundation
Ms. Kaoruko Ieda (Managing Director):

Training plan and sales (expansion of sales

channels)
Mr. Ikuaki Ieda:

Factory guide and maintenance of the pressure popping machine(5) Overview of the training(a) Hygiene management of food processing factories (Theme 1)
The trainees learned the proper hygiene management to prevent contaminations during
the routine work. Initially, they were to change their clothes to the uniform, wear a hairnet, cap, and a mask, change the shoes to work shoes, and check the outfit carefully infront of a mirror. Then, the entire body was rolled thoroughly with a rubber roller toremove dust and hairs and the hands were to be washed. At the production site before
packaging, they were to change the shoes to rubber boots, tack the hems of the trousers
inside of the boots to prevent any rubbish dropping from the hems of the trousers. (Photo72)
Inside of the factory, a special wagon is provided to prevent any items from being
placed on the floor. Basically, the bringing of any private properties into the factory is
prohibited; however, when ballpoint pens are required, only the knocked type without
cap is allowed. In this way, thorough measures are taken.
The trainees also learned the importance of attaching information labels on the
primary products (products after pressure popping) that are packed in bags indicating
the contents and the date manufactured prior to completion of the products,

Photo 72 After rolling through a gum roller,change the shoes with rubber boots.

Photo 73 Cleaning after the operation (Newfactory)(b) Production technology of high-value added popped cereal (Theme 1)
 Ingredient quality control: The main products of Ieda Seika are “kashata” and “puffrice” that are made of rice. For the rice, which is the main ingredient, brown rice ispurchased from the wholesaler and is stored. Brown rice is used as it is not so easily50oxidized as white rice and it is refined through a stone extracting machine before thepressure popping process for the purpose of quality control.
“Kashata”: Produced by coating popped rice with starch syrup or sugar and moldingit“Puff-rice”: Produced by flavoring popped rice
 Pressure popping process: Training was conducted by using the Issho-pot pressure
popping machine that was used by Ieda Seika at the time of establishment, which isthe same size as the pressure popping machine that is currently used in Kenya. The
pressure popping machine is installed on the bench that was built at the L angle.
This structure not only enhances the work efficiency of the operator, but also reduces
the loss by spill-over as the pressure popped products can be easily caught in aplastic tub.
 Flavoring: The trainees learned the basic method of making syrup for producing“kashata” and techniques for mixing the ingredients of different textures and tastes
with flavoring spices. The details of the products that were developed during thetraining are described later. However, the recipes are omitted from this report asthey contain some business secrets.
 Molding: Since this process has been automated, the “kashata” production
techniques at the time of establishment were reproduced. The trainees learned aseries of techniques based on this experience, ranging from the method of making
tools such as molding form and trowels for pressing and levelling, the method of
mixing popped cereals and syrup, and the method of stretching and cutting evenly
inside of the frame. For “kashata”, a square rod type of 75 mm  30 mm  25 mm anda disc type of 60 mm in diameter were produced.

51

Photo 74
Refined rice before pressure
popping

Photo 75
Training for pressure popping
technology

Photo 76
Pressure popping machine
installed on the work bench

Photo 77
Catching the products in the
tub after pressure popping
process.

Photo 78
Cooking syrup

Photo 79
Stirring grains after thepressure popping process

Photo 80Pressing and leveling in theframe

Photo 81
Cutting kashata into pieces

Photo 82
Tools for producing kashata
Trowels for pressing andleveling, cutting rule,stirring rod, disc typekashata mold, and spatula forleveling(c) Sales (Theme 1)
 Approach at direct sales stores: By visiting the direct sales store “Pon Café”, thetrainees learned various products that are produced by Ieda Seika, packaging form,
display method, and products that were made by using popped cereals (sweets) andoffered in the store. On the last day, products of African taste that were made by thetrainees were also displayed for sale.
52 Customer acquisition by demonstrations and events: By participating in the “4thFlower and Food Marche”, the trainees themselves engaged in the sales of the fourtypes of products for the African taste. At the same time, demonstrations of the
production of popped cereals were provided in “Pon Café”. In spite of such a bad
condition as a rainy day, all the products that were prepared were sold out by 2:00 pm.
The trainees experienced both the power of events for customer acquisition andcustomer support from the face-to-face sales such as events and the demonstration.

Photo 83
Packing operation

Photo 84
Sales site of the four types of
products for the African taste

Photo 85
Sample tasting of freshly
popped cereals after
demonstration(d) Observing the approach by small to medium-sized businesses (Theme 2)
Although the trainees did not have the opportunity for visiting the site of local production
for local consumption due to the constraint of the schedule, they observed the approachesof the small and medium-sized business in Ota-ku as organized by Mr. Junichi
Nakayama of the Ota-ku Industry Promotion Association to increase the experiences andunderstanding of the manufacturing in Japan. Cooperation of Ms. Masako Yamamoto ofMizuho Information & Research Institute was obtained for the interpreting.
Although the business fields that were observed by them were not directly
related to this training, the trainees showed a keen interest on the venture businesses
in Japan and innovations of small and medium-sized businesses. They were also
impressed by the courteous and attentive manners that were extended towards theoverseas guests.
The profiles of the companies that were observed are as follows.
 Top Water Systems Co., Ltd. (Mr. Takeda, Managing Director) Techno Front
Morigasaki 202
This company is engaged in designing, production, and maintenance management ofwater treatment systems as the main businesses and supplies the most suitable water
treatment systems to various industries. This time, an explanation was provided for the53

emergency water purification system that was developed by the company last year (2016).
This water purification system is equipped with a solar battery and can be used for 12hours continuously even at a power failure or at the site without a power source. The
system is capable of processing 300 liters of domestic water per hour and 120 liters ofdrinking water per hour. In spite of its mobile compact design, treated water can be
stored in the built-in tank. Through the main purification system, the water that is
supplied by a pump is filtered by the pre-filters in two stages (bobbin type filter andcarbon filter) and drinking water is produced by treating with the reverse osmosis
membrane filter twice. By treating the water that was treated by the reverse osmosis
membrane filter with the ultraviolet filter, sterilized water that can be used for medical
purposes is produced.
Q: The trainee asked a question regarding the filter replacement frequency.
A: Although the frequency varies significantly depending on the condition of the water
to be purified, a prefilter needs to be replaced once a year for the drinking waterused in Japan. When drinking water in Kenya is used, the prefilters may need to be
replaced once in 3 to 6 months. This system must be activated every day since water
inside of the prefilter will deteriorate if the system becomes stagnant for a long time.
A reverse osmosis membrane filter can be used for a comparatively long time as
there is a system that separates prefiltered water into proper water and waste water.
Q: There was a question regarding desalination of salt water.
A: Filtration of salt water needs purification under a high-pressure condition. Since
this system operates at a low pressure, salt water cannot be converted to drinking
water.
 iMott Tokyo Research Institute (Mr. Matsuo, Managing Director) Techno Front
Morigasaki 402
This joint venture business was established by Tokyo Institute of Technology and
Chairman Matsuo is engaged in the research and development of the technology forfilming metals, rubber, and resin with diamond like carbon (DLC).
DLC is one of the most desired materials in each manufacturing field for its
features of high degree of hardness, low friction, biocompatibility, gas barrier property,
adhesion resistance, and corrosion resistance. Film forming of DLC with inconsistentfilms of grid: “segment structure S-DLC” is the patent technology of this company. This
company is engaged in the S-DLC coating service, design, manufacturing, and sales ofthe film formation equipment.
Q: There was a question from the trainee regarding the coating cost.
A: Although the cost varies according to the size, the coating of one side costs around
10,000 yen. For instance, the coating of the scissors used by a professional hairstylist costs 40,000 yen. The price of the scissors is around 80,000 yen. Since the
sharpness of scissors can be maintained and the durability can be improved to up
20 times by coating them, expensive products can be used for a long period of time.
54

In this respect, the coating is not expensive at all. By coating one side of a flat washer
and tightening by placing the coated side, the screw is tightened well and will not
become loose.
Q: There was a question regarding the time spent for the development.
A: The research took 10 years and this is the 6th year of the business.
Q: There was a question regarding the application in the food industry.
A: The product is used for plastic packages of the contents that can be oxidized easily.
For instance, this filming technology is used for packages of Miso and plastic bottles
for hot drinks.
 Rakuten Socio Business, Inc. (Artificial light type plant factory) Techno Front
Morigasaki 103
Since a permission for entering inside of the factory as visitors had not been received, we
looked inside of the factory through the glass window at the entrance of the factory while
Mr. Nakayama explained the company profile. This company is a subsidiary of Rakuten
and was producing frilled lettuces in a hydroponics method by using the LED lighting.
All the frilled lettuces that are produced here are supplied to the canteen of Rakuten
Head Office.

Photo 86
Top Waters Systems
Explanation of the emergency
water purification system

Photo 87
iMott Explanation of the SDLC film forming equipment

Photo 88
Toshin Seisakusho Co., Ltd.
Explanation of the equipmentthat quickly reduces thetemperature of the tires of
airplanes Toshin Seisakusho Co., Ltd., Main factory (Mr. Takahashi, Production Engineering
Department) Omori Minami 4-10-29, Ota-ku (near Techno Front Morigasaki)
They are proud to be a metal processing company that has the technology capable ofconsistent handling from design and development to prototyping and verification and iscapable of transforming a request from a client to the reality. Since its establishment in
1976, the company has been engaged in plate welding, sheet metal, and vent bending
process as their specialty technologies and also is specialized in welding of products of ahigh hygiene standard that are used for medical and food processing fields.
55

Among the many products that have been designed, developed, andcommercialized, we observed the manufacturing site of the equipment that quickly
reduces the temperature of the tires of airplanes and the equipment that nests tires (tiredoubling machine).
Since an airplane cannot take off unless the temperature of the tires that
increased at landing is reduced, the equipment for quickly reducing the temperature oftires are currently used by JAL at Haneda Airport. The tire nesting equipment can nest
tires in double for the tires of the same size and triple for the tires of different sizes,
thereby enabling doubling or tripling the transportation capacity of tires.
This company has a factory in Vietnam also and several technical interns who
were sent from Vietnam were working at this site.
Q: There was a question regarding the training system for technical interns to masterthe technology.
A: Since technical interns from Vietnam learn the basic Japanese before they come to
Japan and have studied the technology to some extent in a vocational school and soon, there is no specific training system and the technology guidance is provided
under OJT.
Q: There was a question regarding their intention of accepting technical interns fromcountries other than Vietnam.
A: Since the interns spend some time under the different culture and customs after
arriving in Japan and they are able to adopt to the society and living environment
more quickly if they have predecessors of the same country with the same language
and customs, there is no plan to accept interns from any other countries.
Q: There was a question regarding the price of the tire doubling machine.
A: The price is between 2.4 million yen and 3 million yen.
(6) Useful technologies (Themes 1 and 3)(a) Improvements of the pressure popping machine Through this training, the trainees understood the significance of operating a pressure
popping machine on a bench at L angle in terms of the work efficiency, product hygiene
management, and improvement of the yield.
 A pressure gauge of a pressure popping machine is an important and expensive
component. To prevent the impact on the pressure gauge when the cover is opened, amethod of attaching a valve in front of the pressure gauge was applied in Kenya also.
However, in some cases, the pressure gauge was broken due to the malfunctioning of
the valve. In Ieda Seika, a coupling (quick joint) is installed between the pressuregauge and the cover to facilitate the attaching and removal of the pressure gauge andthe cover is opened after removing the pressure gauge. In this way, the pressure gauge
is maintained for a long period of time.

56

(b) Tools for producing kashata The method of fixing a table and a molding frame with metal pins and the method ofmarking scales for cutting after pressing the ingredients uniformly can be applied in
Kenya also.
 To mix the popped cereals and syrup for kashata quickly and uniformly, the stirring
rod is rotated by lifting from the center to the outer position, which requires a plastic
container of around 50 cm in depth. This stirring method requires a proficient skill.
By removing a stirring rod while rotating it, the rod can be removed easily without thesyrup and cereals being attached.
 As the tools suitable for pouring the mixed ingredients into the mold and stretchingthem to the four corners and the outside from the center while pressing them, thetrowel and spatula that are shown in Photo 82 are useful as they enable application ofpressure uniformly in a rectangular frame. A plastic sheet is attached to the levellingside of the trowel to prevent the kashata from sticking.
 The size and form of the ruler for cutting kashata in sheet form cleanly after removing
the mold were also useful pieces of advice.
 A mold plate for producing disk type kashata was created. Although this was the firstattempt, kashata of a clean disk shape was produced.
All these tools can be created in Kenya also.
(c) Passing the technology to employees
The trainees wished to use this training program as the opportunity for passing, to theirjunior employees, the useful techniques (traditional production methods) based on theexperiences that have been accumulated by Ieda Seika since its establishment.
(7) Product development (Themes 1 and 3)
By using the ingredients that are available in Kenya, the following high value-added
products of four different flavors were created as a result of the exchange of opinionswith the trainees based on the empirical knowledge of Ieda Seika.
Popped cereals that are currently produced in Kenya are in grain form withseasoning after popping and popped cereal pieces are sold by packing them in plasticbags. However, the use of plastic bags was prohibited by the law, which was enforced
from August 2017. A plastic cup as a substitute for the plastic bag is not viable in termsof the cost and a paper bag is used as the alternative. One of the measures that isconserved is to produce “kashata” by molding it into an easy-to-take form and sell it in atransparent plastic container.

57

Table 19 Details of the product created in the training
FlavorBaobab

Combination (mix)Shape Dry fruits (mixture of mango andpineapple)

 Square bar/disc type kashata Honey Granular popped cereal

 None Granular popped cereal (hops)

 Dry fruit (banana) Square bar/disc type kashata Dry fruit (banana) and wheat (popped)

 Square bar type kashata

Brown sugar

 Peanuts

 Square bar type kashata

Curry Black sesame Square bar/disc type kashata

Cinnamon Black sesame and sorghum (pressure
popped)As the evaluation of the new products of Ieda Seika that has the experiences of thedevelopment of a variety of products, the peanut-containing kashata of brown sugar
flavor lacks in its originality. However, the product is savory and delicious. The kashataof baobab flavor enhanced the flavors of mango and pineapple and the synergy effects by
the combination were received favorably. This product can be commercialized
immediately for its originality. For the kashata with a combination of cinnamon andbanana flavors also, the synergy effects and originality were received favorably and thepossibility for commercialization was suggested. For the kashata with a combination of
curry and black sesame flavors, the mixing ratio and the combination of ingredients need
to be reviewed since the aroma of sesame is lost due to the strong curry flavor.
(8) Overview of the exchange of opinions at the places visited(a) Minamichita-cho (Interviewees: Mr. Ishiguro: Town Mayor, Mr. Kawabata: Managerof the Industrial Promotion Section, Mr. Aikawa: Deputy Manager, Commerce andTourism Department)
Mr. Gichangi, one of the trainees, brought popped cereals of sorghum and millet thatwere produced by him in Kenya as the souvenir. Everyone present sampled the souvenir
and commented that it was delicious although it needed a little stronger seasoning. At
the beginning, the trainees explained the overview of the project of local production for
local consumption and the history of being accepted by Ieda Seika as the trainees.
Initially, the town mayor asked them about the impression of Japan and also
asked each trainee, regarding the family, occupation in Kenya, and the income by thepopped cereal business. He also asked what they were intending to learn from Ieda Seika
that provided the training. The trainees answered each question, indicating that they
wished to master the techniques from production to sales of high value-added products
to develop further the popped cereal business that they are currently conducting in
Kenya.
The staff sincerely welcomed the trainees from Kenya and both parties
58exchanged pleasant conversations in a relaxed environment. The Town Mayor presented,
as the souvenir, liqueur made of mandarin, which is the specialty of Minamichita. Theliqueur has been produced for revitalization of the town.

Photo 89 Courtesy visit to the Town Mayor of
Minamichita (Mayor: Middle on the right row)

Photo 90 Liqueur presented from the Town
Mayor (right end) and Kyoko Ieda (left end)(b) Embassy of the Republic of Kenya (Interviewees: Paul M. Kaliih: Minister-counselor,
Ms. Yagi: Executive Assistant)
At the beginning, the Minister mentioned that the Ambassador could not attend themeeting since he is currently in Kyushu on a business trip. JAICAF explained theoverview of the project of local production for local consumption that is deployed by
JAICAF in Kenya and the history of the traineeship that was accepted by Ieda Seika.
Each trainee introduced himself and reported the details of the training and thetechniques that they mastered in this training. Mr. Gichangi introduced and presented
the popped cereals made of sorghum and millet that were produced in Kenya and fourtypes of kashatas that were produced by the trainees during this training program as
the achievements. The Minister showed a keen interest in the fact that rice, sorghum,
and millet are used as the main ingredients of the products; that baobab, cinnamon,brown sugar, and curry, which are familiar items in Kenya, are also used for flavoring
the products (snack); and that sweets are produced by mixing dry fruits, honey, peanuts,
and black sesame, which are produced locally. Most of the cash crops in Kenya including
coffee, tea, and macadamia nuts are produced in large farms generally under favorable
weather conditions, and most of the cereals that are used by the project as the main
ingredients are produced by small farmers in semi-dry lands. This factor attracted his
attention. The Minister was from Kitui County, which is a semi-dry land, and hoped thatthe expansion of this project leads to the increase of consumption of sorghum and millet.
Since the activities for adding value by processing contribute to the increase of incomeof the producer and the creation of employment, and snacks using cereals improves thenutrition of children, the Minister requested the development of the project. Recently,
59while the dietary intake of meat is increasing in the diet among the middle class and thepatients of life-style diseases are increasing, the Minister indicated the importance of
the use of cereals as his advice.
Asked about his business in Kenya by the Minister, Mr. Gichangi explained thedetails of the business of Gichangi Cereals & Spices and also indicated, as supplementary,
the issue of the product packaging method due to the prohibition of the use of plasticbags from August. The Minister commented whether paper bags can be used instead ofplastic bags. Thereafter, some more questions were asked by the Minister. He asked:
Q: Whether such a project has been implemented in countries other than Kenya
A: Such a project has not been implemented in any other countries except Kenya.
Q: Where a pressure popping machine can be purchased
A: Place your order, and DK Engineering in Nairobi will manufacture a pressure
popping machine in around two months.
Q: Whether the training in Japan is to be continued
A: It cannot be answered as it depends on the budget of the Ministry of Agriculture,
Forestry, and Fisheries.
A: Ieda Seika is able to accept the training such as this training for about one week.
Q: Whether dissemination activities are still continued in Kenya
A: The dissemination activities are still continued.
The Minister is interested in green tourism and indicated his wish for planning farmexperience tours in Kenya targeting tourism. He provided his contact address in Kenya,
extending an invitation to his house as he will return home for a holiday during thewhole period of January next year (2018).
Finally, he also extended an invitation for participation in the Independence
Memorial Event on December 12. He also ordered kashata for 400 persons from Ieda
Seika to introduce kashata of African flavor (baobab flavor with dry fruits) to the invited
guests.

60

Photo 91 Courtesy visit to the Embassy of the
Republic of Kenya (left: Minister and Yagi,
Executive Assistant)

Photo 92 Minister and members of JAICAF(9) Public relations (News interview)(1) Chunichi Shimbun (Handa office

Reporter: Miyako Otsuki)

The article regarding the training program was inserted in the Chita issue ofOctober 29 (Sunday)(ii) Nippon Nogyo Shimbun (Agricultural Policy and Economy: Reporter Tetsushu
Kin)
The article regarding the training program was inserted on November 12(Sunday).
(10) Follow-up of the training in Japan
To confirm whether the techniques that were mastered by the two trainees from Kenya
through the training program that was conducted in Japan during October 2017 arebeing implemented properly, we conducted a follow-up field survey by visiting theactivity regions of the trainees during January 2018. The employees of Ieda Seika
Corporation also participated in this survey as the technical experts.
(a) Mr. Gichangi of Embu County We confirmed that he has mastered the techniques for the operation of the pressure
popping machine and production of kashata (made of popped cereals), each with ahigh level.
 The wooden frame for producing kashata was designed so that it can bedisassembled to facilitate the cutting of kashata.
 To enhance the productivity further, additional mechanization in the processing isrequired, such as introducing a mixer.
 There was a problem in the rice expansion process as some grains do not expand. The
61

expansion rate was improved by adjusting the water content of the rice, which was
the main ingredient. The water content of rice was about 10% and by increasing thecontent to 15%, the expansion rate can be improved.
 Although Mr. Gichangi has already tested 10 or more flavors, more flavors were
tested. The seasoning of baobab and cinnamon flavors that were initially bland wasincreased and also the combination of flavors were tested including baobab andmango, cinnamon and banana, and soy sauce and chili powder, and good results wereobtained.
 He aims at the acquisition of the KEBS certificate so as to sell the products in supermarkets and so on. Although plastic bags can no longer be used due to the legislationin Kenya, the problem was solved by using paper bags and plastic containers. The
future issue is labeling.
(b) Mr. John of Bomet County
 He has mastered the techniques for the operation of the pressure popping machineand production of kashata to some extent. However, too many members are involvedin the work and the work was carried out in a clumsy manner due to the lack ofhousekeeping. Therefore, substantial improvements were necessary to enhance theworkability and productivity.
 Under the instruction of the members of Ieda Seika, thorough housekeeping andspeed-up of the work process were attempted. As a result of the instruction, theworkability and productivity were improved although further improvements arenecessary.
 In the same way as the case of Mr. Gichangi, the ingredient expansion rate was
improved by adjusting the water content (increase) of the ingredients including rice,wheat, and sorghum.
 Since the workplace of Mr. John is located in the region at over 2000 m in altitude,
the temperature of the syrup for setting kashata does not reach the target
temperature (120C). Therefore, the recipes were changed to reduce the target
temperature.
 As the new flavors, cinnamon, milk powder, and charcoals of a medicinal plant wereintroduced. In particular, the charcoal of a medicinal plant deserves a special
mention as the utilization of an ingredient specifically available in the region.
 We observed that Mr. John in a white uniform sold kashatas loose in the market.
This is an appropriate sales method at this stage as popped cereals are low-profile
products in the market. When the popularity of popped cereals increases, sellingthem in stores or supplying them to stores in the market would be appropriate.
 Because of the lack of initiative in his sales method, we provided some guidance on
the sales techniques such as making more effort in product explanation during sales,giving more thoughts to the promotion, setting a sales target, and so on.

62

5. Proposal of new popped cereal processing techniques(1) Examination of new food processing techniques as the startup techniques
As a result of the survey, it became clear that although many operators are interested in
the production and sales of popped cereals, they cannot make up their mind on thepurchase of a machine due to the reasons listed below. To respond to such requests, inthis project, we focused on two food processing techniques, a puff-cracker machine and ahand-baked rice cracker mold. These techniques are similar to the popped cereal
processing technique and the businesses can be started as a private business due to thesmaller investment capital and management expenses that are required than those of
the popped cereal production and sales. The effectiveness of the startup techniques was
examined.
The following evidences were obtained as the obstacle factors of the purchase ofa pressure popping machine.
 The price of a pressure popping machine is too high (sale price about 1000 dollars).
Mainly the machine is installed as a private investment and the concept ofcontributing a fund for the purchase of a machine as a member of a group is hardly
practiced. A motor bike (around 1000 dollars) manufactured in China is a usefulcomparison of the investment.
 Nobody knows, have seen, or have eaten popped cereals. Therefore, the market needs
and the scale are unclear. On the other hand, the needs for motor bikes manufactured
in China are clear.
 Pressure popping processing generates a loud popping noise. It is therefore difficult to
introduce such a machine in urban or residential areas.
 Popped cereal business activities including production, processing and sales require
involvement of many processes such as flavoring, mold processing, packing, andlabeling. Such business activities require basic business skills and experiences as theessential factors, such as ledger entry, management, and sharing of information
relating to a series of revenues and expenditures in addition to the employment of alabor force.
At the same time, according to the operators who installed a pressure popping machinelast year, there are advantage in the installation, such as the higher profit rate than thatof motor bike, large market needs mainly from children and youth, and no competitionin the popped cereal market.
(2) Development of puff-cracker machine
We focused on a puff-cracker machine and a hand-baked cracker mold as the attempt tostart a business in a low investment capital since they are cheaper than a pressure
63

popping machine and can be easily introduced to a farmer as a private investment or agroup with minimal business experience. Based on the results of the survey that was
conducted last year, a puff-cracker machine is easily accessible in terms of the production
techniques and cost, and does not generate a large noise during cooking, which are theadvantages over a pressure popping machine with known obstacles. A puff-cracker
machine will be useful for reinforcement of the development of new products for local
production for local consumption, which is a different aspect from popped cereals.
For manufacturing the machine locally, we received technical support from Puff
Cereal Manufacturing and Sales Limited in Ota-ku, Tokyo and for the cooking plate,which is the core technique, we received technical guidance regarding the size andprocessing. We also purchased a set of adjustment plates manufactured by Yoshimuraand prototypes of the authentic reproduction were produced by Numerical Engineeringby using the NC lathe technology (material cost 1773Ksh, processing cost 3600Ksh). For
the main press unit, based on the information obtained through the Internet, we
comprehensively evaluated machine production suitable for the mass production of themachines by using volume sales materials and second-hand materials that are available
locally and produced a prototype by using a puff-cracker machine of DK by adopting ahydraulic jack used for automobiles.
DK sold and delivered one puff-cracker machine to an organization in Bukura,West of Kenya by the end of the project (February 28, 2018), in the same way as apressure popping machine.
In the product development, technical support was provided by Ieda Seika
Corporation of Chita-gun, Aichi Prefecture.

Photo 93, 94 Iron plates for producing puff crackers, manufactured by Numerical Engineering(left), and prototyping of puff-cracker machine (right) from DK Engineering. A gas cooker witha hole at the center and a second-hand hydraulic jack for automobiles are used.

64

(2) Basic cooking method of puff cracker and evaluation of taste
Ingredient:

100 g

Water:

30 g (30% water content)

Salt:

Around 1.5 g (Stir the whole while spraying with a sprayer. Avoid
forming lump of flour)

Plate temperature: Male type (180C), Female type (200C)
Addition of sugar is recommended (10%).
Table 20 Evaluation of puff cracker taste
Ingredient (powder)
1

Wheat

Evaluation
Good if sesame seeds included

Point
++

No peculiarity
Expands well
2

Sorghum

3

Pearl millet

There is an after taste+

Difficult to expand
Iron like odor?
Dusty

4

Amaranthus

Delicious. No peculiarity+++

Does not expand
Cracks easily
5

Cassava

Burnt. Difficult to cook, but delicious

6

Finger millet

No peculiar taste++

Good appearance
Expands
7

Maize

Hard

+

Aromatic
Tacos
8

Rice (refined rice)

Strong rice taste
Taste of puffed rice

9

65

+

Table 21 Evaluation of taste of puff cracker using various material
Cost per
1 kg

Test
subject 1

Test
subject 2

Test
subject 3

Test
subject 4

Test
subject 5

Test
subject 6

Total
marks

Maize

55

1

3

1

2

3

1

11

Sorghum

60

3

3

3

3

1

1

14

Finger millet

100

2

3

3

2

3

2

15

Cassava

80

1

1

3

3

1

2

11

Pearl millet

60

1

2

2

3

2

2

12

Rice

80

2

3

3

1

2

2

13

Amaranth

700

3

2

3

3

1

3

15

Wheat

70

2

1

3

2

3

2

13

Reduce water gradually from the sugar-based (sugar 300 g + water 150 g) solution. Boilthe water. Reduce the water level until the content becomes sticky. Then, a small amountof honey can be added for flavoring.

Table 22 Evaluation of flavor using syrup
Topping ingredients

Roasted soybean powder+++

4

Cocoa powder

5

Cinnamon+

Masala+++GingerSweet soy glaze (sugar-containing
soy sauce)
Sweet soy glaze (sugar-containing
soy sauce + chili)++

Chili powder
Caramel source

Needs more sweet. Not compatible with sorghum.

Royco (chicken) + olive oil

Like junk food

Instant coffee++

Chocolate+ + + Needs to be stored in a refrigerator

Coconut+++

Cocoa powder++

66

Table 23 Evaluation of flavor added by mixing dough

Ingredient

Evaluation

Coconut

Burnt. Because of too much sugar?

PeanutOil seeped out. Not good enough.

Masala++1

Kumbi Kumbi (termite)+ (No taste). Unique taste. Interesting.

2

Sesame (white)

++ +

Royco
Chili + Royco
Dried fruit(3) Result and review
 Processing for puff-crackers was enabled for all the ingredients that were used.
 Cassava is more easily burnt than any other ingredients. As thecountermeasures, bake by reducing the temperature by 20 degrees or coat theplate with oil.
 A salt intake of 1.5 g may be too high. About 1 g of salt may be preferable if it isflavored later.
 Although sweet topping is popular amongst children, a puff-cracker will beburnt if sugar is directly mixed with the ingredients.
 Roasted soybean powder and cocoa powder add flavors to the ingredients.
 There is an opinion that the suitable price may be around 10 Ksh per sheet.
Basically, the dough should be a mixture of an approximate ratio of powder 100 g, water
30 g, salt 2g. Mix salt in the water in advance and mix the salt water with a sprayer
carefully to avoid forming lumps of flour. Mix by moving hands in the way of cutting forabout 20 minutes.
As the additive, use of Kumbi Kumbi (termite as an ingredient) or a cooking
spice enhances the taste and flavor. Sesame seeds are found to be particularly useful forenhancing taste and flavor. Sugar causes burning of ingredients. Cocoa was not favorable
due to the lack of sweetness. A small amount of roasted soybean powder is favorable toenhance the flavor. If too much is added, the dough does not expand.
Regarding the temperature management, the temperature around 180⁰C to
200⁰C is suitable. A non-contact type thermometer is desirable for conducting proper
temperature management. If a thermometer is not available, drop a water droplet on to
the plate. If the water forms a sphere, the plate is hot enough. To avoid a problem oflocking the plates, the temperature of the male plate should be lower. A slightly lower
temperature (150⁰C to 170⁰C) is desirable for cassava and maize to avoid a failure as
they have a high starch content. When puff-crackers are cooked continuously, the maleand female plates gradually cool down. This does not seem to cause much of a problem.

67However, an inadequate temperature results in a flour-like texture. A high temperature
is desirable for rice.
At the actual cooking, coat the male and female plates with cooking oil inadvance, place around 1.5 tablespoon of the dough on the female plate, shake the plateto spread the dough evenly, overlay the male plate in parallel (do not tilt it to avoid afailure), place the plates on the heating bench, consolidate with a hydraulic cylinder, andopen it after counting around 5. Open slowly initially and decompress quickly at the end
to produce a clean shape (For rice, it seems counting 10 will do).
If the male and female plates are locked as a result of tilting them, cool the maleplate with wet cloth and remove it.
For puff-crackers made of rice, a higher water content is the key to the success.
The content seems to be around 17%.
Regarding the tastes, wheat, pearl millet, cassava, and maize are bland in taste.
They can also be used as the base of an additive. Sorghum has a powdery texture, but
has a good aroma. Amaranthus and finger millet have moderate aroma. Although nochange is necessary for the taste for Japanese consumers, flavoring after making puffcrackers seems to be crucial if local children are targeted as the customers.

Photo 95 Puff-crackers that were made by using 8 types of ingredients68

Photo 96, 97 Baked puff-crackers (left). Ingredients of puff-crackers made by mixing dried
white ants (Kumbi Kumbi) with maize (powder) (right).

Photo 98, 99 Cooking puff-crackers by using different ingredients and examining topping
ingredients (Action Research)(4) Dissemination demonstration experiment
As a part of the project, we provided training for the procedure for using the machineand product prototypes with the Bukura Group that had purchased a puff-cracker
machine. This group also purchased a pressure popping machine. Therefore, theimpressions of the two machines by the participants were compared.
The result of the comparison showed that the participants had a strong interestin the pressure popping machine and had a low interest in the puff-cracker machine
although the machine overcame the obstacle factors of the pressure popping machine.
The following reasons were indicated for their low interest in the puff-cracker
machine.
(a) The work efficiency and productivity are low since crackers need to be cooked one byone. The preparation such as mixing ingredients in powder form is time-consuming.
Therefore, the profit rate is low (in comparison to that of the pressure popping69

machine). These are their strong impressions.
(b) The process requires skillful techniques such as temperature management.
(c) Since gas is used, the machine may be more readily used in urban areas.
(d) Puff-crackers are similar to Malondo (burnt rice created at the bottom of the pot) for
local people and there is a concern as to whether puff-cracker is a sellable product.
In the local region, Malondo is considered to be an emergency food that is consumed
when no other foods are available. Besides, eating such food tends to give an
impression of not eating Ugali adequately. This means that such food has no value
for money. Even if small fishes and white ants are mixed, can they find any value
for money? The market value is low.

Photo 100, 101 Demonstration of a puff cracker machine in Itumbu rural group in Vihiga Country
at the West of Kenya (left). Puff-cracker machine delivered by DK Company. (right). The space
between the disc at the center and the iron bench is not even, requiring adjustments.

(5) Trial of Hand-baked cracker
As a cheaper technique than using a puff-cracker machine, we purchased a second-handcracker baking mold through Yahoo Auction and attempted mass production of baking
molds using the mold that was purchased as a model of the template.
 Disseminate the method of using local agricultural products by involving children.
 Collect nutritional evidence and establish the product as a health food.
 The establishment of the synergy effects by involving researchers and developers has
a strong impact.
 The cost must be the lowest and affordable for the local people. If the cost is too high,the business does not spread.
 The technique has been established. The key factor for the future is continuation of70

promotion activities.
 It is important to show a concrete business model that can increase the income of thecommunity.

Photo 102-104 Trial of a product sample by using a baking mold.

71

Chapter 3 Direction of Future Activity Deployment
1. Result of the project activity(1) Expansion of production of pressure popping machine
One of the achievements by activities in this project is the expansion of pressure popping
machine production. A trial Kenyan machine modeled from a Japanese machine trial
could be manufactured successfully in the last fiscal year. We also organized issues
identified by field activities and worked out their solutions to establish a new technology
for mass machine production. As a result, we have manufactured and sold five machines
in total and are now more machines by expecting orders. We have received orders fromsemi-governmental organs and Japanese private companies, as well as local agriculturalgroups. Technical inquiries are not only from within the country but also fromneighboring countries. They indicate strong interest in and concerns about this project.
(2) Dissemination of popped cereal products
Another achievement is the dissemination and sales of popped cereals, including thestrengthening of their enlightenment. To raise of the social awareness of popped cereals,
we made demonstrations using pressure popping machines at agricultural shows invarious places and widely conducted diffusion and enlightenment activities.
Consequently, we conducted activities a total of 25 times at agricultural shows in thisproject. Popped cereals were highly evaluated and awarded 37 prizes. Particularly at an
agricultural show held in September 2017, President Uhuru Kenyatta came to our boothand tasted popped cereals. Many visitors to agricultural shows had interest and concerns.
We received about 50 to 100 inquiries at each agricultural show. The activities were notlimited to Kenya but also conducted in neighboring Uganda and Burundi.
(3) Activity result of groups introducing pressure popping machine
The number of farmer organizations and entrepreneurs who implemented pressure
popping machines increased one to four in total in this fiscal year. The activities werescaled down in Kitui County and Migori County because of such group issues as a money
problem but are continuing. Difficulty in securing a sales network is also an issue. In
Migori County, kiosks and other stores were secured as targets of sales. Our activities inthis fiscal year were affected particularly by the prohibition of plastic bags that started
in August 2017. The purchasers of cereal popping machines were expected to change
their means of packaging. An entrepreneur in Embu County solved this issue well andpromoted sales by using not only paper packages and containers but also plastic cups
and containers. The entrepreneur in Embu County is turning the cycle of kashata (called72

"okoshi" in Japan) production, processing, and sales very efficiently. Since the averagemonthly sales in a 10-month period became about 47,000 Ksh, the machine charge could
be paid back in about 5 months. The entrepreneur is very enthusiastic about mastering
techniques and active in sales activities. This may be the reason for the success.
(4) Training in Japan
We conducted a training in Japan to help trainees master Japanese technologies of
producing, processing, and selling popped cereals. The trainees were entrepreneurs ofseemingly high business mind from Embu County and Bomet County. The training washeld at Ieda Seika, one of the major manufacturers of popped cereal in Japan. The
trainees learned through sanitation management at food processing factory, anappropriate method of using a pressure popping machine, seasoning and molding as
processing technologies, and sales activities at direct sales stores. We also developed newmerchandise by using baobab and other African tastes, with an emphasis on kashataseasoning and molding technologies important for adding values to popped cereals. We
confirmed that the entrepreneurs in Embu County and Bomet County mastered
technologies acquired in the training by follow-up survey after the training. Particularly
the entrepreneur in Embu County was found producing kashata rather efficiently.
During the follow-up survey, the entrepreneur made efforts to add high values tomerchandise also by developing new flavors.
(5) New agricultural processing technology
In the last phase of this project, we developed puff-cracker machine as new agricultural
product processing technology replacing pressure popping machine. Puff-cracker
machine was verified expectable as a means of solving several issues at theimplementation of pressure popping machine.
2. Direction of future activity deployment
It was proven that, through the activities that have been implemented so far, an
introduction of a pressure popping machine increases the opportunities of local
agricultural products and contributes to the improvement of income and livelihood of thecommunity. As a result, it led to voluntary purchase and installation by individuals andgroups. For the future, the following deployment and direction of the activities are
anticipated.
 Continuation of steady demonstration sales through public events and business fairs.
Increase of the sales through enhanced recognition of popped cereals within thecommunity and stabilization of the business will lead to enthusiastic investments in73

the private sector.
 Continuous training support for the popped cereal operators. Operation managementof the machine and guidance of processing techniques (promote the use of naturalingredients and local agricultural products for seasoning and flavor). In particular,
various innovations are necessary to stimulate the demand; that is, innovations suchas reinforcement of heath-oriented new product development using local agricultural
products specific to the region, labelling, packaging technique, determination of
optimum price and sales volume, adjustments of the ingredients to the suppliers,
certification by the KEBS, and supply to the local super markets and schools arenecessary. Since it is confirmed that subsidy and loan systems from the public support(Youth Enterprise Development Fund, etc.) are available to entrepreneurs for
installation of machines, policy suggestions to the related governmental organizations
are necessary as well as a continuous supply of information to the target groups.
 Support for technical training to engineers of the DK Company as well as
encouragement of subsequent machine processing manufacturers. For the DKCompany, sustained quality and improvements are necessary for the mass production.
 Evaluation of the health contribution of popped cereal processed foods. In this project,
the nutritional values of typical grains that are used for puff processing were analyzed.
It is necessary to compare and examine with general products that are currently
available as to how nutrition-sensitive the popped cereal products that were developed
are. For the ingredients whose health contribution were confirmed through theexamination of such scientific evidences, the possibility of sales including export aswell as local sales is assumed.
 To provide such training and information as mentioned above, the human resource
development of expert staff and the improvement and reinforcement of a system thatenables individual consultation for private entrepreneurs are necessary. To achievethis, it is necessary to utilize, to the maximum, the human resources of the projectteam, including the individuals and groups that started the businesses through thisproject.

74Reference
1. Javis, A., H.I. Reuter, A. Nelson, E. Guevara, 2008, Hole-filled SRTM for the globe
Version4,

available

from

the

CGIAR-CSI

SRTM

90m

Database(http://srtm.csi.cgiar.org)
2. JAICAF, 2017, Feasibility Survey on Local Production for Local Consumption (ChisanChisho)

Activity

andExtensioninAfrica,Final

Report-FisrtYear-(http://www.jaicaf.or.jp/fileadmin/user_upload/publications/FY2016/H28chisanchisho_E.pdf)
3. Business Daily, 2014, Zimbabwean dreams of big snacks brand in Kenya(https://www.businessdailyafrica.com/Zimbabwean-dreams-of-big-snacks-brand-inKenya/-/1248928/2238358/-/lwij9fz/-/index.html)
4. Ueda, T., 2004, The Value and the Price for Consumers, Gakushuin Economics Papers,
vol.41(2)75

76

Appendix 1

Final Workshop Report on;

Feasibility Survey on Local Production and Local
Consumption(Chisan‐Chisho)
Activity
andExtension in Kenya: ‐“Pop cereal project”
Date: 23rd January 2018
Venue: Yoeligen Guest House, Embu County, Kenya.

77

Contents
Final Workshop report on; .................................................................................................................................... 1
Summary .......................................................................................................................................................... 3
Workshop proceedings ......................................................................................................................................... 4
1.

Welcome remarks (Mr. Shinichiro Nishino) ............................................................................................ 42.

Overview and rational of the project (Mr. Dominic Tumbo) .................................................................. 4

3.

Opening remarks (Ms. Yui Takashima) .................................................................................................... 54.

Group presentations. ............................................................................................................................... 5
4.1 Syokinilyi Self Help Group ....................................................................................................................... 5
4.2 OkonyoMigori Self Help Group ............................................................................................................... 6
4.3 Bomet Group........................................................................................................................................... 7
4.4 Gichangi Spices and Cereals .................................................................................................................... 7
4.5 DK Engineering ........................................................................................................................................ 8

5.

Question and answer session ................................................................................................................ 10
5.1 Machine Parts Breakdown and servicing .............................................................................................. 10
5.2 Marketing Strategies. ............................................................................................................................ 11
5.3 Packaging and Labelling ........................................................................................................................ 11
5.4 Flavoring ................................................................................................................................................ 12
5.5 Machine Improvement. ........................................................................................................................ 125.6. Raw materials....................................................................................................................................... 13
5.7 Others ................................................................................................................................................... 13

6.

Conclusion .............................................................................................................................................. 19

7.

Demonstration of the pop‐cereal machine (Gichangi Cereals and Spices) .......................................... 19

8.

Annexes .................................................................................................................................................. 21
Annex 1: Workshop Program ...................................................................................................................... 21
Annex 2: Participants List ............................................................................................................................ 2378

Summary
This report summarized the proceedings of the final workshop of the project, ‘Feasibility Survey
on Local Production and Local Consumption (Chisan‐Chisho) Activity and Extension in Kenya: ‐“Pop cereal project” held on 23rd January 2018 at Yoeligen Guest House, Embu County, Kenya.
The workshop was organized by the Japan Association for International Collaboration ofAgriculture and Forestry (JAICAF) and Bioversity International. This end‐of‐project workshop
aimed to provide an opportunity for participants to share their experiences and lessons learnt
and to develop key recommendations. Participants were drawn from community groups andindividual entrepreneurs who benefitted from the project including Okonyo Migori Self‐help
Group, Syokinyili Self‐help Group, Bomet Popping, Gichangi Cereals and Spices and DK
engineering Ltd as well as representatives from the National Government (Ministry of Culture,
Ministry of Health), County Government, Japanese Embassy, and self‐sponsored entrepreneurs
from different parts of the country. In total of 25 participants was participated.
The workshop featured among others presentations from partners, beneficiaries andstakeholders; a display of products from participating groups; discussions on future prospects andpractical puffing demonstrations by Gichangi Cereals and Spices and Bioversity.
Presentations focused on experiences, successes and failures. These were followed by a long
discussion during which participants made some key recommendations. Participants
acknowledged that (i) the project was overwhelmingly successful as it was providing income toentrepreneurs and groups and also providing a variety of healthy snacks; (ii) interest in themachines and puffing as a business was growing immensely both in Kenya and neighboring
countries as a result of the project, (iii) the pressure popping machine had gone through a numberof modifications and now many of its original problems had been addressed; (iv) althoughlucrative, the business had lately been affected adversely by the government ban on plastics.
The increased interest in puffing as a business has however brought about an increased need for
new actions, among them: training new rural groups that need to start generating income
through pressure puffing; mentoring new machine suppliers; further improvement of thepopping machine; demonstrations of the new cracker machine and addressing the problem of
packaging.
As a result, the workshop participants came up with a number of key recommendations:(i) To form a team to advice on an alternative packaging in the wake of the government ban onplastics,(ii) Owners of popping machines to link directly with DK Engineers in case of machine problems;(iii) Financial and technical support to be sought to address the emerging needs and particularly
supporting new rural groups to acquire the machine and train them on its use.
At the end of the discussion session, the team organized a demonstration of the puff‐cracker
machine, as a complementary to the popping machine. During the demonstration, a few
comparative advantages of the puff‐cracker technology were explained to the participants
including its relatively lower cost, simple structure, ease of operation and lack of a large soundduring puffing.
In the afternoon, the group visited the production factory of Gichangi Spices and Cereals to see
the practical processing of ‘Pongdoreka’ (kashata). This visit gave local entrepreneurs an
opportunity to see the popping machine, adding value to the products and tasting.

79

Workshop proceedings
1. Welcome remarks (Mr. Shinichiro Nishino from JAICAF)
Mr. Shinichiro Nishino of JAICAF gave a brief background of the project. He mentioned the factthat in African communities, local cereals such as sorghum and millets are locally produced but
do not gain sufficient economic value. This is mainly due to lack of value adding as well as
negativity associated with local foods. The situation can however be improved by value‐adding toencourage local consumption and income generation. The term, ‘Chisan‐Chisho’ means local
production local consumption. Under this concept, the Japanese worked towards encouraging
local food production and consumption.
The Japan Ministry of Agriculture, Forestry and Fisheries (MAFF), promotes nutrition‐sensitive
processing methods of agricultural products. Value addition of local cereals through popping has
proved effective. The project started by first identifying a local partner to duplicate the popping
machine. It then identified various self‐help groups to train them on use of the machine andfinally capacity built them on various flavoring and processing of the cereals. This project has so
far managed to do value addition to locally grown products to encourage the locals to consume
them. So far, various products have come out of this creativity. New and interesting flavoring
methods have also been identified like flavoring the cereal products with honey instead of sugar,
or with tamarinds or even dried fruits like mangoes.

2. Overview and rational of the project (Mr. Dominic Tumbo, facilitator of the workshop)
Mr Tumbo noted that the current project had built on the achievements of the first project
implemented 2016 till February 2017. The first project introduced the pop‐cereal machine,
training local groups on how to use it and mobilized groups to pop and sell cereal products. The
second project started in May 2017. Its main purpose was capacity building of groups in marketingskills and strategies including developing various flavoring methods of the popped cereals.
This project has supported the groups to go to over 20 fairs organized for small and medium
enterprises, winning several awards e.g. ‘Best innovations on Food and Nutrition’. The groups
have participated in fairs in neighboring countries of Uganda, Rwanda and Burundi. The groupalso participated in the Japanese Cultural Day at a Japanese School in Nairobi and various
agricultural shows around the country. The machine and the products have been of great interestin all the fairs attended. Following these fairs, several entrepreneurs and agencies have invested
in this machine. These companies include Nissin Noodles Company, Kenya Industrial ResearchInstituted (KIRDI) Kisumu and Kisii and individual, Mr. John Koech of Bomet County.
The project supported two Kenyan entrepreneurs to attend a 2 week programme on processingof popped cereals in Japan. Mr. Elizaphan Gichangi and Mr. John Koech received extensive training
on machine use and various flavoring methods. From the training received, Mr. Gichangi has beenable to modify his machine for ease of use and better results and to include new flavoring
techniques. An expert from JAICAF also came over for monitoring. He gave positive reviews on
their work after the training.
During the fairs, various set backs were noted. The huge popping sound was sometimes mistaken
for an explosion and security agencies were particularly wary about it especially at the time of80

the national elections of 2017. The noise however had the advantage of being a crowd puller
during fairs. The high cost of the machine was another concern. The current cost of a Ksh 100,000
per unit was still out of reach for many interested local groups.
As a result of these two main concerns, DK Engineering has be tasked with fabricating a newmachine, the puff‐cracker machine which has the advantage of puffing flours, has no noise and isrelatively cheaper (at Ksh 40,000). The end of the project comes at a time when many new
entrepreneurs including community groups are beginning to learn about the machine with some
expressing interest to purchase it.

3. Opening remarks (Ms. Yui Takashima, the secretary of Embassy of Japan)
Ms. Takashima interacts with various groups that deal in cultures and food diversity. She
encouraged the groups to take the pop‐cereal business seriously and to use it to improve theirlivelihoods. She explained that this was an innovative business idea and if done right, it would be
helpful the society especially women and children.

4. Group presentations.
4.1 Syokinilyi Self Help Group
This group has been with this project since its inception. It is headed by Ms. Peninah Mwangangi.
Under her guidance, the group has managed to get the machine, do some popping, go to various
shows in and around Kitui County and sell some products. The group is famous for their Kashatas
production.
The following are some of their success: Won first position for the Most Innovative Idea during Kitui County Agricultural Show.
 Visited Machakos Agricultural shows and managed to sell some popped cereals. This event
earned the group a cool Ksh9100.
 Managed to go as far as Nakuru County in Kabarnet to showcase their products.
 Developed various unique flavoring methods. They realized that Tamarind and Baobab
were great for flavoring the cereals. When tried, the products really sold in the local
markets.
 The group also decided to cut on costs of the raw materials. They did this by planting
sorghum in their own farms and used the products to pop.
 To this effect, job creation was done to women and the youth of the area.
The group is also undergoing some major challenges including: Their machine is having big problems. It needs some major servicing.
 Some parts of the machine need to be replaced. This is both costly and time consuming
 Another major issue the group is facing is packaging and labelling. This group had anescaped with the authorities over the same and it backtracked them.
 Lack of a KEBS stamp. The group can’t sell in major outlets without this stamp as requiredby the Government.
 Scarcity of Raw Materials. The County has faced some major drought episodes that has
hurt agricultural farming in the area. This has led to increase in prices of the major raw
materials like Millet and Sorghum.
 Internal wrangles. This group is having problems amongst its memebrs with some not

81being a part of the project.
Despite these challenges, the group has some major future plans to ensure growth and prosperityof the project.
 The group has developed a time plan of the markets to visit within the coming year. This
include Mwingi Agricultural Show.
 The County Minister of Health has plans to sit down with the group and develop ways on
how the county could help grow the team.
4.2 Okonyo Migori Self Help Group
This group is based in Migori County. It was represented by Mr. Charles Mogeni and Ms. Lorna
Akinyi. Just like Syokinilyi Group, this group has been with the project since the beginning. The
idea of rice balls came from this group. They managed to package their rice in sizeable rice balls
and sell locally. This proved to be more marketable to the locals.
The following are some of their success: Visited various Agricultural Shows including Kisii, Kisumu, Migori and Kakamega Shows. In
all these shows, they managed to showcase their product processing and sold to the locals.
 They have also manage to get major awards in Innovative Food Security machine Category.
This showed that the locals and the government authorities deem this machine as apossible measure to improve food security in the area.
 Managed to secure invitation through the Micro and Small Enterprises Department to go
to Burundi to show case the machine. This group managed to transport the machine toand from the country. This experience served as an eye opener to the team as it had teams
from Kenya, Uganda, and Tanzania to the event. The group still managed to win an award
despite the tough competition.
 Major sales. The group has managed to do major sales in the various shows and events
that they have managed to attend. This has improved their incomes level as a group.
 Local Impact. Over time the group has managed to get some specific outlets throughwhich they sell their products. These shops and market centeres have provided a steadysource of income to the group as long as they keep producing.
 The group has also managed to get people interested in buying the machine. Various
private entities like Mr. Koech have bought the machine after seeing it during one of theshows.
The group has also encountered some major challenges including: Machine breakdown. The gauge and bearing of this group’s machine need replacing
 Machine also needs intensive and continuous servicing
 Lack of proper packaging techniques. After the plastic bag ban, this team is stuck on what
to use now to package their products.
 Lack of proper labelling techniques Elections. The election period was quite a tense time in various parts of the country. In
Migori County, the situation was a bit intense. This affected popping by the group andderailed their production.
 Noise pollution. This group has experienced major complaints in regards to the popping
sound made by the machine. It has affected production is commercial places, restricted
them to specific places and times.

82 Lack of KEBS stamp.
The group has some future plans despite the challenges:
 Continued production to keep up with the market demands
 Visit more shows Complete payment of the machine as stipulated before Get the KEBS mark.
 Identify a packaging and labelling technique,
4.3 Bomet Group.
This is one of the groups that bought the machine after having have seen it during one of theevents. It’s a classic definition of the need and value of this machine. It shows that more people
may be interested if it could be made available to them.
Mr. Koech has been a busy entrepreneur. When he saw the machine, he bought it, underwent
training with his son and started immediate production. He even got a chance to go with Mr.
Gichangi to Japan to learn on production and flavoring techniques. With the knowledge gained,
Mr. Koech has managed to create jobs for two young men and earn some extra income for himself
too.
Mr. Koech appreciates that this is a good innovation and it can really help in reducing malnutritionin children of his area.
These are this success so far:
 Job creation for his son and his family in general Has brought in some income to the household Has managed to secure some markets for selling his products. These include Bomet,
Kisiket and Kapkoron Markets.
 Machine is still in good shape.
 Introduction of a new nutrition sensitive product to the local market.
The challenges encountered so far include: Marketing. This technology is fairly new in Kenya. Most people do not know of it. Hencemarketing has been quite challenging for this entrepreneur. Massive advertising id needed
to help the product pick in the market.
 Due to the same, profits are a bit low for him.
He plans to tackle these problems by the following future plans: Keep advertising to introduce the product.
 Collaborate with other members who have the machine to share ideas on the machineand production of the popped cereals.
 Involve more young men to help with the production and in return get a source of income
from the project.
4.4 Gichangi Spices and Cereals
Mr. Gichangi is a real success story of this project. Having been an entrepreneur dealing withspices and cereals, this project fitted just fine with him. He was introduced to it by Mr. Kirori of
DK Engineering during one of his visits to the shop. It got his attention, and he decided to buy amachine. That was when the project was just starting. He underwent training and started
production. Over the duration of the project, he has managed to pay off some of his loan, kept

83his family afloat and grown to expand.
The following are some of his successes:
 Managed to buy a machine. He has also developed the machine over time to solve someof the problems encountered from continuous use of the machine.
 Increased source of income Improved standards of living
 His trip locally and internationally has enabled him meet different people and learn
various kinds of culture Job creation for his young men.
The project also came with its share of challenges.
 Marketing. Mr. Gichangi had to start by hawking off his products while trying to educate
the cereals on the popped products. This took a lot of time and resources.
 Cost of packaging. After the plastic paper ban, he had to get into other packaging methods.
Some of them are quite costly. They led to increase in cost of production.
According to him, this is a new technology. It could be used by locals to increase consumption of
cereals. He urged the other members to not give up and keep producing even after the project
has ended.
He hopes to collaborate with the members to share ideas and educate one another on various
new flavoring techniques. He informed them that the IEDA Company has a variety of flavors that
attracts various consumers.
He welcomed the new entrants to come and learn from his business. He urged them to join the
project as it was a viable business.
After that, he thanked the project team coordinators for the opportunity and the training hereceived.
4.5 DK Engineering
DK Engineering has been part of this project since it as inception. It was tasked with the main
duty of fabricating the popping machine. The first machine really took a lot of hard work andsweat. Finding materials that were compatible and could work well was a real issue. Under Mr.
Yasu’s guidance and trust, the team was able to produce the first two machines.
As with any new technology, these two machines had their fair share of technological defects.
But they did not lose hope. Instead they kept finding new ways to improve the machine. They
ended up making a number of new and slightly cheaper machines.
Over time, DK has been involved in creating a manual for the machine. This manual was finallydone and presented to the team coordinators.
The main successes of this team were: Fabrication of the first machine Modifying and rectifying some problems of the first machine Had an Expo on the machines they had. Pop cereal machine was one of the machines
showcased.
 Fabrication of the puff cracker machine Development of the user guide manual.
 Availability to team members for repairs and consultation on the machine.
 After the Uganda Expo, the Ministry of Agriculture Uganda has been in talks with them to84find ways to improve the machine and hence buy the machine in the long run.
The challenges were: Costly and rare raw materials
 Not many people were buying the machines. They could show interest but they didn’tpurchase it in the long run.
 Some of the members accused them for being slow in giving feedback when approachedby clients.
The lady suggested some of the plans DK Engineering would be willing to undertake to ensurethat the project continues with minimal problems. These were: A promise to improve in their after sale customer service to the clients A documentary to be produced on the machine use and maintenance Training new entrants on proper usage and maintenance of machine. Since mostproblems that the groups faced was due to poor maintenance, it was necessary to train
the client on servicing as well as oiling of the machine.

Syokinilyi Self Help Group

Okonyo Migori Self Help Group

Bomet Group

Gichangi Sprices and Cereals

85

DK Engineering

5. Question and answer session
After tea break, the group came together to discuss some of the common issues that affected
them. The floor was open for questions as well as possible solutions. Those who were trained injapan also got an opportunity to share some of the lessons they had learnt.
5.1 Machine Parts Breakdown and servicing
One of the major challenge across the board was frequent breaking down of the machine. In Kitui,
the machine was currently not working and needed major servicing. In Migori, the situation issimilar. However, Mr. Gichangi has managed several ways to maintain and fix his machine at low
cost.
Like every machine, this one experienced wear and tear after continuous use. The team was asked
to prepare and be ready for such problems. However, some parts could be gotten locally without
involving DK engineering. But if the problem was big enough, DK Engineering could be brought
into the picture and assist. Mr. Gichangi proved that it was possible to modify the machine to suit
his local demands.
Servicing was also mentioned. As noted, none of the groups had planned for servicing of themachine. As a result frequent breaking down of the machine was experienced. They were asked
to have a strategic plan that would cover the same on a frequent basis.
Another problem of the machine was the pressure gauge issues. After much popping, thepressure gauge would sometimes start working inefficiently. This would be due to the pressure
while hitting of the cylinder to open it. Gichangi learnt from his trip that there could be removablepressure gauges. He modified his machine to make his pressure gauge removable through local
materials and knowledge acquired. This has helped him save his pressure gauge from immediateproblems.
In this case, as in many other cases, DK Engineers asked the group members to feel free toapproach them in case they noted any machine defectiveness. They were asked not to stay longtill the problem worsened before they would contact the engineers. The engineers, in return,would work swiftly to help the group fix whatever problem would be ailing their machines.

865.2 Marketing Strategies.
A business is a cycle that involves production as well as marketing of the products. If marketing is
ignored, that business is doomed to fail. Thus marketing of any product is crucial. To ensure
growth of business, some business set up a marketing department that focuses wholeheartedly
to selling and marketing of its product.
The Pop cereal project was developed as a business strategy. So, not only is production of thepops important but also marketing of the products. Since the beginning, this groups have been
having major problems penetrating the market.
Mr. Gichangi went an extra mile hawking the products around Embu market centres. He used theplatform to explain his products to locals, provide some samples to taste and hence hook new
customers. He took advantage of market days to reach many customers. Hawking enabled him
free advertising from one of the media houses that featured him in their print media. He
encouraged the groups to consider this form of free advertising and marketing to reach newcustomers. Sampling of specific well prepared products was also discussed as a method ofadvertising.
The groups were also asked to be innovative and come up with their own marketing strategies toensure sales of the products. They were asked to use the sound as a way arousing curiosity on
potential buyers.
Another way of marketing is through talking to potential buyers. Groups were asked to know andunderstand their products well, then go round informing locals of what it is that they do. They
are then to ask for customer feedback on what better ways to improve their products. This is what
Gichangi does presently. He is focused on flavoring and packaging to ensure maximum consumer
satisfaction.
Another group of people to market to be middlemen. These are people who could get products
from the groups and go resell the products at a small profit margin. The groups were encouraged
to get hold of such people to help reach majority of consumers.
5.3 Packaging and Labelling
Another major problem across the board was difficulty in proper packaging and labelling
techniques. Since the plastic bag ban in Kenya, various industries have been faced with a major
challenge in packaging of their products. The pop cereal project is no different.
Initially, groups used small, clear plastic paper to package their products. These papers we easy
to acquire and were relatively cheap. Since the products were new to the market, the clear bags
enabled consumers to see the contents of what they were buying.
However, since the ban, the groups have been tasked to come up with different methods ofpackaging. They still need clear, small, properly sealed and affordable bags. Mr. Gichangi has
found the small clear food containers to package his products. However, this container is only
viable for large quantities of kashatas. Putting small quantities in it is not economical. For small
quantities, the brown mafuko bags were suggested.
The brown bags are consumer friendly and are accepted by the authorities. However, they posea challenge in that consumers can’t see what they are buying once the bag is sealed. This has led
to decline in sales since people want to buy what the can see. Another bag suggested by thegovernment is a clear plastic bag that meets the threshold. However, after much search, this bags
were found to be very expensive to the groups. The cost of this packaging bag is Ksh300000 for87

100k pieces each of 50g. This led to increase in prices of the products, something that wasn’t welltaken by the consumers.
After much deliberations, a team of 5 people was formed to look into the matter. They are to lookat the government suggested bags and see how they can be modified to work in our favor. They
are also to look at the various regulations regarding nutrition and health standards of our
products. The rest of the members were tasked with going round various supermarkets to findout what other industries were using for packaging their products and see what they could copy.
The specific tasks of this team include:: going round to various supermarkets to find other suitable methods.
: Compare the various cost effectiveness of each type
: Keep the entrepreneurs informed on the progress so far.
: Have discussions with NEMA, DK Engineers, KEBS, MoH, MoA to find the alternative
packaging techniques and any plans by the government towards the same.
The team is to be chaired by Mr. Dominic Tumbo. Ms. Rose Wambu, Mr. Patrick Maundu, Mr.
Daniel Kirori, Mr. Elizaphan Gichangi are the proposed members of the team.
Another major issue in labelling is the KEBS mark. Most of these groups do not have this mark.
Hence limiting them on where to sell. Gichangi got the mark but on some specific products. The
rice pops did not qualify for the mark. At the time of this report, he was awaiting feedback on the
kashatas quality. The team selected was also to look into this issue and where possible help thegroups acquire this mark.
5.4 Flavoring
Since the beginning of the project, different people have come up with various flavoring
techniques. At the start, rice balls were quite unique and interesting. They used to be sold very
fast. However, due to the high sugar content used to make them, this flavoring technique had tobe abandoned. After this came kashatas that are health conscious. This have become the highest
selling products in this project.
Various mixtures were identified then to ensure variety in a pack in terms of nutritional content.
Additives were also used that had to be nutrition sensitive.
The group was asked also think of various marketable flavors that are still nutrition sensitive.
Include fruit additives for great taste as well as some coloring matter that are health conscious.
5.5 Machine Improvement.
The machine has been improved over time. However more is still to be done.
One major change is to have various machines using various sources of heat. From gas to charcoal
to firewood, these are the varieties that we have locally. DK Engineering were tasked to provide
various machines that use each of the sources named above. That way, a new customer could
choose what best suites their need at home instead of buying just one type of machine. On thequestion of which one of the sources would be better, it was decided that this would vary fromone consumer to another depending on their locality, and social status among many things. For
example, Mr. Gichangi preferred gas as opposed to Mr. Koech who preferred firewood for now.
The current machine has a cylinder that holds a maximum of 1kg of raw materials. For personaluse, this seems sufficient. However, for commercial use, 1kg is quite a small quantities if one

88intents to pop over 20kg of a certain product. Thus the engineers were asked to consider making
big cylinders to help reduce the time it would take to pop the cereals.
For the old machines, the engineers agreed to try and upgrade their machines to suit their current
needs. However, this would be done at a fee met by the consumers. The groups were asked tostart with what they have and it would be upgraded as they went forward. They were asked to
first focus on generating income and then they could use this income to upgrade their machines.
Mr. Gichangi has managed to upgrade his own machine and now focuses on production andflavoring to provide quality products to his consumers.
5.6. Raw materials.
In each of the groups, the products to be sold varied due to the various cultures. In Migori, forexample, Sorghum is the most marketable product. In Embu, the rice kashatas and Sorghum arevery marketable.
Kitui County has a foreseen drought nightmare. This means that the locally available raw materials
won’t be in plenty. Thus the prices of these commodities may go high hence affecting production
costs. The team had decided to plant some of the raw materials to cut on cost. However, we justhope that they will be able to use that which they have for production.
In Migori County, the group noted that the local rice did not pop well due to low moisture content.
It had to diverse to the rice from Tanzania which served the purpose well. However, this had its
own implications on the cost of production which relatively went up.
5.7 Others
Noise pollution. One item that was discussed extensively is the advantages or disadvantages of
the noise produced while popping. While some groups felt that the noise could be used as a wayof attracting curious onlookers, another one felt that the noise limited their production level.
Thus DK Engineering together with the team coordinators came up with the puff cracker machinethat doesn’t produce any sound.
For new buyers, the engineers would not only sell them the machine but would also provide after
sale customer service that included training on the machine use and maintenance, provide a year
warranty on the machine subject to some preset regulations, provide variety on the types ofmachines etc. The engineers are to make sure that the new buyers felt motivated and wellequipped to do business with their new machines.
Communication. The group suggested that it would be in their best interest to share knowledge
and experiences even after the project has ended. Both in social media and print media,
discussions would be initiated on how best to improve the products. This media would also be
used to source for assistance and encourage one another to keep going.
Ms. Faith Mbogo was one of the attendees in the workshop. She is an owner of a small enterprisethat deals in making banana crisps and Pumpkin seeds flour. She is a beneficiary of a small projectthat ended some years back. She has managed to survive and grow on her own even after the
project ended. She stated that she had undergone similar problems like packaging and labellingas well as marketing strategies. She encouraged the group to not give up hope once the projectends. She asked them to own their business and do it diligently and that way they would get
major returns. She said the main motivation to them should be job creation as well as improve
livelihoods through the income received. She then thanked the team for inviting her to the89workshop and expressed interest in including our project in her business.
Another major issue that was brought up is that the project was coming to an end too soon. Most
members were feeling as if the end of the project meant the death of the business. However,most coordinators took the opportunities to encourage them not to be too dependent on funding.
Instead they should now grow since they have been provided with the basics of the project. Anemphasis was made in regards to overdependence on project funding. By the end of the
discussion, the group had acquired back the original willingness to pursue with the business ontheir own.
Cost of machine. Another request was made to the engineers that they reduce the original costof the machine. This was done while considering both the engineers and the consumers. However,
the engineers could not lower the said price at the time citing expensive raw materials and labor.
It, however, gave the option of the puff cracker machine which was cheaper than the pop cereal
machine. Dr. Yasu suggested that instead of the engineers reducing the cost of machine, theconsumers could maybe team up and seek community funding like loans to purchase the machine.
He argued that this would help both the engineers and the consumers in the long run. Anotheridea was to maybe find other cheaper machines. Caution has to be exercised when going down
this road because cheaper things may actually be more expensive in the long run. In conclusion,
the price of the pop cereal machine could not be reduced, but loans could help consumers acquire
the machine cheaply.
The group was also reminded to consider this project as a business project and not a development
project. That means that once the project ends, the business should be able to make enoughmoney to sustain itself. That includes replacing or parts, Servicing of machine, paying of
employees, buying raw materials and make some bit of profit. And like all business, it may taketime to break even hence passion and patience have to be exercised a lot along the way. They
were also encouraged to visit the engineers to learn where to buy the spare parts at an affordable
rate and hence reduce cost of repairs.
Our government representative encouraged to group to visit various institutions of government,
showcase their products, explain how this product could positively impact the community andask for guidance in maybe marketing or nutritional value determination. She encouraged themto visit the county offices and ask to be considered as one of the institutions that are working
hard to reduce malnutrition in children. As this is a nationwide problem, she promised that if theyknocked on enough doors enough times, someone would hear them and help them. In otherwords, she asked them not to stay quiet and not inform the leaders, if they need help then it
would be wise to go and ask for it from the relevant personnel.

90

Discussion for challenge and future plans

Demonstration of puff cracker machine

6. Summary of the group discussions
The following were the summary of the project success, challenges and future plans of the groups
as discussed during the meeting.
The major success of this project are:1) Machine related successes.
 Many Challenges associated with machine have been addressed The current Pop cereal machine id much more improved through the DK Engineers
 2 machines have so far been fabricated Youth have been trained to use machine Modifications done for machines
 Gas fired machines on the pipeline to be made
 New machines function better
High demand for the machine in Burundi
 Interest for the machine Uganda
2) Good family business
3) Makes profit from sales
4) Adding baobab flavors
5) Use of local materials
6) Puff cracker machine introduced
7) Planted sorghum millet for group
8) Exhibitions and shows.
 visited many agricultural shows DK showcased Pop machine in the Safari Park Expo and in Uganda. They received
more orders from this events
 exhibition from Uganda was a success
9) JAICAF team very supportive. The group got immense support from the JAICAF teamcoordinators.
10) More products in the market with new and more appealing flavors11) Got awards from events
12) Products appealing to buyers

9113) Introduction of new nutritious products to consumers14) New buyers having have seen the machine in the shows Mr. Koech bought the machine The Uganda government is making a request for machine Many people are enquiring of the machines15) Opportunities to visit other countries like Uganda, Burundi and Japan.
16) Two entrepreneurs trained in japan17) Alternatives to plastic bags: waxed papers, plastic containers, plastic cups
The major challenges experienced over the course of the project are:1) Machine Challenges
 machine defects, i.e. The cylinder and rubber seal
 Pressure gauge challenge and how to modify it Needs more time to repay the machine Frequent machine breakdowns
 Pop cereal machine is quite expensive2) Noise Pollution
 Sound produced by pressure puffing machine the popping sound can bring problems in places in times of insecurity
 Sound challenges, people are scared of the noise.
3) Slow response from the DK engineers
4) Project is ending at a time when the interest is gaining momentum5) Group Internal wrangles
 Some group members are not interested
 Some group members are reluctant to sell
 Divided group: those interested to continue
 Many people left the group like the case of Okonyo Migori Group
6) Poor quality of local raw materials
 Rice varieties have different popping characteristics
 Local rice doesn’t pop nicely in the case of the Migori group
7) No KEBS mark8) Marketing Challenges
 It takes time and energy for a new product to be accepted into the market
 Attracting many people but few are buying
 High millet and sorghum products Lack of awareness of the products
 Products are new consumers‐ hence reluctant to buy9) Plastic bag ban leading to packaging challenges.
The following are the future plans of this project.
1) Sales in market centres, will open new centres for selling2) Raw material readily available3) Communication through social media (whatsapp group)4) Gas may be the way forward for energy

925) There are alternatives for packaging
6) Needs competition on fabricating the machine7) Research on health benefits and safety standards
8) The Engineers perspective They will act fast on any complaint Cylinder sizes will be adjusted , 3kg machine on pipeline
 Bring older machines to them for upgrade but at a cost
 Involve them if any problem with the machine9) County governments’ partnerships.
 Working in partnership with county
 MoH and MALF agri‐nutrition departments will provide some support (technical,
moral etc)
10) Youth and women participants11) Popping documentary needed
12) Task force to look into packaging issue
 Follow up issues on KEBS and packaging
 Team work as partners is needed Keep entrepreneurs informed
 Have discussions with NEMA, DK, KEBS, government13) Need for more follow up by the project Extend the project to benefit more people Technical advice still needed in production
 JAICAF to continue support
14) Need for more training Training for processing
 Engineers to train machine buyers on how to pop
 Train engineers staff to pop different products / operate machines Need for training on marketing strategies
The following was the general advice given to the group:
1) Fortify with natural foods
2) Fortify, color and flavor with food and natural products3) consider using community funds/ loans to access the machine
4) DK is giving one year warranty for a new machine5) Whether gas or firewood as a source of energy depends on locality
6) Machine related; Machine must be serviced regularly If the sound could be improved The engineers to advice on machine repairs Oil the machine bearing every 6 months
 To avoid spoiling the pressure gauge remove it before the pop
7) Marketing strategies;
 MoH to promote the products as a healthy snack
 Have a schedule for popping and marketing

93










there is a market for products
New products need aggressive marketing, a passion, strategy, engaging one self
Make profit to repay machine
Change attitudes to business positively
Looking for new flavors
Need for promotion
Diversify your products
Strategies to promote new products: attend shows, give free samples at first, use
outstanding nutrients for promotions

Opinion cards for the future plan

Opinion cards for challenges

Opinion cards for the success

Other opinion cards

94

6. Conclusion
After the group had finished discussion, the following was concluded:
1. [Extension of the project] A request of project extension was made by almost all ofparticipants to provide room for new entrants. The new initiative would: (i) form a team to advise on an alternative packaging in the wake of the government ban
on plastics,
 (iii) provide financial and technical support to address the emerging needs andparticularly supporting new rural groups to acquire the machine and train them on its
use.
2. [Exploring new partners] Explore more Engineers like DK Engineering. Competition ismeant to enable consumers get the best quality product at the most competitive price.
An idea to have more engineers join the project to produce the machine would perhaps
bring down the cost of the machine. It may also help the consumers get the best quality
machine.
3. [Packaging and Labelling] The problem of packaging was quite evident and widely spreadamong the groups. A team was set up in place to look into it and return back with its
findings and recommendations.
4. [Flavoring] The team was asked to consider more traditional nutrition based flavoring
like hibiscus flower for coloring. Innovativeness was really encouraged here.
5. [Communication] Social Media Communication. Communication is a vital part in any
process to ensure its success. An idea was brought forward to use social media as a way
to communicate and share ideas as well as experiences. A Whatsapp group will becreated to facilitate the same.
6. [Capacity development] Training stuff of DK Engineering how to pop so as to train othermachine buyers. For the new entrants, DK Engineering was asked to include training of
the use of machine as part of their service it offered. In order to do so, they would firstrequire training themselves.
7. [Capacity development] For any project to succeed various stakeholders have to some inplace and play their part. In this, the governments was tasked with training the groups
on nutritional value of their products. They were asked to join members and act likemarketing agent through promoting nutritional education.
8. [Research] [Capacity development] Training on Health Benefits of the products.
Members were asked to research on the health benefits of their products. They werealso asked to analyze the nutritional impact the products on the consumers.

7. Demonstration of the pop‐cereal machine (Gichangi Cereals and Spices)
After lunch, the group was treated to a first‐hand production of pop cereals and kashataprocessing. It was noted that: Mr. Gichangi had used the knowledge gained from Japan to make adjustments on his
machine. These included changing his source of heat from firewood to gas and having aremovable gauge. All these were done without involving the engineering company.

95 The changes done suited his need and hence helped in increasing rate of production.
 The sound from the machine was still evident. He, however, did not seem perturbed by it.
 New entrants were really interested in the process. Many even asked to help in timing aswell as turning the handle to acquire the right pressure for popping.
 In kashata processing, Mr. Gichangi has a clear recipe that he follows to the dot. It
indicates both quantities of the ingredients to be used as well as the procedure to be used.
 He also has a well‐marked table to help guide on the sizes of the kashatas.
 Having all these items in place makes the process look simple and flawless.
 kashatas were really tasty. In the area, they are the most demanded by the consumers.

Bursting the pop cereal machine

making the syrup

Smoothing out kashata

Cutting kashata96

Selling kashatas in the market

Gichangi uses plastic container for kashatas

8. Annexes
Annex 1: Workshop Program[Facilitator] Mr. Dominic Tumbo and Dr. Yasu Morimoto (Field coordinator of project)[Rapporteur and documentation] Ms. Fiona Njagi (Kenya Society of Ethno‐Ecology; KSE)
*Presentation title is subject to change.
0830‐0900 Registration
Opening session
0900‐0920 Welcoming remarks and the
project
Backgroundandobjectives.
0920‐0940 Presentation of achievement
and prospects.

Mr. Shinichiro Nishino JAICAF/Bioversity
and Dr. Yasu Morimoto International
Mrs.
Mwangangi

Peninnah Syokinilyi Selp HelpGroup

0940‐1000 Presentation of achievement Mr. Charles Mogeni
Okonyo Migori Self
and prospects.
Help GroupTea break (1000‐1010) to take tea, snacks and bring them to the conference room.
1010‐1030 Presentation of achievement Mr.
John
Joseph Bomet Communityand prospects.
Kimutai,Group
1030‐1100 Presentation of achievement Mr. Elizaphan Gichangi Gichangi Spices andand prospects.
Cereals
1100‐1120 Achievement and prospects of Mr. Daniel Kiroli
DK engineering LTD
DK engineering
1120‐1230 Q and A comments and Interaction with other All participants. Cards
discussions.
participants.
are used to collect
Mr. Dominic Tumbo and andintegrate
Dr. Patrick Maundu
knowledge from theparticipants.
1230‐1300 Demonstration of puff‐cracker Dr. Yasu Morimoto, Mr.
machineDominic Tumbo
Lunch Break 1300‐1400
1400‐1700 Sharing technique of making Mr. Elizaphan Gichangi
and processing popping cereal

97

Bioversity
International
Gichangi Spices andCereals

98Annex 2: Participants List
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Name
Peninnah Mwangangi
Wambua Mutinda
Charles Mogeni
Lonah Akinyi
John Koech
Elizaphan Gichangi
Lilian Gichangi
Rose Wambu
Margaret Kienja
Nancy Ondiba
Lilian Kanyuga
Faith Mbogo
Yasu Morimoto
Francis Oundo
Dominic Tumbo
Fiona Njagi
Patrick Maundu
Shinichiro Nishino
Isaac Muiruri
Teresia M. Kyalo
Patricia K. Muthui
Ruth Kinoti
Harrison Kairitha
Yui Takashima
Catherine Nabale

Organization/ group
Syokinilyi Group
Syokinilyi Group
Okonyo Migori
Okonyo Migori
Private Bomet
Gichangi Cereals
Gichangi cereals
MoH/NDU
DK engineering
DK engineering
Khana foods ltd
Kikai Foods
Bioversity
JAICAF
JAICAF
Museums
Museums
JAICAF
JAICAF
Nuu (Mwingi) community
Nuu (Mwingi) community
Meru
Embu
Embassy of Japan
Kenzam Ltd

99

Email

chalyongera@yahoo.com

Gichangicereals@gmail.com

Kanyikanyuga@gmail.com

100

Appendix 2

Operation and Processing Manual
Pressure-puffing machine(Yoshimura-Model)This manual explains the operation and maintenance of your pressure-puffing machine(Yoshimura-Model). Please read it thoroughly and follow the instructions carefully.
Doing so will help you enjoy many years of safe and trouble-free operation. Sample ofprocessing puffed cereals also described at the end.

101

Acknowledgement
Financial Contribution: Japanese Ministry of Agriculture, Forestry and Fishery (MAFF).
This publication was prepared in partnership with the following institutions and individuals. Their valuable
contribution is highly appreciated.

Author: Yasu Morimoto (Bioversity International)
Resource persons: Kaoruko Ieda (Ieda confectionary co Ltd, Japan), Fumiaki Yoshimura (Pongashiki sale,
Japan), Francis Oundo, Lucy Munyoki, and Daniel Kirori (DK engineering co Ltd, Nairobi), Peninnah
Mwangangi and Syokinili Women Group Kitui County, Gichangi Mahinda (Gichangi Cereals and Spices
Embu County), John Kimutai and his family in Bomet County, Charls Mogeni and Okonyo Migori Self
Help Group, Migori County.
Editors: Yasu Morimoto, Patrick Maundu (National Museums of Kenya), Shinichiro Nishino (Japan Association for International Collaboration of Agriculture and Forestry: JAICAF), and Yasunori Kanda (CDC
International)
Photos: Yasu Morimoto, Dominic Tumbo, Francis Oundo, Isaac Mwangi, Makiko Naganuma, Yumi Yamane, and Kodai Mori.
Design: Shinichiro Nishino (JAICAF), Seiko Fukuda (Nihon University).

Cover photo:Pressure-puff cereal machine in Kitui County, Kenya©Copy right: JAICAF and Bioversity International (2017). All rights received.
102

Contents
Page
Section 1:

Overview of instruments

3

Section 2:

Operation

5

2.1:

Requirements and accessories for operating the machine

5

2.2:

Operating procedure

6

2.3:

Samples of puffed cereals

13

Section 3:

Maintenance

16

Section 4:

Processing and flavoring of puffed cereals

21

4.1:

Utensils

21

4.2:

Flavoring with sugar (standard)

22

4.3:

Potential seasonings

24

4.4:

Chocolate cube

25

4.5:

“kashata” (cereal bar / biscuit)

26

Photo: Local children in Bomet County enjoying the kashata.
103

Section 1: Overview of instruments

The machine consisted of three major sections, A: Cylinder, B: Fire place, C: Wire mesh cage.

104

Name
1

Iron sheet

2

Lid guide3

Hitting peg

4

Cylinder holder

5

Funnel6

Pressure gauge

7

Cylinder lid

8Center bolt

9

Mesh guide10

Flame stand11

Shock absorber pad

12

Safety valve

13

Rotating handle

14

Lowering handle

15

Slider16

Hooks for cotton bag attachment

17

Hitting peg (same as 3)

18

Peg holding pin

19

Lid guide (Same as 2)

20

Center bold rock bolt

21

Hole for iron rod to tighten the cylinder lead

22

Center bolt (same as 8)

23

Cylinder lid (same as 7)

24

Teflon pressure gasket
105Section 2: Operation
The pressure popping machine or cereal popper is used to produce the healthiest foods and snacks throughaccumulated high pressure by heating the cylinder. It can puff or pop many different kind of cereals andgrains; e.g. Maize, Sorghum, Wheat, Finger millet, Pearl millet, Rice, Beans and Nuts etc. The machine
can use variety of locally available heat sources such as gas, charcoal but this model particularly designed
for using firewood.

2.1. Requirements and accessories for operating the machineName
1 Eye protection
2 Pressure gauge
3 Ear mugs- ear protection
4 Scooping rod- used to clean the machine andremove remaining popped cereals from the cylinder.
5 Rubber hammer- used to open the cylinderwhen the cereal is ready to pop.
6 Skin or woolen gloves
7 Sealing tape
8 Spanners; no; 14, 17, and 19
9 Iron funnel- used to pour the cereals into thecylinderIron rod- used to tighten the cylinder lead
Clean cloth
Clean basins and buckets
Lighter for setting fire
Firewood
Serving spoons1062.2. Operating procedure
1. Preparation of the materials
Wash, clean, remove stones and dry materials under the sun (a day before the operation). The recommended moisture content of the grains is between 15 and 18 % for best puffing. The moisture contentsof polished rice and wheat grain sold in common markets in Nairobi is between 8 to 13%. Washinggrain therefore important not only for cleaning but also adjusting the moisture contents of the grains.
Recommended to add about 60-80g of water for every 1kg of grains (Rice) if not sure the original
moisture contents. This water adjustment process makes well puffing the grains. However more than
20% of the moisture contents makes grain (Rice) hard and reduces the success ratio of puffing grains.
The grain can be packed, sealed in a plastic bag and stayed overnight after the moisture adjustment.
Sample calculation formula and answer:
Adjusting 10% moisture Rice grain 1kg (1,000g) into 18%.
● Water content of the Rice grain:
1,000g x (10/100) = 100g
● Making 18% moisture content Rice grain:(100+x)/(1,000+x)=18/100
10,000+100x=18,000+18x
100x-18x=18,000-10,000
82x=8,000
x=97.56
Adding water: 97.56g

2. Assemble all the requirements e.g. firewood, clean basins, clean cloth, clean cereal, gloves, etc. Cut the
firewood into small pieces.

107

3.

Confirm pressure gauge clean and put sealing tape on.

4.

Check and tighten all the nuts and bolts.

5.

Clean inside the pressure tubes.

108

6.

Put the pressure gauge and make sure it is tight.

7.

Put shock absorbing pad (wooden and/or rubber).

8.

Light the fire in the fire place.

109

9.

When the fire is ready, carefully place the cylinder on the fire place. NB; the cylinder should be open
this time.

10.

Wipe the cylinder using the long spoon and a clean wet cloth

11. Wipe the cylinder gasket using a clean wet cloth11012. Rotating the empty cylinder about 7-10 minuets as pre-heating of the cylinder.

13. The cylinder can hold up to 1kg of grains. Weigh 1kg of cereal while the cylinder heats.

14. Lower the cylinder using the lowering bar.

111

15.

Release template inside the cylinder as pour the cereal into the cylinder using the iron funnel

16.

Close and lock the lid by hooking the hitting peg. Then tighten the center bolt using the iron rod byholding the peg tightly with the other hand (use the globes).

17.

Start rotating the cylinder using the rotating handle (60-70 rotating per minute, or 10-14 rotating per
10 seconds) as continue adding firewood from the side. Rotating too fast or slow makes material
burnt. Make sure the fire is well maintained while you operate the machine. Ensure you keep rotating
the cylinder.

112

18.

Start preparing the cereal trap, attaching cotton bag and keep it near the machine. Keep checking thepressure gauge. Pressure should start increasing after 2-3 minutes and goes slowly upto around 5
M.pa. It increases rapidly after then. NB. Need special attention requires for monitoring the pressuregauge at this time. Keep the clean basin, rubber hummer.

19.

When the pressure reads as per the requirements of the type cereal (See Table 1), stop rotating and set
up the cereal trap in its position (hitting peg supposed to be at the top position).

11320. Once it reaches at the target pressures, set the position of the trap cage. Advice observers to not standin front of the direction of releasing pressure. Hand bell can be useful to alert people nearby. Gently
but surely hitting the peg with the rubber hummer to release pressure. With large explosion sound,
puffed cereal is trapped in the bag.

114

21. Remove the cereal trap quickly and22.

Harvest the cereals from cylinder using the scooping spoon and also from the trap and bag.

23.

When the cereals are in the trap, pour then into the clean basin/bucket.

115

24.

Clean inside the cylinder.

25.

Put another cereal into the cylinder to continue processing.

26.

Sieve and separate defective materials And put selected materials into the bag for next processing.
Defective materials can be grinded into flour for other uses.

116

27.

Enjoy eating puffed cereal or add preferred flavors.

Table 1. Recommended puffing pressures and methods for major grains.
Materials

Pressures (kg)Method

1 Rice10

Puff

2 Wheat

9Puff

3 Maize

9Puff

4 Finger millet

11

Puff

5 Sorghum

11

Puff

6 Pearl millet

10

Puff

7 Greengram

8-10

Puff or Cool down

8 Lablab

8-10

Puff or Cool down

9 Beans

6

Puff or Cool down

10 Soya beans

6-7

Puff or Cool down

11 Grand nuts

5-6

Puff or Cool down

12 Cowpea

7

Puff or Cool down

13 Bambarra nuts
14 Marama bean (EA type)6
6

Puff or Cool down
Puff or Cool down117

2.3: Samples of puffed cereals

118

Some of the grains the project has puffed (top left to bottom right): Maize (Zea mays); the volume expands
more than 10 times of the original grain size, Maize (Zea mays), Rice (Oryza sativa), Broken Rice (Oryza
sativa), Pearl millet (Pennisetum glaucum), Finger millet (Eleusine coracana), Red sorghum (Sorghum
bicolor), Bambara nuts (Vigna subterranean), Greengram (Vigna radiata ), and African Marama bean
(Tyloseme fassoglense).

119Section 3: MaintenanceThe best kind of maintenance is preventative maintenance. Good service and routine checkups can reduced
breakdowns and significantly increase the lifespan of your machine as well as contribute to saving time andmoney.
Inside toolbox

Name1

Toolbox2

Ear mugs- ear protection Pressure gauge

3

Rubber hammer

4

Sealing tape5

Eye protection

6

Skin or woolen gloves

7

Tools; spanners, pipe wrench, priers etc

8Scissors

9

Knife

10

Spare parts; pressure gauge, center bolt, hitting peg, Teflon gasket etc.

120

Wipe inside cylinder with clean duster.

Apply cooking oil inside the cylinder to prevent rusting. Remove carbons using iron rod.

121

Make sure pressure hole is clear.

You can clean other parts using water.

122

Change wooden damper if it is necessary.

Make sure all bolts, nuts and pins are tighten and fixed right.

Check thickness and surface of the Teflon gasket. Requires change if it is <than 2mm thickness (standard
size is 5-6 mm). To make gasket surface flat using sandpapers.

123Section 4. Processing and flavoring of puffed cereals.
* Code of practice of the East African standard, Hygiene in the food and drink manufacturing industry will
be applied to all food and drink manufacturing industries irrespective of their size and volume of production.
https://law.resource.org/pub/eac/ibr/eas.39.2001.html

124

4.1: Utensils

Name
1

Plastic buckets, different sizes

2

Wooden “kashata” flames

3

Plastic basins, different sizes

4

Clean cloth

5

Table

6

Stove / Cooker

7

Saucepans

8

Weight balance

9

Kitchen and serving spoons

10

Kitchen knife

11

Stainless steel or wooden board

125

Flavoring of puffed cereals depend on the type of consumers being targeted. Some of them preferred flavors include sugar, honey, blue band (bread spread), chili papers, chocolate, cinnamon, and fruit flavors
etc. The puffed cereals are flavored to add tastes and preserve them.

126

4.2: Flavoring with sugar (standard)
Directions
1)

Making a sugar syrup
Ingredient

Quantity1

Sugar or/and Molasses

350-500 g

2Salt

2.5 g (one tea spoon)

3

Water

180 mL Step 1: Put sugar and salt into the water and stir and boil continuously for 15-20 minutes over large
heat. Be careful not to let the sugar burn and do not let it crystallize in the bottom of the saucepan.
Never cover the saucepan with a lid.
 Step 2: Never walk away. Continue star to boil over until the mixture begins to thicken and turns
into light brownish in color. It produces a lot of small bubbles where it hardly disappears at thisstage.
 Step 3: Stop heat and pour the mixture (syrup) over puffed cereals all at once and stir with large
wooden spoon for a few minutes to ensure the syrup is well coated and dried.

2) The syrup can be used for most of the products to flavor as follows. Different puffed materials canbe mixed.
Ingredient

Syrup

1

1 L of puffed sorghum

1 and ½ serving spoon

2

1 L of puffed white corn (maize)

2 serving spoons

3

1 L of puffed wheat

1 serving spoon

4

1 L of puffed rice

1 serving spoon

NB: One serving spoon is approximately 50g of the syrup.

Making sugar syrup (left). Adding syrup to puffed materials (right).

127

Stir with large wooden spoon and ensure the syrup is well coated and dried (left). Serving for testing(right).
4.3: potential seasonings
Various spices can be used as seasonings to create new taste and unique additional values for your original
puffed cereals. It is recommended to use natural products which easily available and accessible.
Potential spices for favoring
Spices and favors

Forms

Quantity (g) for 1L puffedmaterials

1

Coco, Chocolate drink

Powder2.5 (one tea spoon)

2

CinnamonPowder2.5

3

Roasted soya bean (soya drink)

Powder2.5

4

CoffeePowder2.5

5

Green tea

Powder

2.5

6

BaobabPowder

3

7

Chili

Powder1

8Black paper

Powder

1

9

Curry

Powder

2

10

Salt

Powder2

11

Soy sauce

Liquid

Some

12

Honey

Liquid2.5

13

Dried mango

Small particles

3 to 5

14

Dried grated coconuts

Small particles

3 to 5

15

Dried pineapples

Small particles

3 to 5

16

Roasted ground nuts

Small particles

3 to 5

17

Roasted cashew nuts

Small particles

3 to 5

18

Roasted sesame seeds

Some

19

Roasted amaranth seeds

Some

128

Directions
 Put puffed materials and spices in a same paper bag and shake until the spices are well sprinkled
and mixed with the cereals.
 For salty flavors such as black paper and curry powder, little quantity of olive oil or palm oil ismisted over the cereals and then applied spices.
 Different spices and favors can be mixed and create own unique tastes.

Puffed rice with green tea powder (left) and coco drink powder (right).
Recipe and photos: Makiko Naganuma (2017)
4.4: Chocolate cube
Directions



Engrave cooking chocolate (250g) and melt with a water bath.
Stir slowly until it melts.

129 Put puffed material and adjust the quantities (about 1L). Less material makes it less cube.
Mix well that chocolate evenly courted around.



Put it in a mold. This time, a 3cm square ice tray was used.

 Put it in the refrigerator, cool it. It solidifies in about 20 minutes.
Recipe and photos: Yumi Yamane (2017)130

4.5: “kashata” (cereal bar / biscuit)
A "kashata" is a traditional Swahili confectionaly snack popular in East African coast region.
Ingredient

Quantity

1

Puffed materials (mixed in different cereals)

4 L (450-500 g)

2

Sugar

160 g

3

Salt

6g

4

Water
Glucose syrup

100 mL

Other ingredients such as rasted grund nuts, cashew
nuts, makademia nuts, grated coconut, dired fruits etc.
can be mixed to add exstra fravours of preference.

Some

5
6

100 g

Directions
Step 1: Mix sugar, salt and water then boil in a saucepan until all the sugar is dissolved (2-3 minutes).
Step 2: Add melted glucose syrup in the pan.
Step 3: Continue star to boil over until the mixture begins to thicken and turns into light brownish incolor. It produces a lot of small bubbles where it hardly disappears at this stage.
Step 4: While preparing the syrup, prepare the “kashata” board (Stainless steel board) and wooden
flames and pour roasted soya powder (also other seasonings) on it.
Step 5: Stop heat and pour the mixture (syrup) over puffed cereals all at once and stir with large wooden spoon to mix the cereal with the prepared syrup in speedy manner.
Step 6: Spreading the materials in the “kashata” flame and apply pressures to shape it. Pressing fromboth sides of the “kashata”.
Step 7: Cutting the “kashata” into favorable sizes and pieces.
Step 8: Remove the flame and ready for packing them.
Note: other additional ingredients such as nuts and dried fruits can be cut into small particles and added in
the kashata.
“kashta” can be served with strong black coffee or tea with ginger.

131

Weigh ingredient (sugar, salt and water) then boil in a saucepan (Step 1).

Preparing the kashata processing board and shaping wooden flame (Step 4).

Pour prepared hot syrup over the puffed cereals all at once and mix well with large wooden spoon(Step 5).

132

Spreading the materials in the “kashata” flame and apply pressures to shape it (Step 6).

Cutting the kashata into pieces using a wooden guide stick and remove the flame (Step 7).

Different sizes and shape of kashata.

133

134

List of Authors

Kanda Yasunori

Director, Department of Environment and Agriculture, C.D.C. International
Corporation-Chapter 2, 3. and 4.

Morimoto Yasuyuki

Associate Scientist, Agrobiodiversity and Ecosystem Services, Bioversity
International-Chapter 1-Chapter 2, 1., 2. and 5.
-Chapter 3, 2.

Nishino Shunichiro

Senior Researcher, Operations Department, Japan Association for International
Collaboration of Agriculture and Forestry, (JAICAF)-Chapter 2, 4.
-Chapter 3, 1.