In today’s global economy, the ability of a nation to innovate and manufacture high-quality goods is paramount for economic growth and development. Kenya, like many other developing countries, faces the challenge of transitioning from an agrarian-based economy to a more industrialized one.

One key strategy to achieve this transformation is through the integration of manufacturing education into the national curriculum, starting from junior secondary schools, polytechnics, Technical and Vocational Education and Training (TVETs), and extending to middle-level colleges. This post explores the potential of incorporating a culture of manufacturing into the Kenyan education sector, drawing insights from the industrial revolutions of the Asian tigers, Israel, and educational philosophies adopted by industrialized nations like China.

The Role of Manufacturing Education

Manufacturing education encompasses practical skills development, theoretical knowledge, and exposure to industrial processes and technologies. By introducing manufacturing education at various levels of the education system, Kenya can nurture a skilled workforce equipped to drive innovation, productivity, and competitiveness in the manufacturing sector. This approach aligns with the global trend of integrating vocational and technical education to meet the demands of modern industries.

Introduction of Industrial Manuals and Formulations

One unique initiative in Kenya is the introduction of industrial manuals with standard formulations and elaborate procedures. This initiative, spearheaded by institutions like The Cosmetics and Detergents Institute under the directorship of the founder, Dr. Herman Koome, has been instrumental in training individuals across all cadres with industrial skills.

By providing access to standardized manuals, students and professionals can learn best practices and acquire the knowledge needed to excel in manufacturing processes. This approach not only enhances technical competence but also promotes consistency and quality in product manufacturing.

Lessons from Industrialized Nations

The success stories of industrialized nations provide valuable lessons for Kenya’s education sector. The Asian tigers, including South Korea, Taiwan, Singapore, and Hong Kong, experienced rapid industrialization by prioritizing education, technology, and innovation.

These countries invested heavily in technical and vocational training, laying the foundation for robust manufacturing industries. Similarly, Israel’s focus on research and development, coupled with a strong emphasis on technical education, has propelled its economy forward, particularly in high-tech sectors.

China, the world’s manufacturing powerhouse, has adopted a comprehensive approach to education reform to support its industrial ambitions. The Chinese government prioritizes STEM (Science, Technology, Engineering, and Mathematics) education, vocational training, and partnerships between industry and academia. Through initiatives like the “Made in China 2025” strategy, China aims to upgrade its manufacturing capabilities and become a global leader in advanced industries.

Implications for Kenya

Incorporating a culture of manufacturing into Kenya’s education system holds immense potential for economic transformation. By equipping students with practical skills and theoretical knowledge relevant to modern industries, Kenya can stimulate entrepreneurship, attract investment, and create employment opportunities. Furthermore, standardized industrial manuals and formulations can serve as valuable resources for small and medium enterprises (SMEs), enabling them to scale up production and compete in domestic and international markets.

Embracing Transformational Leadership: Lessons from Kenya’s President

For the past year, I have avidly followed our esteemed president’s visionary addresses, which champion the revitalization of Kenya’s economy, the imperative of reducing our carbon footprint, and the noble mission of uplifting the lives of the underprivileged through financial empowerment. Through keen observation of his psychology and leadership ethos, I have come to regard him not only as a beacon of statesmanship but also as a profound mentor in the art of transformative leadership.

His unwavering commitment to progressive ideals and inclusive development echoes the aspirations Kenya has harbored since its independence. Under his guidance, I have gleaned invaluable insights into the essence of effective leadership, imbuing me with renewed zeal to contribute meaningfully to our nation’s journey towards prosperity and social equity.

Conclusion Transforming the Kenyan education sector to embrace manufacturing requires a concerted effort from policymakers, educators, industry stakeholders, and the broader community. By integrating practical skills training, introducing industrial manuals with standard formulations, and drawing inspiration from successful industrialization models, Kenya can build a skilled workforce capable of driving innovation and productivity in the manufacturing sector. This holistic approach not only fosters economic growth but also enhances the country’s global competitiveness in the ever-evolving landscape of the 21st-century economy

One hot afternoon, in January 2019, I noticed a missed call alert on my phone, followed by a brief message. It was from a former student whom I had taught a number of industrial formulations after his contracted manufacturer abruptly exited his operations leaving him stranded.

After drawing on the training and problem-solving skills gained from his training by me, this former student positioned himself as a corporate consultant. However, the tone of his call suggested a hint of distress. He found himself faced with the daunting task of refining a metal putty product from a local manufacturer who sought his “expertise” to enhance what had already become a popular brand in the Ukambani and New Nyanza regions. Aware that this challenge exceeded his current capabilities, he didn’t want to miss out on this lucrative opportunity. Hence, he reached out to me, proposing a partnership to tackle the endeavour and potentially share in the rewards.

Amidst the class session I was lecturing, I stepped out to return his call. Following a succinct briefing, I proposed meeting him at the taxi park. We quickly secured transportation towards the factory, which, in terms of scale, resembled one of the largest five manufacturers of paints, adhesives, and putties.

After a brief 15-minute taxi ride, we reached the factory and were warmly welcomed by a friendly female receptionist. She graciously guided us to the boardroom, where the company owner and the marketing manager were engaged in a discussion. Upon our arrival, my former student introduced me to the staff, and I followed with a concise introduction outlining my expertise and professional background.

The conference commenced with the marketing manager sharing insights on the remarkable market acceptance of their metal putty brand in the Ukambani and Kisii regions. Despite its widespread popularity, he expressed concerns about the product’s low ratings and the challenges associated with achieving satisfactory profit margins.

Reverse Engineering

Also, the company director inquired about the feasibility of enhancing the product’s performance to match that of the leading local brands while simultaneously reducing production costs, to which I confidently affirmed that it was indeed achievable. I assured him that through strategic adjustments, we could optimize production processes to achieve both objectives of lowering costs and enhancing product quality. I took the opportunity to challenge the director to bring a sample of one of the best-performing brands in the market for reverse engineering. Moreover, I expressed confidence not only in replicating its performance but also in further enhancing it. This proposition seemed to resonate with him, and he appeared genuinely pleased by the prospect.

In light of the director’s inquiry about my professional fee, and having been briefed by my former student-turned-consultant, who regarded me as a colleague during the meeting, I quoted the previously agreed-upon sum. Without further negotiation, the director nodded in acceptance of the quoted fee and proceeded to inquire about the timeframe for delivery. In response, I confidently stated that the project could be completed within a timeframe of two weeks.

Huge payment

With a gesture of trust and commitment, the director produced a wad of notes held together by an elastic band and handed it to me. After counting the amount, he confirmed that it was my deposit. He then assured me that he would deliver a sample to my town laboratory the following day, reinforcing his dedication to the project

As we wrapped up the meeting, the director kindly offered to lift back to town as he was headed home that evening. During our journey, we engaged in a friendly conversation, sharing stories about our respective backgrounds and the paths that led us to our current ventures. He recounted the fascinating journey of establishing the factory, sharing anecdotes of triumphs and challenges that shaped its evolution. His narrative painted a vivid picture of perseverance and resilience amidst the highs and lows of entrepreneurship.

No sample one week later!

Fast forward to the next week, while working on my paint brand in a factory that doubles as a training Lab one, I found myself puzzled as my staff struggled to locate the metal putty sample I had requested. Confusion mounted as I repeatedly asked if a rider had brought it, only to realize later that my client had personally delivered a 40kg metallic can wrapped in a nylon sack.

It was then that I truly grasped the down-to-earth nature of my client. Despite my request for a small sample, he had gone above and beyond by delivering a substantial amount himself. This act of personal commitment and sincerity underscored the strong partnership we were forging

Upon receiving the 40kg sample, I directed my staff to extract 80g of the material and conduct a series of procedures to analyse its properties. Meanwhile, during the following week, I personally conducted experiments with another sample, applying it repeatedly to my office window pane metal to study its curing characteristics and note other significant features and properties. Through these experiments, I realized that the sample I was dealing with was indeed of premium grade.

I also identified a few shortcomings in the brand, which I attributed to either cost-cutting measures by the manufacturer or oversight in quality enhancement. These observations were crucial in informing our strategy to ensuring that the improved product would surpass the existing standards in the market in terms of quality and performance

I promptly reached out to the client to share the findings and update him on the course of action I intended to take. I discussed the steps required to duplicate and further enhance the features of the premium-grade sample we had analysed. To that effect, I also contacted my long-time associate, a senior polymer technician who works on contractual basis, to help me with errands to source for the relevant raw materials and assign further duties in procedures.

First Factory Trial

With preparations complete, my technician and I were ready for the first factory trial at my client’s facility. Meanwhile, my student-turned-partner arranged a meeting with the factory director, their marketing team, and lead production managers to witness this pivotal moment

As the first factory trial progressed according to schedule, we made several observations and recommendations for the second phase of improvement. The director and the team were receptive to our feedback and recommendations, showing appreciation for our efforts. In a gesture of gratitude and confidence in our collaboration, the director presented another wad of notes, this time noticeably larger than the first one.

Creating new formulation from scratch

Recognizing the panel’s suggestions to the improvement meant lower cost of production and quick setting (hardening) I swiftly realized that we could substitute the conventional linseed resin-which is typically used in putty formulation-with a lesser-known polymer that is locally produced as a by-product of processing soya oil. This alternative presented a promising solution that not only addressed the cost concerns but also offered potential enhancements to the product’s performance and quality.

Despite my proposal, my technician, a polymer specialist in adhesive technology, expressed strong doubts about the viability of substituting the linseed resin with the alternative polymer. He recommended abandoning the idea altogether. However, I remained steadfast in my decision and directed him to a local factory to source the polymer and other necessary catalysts. Despite his reluctance, he eventually complied, albeit with evident reservations. Another disappointment awaited when my technician went to collect the sample from the factory. The sales manager inquired about the intended use of the substance. Upon learning that it was for putty formulation, the sales manager vehemently refuted its suitability for such purposes, even threatening not to sell it. Despite the resistance, he eventually sold us 5 kilograms of the milky white substance.

With the materials delivered to our town laboratory, the junior technicians commenced work on the formulations according to my instructions. The process proved daunting, marked by numerous trials and errors, as well as repetitive and exhausting efforts. Three days later, I personally oversaw and tested the new product, this time in the absence of the senior technician who was engaged in other duties contracted by a local adhesive factory.

To my amazement, the new product exceeded expectations, performing exceptionally well in testing. Furthermore, the cost of production had significantly decreased to 13.75 shillings per kilogram, translating to 550 shillings per 40kg can. Eager to share the news, I called my partner, the former student, to provide a routine update, and he was thoroughly impressed. Wasting no time, he promptly contacted the director to relay the positive news about the second phase of improvement. The director immediately scheduled another meeting for a demonstration at the factory.

Second Factory Trial

Accompanied by my hired senior technician, we conducted a second trial that yielded remarkable results: the product exhibited one-hour curing, self-levelling properties, and formed a remarkably strong film. This achievement filled the company director with joy, particularly upon realizing the significant cost reduction by 200 shillings per 40kg.

In response to his inquiry about whether we had decided to produce premium grade in favor of the more selling medium grade, I explained that we had effectively achieved both objectives. We had produced Grade One (retailing at Ksh. 3,500 per 40kg) as well as Grade Two (retailing at Ksh. 1,000 per 40kg) all at the cost of Ksh. 500!

I suggested that Grade One could be tinted Grey and Grade Two Black. In both cases, they would serve the same purpose, with Grade Two proving a superior quality in performance for customers in the building industry.

With our objectives satisfactorily achieved, my partner and I called aside our client and presented the final write-up containing the formulations and procedures. We concluded the business on a positive note, recommending that our senior technician remain behind with the client to guide their production staff on tinting the product and sourcing raw materials. And with unanimous agreement, we finalized the matter with a check for the balance owed.

A market hit

Two months later, my client called, alarmed by reports of shops re-packaging and reselling Grade 2 product as Grade One, amid huge demands from his Mombasa road factory. I reassured him that as long as he maintains the integrity of his product when selling to customers, any subsequent actions by resellers are beyond his control and should not detract from the quality of his brand.

Remarkably, even five years later, the brand continues to perform exceptionally well. It’s heartening to learn that a major paint company has recognized the quality of the product and is now purchasing it directly from the factory and repackaging it in their traditional label.

Senior Technician secures permanent employment

It was indeed an adventurous journey. A week later, my technician reached out, seeking advice on whether to accept a monthly salary from the client for a permanent position in the factory. Knowing his circumstances as a father supporting three children in university and relying on contracts, I encouraged him to accept the position. It seemed like a stable opportunity that would provide security and stability for him and his family.

Breach of trust

However, after four months, he approached me seeking new leads with another prospective employer. While I refrained from probing deeply into why his contract ended prematurely, his track record with previous employers gave me pause. Despite my decision to maintain distance from his personal affairs, I couldn’t immediately assign him new duties. Eventually, he took it upon himself to share the proprietary technology meant for my client with other manufacturing houses, charging a nominal fee of 50,000 shillings or even less.

Consequently, the ground-breaking formulation intended for patenting by my client, which held the potential to elevate the factory to the forefront of high-quality, low-cost commodity brand manufacturing in East and Central Africa, became widely known, akin to spilled beans on the ground.

Important Lessons:

1. Respect and Value All Consultants: Acknowledging the expertise and potential of all consultants, regardless of background or experience, is crucial. Every individual brings unique perspectives and insights that can benefit a project or organization, even if initial perceptions may suggest otherwise.
2. Protect Intellectual Property: When a consultant makes a significant discovery or invents something new that could benefit the company, it’s crucial to protect that intellectual property. Patenting the idea ensures that the innovation is legally recognized and gives the company exclusive rights to its use, preventing others from copying or profiting from it without permission
3. Fair Compensation for Consultants: When hiring a professional consultant, it’s important to compensate them fairly for their expertise and services rendered. Consultants often bring valuable insights and solutions that can significantly impact a company’s success. Paying them well acknowledges their contributions and helps maintain a positive relationship.

Dr. Herman is a medic-turned scientist, an esteemed researcher and polymer chemistry scientist, boasting an impressive track record of achievements and breakthroughs in various areas such as new product formulations, factory setups, and product developments. He has authored several Industrial practice books and he is a regular contributor to Academia.edu

When one of our blog posts highlighted the accessibility of training for creating caffeinated confections, it garnered significant attention online, prompting enthusiastic inquiries from interested clients.

While caffeine can provide temporary benefits in terms of alertness, focus, and mood enhancement, it is advisable to consume it in moderation and be mindful of its potential health implications.

Role of caffeine in our body

Improved Physical Performance: Medically speaking, Caffeine can improve physical performance by stimulating the release of adrenaline, which increases heart rate, blood pressure, and the release of glucose into the bloodstream. This can lead to enhanced endurance and strength during physical activities.

Mood Enhancement: Caffeine consumption is often associated with feelings of well-being and improved mood. It achieves this by increasing the production of neurotransmitters like dopamine and serotonin, which are involved in regulating mood and emotions

Have you ever consumed caffeine?

The probability is 1: On average, individuals, including children, consume a notable amount of caffeine, in coffee. Adults who take energy drinks consume quite an amount of caffeine. However, excessive consumption of caffeine can lead to anxiety and exhibit drug-like effects.

Why is caffeine generally safe for coffee drinkers?

The reason coffee drinkers are not adversely affected by caffeine is because the dosage available in coffee is typically lower than that of a pure extract. Boiling coffee during beverage preparation does not result in potent doses that could lead to addiction. Conversely, pharmaceutical extraction of caffeine, when consumed raw or in excessive amounts, poses a risk of overdose. In regulated doses, caffeine extracted pharmaceutically is utilized as an active component in energy drinks. As I have meticulously demonstrated in our teaching Lab, caffeine can also be incorporated into products such as chewable tablets, sweets, and chewing gums to provide a substantive dosage to consumers.

Understanding Pharmaceutical Doses of Caffeine

“Pharmaceutical doses” in this context refer to the specific amounts of caffeine that are used for medicinal or therapeutic purposes, typically as prescribed by healthcare professionals. These doses are carefully measured and controlled to achieve desired effects while minimizing potential side effects. Pharmaceutical doses of caffeine typically range from 100 to 200 milligrams per dose

Potential Health Benefits of Therapeutic Caffeine Doses

Therapeutic doses of caffeine offer a range of health benefits. They can enhance alertness and cognitive function, making it easier to stay focused and attentive. Caffeine is also known to alleviate headaches and migraines, providing relief from discomfort. Additionally, it can boost physical performance and endurance, making it a popular choice among athletes. For those with respiratory conditions like asthma, caffeine may offer some relief by helping to open up the airways. Furthermore, caffeine can combat feelings of fatigue and drowsiness, providing a much-needed energy boost. Some studies suggest that caffeine can increase metabolism, potentially aiding in weight loss efforts. Moreover, it has been found to alleviate various types of pain, including muscular pain and post-operative pain, offering a natural alternative for pain management.

Navigating the Nuances of Coffee and Caffeine Dosage

As discussed earlier in this blog post, coffee drinkers may not experience all the health benefits mentioned above, except for relief from fatigue and improved mood. These effects are often sought after by coffee enthusiasts, who may crave for a cup during tea breaks or in the afternoon. This is because the dosage of caffeine available in coffee is generally lower than that of a pure extract. The process of boiling coffee during beverage preparation does not yield potent doses

Training

I’m eager to share some insights with you on food value addition, particularly the process of extracting potent caffeine from the coffee you purchased at your local supermarket.

But before I delve into the intricacies of caffeine extraction, which will not only enlighten you in many areas of pharmacy but also reveal an easy way to capitalize on coffee and potentially make a lot of money, it is noteworthy that caffeine extracted from coffee beans or processed sachets bought in supermarkets can be used in various food and beverage products. Some common examples include energy drinks, caffeinated chocolates or candies, coffee-flavoured desserts or ice creams, and even caffeinated chewing gums or mints.

Additionally, caffeine can be incorporated into functional foods or supplements aimed at enhancing alertness or energy levels. How do we extract? How do we incorporate it into the above named possible products?

And before abruptly concluding this discussion, out of concern for ethical considerations and potential scrutiny by regulatory authorities, I have remembered that after the recent discussion on value addition, I received an inquiry from a follower regarding the extraction of cathinone and cathine, the psychoactive components present in Khat (Miraa). They inquired whether it’s possible to teach this extraction process and if the resulting compounds could be used in various consumable products like energy drinks, candies, and desserts. This suggestion, according to the follower, aims to discourage the consumption of raw Khat, which is often seen as unsightly and unhygienic, especially in professional settings where chewing the twigs and leaves of Muguka are associated with backwardness.

For professional consultation, training and raw material sourcing, get to us through a Mr. Evans, our chief training coordinator or Ms. Kiki, immediate former chief training officer, now the corporate affairs manager, on Mobile no. +254 710 20 23 26. You can reach out to me on my Email address: hermankithinji@gmail.com

In the bustling world of consumer goods, one industry stands tall as the indisputable titan of income generation: the food industry. Why? Because everybody eats. It’s as simple as that. With over 60% of the global population indulging in at least two meals a day, the demand for food products is not only constant but ever-growing. From the early morning breakfast to the late-night snack, food is an integral part of our daily routine, making it the cornerstone of the consumer market.

Compared to other industries vying for consumer attention, such as detergents, the food industry reigns supreme due to its universal appeal and essential nature. While detergents and household products play their part, they simply cannot compete with the widespread consumption of food products. After all, while you may not need detergent every day, you certainly need to eat.

One of the key factors driving the dominance of the food industry is the ubiquitous presence of food products in various settings. Whether it’s at home, schools, workplaces, or during travel, food is an ever-present necessity. Hotels and restaurants cater to travellers and locals alike, ensuring that food remains a thriving sector of the hospitality industry. This widespread consumption across diverse environments solidifies the position of food products as indispensable commodities.

Moreover, the rise of processed foods has further bolstered the dominance of the food industry. Products like cereals (including favourites like Weetabix), cakes, cookies, powdered milk, canned goods, and frozen meals have become staples in modern households. These processed foods offer convenience, longevity, and often enhanced flavours, appealing to consumers seeking quick and easy meal solutions in today’s fast-paced world.

The popularity of processed foods is evident in their market performance, with sales often outpacing traditional raw food items. While staples like rice, grains, and fresh produce remain essential, processed food products command higher prices and generate substantial revenue due to their widespread adoption and perceived value

Which way to go? Food Product or Soaps/Detergents?

As a prospective manufacturer weighing the options between food products and detergents/cosmetics, several factors come into play. Both industries offer unique opportunities and challenges, making the decision a nuanced one.

In the food industry, products like sausages, ice cream, bread, fresh juices, morning cereals, biscuits, energy drinks, and juices boast attractive profit margins. However, they also come with the challenge of a shorter shelf life. While these products may fetch higher profits per unit sold, the need to manage inventory and minimize waste becomes critical. Additionally, food production may require more stringent regulations and quality control measures to ensure safety and compliance with food standards.

On the other hand, detergents, soaps, lotions, and cosmetics offer products with longer shelf lives and potentially lower production risks. These items may have lower profit margins per unit compared to certain food products, but their stability and durability can lead to more consistent revenue streams. Moreover, the demand for household and personal care products remains relatively stable, making them reliable investments in the long run.

When making a decision, prospective manufacturers must consider factors such as initial investment costs, production complexity, market demand, regulatory requirements, and profit potential. Ultimately, the choice between food products and detergents/cosmetics depends on individual preferences, risk tolerance, and strategic business objectives. Both industries offer opportunities for success, but careful evaluation and planning are essential to maximize profitability and minimize risks.

Join our daily classes on manufacturing Energy drinks, Juices, Morning Cereals (like Weetabix), Biscuits, Caffeinated Sweets (to Keep you awake while working long hours or driving), Slimming Tea, Chocolate, Paediatric Porridge formulas, Yoghurt, Food Seasoning, Noodles, Peanut Butter, Fruit Jam, Candies etc.

For more information, reach me via Email: hermankithinji@gmail.com. Call/WhatsApp us on +254 723 424240

In a candid admission shared on this platform earlier, I reflected on a significant memory from my time in Form 3 at Garba Tula High School. It was during this period that my seating arrangement, orchestrated by our class teacher, Mr. Mutua, led to an unexpected encounter with a girl who regularly used a cream known as “Pears.” This particular brand held immense popularity in the 1980s, and its fragrance stirred deep nostalgia within me, evoking memories of my auntie, who had lovingly cared for us during our childhood years when I was around 6 or 7 years old.

As time passed, I found myself drawn closer to this Muslim girl, despite the apparent differences in our religious beliefs. This seemingly trivial encounter, steeped in the scent of a familiar cream, served as a poignant reminder of the profound impact scents can have on our emotions and connections with others, transcending barriers and fostering unexpected bonds.

Scent and Chemistry of Attraction

Having graduated from college, where my studies included a unit on neuropsychology, I can confidently affirm the long-held belief that scents in perfumes play a significant role in attraction. Scent-induced neural responses can indeed contribute to enhancing mood, increasing arousal, and fostering feelings of intimacy and connection. This phenomenon arises from the intricate chemistry involved in scent processing within the olfactory system and the brain centres within the limbic system, such as the amygdala and the hippocampus.

Here’s a simplified analogy of how scents are processed in the brain: From the olfactory bulb, scent information is transmitted to several brain regions, including the limbic system and the hypothalamus. The limbic system, known as the emotional centre of the brain, regulates emotions, memories, and behaviours, including those related to sexuality and intimacy. Meanwhile, the hypothalamus, nestled below the thalamus, is vital in governing physiological functions like hormone secretion, sexual behavior, and reproductive functions. It integrates scent-related information with hormonal and physiological responses, shaping our emotional and physical reactions to different scents.

Which scents are aphrodisiac?

Certain scents, like sandalwood, jasmine, cinnamon, and rose, have distinct profiles that directly influence emotions and physiological brain activities. For instance, the warm and spicy aroma of cinnamon is believed to possess stimulating and aphrodisiac properties, potentially increasing blood flow and arousal, leading to heightened sensitivity and pleasure. Rose, with its sweet, floral fragrance, is often associated with love and seduction, evoking feelings of romance and intimacy. Sandalwood, known for its warm, woody scent, is revered for its aphrodisiac properties, promoting relaxation and intimacy, making it a favoured choice for sensual fragrances.

Moreover, the inhalation of lavender fragrance has been linked to changes in neurotransmitter levels, including increased serotonin levels, known for mood regulation and relaxation. As lavender influences the limbic system, comprising structures like the amygdala and hippocampus, it plays a pivotal role in regulating emotions, memory, and stress responses.

Formulating Aphrodisiac Scented Perfumes

It’s worth noting that different doses of each scent can yield varying mood-altering effects, enhancing physiological brain activity. For example, studies have demonstrated that exposure to lavender aroma can decrease amygdala activity, involved in processing emotions like fear and anxiety. Additionally, blending and maturing aromatic oils can enhance the scent profile, further endearing it to the wearer.

It is pertinent to acknowledge that we the scientists, possess the capability to manipulate specific synthetic aromatic compounds present in select natural sources like civet, musk, or ambergris. By modulating these compounds, we can engineer scent profiles bearing resemblance to sweat or bodily secretions, thus imbuing fragrances with attributes that elicit primal or sensual responses.

In essence, the science behind perfume scents and their impact on attraction and mood is multifaceted, involving intricate neural pathways and physiological responses in the brain. Through a deeper understanding of these mechanisms, mixing ratios and compatible selections, we can appreciate the profound influence of scents on our emotions and interpersonal connections.

The training on Special Perfumes

In our Special perfumery classes, we delve into the fascinating theory behind the essence of attraction found in select types of aromatic oils. Our goal is to empower students with the skills and knowledge needed to design perfumes with aphrodisiac properties.

While our course may come at a higher cost compared to standard perfumery classes, the investment is well worth it. These specialized perfumes command premium prices in the retail market, offering students the potential to earn substantial returns on their investment. By equipping students with the expertise to craft sought-after fragrances that tap into the power of attraction, our course opens doors to lucrative opportunities in the perfumery industry.

Feel free to contact us for training, raw material sourcing, and general enquiries. 0723424240

In recent years, the manufacturing of whole wheat breakfast cereals from wheat has indeed emerged as a promising venture worldwide, particularly within the value addition chain sector of crop processing. This trend offers not only opportunities for economic empowerment but also sustainable growth. As foreign companies capitalize on the demand for biscuits and morning breakfast cereals, Kenyan entrepreneurs have the chance to tap into this lucrative market by converting locally grown wheat into whole wheat breakfast biscuits.

This shift towards local value addition holds immense potential for empowering Kenya’s micro economy. By utilizing locally sourced wheat, entrepreneurs can create employment opportunities across the value chain, from wheat farmers to biscuit producers, distributors, and retailers. This not only boosts income levels but also contributes to poverty reduction and improves standards of living within communities.

Furthermore, venturing into whole wheat breakfast cereal manufacturing enhances food security by diversifying the food supply and offering nutritious options to consumers. With Kenya’s rich agricultural landscape, such initiatives strengthen the resilience of the economy by reducing reliance on imported food products and promoting self-sufficiency.

Our short industrial skills training program on food value addition has had a significant impact on individuals who have fully embraced manufacturing in this field. In 2020, following the COVID-19 lockdown, I was approached by eLengo, a French-owned global Farmer’s training academy, to develop an educational 1-hour online lecture on adding value to locally grown tomatoes. The video, uploaded on their online platform, received an overwhelming response, with hundreds of thousands of views upon its premiere. To date, it has amassed over a million views across five continents, and my inbox has been inundated with congratulatory messages, invitations, and inquiries.

Training

Locally, we have conducted training sessions on various aspects of food value addition, including processing powdered milk from freshly milked milk, manufacturing tomato sauce, peanut butter, and producing nutritious paediatric porridge.

In 2022, I was approached by a prominent pharmaceutical professor from a local private university for consultation on converting bee honey into powder. Additionally, a former college mate, now a paediatric care specialist at a Rift Valley referral hospital, sought my expertise in the manufacturing of paediatric powdered milk, a project we are currently collaborating on.

These examples highlight the growing interest from individuals and corporates in leveraging food value addition techniques. It underscores the demand for knowledge and expertise in this area and demonstrates the potential for collaboration and innovation within the food industry

How to make Weetabix

We have recently initiated training sessions for individuals interested in learning how to process locally grown morning cereal, akin to the popular brand Weetabix. Our comprehensive course spans three hours and covers essential topics in food science, basic processing techniques for wheat, and the creation of high-fibre morning cereal resembling Weetabix. Additionally, the course delves into the critical aspect of vitamin fortification, ensuring that the final product is not only nutritious but also meets essential dietary requirements.

Is it profitable?

Yes, Weetabix production can indeed be highly profitable, with potential returns of over 500%. To illustrate, let’s consider a simple cost analysis:

• Cost of Wheat: Approximately 100 Shillings per kilogram.
• Retail Price of Weetabix: A 112g pack retails for 96 Shillings, equivalent to 857 Shillings per kilogram.

When we compare the cost of raw wheat to the retail price of Weetabix, we find a significant mark-up. Assuming that packaging costs, labour, and processing expenses are accounted for, the cost of converting one kilogram of wheat into Weetabix-like product would be approximately 700 Shillings. This translates to a net profit margin of around 700% once the product is sold at the retail price. Therefore, based on these calculations, it’s evident that Weetabix production can be highly lucrative and profitable for entrepreneurs in the food processing industry

Final Note: As Kenyan entrepreneurs embark on this journey, they play a pivotal role in fostering inclusive growth and driving economic transformation. By capitalizing on local resources and harnessing the potential of value addition, they contribute to the overall development of the nation. This represents a significant step towards building a prosperous future for Kenya, one biscuit at a time

For more information about the course, training charges, duration and investments budgets, please talk to our corporate affairs manager, a Ms Irene Kiki, on mobile no. +254 710 202326 or our Chief training manager, a Mr. Evans on Mobile No. 0799 888 162. You can also make general enquiries through mobile phone number +254 723 424240

Are you looking for a lucrative business opportunity that doesn’t require a massive investment? Consider venturing into small-scale manufacturing of herbicides, especially non-selective ones.

As Kenya continues on its trajectory of economic growth and industrial expansion, under the able leadership of President Ruto (PHD), opportunities abound for investors in the manufacturing sector. By tapping into the resources and infrastructure available within the country, upcoming, small scale investors can capitalize on the growing demand for herbicides and contribute to the nation’s agricultural productivity and sustainability.

Market for Herbicides

Herbicides are versatile products with a wide range of applications. Herbicides, particularly non-selective ones, are in constant demand. With increasing concerns about weed control in agriculture, landscaping, and industrial settings, the market for herbicides is ever-expanding. And by manufacturing these products, one can tap into a fast-moving market with consistent demand.

Generally speaking, herbicides are used during planting seasons for pre-emergent weed control, during weeding seasons for post-emergent control, and even during off-seasons when certain plants are not in cultivation. This year-round demand ensures a steady stream of customers for your herbicide products.

Simple and Easy Manufacturing Process:

The process of manufacturing herbicides is relatively simple and straightforward, making it accessible even for small-scale operations. With the right equipment and formulations, you can produce high-quality herbicides efficiently.

Minimal Equipment Requirements:

Unlike some manufacturing processes that require heavy machinery, herbicide production can be done with small electric mixers. Since most herbicide products are in liquid solutions, mixing and compounding can be accomplished with compact equipment, reducing the need for large-scale infrastructure.

Are Raw Materials Available?

In the realm of herbicide manufacturing, securing raw materials is a critical consideration for local small medium scale manufacturers. Fortunately, in Kenya’s rapidly progressive economy, accessing raw materials shouldn’t be a cause for concern. As an indisputable fact, Kenya boasts a fast-expanding local manufacturing sector, characterized by vibrancy and growth. This burgeoning industry has attracted numerous industrial players, including those in the pharmaceutical and agrochemical sectors.

Notably, Kenya has seen the emergence of giant pharmaceutical raw material importers, catering to the needs of the rapidly growing pharmaceutical industry as well as the agrochemical manufacturing sector. And with established importers like Arichem, ASL, DECASE, Betty Industrial Chemicals, and Brentang, cottage industry players in the herbicide manufacturing sector can rest assured of seamless access to high-quality raw materials. These companies have built robust supply chains and strong relationships with global suppliers, ensuring timely and reliable delivery of raw materials to meet the demands of the local market.

Competitive Professional Training:

In today’s rapidly evolving manufacturing landscape, staying competitive requires more than just access to raw materials and equipment. It demands expertise and proficiency in every aspect of the manufacturing process.

With over ten years of experience in training professional manufacturers, we have established ourselves in Africa as leaders in the field. Our comprehensive training programs cover everything from formulation techniques to quality control measures, ensuring that participants are well-prepared to meet the demands of modern manufacturing. From mastering the intricacies of herbicide formulation to implementing effective quality control measures, our training equips one with the tools and knowledge needed to thrive in today’s competitive market.

Recognition from Regulatory Authorities:

Our commitment to excellence has not gone unnoticed. We are proud to have trained senior quality inspectors (on other subjects) from the Kenya Bureau of Standards (KEBS), further solidifying our reputation as a trusted source of expertise in the manufacturing sector. Our training programs are designed to meet and exceed industry standards, ensuring compliance

Profitability

The average market retail price of most herbicides goes for Ksh. 2,000. On the other hand, the average cost of making the same is Ksh 400 Per Litre  

Product regulation

Pest Control Products Board (PCPB) is responsible for regulating the registration, sale, distribution, and use of pest control products, including herbicides, in Kenya. Manufacturers are required to register their products with the PCPB before they can be marketed and sold in the country.

Herbicide manufacturers must also comply with environmental regulations to minimize the impact of their operations on the environment and natural resources. They need a letter from the Environmental Management and Coordination Act (EMCA) which governs environmental conservation and management in Kenya.

Course Duration

A week of intense theory followed by a day or two for practical is good enough to equip the learners with the mandatory skills to qualify them to manufacture herbicides with minimal supervision.  

For more information, do not hesitate text/call us on tel. no. +254 723 42 42 40/+254 710 20 23 26. You can also request to book a consultation appointment with Prof. Herman.

The alarming trend of fake fertilizers circulating in Kenya has become a pressing concern as the agricultural sector gears up for the planting season. Reports from agricultural experts and concerned farmers have shed light on the presence of counterfeit fertilizers in the market, posing a significant threat to farmers’ livelihoods and the nation’s food security.

These counterfeit products, often packaged and branded to resemble reputable brands, are being sold at lower prices, attracting unsuspecting farmers looking for cost-effective solutions. However, not all brands labelled as fake are necessarily counterfeit. Some come from reputable manufacturers but lack sufficient nutrients, rendering them substandard and ineffective.

The compromised nutrient content and inconsistent composition of these counterfeit products result in reduced crop yields and poor-quality harvests, leading to monetary losses for farmers. To address this issue, government agencies, regulatory bodies, and industry stakeholders must collaborate to strengthen oversight and enforcement measures.

Manufacturers of substandard fertilizers also play a crucial role in ensuring product quality. Implementing thorough observation of Standard Operating Procedures (SOPs) and introducing professional development programs for factory workers can enhance professionalism and quality control in the manufacturing sector.

In my own thought, implementing a branch of surveillance within the Kenya Bureau of Standards (KEBS) that involves field inspectors visiting fertilizer factories and conducting inspections can be a proactive step in ensuring quality control. These inspectors can assess production processes and conduct oral tests on internal quality control practices to verify adherence to standards.

Additionally, introducing professional development programs for factory workers, similar to Continuous Medical Education in healthcare, can enhance professionalism in the manufacturing sector. These programs would provide workers with updated knowledge and skills relevant to their roles, regardless of their initial training. Field officers with expertise in specific industries, such as fertilizer production or paint manufacturing, can engage production teams to assess their understanding of critical processes.

For example, in fertilizer production, inspectors can inquire about how the production manager ensures that nitric acid reacts with calcium carbonate to yield enough nitrogen for CAN 0-27-0. Similarly, in the paint industry, inspectors can assess the knowledge of production managers regarding adjustments to the Pigment Volume Concentration variable to produce silk paint with optimal refractive index and sheen, as well as the right Volume Solids and excellent Dry Film Build. The latter factor plays a crucial role in determining the paint’s durability on the walls

By engaging with production teams and promoting knowledge exchange, these initiatives can contribute to improving quality control measures and ensuring the production of high-quality agricultural inputs and paints in Kenya. This, in turn, would enhance consumer confidence, protect farmers’ interests, and support sustainable agricultural development and infrastructure maintenance.

By fostering transparency, accountability, and regulatory compliance within the fertilizer industry, stakeholders can uphold the standards of quality and integrity necessary for sustainable agricultural development. It is essential to prioritize the integrity of agricultural inputs to safeguard farmers’ interests and ensure the long-term sustainability of the sector

Am launching a new book: “Implementing Standard Operating Procedures in Industrial Manufacturing for Optimal Efficiency and Quality” for industrial production managers. This book aims to rectify outdated practices, errors, and misconceptions especially in batch corrections, error detection, hygiene practices, and the preparation of pre-batch test samples. For more information, please reach out to me on my personal email; hermankithinji@gmail.com

Our latest publication, “Know How to Make Standard Fertilizers at Home,” has created a buzz among our online fans, with many appreciating the effort we have made towards disseminating knowledge and “revealing the most classified industrial secrets” to the manufacturing enthusiasts.

Nothing could be further from the truth. Our first publication, released in late 2013, was bought for Ksh. 12,000 by a resident of Mombasa, much to the amazement of our director, who had indicated that the book was priced at Ksh. 2,500 before its launch. This served as an eye-opener for the director, motivating him to increase and improve the content to add value commensurate with the price. In a 2014 interview with a local media outlet (KTN), our director disclosed that he created the manuals to empower customers with manufacturing skills that were not taught at universities or middle-level colleges, despite years of study in relevant fields. A graduate of medicine and biochemistry, he pointed out that his passion for venturing into book writing alongside training was fuelled by the desire to close the gap he noticed while trying to hire co-workers for his small pharmaceutical lab, which he had established three years into his practice. During his lengthy interview, he disclosed why he shifted from medical practice to manufacturing.

During an end-of-year meeting one evening, he revealed to us that after observing many people demanding the manuals without bargaining, he recognized the potential for making money by selling them. This eventually led to another stream of income: selling the raw materials and machinery—a trade he has adeptly managed for the last decade. To maximize his expertise in writing the manuals, he engaged local and foreign (where he studied) university professors, factory technicians, and research fellows in compiling subsequent editions. Coming from a family of writers and researchers, his contributions to some of the work featured in the manuals are supported by deep scientific theories, principles, and precise procedures for product manufacturing which his clients appraise.

The fertilizer making book

The latest manual, ‘Know How to Make Standard Fertilizers at Home,‘ has not only stirred interest among many individuals seeking to manufacture as a means of generating income but has also served as an eye-opener for thousands of farmers. They see self-production of fertilizer as an effective method for overcoming the capital burden on farm inputs, especially given the recent hike in fertilizer prices caused by shortages in local supply.

Created in collaboration with leading agronomists, professors, research institutions, and production technicians, including Mr. Waweru, from selected factories, the manual highlights common fertilizers used in the Kenyan market, the theory behind crop/soil fertilization, principles of chemical reactivity in creating fertilizers, and importantly, formulations and procedures for making various types of fertilizers. Additionally, the book reveals the science behind rooting/growth stimulation through hormonal interference and chemical/biological preparations that promote root growth for effective nutrient uptake by expanding the surface area of the roots. In total, the manual has formulations and procedures for making 27 different types of fertilizers

It’s intriguing to learn about the diverse methods of preparing principal reactant raw materials for fertilizer manufacturing, utilizing different chemical reactants or alternative routes in this manual. In cases of market deficit, alternative chemical reactants can be used to replicate their equivalents, enabling industries to overcome challenges of occasional emergencies or inadequate raw material supply shortages. The manual contains all the information, processes, and procedures necessary to achieve this.

Who can use the Manual?

The manual can be used by any person with the ability to read English and grasp a few scientific concepts in order learn how to formulate selected types of fertilizers, including designer fertilizers—both granular and liquid (foliar feed).

Book Content

In addition to formulations and procedures, the manual includes a comprehensive list of raw material stockists in Kenya, ranging from wholesale to retail. It also features machine fabricators and importers. Moreover, it provides information on where to obtain packaging materials such as nylon sacks lined with polyethylene sealant material, sack printers, and sources for hand-held sewing machines for the sacks. Attached is a list of content available for download in PDF format.

Can manufacturing be done without machines?

Certainly, yes. The book explores methods of fertilizer production, especially the liquid type, without using mechanical gadgets. For farmers or manufacturers who want to make their fertilizers with machines but have limited capital, the book includes a section that addresses this issue, often providing references for sourcing small electrical mixers and cheaper versions of the larger machines that are necessary, especially in granulating

How is the manual beneficial to the buyer?

Similar to other manuals that have empowered individuals to create industries, this manual serves as a guide for formulating and producing fertilizers for personal gardens or for commercial sale. By following the instructions in the manual, individuals can significantly reduce the cost of inputs while generating income through the manufacturing and sale of quality fertilizers.

Consider this scenario: A maize farmer owns 1000 acres of land and needs to apply NPK fertilizer. Each acre requires 100kg of NPK 20:20:20. Therefore, the farmer needs approximately 100,000kg (equivalent to 2,000 bags) of fertilizer.

Assuming each bag retails at Ksh. 5,000 based on recent market prices, this large-scale farmer would need to budget approximately Ksh. 10,000,000 to rehabilitate the vast ranch for two seasons of farming!

However, with ten million Shillings, the farmer could set up a large-scale factory on just one acre (out of the 1000 acres) and produce fertilizer with half of the allocated budget. Moreover, the surplus fertilizer could be sold to neighbouring farmers, further increasing revenue.

How does the Manual compare, in terms of price, with other types by the same author?

In comparison to other manuals authored by the same individual, the price of this 130-page fertilizer manual may seem somewhat ambiguous. Our highest retailing manual in the portfolio is priced at approximately 185,000 Shillings. This begs the question of why our manuals are priced higher than ordinary textbooks found in bookshops.

The simple answer lies in the nature of these manuals—they are factory plans! Our chief author, Dr. Herman, often emphasizes to everyone that no individual or corporation willingly discloses their trade secrets. If they do, it could potentially cost millions of monetary units.

For instance, companies like Colgate or Coca-Cola guard their brand success secrets zealously, not to mention the formulations of their products, even to the highest bidder! Conspiracy theorists even believe that the education system and curricula of a country are controlled by industrial cartels, akin to the pharmaceutical industry.

Therefore, according to Herman, when presented with the opportunity to learn what the education system cannot offer or to obtain classified information, one should seize it, regardless of the price!

For price of the “Know How to Make Standard Fertilizers at Home” please WhatsApp me on mobile no. +254 710 20 23 26. The manual is also available in Somali, French and German translations.

Kiki

The common questions we get from concerned young manufacturers is whether the foam mattress business is viable in Kenya. They also ask whether the foam mattress making is profitable

In our honest response, we tell them that any business that is being conducted either in large scale and/or being conducted by many people, especially Indians and Somalis is a healthy market marker of good productivity (read profitable).

Now, the manufactures of foam mattresses are quite a number with the more serious manufacturing firms churning out thousands of pieces every day. Kenya, a country of 50 million people, is made up of consumer market that absorbs all this production, making foam mattress production promisingly healthy to infinity.

Success Indicators

Success Indicator 1: Just have a look at the thousands upon thousands of furniture manufacturers scattered in roadsides of every town in Kenya. Their merchandize (sofa seats) never lack buyers. Assuming that people plan for beds before budgeting for seats, then a true testimony indicative of ‘higher demand for mattresses as essential commodity’ holds

Success Indicator 2: The number of school children joining boarding schools (and colleges) at any level every year is directly proportional to those who leave their parent’s home to start their own new lives. They all need mattresses as priority, which a significant number of them spread on the floor before buying beds. Last year alone, about 1 million pupils joined form 1 boarding. Therefore, 1 million low density foams found their way out of the factories to schools in January alone!

Success Indicator 3: The numerous mushrooming new hotel lounges and Airbnb’s on daily basis not only signify expanding need for foam mattresses, but act as ready market for foam mattresses.

Success Indicator 4: The numerous upcoming new unoccupied units in the suburbs, estates and rural housing developments, whose occupancy, will definitely need beds and mattresses. This, without saying creates a robust market for foam mattresses

Cost of making mattress

An example is given of an ordinary foam slab measuring 4 x 4 x 6 inches. It is a standard size for many homes and retail prices range from 4,500 to 5,000 depending on the density. The overall cost of production, which is estimated to be Ksh. 2,313 can be traced to raw material which are calculated based on the volume, (20,736 cubic inches). Part of the ingredients is filler material, barely retailing at 10 shillings per Kg and the additives (4 of them) weighing slightly less than 700g, and costing nothing more than 300 shillings.

Without divulging further details about the main reactants, which will cost approximately 1,600, additional costs can be from cover fabric material (5.2 sq. meters), which, if retailing at 45 shillings per meter square, costs about Ksh. 243. Overheads (labour, transport, rent, sewing etc. is calculated as 10% of the overall cost of production, not forgetting the dust-proof polythene wrap

Computing all of the above, the manufacturer is capable of making 1,500+ per mattress, which over 75% profit. In fact, mass production will enable a manufacture to clinch 100% profit. It is also noteworthy that some mattresses destined for the higher market, e.g. 6 by 6 with a thickness of 10 Inches can be made with a cost of 5,500 and sold at wholesale price of 10, 500, fetching a whole 5,000 Net profit!  

How Foam Density is used to maximize profitability

Seasoned foamers will tell you that the secret behind successful foaming business relies on producing of mattresses based on varying densities. The density of a standard medium foam is 24kg/sq. inch. If a manufacturer needs to produce a foam size of 20,736 cubic inches-as previously discussed above-with a less material, he will accelerate blow reaction at the expense of gelation reaction, effectively producing a voluminous foam filling the 20,736 cubic inches. Obviously, this foam will last slightly less compared to the medium density one.

More enterprising foamers like the Thika-based factory will even increase the blowing to achieve the same size of the mattress with a density of  < 18sq. metres, cutting the cost of production by half! This is, however, for school mattresses which, according to some manufacturers, must be changed (bought) every year.

It is also worth noting that over densifying the foam mattresses by addition of more fillers, cuts down the cost of production but at the same time producing foams of low quality. Over densified foams (density > 28Kg/sq.2) look very attractive to the buyer but once the new owner (buyer) of the mattress lies on it for three days, it forms a dent akin to a collapsed slab.

Raw materials

The main worry about business start-up is availability of raw materials. Fortunately, for the foam mattress, we have quite a number of importers located in the Industrial Area. Great raw material importers like Arichem Ltd., Betty Industrial chemicals among many others, have competitive prices. Small retailers scattered in Kariobangi, Baba ndogo and Korogocho provide easy access to these chemicals.

Future of the market

With a growing population and constant demand for the foam mattresses, there is a pie of the cake for everyone. What is important for the new entrants is to understand the dynamics of marketing, creating sound marketing strategies that scheme how to ‘steal’ the customers of the pioneer brands. Quality, Price and Branding are the key strategies among 5 others that we teach new manufactures in a mentorship programme dedicated to our students free of charge.

Ideally, a new manufacturer must focus (however gradual) on building a clientele base of 1000 customers every month. With profit margins of about 1,000 for lower density mattresses and 1,500 for medium densities, a new manufacturer can comfortably make Ksh. One million to 1.5 Million every month. This is exemplified by a Mr. Adan, who undertook the foam making course in early 2019 and Mrs Bett, she of Libra Comfort Mattresses.

Start-up capital and Size of factory

Foams are quite bulky but with proper planning, trimmed pieces can be piled up to maximize space above. A trimmer machine fabricated by us takes up a space of about 15 square feet. Mixer and moulding block occupy a lesser space. Start-up can be anything like 30k. this assumes the manufacturer wants to start by making seat cushions that may not necessarily need specialized cutting equipment.

Would you try a hand in foam making business this year? Kila kitu ni kujituma joo! We will hold your hands and lead you professionally with 100% dedication.

Kiki 0710 2023 26

In a well-researched and meticulously compiled article published by Natalie Cowling, a South African based researcher, in Sep 22, 2023, she disclosed that Agricultural activities in Kenya used over 300,000 metric tons of fertilizers in 2019.

Natalie made these subtle revelations on Statista, a global data and business intelligence platform that collects statistics, reports, and insights on over 80,000 topics from 22,500 sources in 170 industries. Statista was Established in Germany in 2007. It operates in 13 locations worldwide and employs around 1,100 professionals.

Well, these are not news, especially to those who know that Kenya has an arable land of 9.9 million hectares out of 58.2 million (582,636 Km2) of available land.

The information contained in the said report stated that Phosphate was the most used nutrient in fertilizer products, amounting to 150,000 metric tons and others like Nitrogen, Potassium etc. followed closely.

Now, according to another well researched information in our recent publication of “Know how to make fertilizers at Home”, statistics list DAP, MAP, TSP, SSP, NPK, NKP as the most widely used fertilizers in farming with consumption rating of 48%. CAN, ASN, UREA, etc. follow closely with at consumption rate of 25%

What does the above report mean to a local manufacturer?

Well, 9.9 million hectares of land under cultivation has enough crop coverage that consumes 300, 000 metric tons (300 million kilograms) annually. Assuming the average Kg of fertilizer sells at 100 shillings, then, we can safely conclude that at least 30 Billion shillings are pumped into farming in Kenya annually. Who takes the money, and what percentage, or average net profit do the manufacturers take?

Few fertilizer manufacturers in Kenya!

According to a local newspaper, The Star, the government had spent 12 billion in 2023 on fertilizer subsidy. That amount is slightly below half of the 30 billion shillings pumped yearly on fertilizer. Clearly, it shows that local production, however robust, was below par by under half of what is averagely required in the country. It is noteworthy that much subsidized fertilizer came from outside Kenya, precisely Russia.

In spite of the seemingly widening gap in fertilizer supply in the country, Kenya, has, nevertheless, a healthy number of local manufacturers, all 27 in number. The notable ones are Mea Limited, Syngenta, Yara, AGIL, Devji Meghji & Bros Ltd, et.al.

In the same vein, a local business daily, published on October 7 2020 quoted the then CS for industry, a Mr. Peter Munya, as saying that a Sh3 billion NPK Compound Granulation plant slated to supply 100,000 tonnes of fertiliser-effectively serving up to two million farmers in the country annually, was being constructed in the country. According to the vocal cabinet secretary, the manufacturing plant was set to open in Nakuru by end of the year (2020), in “what is expected to boost farmers’ yields in 2021.”. no much information has been gathered by our internal researcher on the monster plant by the time of publishing this post.

All in all, the above facts are a pointer to the urgent need for local manufacturing to scale up the production of fertiliser, and moreso, affordable one, for the vast local market. But will they keep up with local consumer demand?

That is the reason why his article is published. What is needed to produce fertilizer? What’s the minimum cost of production? Is someone able to start production within a limited space, like rural backyard of the home? What are the regulations and other statutory demands for a small, medium and large scale manufacturer?

In the Part 2 of this article, we shall also explore the possibilities within reach for individual large scale farmers to produce their own fertilizers with an aim to cut down the cost of production through self-sufficiency. Also, we shall be discussing what our new 120-page fertilizer production manual is all about and the impact it can have for small, medium and large scale wannabe manufacturers, especially hustlers, school/college leavers who would want to supplement income by trying a hand in manufacturing.

The Part 2 of this article will also make inroads into estimates of production of various fertilizers, as well as the average net profits expected. So far, we have trained three individuals on fertilizer making. We shall be revealing (with their permission) how their experience with the training in our town lab was and what future plans they have for their new dreams.

This post is written by Dr. H. Koome, Chief Training Administrator

To get a copy of the Fertilizer making manual, please talk to our Training coordinator, a Ms KIKI on mobile number +254 710 20 23 26

In the unforeseen future, schooling will become 110% virtual, and classroom setups will be a past history.

Yesterday, I was approached by the marketing executive of Express Marine Engineering corporation, the manufacturers of the marine equipment, refrigeration and assemblers of cosmetic making soap machines. They requested me to use my Pedagogical acumen to articulately narrate the working of Duplex Plodder Machines and to explain a very important feature that is associated with this model.  

I won’t dwell much on the ordinary plodders and for the sake of all, I will use simplified, layman’s language as much as I can. But to start, many of us who have interacted with ordinary soap making machines and soap making processes can attest that the element of waiting is there and must be respected.

Time spent for fresh mixture to undergo complete saponification (curing), waiting for the first and second noodles to dry etc. all constitute time needed to ensure the final billets (bars) come out ready for wrapping

It is a different story for Duplex machines which are built with double extrusion barrels joined in the middle by a special box-the Vacuum Chamber-where the first noodles are passed through before being produced for the second time in the second barrel positioned lower than the first. The Vacuum chamber in these conventional machines, plays a crucial role of drying the noodles and de-aerating (removal of air) them to modify texture and accelerate secondary curing.

Drying is a crucial stage in bar soap manufacturing as it affects the physical properties of the soap. The optimum moisture content at the end of the drying stage determines better performance and productivity on the finishing line. What does this mean to soapers?

Ordinary Plodders

As we can see, soap manufacturing using ordinary (Single Systems) Plodders, commonly abbreviated as SSP involves mixing the raw materials in a saponification tank and then pouring the mixture into a receptacle to allow complete the process leading to curing. The curing process takes a substantial amount of time, mostly 4-5 hours depending on the Total Moisture Value in the soap.

Once the soap cures, it is fed into the plodder via the hopper and extruded as noodles. The second round of extrusion produces noodles of a smaller thickness. This process is mandatory as it homogenizes and mills soap, reducing the particle size for greater compaction and fine texture. The third plodding cycle produces bar soap of varying sizes. In between the intervals, noodles bust be allowed an hour to two for dying. Technically, ordinary machines make three runs to get the soap and time required to get the final soap is lengthy since noodles must dry. It is not so for Duplex Machines.

Duplex Machines Produce Soap in One Run

Duplex Machines, popularly abbreviated as DSP’s (Dual System Plodders), extrude noodles and soap in one run, effectively shortening the time of extrusion by half. Therefore, DSP machines are primed to run once. The first upper barrel is supposed to plod noodles which are already crushed by a roller mill before loading them into the DSP machines. The noodles pass through a vacuum chamber where noodles are dehydrated under negative pressure conditions.

But since a few operators of Duplex machines my not involve the roller mill, the DSP machines run twice like ordinary plodders but this this has an advantage to the operator. Here, the soap is super refined because it is noodles thrice. It is therefore advisable for people manufacturing soap with a DSP to also invest in Roller Mills. The Express Marine Engineering offers a reduced price for the Roller Mill as an incentive to the client to purchase the two. From my own experience, purchasing the whole set with the roller machine saves the buyer 30%. Besides saving money and electricity, it makes soap production experience superb, producing soaps that can pass for Sunlight and Geisha in texture.

How does the Vacuum Chamber Work?

The thermodynamics surrounding Vacuum Chamber Drying are quite complex and since am limited to making a story aimed at enlightening the common man, I may not delve deeper on the matter. However, for general knowledge, vacuum chambers in DSP Machines are a one complex setup. The technology is on another level. It is not just a fabricated box per se. The apparatus is built as a rectangular or conical prism of 6mm iron cast, served with non-return valves pumps (mounted in the lower machine body) that generate negative pressure to the required millibars

A DSP User Manual I am currently holding in my home study desk, talks of the Vacuum Chamber mounted on the machines as having the Gas transfer types of vacuum pumps which work by mechanically removing gasses through positive displacement or momentum transfer.

In my own experience (we regularly maintain the Express Marine Plodder machines), positive displacement vacuum pumps have chambers that alternately expand and contract with check or non-return valves to draw and eject flow. Yes. This is how complex it is!

Advantages of using Plodders mounted with Vacuum Chamber

Time saving: Soap drying is instant and therefore no need to air-dry the noodles.
Energy (Electricity saving): No repeating of noodles to machine-dry
More profits: Also, the soap technician can increase the amount of water calculatedly (MVC of 21%) thereby achieving a higher volume to mass ratio (VMR) soap and packing it within minutes of production. This means more money!

Note, ordinary plodders cannot extrude noodles or soaps whose moisture value content (MVC) is above 11.8%. The noodles will take ages to dry and the surface texture of the forced extrusion will resemble maize cobs

For more information about Express Marine Engineering Corp machines, please send them an email on expressmarine.ke@gmail.com

Not long ago this year, I received a distress call from a factory making rebonded foam mattresses. While en route to Nairobi, I dutifully passed by their vast factory, and after a pleasant welcoming by the Asian owners, I was shown around the production area, packed with piles of thousands of slabs that were made ready for the market. But something was amiss with them all: Tensile strength, elongation and tear resistance were below par. That is the reason they called to enlist our services as an institution.

After listening carefully as they explained the procedures and processes they employ, I noted down a number of technical errors and omissions that led to the poor performance. The second day I send them a list of Items to buy that would aid in batch correction and proper re-batching procedures. In the meantime, I organised with one of my junior technicians to go and help with the procedures that I had outlined — in a copy sent to each of them including my technician.

Hopefully, they were able to make corrections and re-batch the slabs. My technician, as happens with many others in their characteristic mischief world-over, may have colluded with some of the staff (read director(s)) and agreed on a “cut” below my professional fee, effectively side-lining me!  My call to the factory’s office to enquire on the progress, in anticipation to visit and certify the work after it is complete, was met with negative tone, and a contradicting account of what he (my technician employee) had updated me in the initial trials which were evidently indicative of great success.  Well, it didn’t come as a surprise to me because among the many setbacks consultancy firms like ours suffer from occasionally, is gross misrepresentation by (morally corrupt) employees that the management trust and malicious sabotage in cohort with sly clients.

Nevertheless, my routine journey to revive businesses that are near-closure due hefty losses accruing from batch errors did not end there. The following month I was invited to a factory with the exact replica of problems that faced the one I helped in Thika, and this time I was wiser. With help of my staff, we tackled the problem in a record of two days and as I type, they are happily churning out quality re-bond mattresses.  That was by the way!

What is a Rebond Foam Mattress?

In layman’s terms, Rebonded foams are types of mattresses made from a combination of multiple densities of foam scrapings (wastes) which are broken down and re-bonded under mechanical pressure into new blocks of consistent High Density Rebonded Material, cut into desired lengths and widths.

In technical language, rebonded foams are also called Orthopaedic Mattresses. Reason is that they are dual-supportive as the rigid side of the mattress gives support to person’s back, and the soft side pampers your back, relieving the back from any pain and pressure. Rebond foams, as they are fondly known, are characterised with firmness and flexibility

What prompted recycling waste PU into rebonded Mattress material?

Being the sixth largest synthetic material in the chemical industry, PU wastes, classified as hazardous waste, posed severe threat of environmental pollution in terms of landfills, given its bioaccumulation and non-biodegradable nature. Even earlier attempts of incineration as a disposal method, the process produced a large carbon footprint and exacerbated the global warming. Since then, scientists hatched a plan on better ways to solve the problem of recycling that would promote “carbon neutrality” and “carbon peaking”. Thus rebonding became a better way handling the PU waste.  

Raw Materials

The main materials for rebond foam mattresses are PU foam wastes (scrapings) meticulously sorted into desired foam types, shredded to specific sieve sizes and staged for magnificent transformation by harmoniously blending with the adhesive and then molded by compression into desired sizes and densities. Locally, the source for scrap PU foam is getting scarce and scarce by day because the output is less than demand (by factories). Last year, I visited a medium sized company producing rebond foam mattresses and amongst their import (as raw materials) were used, partially shredded clothes compressed in bales. China and India are the biggest global exporters of this PU scrapping, and Kenya is the biggest consumer of the material in (East and Central Africa) for the rebond foam mattresses  

Process of Rebonding

The rebonding recycle process is carried out in the presence of special adhesives that makes it durable, strong and versatile. Such mattresses have higher density, long-lasting and don’t form depressions due to heavy weight (as in very fat and big users) on prolonged use. They are the current craze with foam mattress manufacturers in Kenya, often priced higher than traditional PU Foams.

The techniques of rebonding PU scrapings alongside other fibres require skilled labour with some background chemistry on behaviour of different rebonded material, especially in regard to their varying densities, and pressure applied during compression molding that may modify the final density, Indentation, Load bearing capacity and Tensile strength of the new foam mattress.  In the case of my client, one of the main issue with the bonding was using MDI in its raw form (undiluted), which posed application and distribution problems, leaving several, if not many, scrap particles un wetted.

Cost of production of rebonded foam mattresses

With many years of teaching Foam Mattress formulation, good exposure to raw material pricing in our daily consultations and factory setups, our own investigation found that local re-bond mattress stores are selling mattresses at mark-ups of up to 300% – which means customers are paying Ksh. 40,000 for a mattress (size (6x6x20) that cost about Ksh. 12,000 to make. Online mattress retailers have even higher overhead costs, and are able to sell at much higher margins.

Given that the bulk of the raw materials for rebond mattress is imported, the above profit margins are still low by international standards because prices of the imports are usually higher than locally sourced. They also need time to wait and prone to technical maritime delivery delays.

Therefore, understanding the profit dynamics coupled with new formulation techniques which allow incorporation of plant fibre can be instrumental in cutting down production costs by further 200%, besides

Maximizing Profitability Through Raw Material Supplementation with Fibre

In our previous postings, we have showcased how banana stems can be converted into fibres and pulp capable of making soft absorbent material akin to cotton wool and making papers respectively. We have also, on our blog, explored in grater depths, how such fibres (that resemble white cotton wool) can be used in making sanitary pads. The good news is that the processed fibres can equally be used in filling mattress, pillows and making sofa seats. This leaves no doubt that such fibres can too be used as filler material in Rebond Foam Mattresses, where they will reduce dependence on the PU scrapings by over 80%, delivering high resilience, durable and high density posturepedic mattresses that are also cheap to produce.

Banana stems aside, one is able to process fibre (that looks like white cotton wool) from the notorious Lake Victoria water hyacinth, thanks to our newly introduced course in plant material recycling and value addition for domestic and wild plants.

Knowing how to blend the fibre with PU scrapings in alternate layers can create a compatible profile that bonds well to make a good foam slab. For example, a 1200GSM mattress filling with plant fibre (banana stem fibre or sea weed fibre) will provide a thick comfort layer with more loft (height/bounce) to the layer.

The future of Re-bonded PU Foam Mattress

While the rebonded mattress rely on raw materials that are seemingly inadequate locally, their pleasant turnovers (profits) are a motivating factor for bigger companies to go an extra mile and import the materials-which are locally scarce. It is therefore a business that will carry the day. Harnessing the locally available materials in the form of plant fibres, mixed with ordinary raw materials like Polyol will negate the need for PU scrapings, while the quality of the final blend will be superb.  

On the other hand, traditional PU Foams (the ones made with Polyol) will remain dominant in the market due to availability of raw materials, good margin profits and consumer popularity.  

Final remarks

The abundance of fibretic plant material in Kenya is so big that it constitutes a renewable resource, which when exploited properly, Kenya, as a country, can earn huge foreign currency through export of processed plant fibres. As a matter of fact, if an entrepreneurial organisation trains its eyes on the Lake, harvesting about 100 Tons of Lake hyacinth and processing it in a week’s time, it can be making 1ton of fibre. Banana pseudo (false) stems, have a higher fibre content yield and this can have bigger returns.

Will you enrol yourself or loved one to know how to process plant fibres?

For more information, please call/text Ms Kiki, senior coordinator of training. Mobile: +254 710 20 23 26.

You can also talk directly to Dr. Herman through Email hermankithinji@gmail.com

Our recently introduced course on Fibre and Pulp processing from plants was such a huge success that attracted calls from as far as Mali. Besides pulp and fibre processing, the course also offers knowledge and skills in Eco-friendly (cheap and biodegradable) Sanitary Pads Production. It is at the backdrop of this development that is subject to more elaboration in the following discussion.   

Lower Cost of Garments

Everyone wears clothes, manufactured by Textile Industries both locally and from far abroad. These clothes are made up of cotton and polyester as the traditional material. They are not cheap though, and this is what makes second-hand clothes a darling for many Kenyans who cannot afford brand new outfits. The second-hand clothes industry is the biggest in the world because the largest ready markets are in Africa and Caribbean countries. Some countries like Kenya, keen on promoting local textile industry as well saving money sent abroad to buy the Mitumbas, have had numerous debate on whether to ban these imports or to regulate them for “trade balance”

While cotton and polyester are currently still the most used fibres in the textiles industry, other natural fibres such as banana seem to have a growing interest with global textile producers and designers. These natural fibres are viewed as a potential cheaper alternative source that are also eco-friendly. As available literature and our own findings note, the banana fibre is soft and silky to the touch, yet breathable, making it a comfortable choice for clothing items like shirts, pants, and dresses.

Processing Banana Stem Fibres

Banana stocks that become agro-waste after harvesting the fruits provide a ready cheap source of the fibres badly needed in textile industry, paper and pulp industry, making of napkins and sanitary pads. Notably, quality Tea bags, adsorbents cellulosic yarns can be made from banana fibre. Cellulosic yarn has great mechanical properties and a nice sheen, which is also why it is often described as a vegan alternative to silk.

Why Banana Fibre?

Compared to other fibres, the production of banana fibre is extremely resource-efficient – the fibre is obtained from a resource that is cheap, renewable and widely available, and no additional water or land are needed for its production. If left untreated, the fibre is also entirely biodegradable, and its production has the potential to create new jobs in rural areas, boosting the Kenyan economy astronomically and reducing landfill pollution.

Many Banana Stems in Kenya

Kenya has 582,636 Km2 of available land (about 58,263,600 hectares and only 17% (about 9.9 Million Hectares) has adequate fertile soils and supports rain-fed agriculture. Of this fertile land, 80,000 hectares are under banana plantation. A Hectare of land can accommodate an average of 700 Banana trees. This means that, on average season, we can produce 56 Million (56,000,000) banana trees which are 12 Banana Plants varieties (popular among them being Plantains and N’gombe). This massive occurrence provides a material enough to provide the needed fibre for the industry.  Banana plants grow rapidly in just 9-12 months.

Safe Sanitary Pads

Traditionally, papyrus, Moss, grass, Bandages were used during menstrual periods. Of 2.6 million schoolgirls who lack access to affordable and hygienic sanitary towels (according to UNESCO), a number of them use mattresses, exposing them to even more health dangers   The modern sanitary pads have added chemicals, scents and are often associated with Irritation, Itchiness Skin rashes, allergy and lead to very serious health problems due to the presence of microorganisms.

Besides being cheap and user friendly, Banana fiber is a natural super-absorbent material that is highly effective at absorbing fluid and it has natural porosity which can allow fluid to move through and stored in it.

Training

Preparation of the fibre from raw banana stems is a course taught in our Town Laboratory at a fee determined through individual assessment recommendation by our training coordinator, a Ms KIKI (+254 710 20 2326). Also, manufacturing of Sanitary Pads from Banana Stems, manufacturing of Woven Teabags is also done by us at a fee.

Various fragrances affect spontaneous brain activities and cognitive functions. Actually, scents (fragrances) often prompt immediate emotional responses and have overall physiologic effects such as mood, stress and an influence on working capacity. This has been demonstrated through electrophysiological studies.

Human beings, as well as animals (Monkeys, Cow, Elephants etc.) are created with a sensory organ which comprises of olfactory epithelium, olfactory bulb and higher olfactory cortex, all making a system (olfactory system). One cannot switch off the system, just as we would close our eyes, probably in a bid to avoid watching a disturbing scene.

And Since the sense of smell cannot be turned off, marketers are becoming aware of its usefulness in communicating with consumers. Over the last few decades, consumers have been increasingly influenced by ambient scents, which are defined as general odors that emanate from a product and are present as part of the retail environment. Some traditional popular scents for example, the Johnson’s Baby Powder Scent, when incorporated in home-made lotions, is likely to sell more than a lotion with Pure Lavender or Jasmine

From evoking nostalgic memories to stimulating appetites, this use of scent in product manufacturing has immense potential to create memorable brand experiences and influence consumer behavior, besides visual and auditory dimensions of branding.

Scent branding has the power to forge strong emotional connections between brands and their consumers. As a result, this invisible form of branding offers businesses a unique opportunity to establish a distinct and lasting identity.

Here in Kenya, for example, 20% of the consumer response to products like Bathing soap, Hair shampoos, Detergents, Skin and Hair care cosmetics is influenced by Scent Preference. This means that a brand without a good scent may lose 20% of its customers!

Scents and Memories

In our adulthood, many of us have had experiences where a certain smell—perhaps, Dettol, Fresh uncooked fish or the fresh bathroom smell -floods our brain with memories of a distinct event, eg. Hospitals, Auntie’s home or location that we associate clearly with certain emotions

I remember the year I joined Form 3, in Garba Tulla High School, our seating arrangement saw me have a Boran Lady, Ms Halima Halake, as my desk mate. She used to apply Pears, a cream brand that was very popular in the 80s. The last time I smelt the cream was in late 80s but I remember our “Auntie” our then house help used to apply it.

The very day we shared the seat with Halima for the first time, the memories of the house help, whom, together with my siblings we were very fond of, became vivid and often made me feel sleepy. I developed an unusual friendship with the girl that my desk mates used to say jokes that were unpleasant.

Again, in my first pre-clinical assignment in Masaka regional hospital, Uganda, I visited the Nurses Station in surgical ward and the Dettol Smell reminded me of our Rural health centre in Ruiri where I was given jabs by Timothi, a Clinical Officer in the early 80s following a bruise I sustained after head-to-head collision with fellow nursery school pupil (a Mr. Thiolo, pronounced as Siolo) while running around the classroom.

Bad Memories Stress Disorders and Attraction

While some craftily made scents can arouse positive emotions like man-to-woman attraction, it is also noteworthy that some smells can be linked to strong negative emotions, a connection which can play a significant role in contributing to post traumatic stress disorder (PTSD). Some people cannot withstand the smell of perfumes that were used during burial and funerals of their dead loved ones even after many years past the incident.

How to Duplicate Popular Scents

In our routine classes for Perfumery, our trainees often ask us if we can reproduce some scents that belong to powerful brands such as Cussons and downy. While the answer is always on the affirmative, we are quick in reminding them that these are patented and in the case of the expired patent, we can produce the exact replica of the scent, including that of Cussons Imperial Leather Soap, Downy etc.

It takes a dedicated research, trial and errors, time and resources to copy an existing scent. I remember very well in 2020 during the Covid lockdown, I spent most of my time in Lab 3 doing a number of reverse engineering for some products from the Middle East brought to us by clients from Somalia. Among the achievements I made was duplicating Downy Scent with 99.8% specificity. In the year 2022 February, I managed to create Cusson’s Imperial Leather scent with 99.7% specificity. The task of reverse engineering is always tedious, and in the case of Scents, temporary olfactory damage (medically known as Anosmia) can occur. We invite everyone to sample our Scents in Lab 3. Training on general perfumery is also done on daily basis. Talk to our training coordinator Ms Kiki on Mobile number 0710 2023 26

This article is written by Dr. Herman Koome Kithinji, MD

If you ever thought of starting a Matchbox making company in Kenya, you will probably be the fourth manufacturer. This is on assumption that the recently trained entrepreneur in our school will delay a little bit before launching.

Safety matches are an everyday requirement for 99% of households, without which, no cooking, lighting cigarettes, candles, etc. can take place. They are placed the second most used household non-edible item after energy (Gas, Charcoal, Kerosene and Electricity combined). In the list of household expenditure, they are rated fourth after cooking oil, salt, Onions and soap.

Few manufactures in East Africa

Kenya’s vast population of 50 Million people (about 16 Million households) is served by 10 brands of Safety Matches whose manufacturers are only 5. Of these 5 manufacturers, only 3 are domiciled in the country. One of the local manufacturers of the safety matches has 6 brands of the same commodity in their portfolio, leaving the other two local makers with one brand each. Zebra, a common brand in many households is from South Africa, while Krishna is from Uganda  

Inspecting the wider market, the east Africa Community, having a population of 485,066,925 million people (about 161.6 Million Households), is served by the said 9 brands.

The market scope

Here in Kenya, the leading safety matches manufacturer, Mach Masters Ltd, produce 5 top brands under one roof, which include Rhino Farasi, Kifaru, Simba and Paka and Kasuku. The firm commenced production in 1998.

Ndovu, another popular local brand is produced by Rhino Matches Limited.  Kenafric Matches Limited, which is the third local manufacturermakes The Big 5 brand. Since the Kenyan market is big, though not bigger than Tanzania, DRC Congo, Uganda, the 3 local firms seem not able to fully satisfy the local consumership and therefore, foreign brands like Zebra, Swala, Krishna, Elephant and Toto have a share of the national cake. Zebra and Krishna brands are owned by Associated Match Company Ltd (South Africa) and Makepasi Match Ltd (Uganda).

Each household consumes an average of 3 matchboxes every month. Kenya alone, with 16 Million households, therefore, consumes an average of 48 million matchboxes every month (576 Million matchboxes per year). In east Africa, consumption of this basic commodity is in the tune of Five Billion, Eight hundred and twenty million, Eight hundred and three thousand, one hundred (5,820,803,100) matchboxes per year. These figures are mind boggling, but they attest to the affluence with which the local manufacturers in Kenya are associated with. In fact, in one of the local manufacturers website, they boast of employing “over 500 employees and a fleet of over 20 cars”. Remember, this is a company with modern computerized production machines that need little human involvement. The firm also discloses in their website that at the beginning, they operated on very basic level, meaning that a new entrepreneur doesn’t really need to start with millions of investments.

Investing on Safety Matchbox Manufacturing

Basic knowledge and understanding of a product, Interest, financial commitment and good marketing are the turnkey in industrial manufacturing. An industrial mentor acts as the bridge between the new manufacturer and source of knowledge and motivation

Our 13 years of training and mentoring young entrepreneurs, overseeing their market take0ver has always served as a source of motivation. Early this year we announced the start of Safety matchbox training and the news were received positively.  

A week ago, we trained a client from Makindu who successfully completed the three-day course and was immensely satisfied. We demonstrated to him that it is not a big deal to start off the business (whose knowledge and expertise he has acquired) at a lower level. And he is set to do that.

Cost of Production

The matchbox manufacturing is divided into two facets: Box making and matchstick production, both of which may require different approaches. The average cost of making matchbox alone is approximately Ksh. 80 cents, while cost of making the 50 matchsticks is approx. 0.60 cents. This will, however, depend on the level of financial commitments. At wholesale procurement of the raw materials, the least cost of producing a well branded matchbox with 45 matchsticks is Ksh. 1.50. on the higher side, the manufacturer, purchasing raw materials from third party (retailers) can make the said unit at a cost of 2/-. This is not bad, considering that both are getting over 100% profit.

Raw material and sourcing

Interestingly, the raw materials used in making the matchsticks are available from school laboratory chemicals and equipment stores, making them easy to find and within reach for both cottage industry and high level manufacturers. Some of the raw materials have common usage in both pharmaceutical and cosmetic industry, further making their availability not only easy but quite cheap.  

Machinery

There is one common principle in industrial operation that assert: Whatever the hands produce, machines too can produce, and whatever the hands can produce, machines too can. There are FOUR basic operations in manufacturing of safety matchbox.

The first operation is making the matchbox (not matchsticks). This involves folding and gluing the paper material which has been printed and cut into shape through a die cut. The two sides of the matchbox’s outer cover are impregnated with combustible material by a means of a small roller and left to dry. This, in most cases is 100% manual.

The second operation involves combining the reactants and stirring them together to form a paste. Batches less than 20kg can be comfortably mixed with hands or small modified kitchen blenders. Bigger batches of 200kg to 1 ton can be done with motored mixing machines.

The third and most important step is impregnating the wooden sticks with the paste, producing ball-like tips at the end of the sticks. This process, though manually achievable, can be a little cumbersome and uniformity of the coat (0.07g per stick) may not be achieved. Therefore, a small locally fabricated machine can achieve impressive results besides aiding in big batch handling. The fabricated machine can be supplied along with a drying chamber for the wet sticks (instead of air-drying) if the process is to be hastened. The final step is placing the matchsticks into the matchboxes. This is 100% manual in most cases.     

The chemicals can be sourced from Betty Industrial Chemicals Limited among many other suppliers in town. The machinery can be designed by us and fabricated by Gilead Auto Machinery workshop in Kariobangi.

Legal Documents

The KEBS’ stringent measures must be met accordingly and part of our training comprises familiarising the trainee with the KEBS standards and procedures for certifying Safety Matchboxes. County Trade licences are also mandatory

Training Fee

Corporate training and Individual trainings are charged differently. Out Chief Training Officer, Ms KIKI can evaluate the training charges based on the client’s needs and recommend the fee which ranges from Ksh. 75,000 to 1.2 Million Shillings. You can reach Ms KIKI on mobile number +254 710 202326 

Conclusion: Anyone can start, own and run a Safety match manufacturing business. The business is a multi-million-shilling earner. Machines can be locally sourced at the fairest prices. Minimum capital investment is Ksh. 40,000. The market is humongous, and neighbouring countries extend the catch.

The business is a low-risk investment compared to food products.  

Would you like to give it a try?

When Kenya introduced a law banning the single-use plastic bags (Jiwala) in 2017, the UNEP and other Environmental conservation bodies applauded the move that was intentional in reducing landfill Pollution. However, little was achieved in management of the multi-use plastics waste, mostly the drinking water bottles, that account for the fifth of the 2,400 tons of solid waste generated DAILY in Nairobi alone.

1000 Drinking Water Manufacturing Companies in Kenya

According to a local PET bottle recycling company CEO, Joyce Gachungi, Kenya has over 1,000 companies that are producing bottled drinking water in the country. Add to the tens of thousands of Soda Bottles bought every single day, and the true picture of the plastic bottle litter (garbage) menace will suffice.

Converting PET bottles waste into a million Dollar Empire

PET, or polyethylene terephthalate, is the chemical name for the PET bottle material. Polyethylene terephthalate, therefore, is a common thermoplastic polymer resin of the polyester family and is used in fibres for clothing, carbonated beverage bottles, drinking water etc. thanks to its versatility in thermo-processing which achieves clarity, various shapes and is easy in handling.

With a little knowledge in chemistry about the PETs, one can choose to convert the used bottles to make materials for numerous fast-moving industrial products such as non-woven carpets, Wadding, Filtration materials, Polyfil (Fibrefil) stuffing for cushions and quilts, Geotextile, and Spinning yarns and thence create an empire out of it.

Fiberfil stuffing, is processed from the PET bottles and is used for making bed pillows and cushions. These two products are currently the leading FMCGs (Fast Moving Consumer Goods) in East and Central Africa.

The Lady Hawker at the Supermarket Parking Lot

The first time I bought Polyfil Pillows was during COVID Lockdown. While walking out of “Powerstar” Supermarket, a lady courteously approached me while I was opening my car booth and asked me (while smiling) to purchase “two Pillows” meaning mine and wife’s. At first I declined the offer, pointing that I had many in my bedroom. She convincingly told me that “these are not the usual pillows”, adding that “they are very comfortable, and that’s why she is suggesting I buy two”. I decided to give them a try and on arriving home, my Daughter picked them while screaming with joy. I reminded my wife to sterilize them and encase them with clean pillow cases before we lie on them. And for sure, that night, I slept loudly with kingly comfort. My wife marvelled at them and suggested we add more for the rest of the family. I asked her to remind me to instruct my secretary to forage through the Polymer Chemistry books we have for training and make something worth out of it for our followers.

Polyester Fiberfil is a fine synthetic dense fibre, made into white yarns and commonly used for stuffing pillows and look fluffy, soft kind of, like a ball of cotton. Polyester Fibrefill It is made from recycled plastic PET bottles through a non-expensive process to make what is known as Recycled Polyester Staple Fibre (RPSF).

With numerous applications, not mentioning fibre-filled high density mattresses, one is capable of creating products capable of building a multi-million-dollar empire, whose raw material is the “waste”

“Free” Raw Material to RPSF Yarns to FCMG

The process of converting waste water bottles into RSPF fibre yarns is not as demanding and capital intensive as it may sound. Neither is it not out of reach for the commoner who is interested in creating an alternative source of revenue with what is considered waste, and again, what is almost available as FREE Raw material.

At our Institute, we orient the learner with the processes, take him/her through basic classes of converting plastic bottles into RPSF and finally value addition, as in Pillow making. Small machinery to facilitate the conversion will be needed and this is part of what we train. We also fabricate the machines in our teaching workshop that can aid in the process flow that will achieve standard products that must meet stringent requirements of quality control tests which measure color, composition, and length of the fibre, amongst other criteria as per the Kenya National Bureau of Standards (KEBS).

Profitability

The Fibrefill Pillows go for an average of 400 shillings, whose cost of production is approximately Ksh. 120. Now, assuming the pillow encasement is 1 mitre square (Ksh. 35) and the sewing thread is 5 mitres (Ksh. 0.50), Labour (Ksh. 10), we can easily do math for the total cost of production:

To fill one standard (20” x 26”) one will need approximately 900g of the RSPF. One Litre empty bottle weighs approx. 30g. Therefore, we need 30 bottles to make RSPF of 900g. Buying each used bottle at Ksh. 2, one will need Ksh. 60 to purchase 30 pieces of them. Processing them into a RSPF yarn using Power Optimized Extruder cum Spinning machine model iPRO-Ex 30 one will spend 0.3 Units of Electricity (Ksh. 8.00) per Kg. Total expenditure is therefore Ksh. 35+0.50+10+60+8.0=113.50/- add Ksh. 1.50 for process waste and overheads that include branding, transport, Labour etc. Total expenditure to make one Fibrefill Pillow is Ksh. 115.00 Net profit = 400-115= 285/-. Assuming a manufacturer with well branded pillows, well marketed via digital and other forms including TV and Road Shows, is doing sales of 10,000 pieces a month, that’s a whopping 2.85Million. meanwhile, youth organisations collecting at least 1000 bottles per day can gain over Ksh. 2,000 on daily basis.

Local Textile Industry and Reduction of Landfill by County Governments

At the government’s level, the much publicised Vision 2030’s Industrial Parks can make a pilot project in collecting the over 44,400 used plastic bottles every month, creating income for collectors who are mainly youth and young single mothers. The processed material from these PET bottles can make Spurn yarns for geotextile industry which can significantly reduce imported clothes among many other things.

Community Courses

With our well established training and consultancy firm, and knowledgeable staff members, our 14-Year experience in Industrial Skill Training, we have shaped the training landscape in Kenya by providing individualised training in manufacturing of over 80 products including Automotive Paints, Sugar, Powder Milk, General cosmetics and all types of detergents. We conduct group and community training and capacity building on various industrial Skills including Foam Mattress Manufacturing, Machine design and fabrication for Sugarcane juice extraction and sugar processing, Waste Paper recycling, Sanitary Pads Manufacturing using Banana Fibres, Fertilizer making, LCD Screen production, Radio Frequency Modulators manufacturing and Environmental conservation.

This article is written by Dr. Herman

Senior Polymer Chemistry Specialist

And published by Kiki Irene,

Chief Training Officer (0710 20 23 26)   

Many of us here must have seen some clear and often odourless coconut oil packaged in small bottles in retail shops and often bigger (500ml) ones in Supermarket shelves. In shops along Dubois and Keekorock road, off River road, small bottles of 50mL make up 6% of the beauty products stuck in the shelves of the ever-busy shops. We can all agree that they are used as cosmetic oil for hair and to some extent, skin. We can also agree that it definitely comes from (crude) coconut oil. But how is it processed?

It starts with extraction

Coconut fruits, growing abundantly along the coastal Kenya, are harvested and dried. Copra is expressed for the oil, which comes out thick and a little gummy. In its crude form, it is viscous and oftentimes turns solid in cold weather. Before invention of modern ways of refining coconut oil for cosmetic use, its characteristic coconut aroma is what greeted the user.

Processing Crude Coconut Oil

To make it user friendly, the crude coconut oil can further be processed to remove or reduce the strong natural aroma, make it maintain its liquid state even in cold temperature and make it sparkling clear. It also improves greatly the value of the oil. To achieve this, it calls for acquired knowledge and skills in processing it to that standard. How is it done?

In our routine classes for Edible Oil refinery, we introduce the learner to the basics of oil refining, a theory featured in the second chapter of our well-structured, 30-page curriculum. The theory adequately prepares the learner to understand the dynamisms in crude oil purification, laying strong emphasis on odour removal, reduction of free fatty acids (that cause cholesterol build-up in blood vessels), de-acidification of the oils, colour removal and control of rancidity.

Simplified Home Based Methods of Purification

For oils not intended for consumption, especially Sesame oil, Avocado Oil, Coconut Oil, etc. the purification methods are superficial and non-involving. For example, coconut oil can be purified at home without the need for machinery. Up to 100L of crude coconut oil can be processed at home within a week, with only the basic kitchenware. A well processed coconut oil will reduce the characteristic odour by 95%, remove Free fatty acids and waxes up to 100% and Phospholipids (gums) up to 98.5%, making the crude coconut oil 100% pure for hair application, cosmetic manufacturing and medicinal product manufacturing.

Value Addition and its benefits

While crude coconut oil is preferred for soap manufacturing thus cheaper market price, the more refined one retails at double price of the crude type. The cosmetic use for the refined one outperforms the crude one, hence monetary rewarding for processors. A 500mL of the refined oil in most supermarkets, including the neighbouring “Powerstar Supermarket”, goes for Ksh. 500. This puts a litre of the same at 1,000 shillings. Assuming the cost of refining the crude coconut oil is Ksh. 10, and the packaging material is 60 Shillings, labour and Clear sticker for each 1L @ 15 Shillings, we can universally agree that the cost of processing a crude oil (bought from Betty Chemicals at Ksh. 200 Per Litre) will be Ksh. 85.

Profitable?

Therefore 85/- (Cost of processing) PLUS Ksh. 250 (cost of crude oil) will add up to Ksh. 331/-. If selling it at Ksh. 1000, the Net profit will be Ksh. 669, representing over 100% profitability. Packaging the oil in 50mL bottles, each retailing at 65Shillings (wholesale price at Keekorock Road), the product will fetch approximately Ksh. 1,350/- further pushing the profitability to over 300%. This assumes that each individual 60mL bottle will be bought at Ksh. 10 per piece.

Course in Oil Refining

Our curriculum is structured to offer Full Refining Process and Partial refining process (for Edible and non-edible final product respectively). Both courses are charged differently, with the former going at Ksh. 120,000 and the Later at 65,000. Our flexibility in pricing of these courses offer corporate and individual parties a chance to learn the Art of Edible Oil Manufacturing at a relatively lower cost. Our senior most Training Coordinator, a Ms KIKI, can evaluate the financial needs of the less privileged interested learners and upon her recommendation, a special waiver can be preferred.

A TOT course for interested training schools and firms such as Centre for Industrial Technology –CIT, Nairobi Cosmetics and Material Suppliers Ltd.  Etc. is available at Ksh. 700,000 Shillings.

For more Information, please contact Kiki at Mobile No. 0710 20 23 26.   

Oil Refining and selling by a small farmer looks like an unrealistic optimism. But arming oneself with the right Knowledge on how to turn crude (freshly expressed) oil into edible type is all the small farmer (or even a trader) needs to invest on

Three years since we introduced Oil Refining Course at our institute, we have churned out few people who are now doing mini-commercial manufacturing of cooking oil, thanks to abundance of locally grown canola oil and thousands of acreage of Macadamia trees.

How the Course Started

My interest to introduce the course was sparked by a neighbour in Githurai’s  ‘Millenium’ Flats godowns where I used to store Machines and few chemicals. The two young men, whose store was adjacent mine, used to make cooking fat. I didn’t bond much with them because I rarely visited the store unless when bringing in the machines, or taking visitors to view their orders before carrying them off. I shared my brief experience about the Millenium Flats “encounter” with Kiki, then a student at a local University. She encouraged me to take up the task and my first client was one Mr. Lawrence who was employed by a sunflower farmer in Kisii. So far, various local and international manufacturers including Mr. Salim (Congo), Mr. Moise (Congo) and another gentleman from Tanzania have immensely benefited from the training which has also Shaped their future.

What Does It Take to Manufacture Cooking Oil?

Professional knowledge is pre requisite. Refining Machinery (which are not complex after all) and most importantly the raw material (crude Oil) are among the things one must budget for, not forgetting KEBS certification which is mandatory. Space for the business not need worry a small farmer because even kitchen can provide an adequate production space-after all, cooking oil is a food product and levels of hygiene in a well-kept kitchen can provide a conducive environment for manufacturing the commodity.  The compound, especially in a rural home can act as a storage facility for the raw material as well as finished product. Other secondary requirements can be an oil extractor machine, also locally available on order.

Minimum Capital Investment

One of the motivating factors that greet our students is the simplicity of the process when we produce 100% pure edible oil from crude specimens we purchase from Betty Industrial Chemicals Ltd. The 2 x 7 feet laboratory bench in our town offices, packed with a small weighing scale, 4 500ml beakers, thermometer and a small electrical mixer serves as the ‘factory’ for the 1 L edible oil we make during the practical session. That small area of production (the bench) can do maximum 50L within 5 hours, assuming we wanted to make a sizeable batch for mass testing. This means that with machines and equipment within the price range of 50,000 Shillings (400 USD) to 150,000 Shillings (USD 1,300) can enable a small farmer to start a tangible cooking oil manufacturing project.

Raw Material

Kenya has not, so far, explored massive cultivation of oil seed plants like Indonesia and the West. However, with the recent shortages and subsequent rise in prices of cooking oils, further constraining livelihood of Kenyans, traders have been forced to think outside the box. A prominent Canola farmer in Central Kenya has acted as a classroom for would-be manufacturers and YouTube clips of his interview by local media firms have fuelled desire to start local edible oil manufacturing business. I personally knew about the farmer when one of my royal clients, a Ms Petronila, a Canadian Resident of Rwandan Origin Visited me in 2022, enroute to Murang’a to collect Oil Seeds from the farmer. Great conversation between me and Madam Petronila stirred my desire to think of how rural farmers can be recruited into farming Canola, which takes only 4 months to maturity and eventua harvesting.

The African Journal of Plant Science and Biotechnology estimates that macadamia nut industry is currently made of approximately 900,000 trees of varying ages from one year to over 30 years, grown by over 100,000 small-scale farmers with an average of 6-100 trees per grower. This is an appetising news. Another research journal somewhere laments how Macadamia nuts go into waste, citing low industry uptake from foreign processors and how poorly remunerated the farmers are, in terms of purchase of the farm produce.

Given the political goodwill President Dr. William Ruto has shown on farming, is it not wise to seize the moment and form Farmers SACCOS which can buy the nuts from within themselves and process for themselves the much needed cooking oil? Can’t local county leadership mobilize farmers to do massive canola plant farming in areas that favor their growth? I remember one of the goals of Vision 2030 was local industrial growth and self-sufficiency. We have resources scattered all over, excellent political goodwill and good presidency.  Corrupt politics and developmental myopia will only stifle county industrialisation. It is up to individuals now to take it upon themselves and set family projects that can address cooking oil shortage and skyrocketing prices.

Future of the Industry

In one of my earlier articles on Oil refinery, I gave an estimate of cost of production of One litter of edible oil from crude. I also gave an insight on the profitability of the venture. But today we can also learn that a family setting aside only 3 Acres for Canola Oil farm, can supply a constituency with refined cooking oil. That family can also educate their children to Universities (even abroad), and build a family Maisonette, drive big cars and live happily ever after.    

I was recently tagged in a facebook post whereby one member of the group (which I rarely visit unless tagged) had requested if he/she can be taught how to make “JiK Colours” (obviously the member meant Oxygen Bleach. By tagging me, my friend Job Gilo probably wanted to draw some attention to me, reminding me of how I saved their firm from making losses and how astounded their trainee staff were when they realised that for a long time, they could probably be selling wrong products to their faithful consumers.

What is a Bleach?

Bleach is the generic name for any chemical product that is used industrially or domestically to remove colour (whitening) from fabric or fibre or to clean or to remove stains in a process called bleaching. Bleaches can be Chlorine based (hypochlorite bleach) or Peroxide based (Oxygen Bleach).

There is a plethora of details, thanks to the complex science revolving around bleach as an industrial science, but in summary, hypochlorite bleach (regular bleach) generates sodium hypochlorite and chlorine dioxide to effect its activity against bacteria, color and many industrial applications including wood pulping etc. on the other hand, Peroxide-based bleaches are characterized by the peroxide chemical group, namely two oxygen atoms connected by a single bond, (–O–O–). When this bond is broken, it gives rise to very reactive oxygen species, which are the active agents of bleach.

But how safe is the Jua Kali Bleaches hawked from door to door in our estates?

As you may be aware, Regular Bleach (Chlorine bleach) literally discolours, but this action takes place under controlled pH which the manufacturer must stabilize (make stable). Failure to stabilize the pH results in oxidative attack on the cellulose fibres of clothes, degrading them and this often leads to premature wear of the clothes. For Oxygen Bleach e.g. JIK COLORS, the efficacy of hydrogen peroxide bleaching is directly proportional to the increase of its pH. The significant increase in bleaching outcomes occurs from pH 6.0, with maximum effectiveness achieved with pH 9.0. allowing the pH go up, especially due to poor pH stabilisation, will often to holes forming on the clothes.

What is the Shelf life of Chlorine Bleach?

At some Kamukunji Shops, one is likely to purchase a Jua Kali Hypochlorite Bleach brand that is no longer potent. Once Sodium Hypochlorite bleach has been made, it starts to decompose from Day 1. This decomposition rate is exponential, not linear, and therefore, a significant amount the ACTUAL BLEACH is lost by the time 3 months are over. Precisely, at the decomposition rate 0.001% per hour, if, say, a hypochlorite is made with initial Available chlorine of, by 6.8%, in 90 days (3months), the available chlorine will be 3.8%. This assumes that factors that accelerate decomposition (Light and Temperature) are kept constant. The latter factor probably explains why your Hypochlorite brand MUST be stored in WHITE, OPAQUE and significantly thick Jerri can to reflect back light which carries UV rays that attack the product.  

Did you know that Some well formulated, professional brands such as “RIQ” and “JIK” can be used to sanitize drinking water? Thought we should also let you know.

This Article is Authored By

KIKI, Chief Chemist and Training Officer

Our Curriculum on Industrial Fabrication and Machine Building Course, conducted in collaboration of CIT is officially out.

The course is centred around the fast moving, yet easy to make machinery that are a must-use in the construction, laundry and production industry

The following machines can be designed and fabricated (to International Standards) that ensure total consumer satisfaction, with ease of operation, low maintenance, high resale value and low power consumption and superior aesthetics as the core values of the training

➡️ Automatic Laundry Machine

➡️ Soil Compactor

➡️ Automatic Screen Printing Machines

➡️ Motorized Land Tillers (Effectively replaces Animal Labour and Cruelty)

➡️ Loud Speakers

➡️ Rotary Chicken Roasters

➡️ Automatic Remote-controlled Gates

➡️ Safety Cabinets

➡️ Semi-automatic soap making machines

➡️ Chain Link Making Machines

➡️ Industrial Stirrers

➡️Farm Drones

Positive Impact on Community and Families

When School and College leavers learn practical skills in manufacturing, and considering the fact that these are fast-moving products, there is self-employment thus assured income for young families. The community also stands to benefit a lot with improved farming methods that will utilize machines instead of animal and human labour that immensely degrades health and propagates unconstitutional animal cruelty.

Fee and Training Duration

The training is considered “Jua Kali” but borrows heavily from the Chinese machine designs, framework layer out and Mechanical Principles, and our classes start with mandatory 20 hours (spread over two weeks) basic introduction to metal engineering, metal fabrication, electrical and electronics installations and Product Finishing. The latter helps achieve aesthetics (beauty finishing) of the product that matches international standards.

Actual fabrication training is carried out in our well-equipped workshops previously serving as Machine Maintenance Workshop situated along Komarock Road and duration is 2 weeks to 3 months. Done and supervised by seasoned craftsmen, blacksmiths and qualified engineers, the training is guaranteed to enable the learner (whether schooled or not) to make workable products that have no difference with the Chinese Imports. The fee depends on the subject and ranges from 50,000 to 400,000.

It is noteworthy that the training meets KEBS standards and the learner will take his machine home. International students are housed in nearby hostels.

For more information Call Kiki on Mobile No. +254710202326

A couple of months ago, our meeting with a top hair care specialist in Mombasa heralded a new insight into how research and innovation can be synergistically combined to address major challenges in hair care product development.

After the lengthy discussion and exchange of ideas, I went straight to the laboratory and started working on a novel hair product that can restore sheen, promote rapid hairline restoration, strengthen the hair fibres, caution hair strands against heat damage when blow drying, and induce cosmetic curls. All this work was is based on what we know about hair, what we teach and what we regularly interact with during routine online consultation

So far, previous research findings and part of the theory classes we give in our Town Lab has demonstrated the optimal stress threshold of 10 heating cycle for SEM and 5 heating cycle for CRS, that a normal hair can withstand when it is exposed to hot combing (Blow dry) in salons and at home.

How Heat and Chemical Treatment Damages Hair

For starters, the hair, like the skin, undergoes various internal and external aggressions. Among the external aggressions are also the environmental factors like heat stress and the accumulation of numerous chemical or physical treatments that attack and weaken the hair fibre. The use of heat styling appliances such as straighteners, curling irons and hair dryers can have temperatures that reach extremely high levels, often depleting the protective lipidic film, and causing cracks in the cuticle and eventually causing detachment of the scales. Besides, heat stress damages the fibre in depth by causing evaporation of water and appearance of heat bubbles and degradation of keratin, a heat-sensitive protein. This in depth damage  causes hair to becomes rough, dry, dull and brittle with split ends.

Without delving deeper into the biology of the hair, I can summarily describe hair fibre as the visible part of the hair, which is made up of keratinized cells arranged in three layers: the cuticle, the cortex and the marrow. The keratinized cells are hard and fibrous protein substance that gives the hair its strength and elasticity. It is made up of long chains of amino acids, including cysteine, rich in sulfur, which plays an important role in the cohesion of the hair. In fact, the keratin chains are sealed to each other by Disulfide bridges: stretched between two neighbouring cysteines. These bonds are The Weak Bonds and the very Strong Bonds which are truly characteristic of the keratin structure. However, they are also the weak point of the hair structure because they are sensitive to attack by chemicals, especially Lye. (Remember the NO-LYE Styling Gel?)

The Weak bonds (salt bridges and hydrogen bonds have keratin chains organized into protofibrils, then into microfibrils which are themselves the constituents of the macrofibrils and prone to attack by excessive heat and chemical attack.

The new Product

We invested in several weeks of trial and error to come with a thermo-active hair care product that protects the hair from heat, acting as a heat shield to preserve the fibre of heating devices.

The new product incorporates 13% polydimethylsiloxane (PDMS), a sealant for the hair, helping to retain moisture and prevent protein loss. PDMS has, over the years demonstrated ability to significantly improve the health of their hair, making it softer, silkier, and more luminous. It has superior lubricating properties and induces the characteristic soft and smooth feel once the product is rubbed on the hair  

Furthermore, the ability of this substance to seal moisture in the hair can be particularly beneficial for those with dry or damaged hair. We have also incorporated prime natural humectants to aid in restoring the native properties of the hair as much as possible, providing the hair with pleasant features such as easy combing, smoothness, softness, and glossy appearance. The product’s ability to stimulate re-growth of hair is conferred by special marine oil that revitalizes keratinocytes   

Without divulging further details about the composure of this new, unique product, readers are informed that it has a close semblance to jellies, but a little whitish akin to a light lotion. It is slippery and has mild coconut scent, thanks to 12% virgin coconut content. Lots of traditional herbal extracts from Mount Nyiro ( Ldonyo Le Ngiro) in Samburu North, bordering South Horr  (Marsabit) where the Samburu Natives and their counterparts share the almost similar kinky, fine and curly hair.

Product on Display

As is traditional with us, we invite interested individuals and corporates to sample the product. It meets all the KEBS specifications namely Microbial Stability, pH, Odor, Consistency, Insoluble matter etc.

A MSDS is available upon request  

Training

Training for the product is available at Ksh. 700,000 Shillings (USD6,700)

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The Writer is Dr. Koome H. Kithinji

While on my routine evening shopping for soft drinks at a Supermarket in Roysambu, I bumped into a shelf with two local brands displaying Powder Detergents, 3.5Kg packed in 10L buckets:

Toss and Persil Persil are prominent brands in Kenya whose retail prices are 1,140 and 1,400 Shillings respectively. Of course, the disparity in the prices may be anything to do with brand strength and quality. Anyhow, both brands meet the KEBS standards while individual preference for both is influenced by performance, physical properties and feel. Both are perfumed but the scent is subject to personal individual preference.

Influence of formulation on Detergent’s Performance

It should be noted that the ability of the powder detergent to perform better (in washing) when compared to another, purely depends on the Total Surface Active Matter and the ability to complex salt ions in water (desalination).  For example; a powder detergent with Total Surface Active Matter (TSAM) of 14.5 has better grease removal that that of TSAM of 12.5%. Sodium carbonate and Sodium Tripolyphosphate (STPP) play a crucial role in mineral complexation thus softening the laundry water for easy cleaning. The rightful ratio between the two and the overall usage rate performs the magic. Also, perborates, which decompose into peroxide, effectively bleaching the stains, are an item of critical consideration when formulating a performing brand. Knowledge and expertise of formulating using these variables helps manufacturers to grade the powder detergent as Premium (best performing), Medium Quality (moderately performing) and Economy Grade (lowly performing). Obviously manufacturers won’t write this on the labels for fear of marginalising the brand, but the cost of individual brand will say it all.

So, what has the price to do with today’s conversation?

The current cost of producing 1000g (1Kg) of standard Powder Detergent is Ksh. 137. This assumes that the raw materials are bought from Retail Chemical Shops in the City. Production of the same amount costs slightly less (Ksh. 118 per Kg) if the raw materials are sourced from wholesale stockists such as Betty Industrial Chemicals, Arichem and Neru.  

What is the Math here? For a small scale manufacturer, 3.5 Kg will cost about Ksh. 480/- while a large scale manufacturer is likely to use Ksh 413 Shillings to produce the same amount. The 10L buckets in which these powder detergents are packaged into, are widely available locally at Ksh. 200 if bought at wholesale price.

Ksh. 700 making fully packed 3.5Kg

I analysed the labels on the two buckets and the Toss’s was A4 Size while the Persil’s is slightly less than A3. Obviously, the cost of the full-color labels are a factor in the retail price because it affects the overall cost of production. If, for example, assuming the labels are printed offset, the cost of printing the A5 Size is 5/- and that of A3 is 8 bob, we can then safely conclude that producing a 3.5 Kg Powder detergent at a Small scale would cost you approximately Ksh. 700 (480 + 200 + 5 + 15). 15 bob is overheads. Producing the same will cost 636/- if the raw materials are bought in wholesale prices. Further, the prices may vary +/- 15 depending on the variables that affect the overall quality.

With retail prices at 1,140 and 1,400 for Toss and Persil brands, it is a healthy indicator that profits are between 50-80% (assuming one is selling the merchandise through wholesales to retail shops).

While our today’s discussion has focused solely on the 3.5Kg Bucket, we have to learn a lot about those other brands that are packaged on pouches and 10/20kg bags.  We also have to learn a lot about those brands from a neighbouring countries that are retailing at Ksh. 180 per Kg when locally produced brands like OMO, Sunlight, Persil, Ariel et al are going for Ksh400 and above for the same amount (1kg). But in a nutshell, it is all about Taxation Regimes for Raw materials in Various countries, Brand Strength, Quality (in reference to Total Surface Active Matter,), Formulation and the Target Market.

Training

For years now,we have trained and mentored a number of entrepreneurs who are now manufacturing Powder Detergent successfully. The training is well structured to accommodate deep theory on surfactant and dirt chemistry, quality management raw material management, entrepreneurship and KEBS registration. Once qualified, the trainee can be able to understand the distinctions of Grade 1, 2 and 3, and how to formulate each grade to suit the customer’s purchase power and most importantly, preference.

Conclusion

Manufacturing the 3.5Kg Powder Detergent (not to be confused with Industrial Powder Detergent), is not only profitable but easy to actualize. Why? Because the packaging is not as complex and capital demanding as the Pouches, while labelling papers are manually stuck stickers. Also, the fact that many families and institutions prefer buying the bulkier 3.5Kg to mitigate the effect of the rising cost of living, makes the production of the 3.5kg a sure bet. For more insights on the business, please book a session with us through our Training Manager, a MS Kiki Mobile: +254 710 20 23 26. You can also whatsapp directly to the school on +254 723 424240 for immediate attention.   

FACT: Your favourite local brand of Laundry Bar could be a Synthetic Detergent Cake Bar Soap

“Oil-Less” Bar Soaps Soap

Our recently launched Oil-less Soap making technology, is a game changer in the soap making industry, where the erratic supply chain of oils, which is the basic raw material, has constrained and nearly edged out cottage industry manufacturers who cannot afford wholesome purchase of the oils. Commonly known as Synthetic Detergent Cake or Syndet Bars, the basic raw materials included in its manufacture are oleolipids blended in a mixture of biopolymers, filler material, water and caustic soda to achieve the homogeneity, character and minimum fatty matter content, and, of course, a TSAM of 5% and above.

World over, including Kenya, Synthetic Detergent Bars are very common, and examples of popular brands are “Nevlon Glo”, “Fab”, “Taj”, “Fena”, “Rin”, “Henko”, “Sudz”, etc. Locally, recently lunched brand “SHOKAR” is gaining popularity in the Coast where locals praise it for the ability to lather “extremely well” in the salty water and “feels better” on the hands, according to one local consumer in Msambweni, South Coast. The brand belongs to a local raw material dealer.  

Oil-less laundry soap, has a rich and intriguing history dating back in 1930 when German scientists developed synthetic detergents to overcome post-World War-I shortages in key ingredients then used for soap: animal fat and vegetable oils. Two decades later, precisely 1957, Syndet bars manufacturing gained momentum when the first Indian factory to manufacture synthetic detergents was set up by Swastik Oil Mills in Wadala, Mumbai. History narrates that, even though key ingredients are imported in India, manufacturing of Oil-less bars still cost far less than importing finished detergents. In foreign-exchange penny-pinching India of the time, this is a key selling point.

Back home, the same challenges that led to discovery of oil-less soap in Germany, India and many other developed states, have plagued the vibrant soap Industry, threatening to shut down small scale manufacturers whose operation budget cannot allow them place huge orders to facilitate uninterrupted manufacturing. Heavy reliance on imported oils has mystified alternative processes among the industry’s majority players and this has hampered innovation.

Our intervention research aimed at keeping the jua kali soap manufacturers afloat has yielded positive results after we introduced Synthetic Detergent Cake Soap Technology that empowers individuals and corporates to create KEBS-Certifiable laundry bar soaps that use oleowaxes (easily obtained in the market at lower costs). The soaps made through this technology match the quality of the prominent local brands. It has average to mean lathering, superior foaming and long lasting, compared to most Grade II laundry bars. Though “oil-less”, the soap has Total Fatty Matter requirements that make it safe for skin.

Cost of Production

As it is with normal ordinary soaps and detergents, the qualifying factor in manufacturing is the Cost of Production vis-à-vis the Sale value. Oil-less Soaps have an average cost of 60 Shilling for an 800g Bar and this gives a local manufacturer the impetus to switch on to this type. The assurance of abundant raw material supply alone, is enough a reason to produce oil-less soaps that are already a popular washing product in the G7 Countries

Machinery and Process

Syndet Bars have the normal curing process of soaps, but shorter window. Once cured, a typical soap mass that ensues can be plodded with the ordinary plodders but, again, the soap is mouldable with normal moulding trays.  While the ordinary bars may require manual mixing (as in home cottage manufacturing), Syndet Bars require high shear (rapid) mixing before pouring them into the moulds. This, therefore, requires the small scale manufacturers (commonly referred to as “Jua Kali”-what a name!), to invest in a small electric mixer (Kitchen Blenders) for batch sizes less than 10kg. Above 20Kg, our Workshop can fabricate small geared mixers that can handle effective mixing of 50-75Kg at a cost of 24,000.

Raw Material Availability

Syndet Bars Require 4 Different types of basic raw materials-water included. Other miscellaneous raw Materials include perfume and colour. All the materials are easily accessed and since they are also used in other industrial processes, e.g powder and liquid soap making, paint manufacturing, tanning, general cosmetics manufacturing and silicaceous material (read Sodium Silicate), there is no fear of any of them running out of supply.

Legality

Syndet soaps can be fashioned to cater for laundry only or even bathing (as Cleansing Soaps). The regulating oversight body-KEBS, has Standards that favour the Syndet Bars under EAS 31  

Training

For corporate and individual training, general consultation, please liaise with our training manager Ms Kiki on Tel no. +254 710 20 23 26 or call the school on Tel. +254 723 4242 40.

When I acquired my first automotive in the month of June 27^th, a second-hand Premio sold to me by the then founder of Dodi Autotech (I can’t remember the names well, but he had just retired from a senior Position from one of the big banks), but my broker was a village mate, a Mr. Muchena (RIP). The latter, lived a very lavish lifestyle and we could occasionally go to pick vehicles he sold (he used to drive them with a size A4 banner at the rare wind breaker screen written “For Sale”). One thing I noticed about the choice of his carwash garages is that they were very costly and extremely busy. The second thing that attracted my attention was an accessory of products in stylish small bottles with black labels with Arabic writings in yellow. Among the items was what I noted was a shampoo in a 1L bottle, equally branded expensively. When it came to my turn to take my new car for cleaning, somewhere in Komarocks Estate, they didn’t have those queer accessories. Few years later I found myself in Lavington neighbourhood carwash booths and by contrast, their charges were slightly higher compared to those of Eastland then. On enquiry in a bid to bargain, one very honest attendant disclosed to me that the carwash shampoo they use is equally expensive, besides waxing the dashboard and deodorizing the carpets.

Car Detailing Industry

Just like the developed countries, the car detailing industry in Kenya has a notable growth, as is witnessed with the mushrooming car wash ‘garages’ in every estate of our major cities as well as rural Towns in Kenya in the past Ten Years. As at now, there are no very accurate figures available to enlighten us more about the precise number of car detailing booths across Kenya.

However, quoting a respectable international research organisation, Transparency Market Research, “the industry’s global growth estimates puts the global car detailing market growth and development projection at a CAGR of 9.6% from 2022 to 2031, with a market size worth $ 3.35 Billion”, it is safe to conclude that it is an industry worthy not ignoring, especially here in Kenya where, according to a local daily “The Star”, the number of newly imported cars in 2020 was 107,499.

Carwash Shampoos

Before any form of car detailing is carried out, a car shampoo is routinely used to remove dirt, stains grime in preparation for car detailing. But what many refer to as “car shampoo” is just, the ordinary liquid (multi-purpose) detergent that akina mama concoct at home and sell in 5 Litre jerry cans at throwaway price. Needless to say, “jua kali” car wash shampoo exposes motor vehicle paint finishing to degradation which manifests as gradual loss of gloss, lustre, fading metallic or pearl shine in most expensive cars. What many car wash garage attendants will not tell car owners is that the inexpensive shampoo they use to clean their motors vehicle will cause them to repaint (an expensive undertaking) their cars when they want to sell it off or make their machines look old though the Plate Numbers are recent. Also, shampoos with high phosphate levels that have a direct impact on clear coat

So, what is the best carwash Shampoo? How is it made?  

A good carwash shampoo is much different, in formulation, from the ordinary liquid detergents. Where the traditional multipurpose detergents may be formulated with a pH of 9, and at times even 13, modern, standard carwash shampoos have a neutral pH which will keep the natural wax applied on the PVC parts intact. It will also allow the synthetic sealants on the motor vehicle to last longer.

A good, professional carwash shampoo must also contain a lubricant, notably a silicone. This lubricates the paint work, cover the wax with a thin protective layer to preserve the buffing lustre appearance of a car  

High quality carwash is also high in suds, envisaged by good foam generation, which helps to encapsulate the dirt particles and mechanically dislodge them off the body surface.

But, wait. Not all carwash shampoos will have all the above properties combined in one formulation. Actually, carwash shampoos are made or categorised according to where they are being applied in the cleaning routine. For example, some imported carwash shampoos have a Volatile Organic Component (VOC), whose task is to remove residual waxes on protective coatings containing greasy compounds such as glazes, sealants. Now, this helps us understand that there are two major classes of Carwash Shampoo: Prewash Snow Foam Shampoos, Alkaline Shampoos and Solvent Based Neutral Shampoos.

A good manufacturer needs to understand the nitty gritty details of these shampoos and their rightful applications and the deal is done.

Car owners, especially the personal (private) types, are so attached to their pricy machines and most of them, especially women, would spend any amount of money when it comes to grooming them. It is a place where they spend hours on traffic jams, a place where relatives and friends aboard while hiking a lift, and so on. Owners of SUVs, fuel guzzlers and more fashionable cars would spare nothing when it comes to appearance of their pricy possessions.

After all, if they can afford to fuel them daily to and from work, why not give them a special weekly treat?  

Profitability of Carwash Shampoo

A quick search online reveals that professional carwash shampoos are priced way more than ordinary hair shampoos and general liquid detergents. In fact, some well branded shampoos fetch Ksh. 900 a Litre. While the most expensive carwash shampoo brands selling in Kenya retail anything like 1,500 per 500Ml, locally made professional carwash shampoo brands retail an average of 500 a Litre. This is quite motivational for manufacturers aiming to try their hand on this alternative market for detergents. But it is how you do it, and not what you make, that dictates how your earnings will be like. Formulating the car shampoo can be tricky if someone is not well versed with dirt chemistry and special detergent formulation knowledge. It will take years of online research, trials and errors, and probably ages before one competes at the same playground level with the more seriously formulated and branded carwash shampoos from Dubai, Turley and south Africa.  

Tips on formulating A Professional Carwash Shampoos

Avoid formulating carwash shampoo the usual multipurpose way. This is because the latter causes clear coat oxidation ruin the PPF. It also degreases natural waxes and synthetic sealers within no time.

Incorporate both Anionic, Amphoteric and cationic surfactants in your formulation. The Amphoterics boost foam generation and can be utilised a very well in Prewash Foaming Shampoos

If Possible avoid Salt because it promotes rust, especially where water does not penetrate well during rinsing. Use alternative ionic thickeners such as Sodium Metasilicate which, coincidentally possesses anti-rust properties. Remember, salt and other like-elements initiate the gelation of SLES, thus voluminize and thickening detergent systems, a feature considered aesthetical for consumers.

Include some VOCs in your carwash cleansing shampoo. They help remove residual waxes and other protective coatings containing greasy compounds such as glazes, sealants.

Adopt the use of non-ionic surfactants (alongside Anionic surfactants), preferably at the usage rate of 5%. They are powerful emulsifiers, meaning they will remove the greasy dirt more efficiently. Having superior wettability that favours stubborn stain removal, Non-ionic surfactants also adapt very well on hard water, despite them having poor foam generation which is provided by the anionic surfactants.

Manage the pH of your carwash shampoo. pH neutral formulas, that contain a synthetic wax or sealant that helps to protect the film or vinyl from sun exposure.

Branding: Branding is defined as giving your product visual Identity. A well thought-out, complex clear-detailed graphics will do the magic. One thing I have come to learn is that Kenyan consumers have a passion for foreign-made things. Just like High-end Salons and Barber Shops whose charges are a wonder to ordinary Kenyans, the carwash booths in leafy suburbs, near night clubs and Saturday outing Barbeque Joints will not bargain when it comes to purchasing car grooming accessories. And as motorists become more and more aware of the importance of grooming their motorcars, the demands for professional carwash shampoo keep on soaring. Shall we forever keep importing the detergents from Uruguay and Turkey for this insatiable market?

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Our New book “Makeup Manufacturing Self-Instructive Manual” is a first and the latest unique innovative product for those willing to invest a sizeable amount of money to acquire it. The book is aimed at empowering general cosmetic manufacturers and newbies in doing a new thing differently. The makeup manufacturing course offered by this self-instructive manual will in turn help its buyer acquire knowledge and skill needed to invest in this highly lucrative glamourous and sparkling virgin industry and tap the immense monetary opportunities the market for makeup offers.

How is Makeup Market Size in Kenya?

According to a well-researched piece of article by one of the biggest media in Kenya, It has been estimated that the market for beauty products and services in the country is valued at over KES 20 billion, making it one of the most attractive markets for investors.

Another finding by an international market research organisation stated that as of 2017, statistics showed that Kenya’s colour cosmetics market alone was estimated to be worth 5.4 billion shillings with an average annual growth of 22%, meaning that as of 2023, the market size is somewhere within 8 billion. This humongous, ever expanding market is being served by big international brands like MAC, Victoria’s Secret, Sleek, Petal Fresh, Freeman, Mary Kay, Simple, Bath and Body Work, Black Opal, Flori Roberts and Ombia (Austria). The only Kenyan makeup manufacturer, Suzie Beauty was acquired by a local multinational Fast Consumer Goods manufacturer, Flame Tree as part of their larger plan to expand their FMCG business in which they are already big players. Flame Tree Africa are even listed on the Nairobi Stock Exchange.

Opportunities for Makeup Manufacturers in Kenya

The beauty and cosmetics industry has become Kenya’s new hub of investment that is pulling in big money to establish new lines of business and also to snap up successful enterprises through multi-million-shilling acquisition deals, such as witnessed in the acquisition of several home-grown brands such as Nice & Lovely, Safisha, Suzie Beauty etc.

This clearly points out that a well-established and managed brand can earn the owner instant fortunes to the tune of billions, equally compensating time and resource sacrifice that he/she may have incurred. By and large, makeup brand manufacturers can earn very well from the normal routine income that the brand trades on daily basis

Key Drivers of Makeup Industry Growth in Kenya

As it is always the norm, an aspiring investor will always look around for information on market markers that will act as surety and motivation for his undertaking in investing in a  self-sustainable market. In a nut shell, the key drivers of makeup growth industry in Kenya can be summarized as Product innovation and product line extension, growing trend in male grooming, sustained growth in emerging markets, the growing interest for natural and organic products and services. Also, digital engagement, a rise in the number of middle class earners who form the biggest market for makeup products in Kenya.

How will a newbie benefit in Venturing into this Market?

Our past experience in initiating, motivating and nurturing business entrepreneurships, if anything to go by, should give hope to anyone aspiring to become a local manufacturer. Over the years, we have witnessed growth of the now big corporates whose owners came to us for enquiry, either out of curiosity or determination to start family projects, that ended up well after taking classes, registering brands, acquiring KEBS certification and mechanizing production. We have witnessed growth (from inception) of brands Like Clario, Dalwatt, Betty Industrial Chemicals, Durax Paints, etc. Again, Revola Kenya, AVI, Vassion etc. are national brands whose respective owners we mentored are spreading their presence in East and Central Africa. And many more whose privacy we must respect.

The new entrants in Makeup Industry will not only see their home-grown brands competing favourably with foreign-owned ones, but will also be netting more income (since the cost of production will be lesser) as this will compel both middle and the majority low class consumers to pick their brands as an alternative. This of course, calls for good branding, workable formulas and innovativeness for the new entrant. Remember that makeup is so personal and users of the commodity usually treat them with a lot of caution. There is no room for mistakes. Once a makeup reacts with user’s skin or does not bring out the determined results, the brand’s negative vibe spreads across like a wild fire, hence the need to do it correctly.

Start-up

Fortunately, for the makeup manufacturing, production cost is lower compared to the mainstream cosmetics. What will probably put the manufacturer of makeup to task is quality and packaging, which we have solutions for as an institution. 20,000 Ksh is enough to start about 10 dozen of each category of makeup such as Primers (Face Foundation primer, Eyelid primer, Lip primer, and Mascara primer) Eye Makup, Lip Makeup, Concealers, Tinted Moisturizers etc.   

Raw Material

The makeup components are 90% shared with mainstream cosmetics and pharmaceuticals, while the pigments, powders like bentonite clay etc. are well stocked by mainstream chemical suppliers. The personalised cosmetic jars are a-call-a way, with many reliable local importers of Drug and Cosmetic raw materials like Arichem able to run the errands and delivering in time with even more cost-friendly terms.

Market Entry

Considered a daunting task by many, penetrating the market is actually the easiest thing to achieve if only your brand is well done to the international standards. The Book, authored in extensive collaborative research, sample reproduction and consultations with reputable quality control firms, medical dermatologists and two beauty colleges in Kenya,  has an extended definitive guide on how to approach the market, like direct supply to Salons with high customer traffic, Planning and executing marketing campaigns for beauty products, doing product outreach programs by distributing samples to cosmetic shops and more importantly, linking you with the dealers (Distributors and Wholesalers).

It should be well noted that Salons are considered the easiest entry points for makeup products because some of the outlets are visited by high-end-clients, celebrities and business-minded persons who are eager to grab any opportunity that presents itself especially in re-selling or bulk supplying.

 Some salons in Nairobi serve high spenders (some known celebrities like Bahatis spend over 10,000 almost on daily basis due to their nature of work) and the owners can strike a win-win deals with a local manufacturer provided the finishing of the product does not resemble some liquid detergents mixed and packaged in drinking water bottles retailing at Ks. 50 a Litter, or those plates and water glasses found on eateries at Gikomba and Korogocho.

      

Part of professional branding requires aesthetic labeling that is enticing to the would-be client. Products in clear containers, especially Handwash, Shower gels and Shampoos look more appealing when the labels are also transparent, nicely done with good graphics especially flowers and so on. And a casual walk along Dubois road and Supermarkets always makes one believe that we, as Kenyans, are far much behind in manufacturing.

In the African culture where ” anything that comes from abroad” looks nicer than locally made products, introducing your locally made but well branded product is one of the ways to improve sales. Majority of the shoppers looking out for “imported” products oftentimes do not care about the country of origin or the manufacturer’s name, provided what their eyes have liked is within reach.

Unfortunately, the typical local manufacturer does not strive to have their branding emulate the “west” or foreign imports, often finding themselves lagging in terms of sales where their products share the same shelves. This is partly attributed to poor branding culture and limited choices. For example, one morning of December 2020 when we set out to have our client’s newly created brand well labeled with clear stickers, we scouted for firms that would offer the service. But to our surprise, non existed online and we extended our search to Jiji. With a sigh of relief, we encountered 3 persons who had posted about clear stickers but without much information about the subject. We picked their mobile phone numbers and surprisingly, upon enquiry, they appeared non committal. We however pressed one of them who sounded like he would help. And enthusiastically he gave us directions to his office somewhere in Gill house but upon reaching there, he switched off his phone.

Later, a good friend of ours, a Mr. Hassan, gave us contacts of a firm in Baba Ndogo. It is an Indian firm but their positive reception met us with even more surprise. Minimum order took nearly three hundred thousand Shillings (about 3000 USD). Graphic re-design alone took an eighth of the original amount as an extra fee. That is when our director decided to set up a product Branding Office that would bridge the gap, making the service available to any client at even more affordable rates.

Since it’s inception, we have served a number of clients, often offering pocket friendly charges for product branding which includes name appropriation, label design and clear sticker printing. The latest being Clario brand, Revola and Vasson brands. Below are some of the photos taken from our branding desk

One roll with as many as one thousand stickers can go for as little as 15,000 but this depends on the size of the individual stickers. Individuals who want few clear sticker can also get them printed by us. We also sell semi automatic labeling machines and many other related services.

For clear sticker printing, product name appropriation, logo design and general graphic design, please talk to us on WhatsApp +254 723 42 42 40 or call for immediate assistance. Aren’t you sorted out now? 😁

The recent rise in soap making raw materials, among them Sodium Silicate has had many soap manufacturers wondering whether it is still tenable to use it in soap making, especially now that its price has doubled (from Ksh. 50 to Ksh. 100 per kilogram), equalling the price of most oils.

While Sodium Silicate is widely used as a filler material (to lower the cost of production) and therefore, by default, becoming the most suitable cheap replacement for oils, its rise in cost would make it sensible to decide that it is no longer a needed additive in the formulation of laundry soap. The decision can be amplified by further reasoning that it is, after all, the cause of lower total fatty matter content which degrades the soaps quality to Grade II according to the Kenya National Bureau of Standards’ grading criterion. But how correct would it be to strike Sodium Silicate out of the manufacturer’s list of raw material?

In our mandatory 10-15-hour theory in soap chemistry, much is covered concerning the use of Sodium Silicate in Soap (Laundry) Manufacturing and its benefits in 10 other areas of its application in Laundry Bar Soap.

Among these benefits are production cost savings, increase of cleansing power of soap, Deflocculant role, Prevention of Soap sourness, Alkaline buffering role, Viscosity control, Emulsifying role etc.

As an Emulsifier, for instance, Dr. Herman asserts that the use of sodium silicate in soap acts as a bridge between water (polar) and fatty acids (non-polar); Thus, sodium silicate molecules fall into the category of surfactants (active substances that are deposited on the surface and cause kinetic stability of the emulsion). Herman goes to further to elaborate the Silicate’s role in Laundry Soap, citing that Sodium carbonate and sodium hydroxide solutions in water are no longer used to neutralize fatty acids (as it was the tradition in early ages) and to soap fats and oils, but aqueous solutions of silicates sodium are used. ‘In addition to improving the quality of the product, this also reduces the drying process during the final production of the soap’ the senior educationist adds.

And without going deeper into the chemistry of Sodium Silicate for the sake of saving the reader’s time, let us go straight to the point. Sodium Silicate in laundry soap contributes significantly to the weight of the soap due to its high density. One afternoon, a former soap class graduate who had excelled in soap making and selling in Eastleigh knocked our Town Lab’s door and his disappointment could be discerned almost immediately, as he sighed with relief while finding a seat to rest after scaling the upstairs to fourth floor. After acknowledging the presence of the ‘new staffer’, he asked the director’s daughter who was manning the reception desk about the Mwalimu’s whereabouts. And in no time, Mwalim entered when he was explaining how the current bars he was making were weightless. They exchanged pleasantries and he begged the businessman to recount what he was narrating. After keen listening as it is his character, the director smiled and asked him whether there was something he was not including in the soap. Abdikadir was quick in answering to the affirmative, pointing out that he had stopped using Sodium Silicate because its price had equalled that of the oils and scarcity had started biting.

Sodium Silicate, by default, has high density (1.65 g/cm³) and therefore its use helps add weight to oils which have densities between 0.81 to 0.9g/cm³. This means that making soap with oils only, as is the preserve for bathing soap (whose Total Fatty Matter Content must be equal or above 78%) will see a Kilogram of the bar weighing about 89g less or more depending on the oils used!

It is therefore, not an option, to entirely divorce the use of the weight-adding ingredient however much it is viewed as a no-value in the wake of its high cost . Further, the sodium silicate’s alkaline nature supplements the Sodium Hydroxide (Caustic Soda) helping to reduce usage of the latter to avoid what KEBS would term as ‘Excess Alkalinity’.

Isn’t it wonderful learning the Industrial Chemistry in Manufacturing Consumables? Join us for comprehensive, insightful daily classes for Soap Manufacturing as well as 89 other courses in our Town Lab. Get in touch with us on Mobile No. +254 723 42 42 40.

Branding is defined as giving your product a visual identity, in which, printing the labels, particularly of the round containers on the tins themselves, constitutes professional branding.

When we started the journey of empowering individuals by training them industrial manufacturing, the challenge we encountered immediately was the need to provide them with raw materials, packaging as well as machinery. For the latter, we successfully liaised with a number of local importers of raw materials with which we have established firm relationship between our trainees and them. With growing need for professionally made labels, we too established local firms that print transparent labels, PVC labels as well as laminated labels for various types of cosmetic packaging.

Bucket Labeling

Paints, Varnishes and other metal coatings are packed in metal tins, plastic buckets as well as jerrycans. Small scale manufacturers whose level of production is low have always been marginalised when it comes to acquiring printed buckets for their products. As part of solution-finding firm, we liaised with Mehta Plastics who print their both metal and plastic cans at flexible terms.

Meta Plastcs Printers can be reached at 0721 264 147 (Ask for Manur). They offer printing services for a wide range of round containers including cups, drug bottles, paint cans etc.

When social media blogs are enticing readers to their article links under the frenzied headlines: “The 5 Most Marketable Degree Programs in Kenya” they are not offering solutions to the majority of their followers who, for some reasons, did not qualify for the programs post-secondary

They do not offer any hope to those who may never attend University either. On the contrary, educating school, college leavers and the general public on what best manufacturing careers one can pick, will abundantly address the apathy in the job market.

While career manufacturing training is affordable and accessible by nearly everybody, educating the public on the choicest available courses will influence a positive thought process and most likely encourage them to pick a course of their liking.

In developing economies like Kenya, manufacturing of Wood Varnishes can thrive well even from the backyard of your rented apartment, since processes involved in manufacturing of this rather fast moving industrial product do not require complex technicalities and machinery that are normally associated with environmental pollution (emissions and noise), often attracting the wrath of law enforcement agencies and envy of the neighbours

Through experience gained in our daily Consultancy, training and mentorship programmes, we have identified quite a number of manufacturing ventures that can be exceptionally productive even with less capital and labour retirements, Wood Varnish production being one of them

In June 2020, our first client for Wood Manufacturing entrusted us with the training, amid doubts that he would compete with big brands. Today, DABCO Coatings, which also manufacturers Paint, Fillers and Special Metal Coatings is among established brands whose formulations, we can attest, are of highest quality with strict scientifically sound development. The owner, who has allowed us to feature him on this post, started with almost nothing, apart from training, three 20-liter buckets, wooden ladle and weighing scale. Without going into greater details that may violate his privacy, let us see how you would have your brand in the many Hardware stores around Nairobi estates with partly 20,000 shillings.

Wood Varnish, a common decorative coating for wooden surfaces including furniture, doors, wooden carvings, tables, coffins etc., is made through a well-structured formulation that incorporates about 8 ingredients for a standard final product. Unlike paint that incorporates pigments that make the need of an electric mixer for dispersion necessary, the Varnish, especially the Glossy ones, do not need pigments, effectively negating the need for mechanical mixers. Mahogany and other multi-coloured varnishes use Dyes (not Pigments) and their dispersion is easy since there is no need to involve much energy in solubilising them. Sealers, an important class of wood coatings that oftentimes go hand in hand with Varnishes may use small electric machines because when the materials are homogenised, viscosity build-up may make manual mixing tiresome a lot. Also, the homogeneity, which is a quality aspect of the final product, ensures a smooth textured product. Nevertheless, the use of small geared mixing gadgets (Variable speed Dispersers) worth Ksh 14,000 come in handy. On the other hand, raw materials will take about Ksh. 5,000 while containers (usually the metallic cans) will cost about 1,000 shillings.

Detail about the trade requirement

Money is the fundamental requirement for any activity. The level of expenditure determines the output level thus profitability and savings. However, for small scale manufacturers vowing to start up business of whatever kind and with whichever amount they have, no amount of discouragement can dim their dreams. We have all heard or read biographies of well-known billionaires who started their business empires with as little as Ksh. 5,000. Well known figures like the late Njenga Karume, Equity Bank founders, started at the level that was a ridicule by their peers. Why can’t you? For them, those old days, it was about personal wit and risks that outgrew social hostility, environmental incapacitations and managerial skill apathy. In sharp contrast, the modernity accords an individual an opportunity to learn professional skills in manufacturing, business management and mentoring in one sitting, effectively preparing one to initiate a flawless process that starts with planning, financing and actual manufacturing with minimal risks.

Assuming a newbie manufacturer has all the basic requirements of an industrialist-that is to say Knowledge, space and manpower- then it would be right to say that equipment (mixing vessels), machinery (electric mixers), raw materials and probably licences is all what he/she should budget for.

Detailed Breakdown of the Costings

For Wood Varnishes, the raw materials budget is what one will take a keen interest on. Assuming the initial batch size is 30kg (60 cans of half-litre) is what the manufacturer wants to produce, it would literally need a budget of anything close to Ksh. 6,000. Making a one litter of Wood Varnish is Ksh. 180. The same sell for anything between 400-600 depending on the quality and brand value. Some varnishes, however, like Two Pack Epoxy Varnish may consume as much as Ksh. 600 to make a One Litre which sells for around Ksh. 2,300.

Less batch sizes can be made by manual mixing of the raw materials, but for bigger batches (about 20Littes or so) that need to be fine-textured with professional appealing, Speed Variable Electric Dispersers (SVED Machines) are a budgetary factor to consider. The machines that are electric motor driven with a gear button cost anything between 15,000 to 24,000. They are handheld and can disperse a load of 100 Litters of Wood Varnish and Wood Sealers. Literary, a small scale manufacturer can make up to 3,000 litters of wood varnish per day with these portable, hardy gadgets

Equipment needed for the backyard manufacturing of wood Varnishes are the normal household vessels for mixing, however, 20L buckets, about three of them each costing 200 shillings can be budgeted for. Metal cans (not plastics) for 500ml go for about 30 shillings each. Labels for each can be made by offset printing that make it cheap. A more professional packaging will need the metallic cans printed directly and Mehta Plastic & Metal Can Printers come in handy. Recently, talking to the director of the printing firm, I was happy to hear they can print a minimum of 100 cans at a cost of Ksh. 10 per can.

Of course Standardization Certification for your product is another aspect of the budget considerations we cannot ignore. This can be well explained upon reaching us for available options by the Quality Control Agency.

The Market

The decorative industry is vibrant and specifically for wood finishing, the consumer (carpenters) are not biased towards specific brands. What matters to the majority of them is quality and price. A little persuasion by the marketers of your Varnish Brand goes a long way in influencing loyal customers of old brands to shift their focus on the emerging (new) ones.

Carpentry shops scattered across Nairobi County are over 500. On average, each carpentry shop consumes about 3 cans of Wood Varnish Every Week. That is to say about 6,000Litres (6 Tons) of Wood Varnish are consumed every month. Have you ever been ushered into an empty Matatu while the one in front is almost full, and immediately you seat down, the one you declined to enter leaves immediately making you feel silly that the “Makangas” really got you? That is exactly the same experience with marketers: The customers of established Brands like DALWATT and POLYPAINT are the potential candidate consumers of your little known brand. Persuasion marketing therefore, is key.  Planning for sale projections of at least 50 Litres a day in the vast market (a pie of 10%) is achievable by employing only two sales reps who, must reach at least 20 carpentry workshops at any time.   50 litres can therefore, assuming you are selling at the price of 500 per litre, get you a cool 10,000 shillings as PURE PROFIT (assuming you are getting a net profit of 200 bob per litre after factoring in the labour, salaries and commissions). To make the product move a little faster and benefit from the economies of scale, you can vend your Varnish in half-litre (500ml) cans. A spirited manufacturing and aggressive marketing can earn you 300k every month within Nairobi County and a cool 1.5 Million in 5 biggest cities and towns.

Starting

The critical aspect of manufacturing is Knowledge and Skills, without which, three things can befall a manufacturer: Low Quality Products leading A No-Return Customer, Losses due to mismanagement of raw material, losses during manufacturing processes and lastly, loss of customers to competing brands that are viewed as better performing.

Wood Varnish and Sealers utilise polymeric raw materials as binders and Highly Reactive Additives used as Siccatives, Film adhesion promoters and anti-skinning agents. Their use is usually in critical usage ratings that can see a competitor’s brand performing better than yours, or worse, your product losing qualities that are needed to make the product competitive.

Being the only Institute in East and Central Africa spearheading training on Industrial Skills, and on introducing the Industrial Course on Paints and Coatings, we summoned reputable industrial quality control managers drawn from various local manufacturing firms who chipped in the relevant information needed for a complete training module modelled on sound formulation, quality control, internal standardization and monitoring. So far, the manufacturing firms (especially for the Paints and Coatings) we helped start under our direct mentorship are a true testimony of what a professional training can achieve.  

Certainly, we would welcome your gesture to join us for high-level training for your Quality Control Managers, Production Managers, and even Individual manufacturing. Course is structured to take 15 hours spread across the week according to the student’s availability. For charges and offers, please see our catalog. You can also save this number +254 723 4242 40 on your phone and view our offer statuses. Training is daily.

With an increasing and ever expanding Paint Market in Kenya, dealership in Paint Manufacturing is a sure economic activity that can generate good income even when carried out at basic (home level).

The minimum requirement for a startup paint manufacturing, if our 4-year experience in training and setting up Micro enterprises is anything to go by, is partly 40,000. This includes raw materials and packaging containers, a small Chinese imported machine and few labels.

Huge Profits

Raw Material, budgeted at 28,000 is enough to make 140L of high quality Interior Emulsion Paint (Vinyl Silk). That is Seven 20-Litre buckets, each Retailing at 12,000 per bucket. This Means, the manufacturer, giving each bucket at 11,500 to a retailer (who in turn makes a profit of 500 bob per bucket), makes Ksh. 80,500, a profit of Ksh 52,500. The profit can be quickly ploughed back (52,500 + 28,000=80,500)to make more paint (300L) and so on.

Other Requirements

The previous paragraph may have stirred up our optimism, but nothing really comes without sweat. The above startup capital may be borrowed from a microfinance institution or raised by 4 friends (7k each from mobile loan) but prior preparations must be made: Professional Training and KEBS.

Role of Proper Training

Unlike many industrial product manufacturing that require less keenness, paint, being a polymer based product, needs a deeper understanding of the chemical reactivity of raw material in production process as well as top quality management acumen. And these are essential requirements in producing a top quality paint that will be the exact, if not better, quality of the 5 giant brands in the country. In short, the paint you deliver to Mothokinju and other Hardwares must not be regarded as a “Lesser brand” or better still, a”Juakali Paint”. This also means that branding must be equal to the task.

KEBS Standards

Paint is among the top rated products that are strictly regulated by KEBS. While it is (criminally) possible to make and sell on-site without the Standards Document, the risks it carries is higher than the loss incurred if a slight mistake gets along the way when manufacturing is done by half baked manufacturer, often forcing the manufacturer to discard the whole batch. KEBS certification also helps the retailer to have more confidence of your product, though it must not be obvious to the retailer that it is made from backyard.

Maintaining professionalism in manufacturing of Paint calls for thorough understanding of the paints performance based on standard formulations, equipment use and quality control. For example, the Premium Silk paint must have a Dry Film Build (DFB) of 60 microns and above, while the Pigment Volume Concentration (PVC) Should be anywhere between 35-45%. The Volume Solids, on the other hand must be 60-70. Lesser grades (economy type) may have the minimum VS of 50%, while Opacity in Contrast Ratio of the paint could be 90%. The resin for the premium type is usually Venyl Acetate, and not Vamveova as it is in cheaper grades. All this is taught by our overworking technicians who are top Polymer Scientists and Certified Experts in Paint Manufacturing for big brands like Dalwatt, Durax Paints and DABCO.

Training fee

Upon introduction of subsidized training Charges duped “Promos”, we have seen heightened interest on our training offers since they present great opportunities to learners who may feel that our normal corporate charge rates of 126, 000 per individual are high. The promo rates range anywhere between 15,000 to 45,000 and the training takes a minimum of 54hrs distributed over 10 days. Maximumly, the training period can go for 1 month.

Finding Market

The prime market for the Paint is the Construction Site, where the manufacturer presents his/her well packaged and labeled 4L can as the sample to the Site Manager or Engineer. Upon acceptance, the Site Contractor will negotiate the price and make orders. Even if the manufacturer doesn’t have capital for making the paint, proper negotiation skills will endear him/her to get down payment from the Contractor and this money will enable her to produce paint required for the site. Other markets are approaching Rental house Caretakers who are repairing vacated houses in anticipation for the new clients.

Fabric softeners are used during the rinse cycle, which is the final stage of the laundry process. Their purpose is to provide fabrics with a range of beneficial qualities, for example reduce fabric roughness (so-called “soft hand”), eliminate static electricity build-up, improve the ironing effect and ensure a pleasant scent. But before we see the composition of a super effective fabric softener, let us understand the physicochemistry of fibre damage during washing as an excerpt from our Fabric Softener Manufacturing Technology Class;

Fibers that make up fabrics (Shirts, Dresses, Coats, Towels, Bedsheets, etc.) often get exposed to considerable damage during the laundry process. A prominent role of wear and tear as well as fabric aging is played by friction processes occurring between individual fibers and between the washing machine drum and fabric fibers.

An additional factor is chemical damage of fibers, which arises from interactions with solutions often containing aggressive detergents and having relatively high pH levels. Consequently, after the laundry process, the fabric fibre surface is frequently destroyed, heterogeneous, with multiple damaged microfibers sticking up from the surface. As Dr. Herman, the brain behind development of a local famous brand (name withheld) says, the ingredients of laundry washing agents may accumulate on the surface of washed fabrics. The phenomenon is referred to as incrustation, and its most common cause is the build-up of a deposit on the fibre surface, consisting of water insoluble calcium soaps. He further adds; ‘Since the surface of such deposits is very rough, the fabric does not have a soft hand.

Qualities of a good Fabric Softener

Fabric softeners are expected to be easily dispersible in water and should not cause fabric yellowing and corrosion of structural elements in washing machines. Just like the name suggests, fabric softeners must make the fabric soft. The products are also referred to as anti-static agents or fabric softeners

Composition of a Standard Fabric Softener

Apart from a Cetostearyl Alcohol, famously known as ‘Conditioner Flakes’ in chemical shops and High Diffusive Fragrance such as Activated Lavender, Fabric softeners usually have the form of aqueous dispersions of cationic surfactants, such as quaternary ammonium salts (quats), pyridine and imidazole salts. All these play an important role of reducing fabric roughness and elimination of static electricity build-up to improve the ironing effect. However, there are other uncommon additives such as Silicones-which Jua Kali (homemade) fabric softeners do not use-that can be of great value addition to a standard KEBS-Certified Formulas in improving textile surface wettability.

What is Textile Surface Wettability?

Textile Surface Wettability is the tendency for a water droplet to spread on the fabric surface, which mainly depends on the contact angle of the water droplet and the fabric surface. Textile Surface Wettability is technically referred to as Hydrophilicity and hydrophobicity, which presents two phenomena of the wettability based on the tendency to absorb or repel the water accordingly. Many textiles need the hydrophobicity or hydrophilicity based on the end use application

Silicon Additive: An important group of compounds used as additives in fabric conditioners are silicones, mainly those including a quaternary nitrogen atom in their structures. The presence of a nitrogen atom gives silicones a cationic nature, and thus, increases their capacity to become adsorbed on the surface of fabrics such as cotton greatly increasing the softness of such fabrics. Furthermore, Silicones incorporated into the fabric conditioner formulation increase the efficiency of cotton fabric re-wettability with water by 62%. This, according to Dr. Herman, increases, good water absorbing capacity, a desirable property in towels. Dr. Herman is quick in noting that in contrast, some fabrics are intentionally hydrophobized in order to protect them from moisture. He says that Hydrophobicity is one of the requirement to achieve water-repellent property in several textile applications such as sportswear, protective clothing, medical, automotive, home, technical and industrial textile applications.

Other must-use additives are Tetra sodium (or Disodium) EDTA and Sodium Benzoate. They provide ionic and microbial stability respectively, where the former ( Tetrasodium EDTA) functions by bonding to metal ions in salty and non-salty water, and inactivating them, to prevent deterioration of the product, which also prevents them from depositing onto the fabric fibers. Most importantly, EDTA improves effectiveness, stability, hard water performance, rinseability, clarity, fragrance integrity, and shelf life of formulations. Sodium benzoate, which can often be substituted with parabens and/or Phenoxyethanol ensures that microbes do not get away with the shelf life of the products

Prolonged Fragrance

A selling feature in fabric softeners, it comes second from conditioning effect of fabric softener. The manufacturer of a fabric conditioner must understand the volatility characteristics of the intended fragrances and modifying their retention. Common combinations of fragrances are acyclic monoterpenoid odorant compounds such as Linalool.

Linalool is commonly found on the list of high-end (famous brands) skin products like Lotions and Creams. However, the same ingredient is intentionally omitted in fabric softener brands as a trade secret. Linalool, which amplifies the aroma in fabric softeners is rated as the most potent odorant among many fragrant compounds, with an average OT of 3.2 ng/L and its use as an additive in the fragrance blend to boost and amplify the scent is subject to its commercial synthesis that includes oxygenation on carbon 8, giving it a substantial effect on the aroma profiles of its structural derivatives together with that of linalyl acetate. Our classes on Perfumery expound this phenomenon and equips our students with much knowledge on Scent Technology that includes improving of Scent Potency through blending and Fixation.

Many thanks to Betty Industrial Chemicals and B&K Holdings for their voluntary contribution to this blogpost. For more information and training, please Call/Text Whatsapp +254 723 42 42 40

As the title suggests, the current cost of producing an 800g long piece of bar soap is ONLY Ksh 100. It may not only look like an achievable feat, yet it is even more feasible.

The resent escalation of the cost of soap making materials by over 80% has battered small (part-time) home producers of the valued (basic)commodity that every household holds dear, edging them out of the manufacturers’ league. However, those who have been resilient, focused and determined in manufacturing have seen the lighter side of the situation which has, in fact, come as a blessing in disguise.

Part of the reason why the resilient, focused and determined local home-based soap manufacturer has heavens to thank is that he/she has found herself at the very centre of what the economists refer to as Ceteris Paribus 

Technically, this is where a demand curve or a supply curve is a relationship between two, and only two, variables: quantity on the horizontal axis and price on the vertical axis. The assumption behind a demand curve or a supply curve is that no relevant economic factors, other than the product’s price, are changing. That is, all else is held equal.

In a nut shell, when the supply chain for Palm Oil broke due to COVID-19 travel restrictions and the recent Russia-Ukraine, the production of soap, mainly by small firms was affected, limiting the supply of soap. This subsequently caused the product’s retail price to shoot upwards by almost 100%, fuelling demand.

On the other hand, though, at the same time, the cost of production rose marginally with 50-60%, the profit margins improved phenomenally.   With ease of restrictions leading to resumption of supply of the raw materials albeit slow, coupled with emergence of alternative sources of oil, the small manufacturers who are now able to buy the raw materials in bulk through reliable and stable connections, are smiling all the way to the bank

It is advisable that, with the promising foreseeable future in soap industry, those who are capable of securing good functional machinery and equipment, spaces and good manufacturing mentorship (professional training) should do so now and wait for the rains.

Budding Net Profits

Just before the disruption of raw material supply chain and subsequent astronomic rise of the laundry soap at the retailer’s shop, the net profit was between Ksh. 20 to 60 per piece of 800 and 1000g bar. With doubling of the retail price for the same commodity, the net profit now ranges between Ksh. 80 to 140. Of course this is with the assumption that overheads, middlemen and taxes have been factored in.

Ksh. 100 per 800g Bar

Computation of the above cost is derived from the current average costs of raw materials from renown local suppliers, taking into consideration that the soap in reference is Grade II with Total Fatty Matter Content (TFM) of 55%

Current Prices Vs Traditional Prices

Sodium Silicate that was retailing at Ksh. 47 (according to Betty Chemicals online price list) is currently retailing at Ksh. 100 while Palm oil that was retailing at Ksh. 60 is now costing Ksh. 105 (Betty Industrial Chemicals) ans Ksh. 120 (Soapwide International). Caustic soda whose price was Ksh. 89 (Betty Chemicals 2021 catalogue price) is now being vended at Ksh. 180, a 100% increase. Nevertheless, with the new exorbitant prices that the local manufacturer has to contend with, accurate and professional formulation of laundry bar soap will see the local soaper incurring anything between Ksh. 100 for a 800g bar and Ksh. 115 for a 1kg bar soap whose retail prices range between Ksh. 200-230 and Ksh. 250-300 respectively.

The (trending) jokes that the price of soap is more than that of the ‘karai’ (basin) aside, a local manufacturer needs only Ten (10) families with regular consumption of 1kg bar every week to educate his/her child through the Secondary school without the kid ever being sent away for school fee.

Isn’t soap manufacturing not a viably promising business venture for everyone in Kenya?  

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Medically speaking, ageing is the progressive accumulation of more or less random changes. I will not go into greater details of this statement since this blog is aimed at giving an insight to cosmetic manufacturers (outside our classes) the knowledge of the basics in anti-aging cosmetic preparations.

Cosmetic formulists must know the functioning of the target organ (skin) whose products they are making. This helps in preparing functional, safe and sound products that will produce noticeable and appreciable results by their clients. Our cosmetology classes equip future manufacturers of skin care products with professional cosmeceutical and medical knowledge of drug (including cosmetics) metabolism, excretion and pharmacokinetics

Understanding Your Skin

Skin, being the largest organ and obviously the most outer part of the body, has a very important role such as protection, body temperature regulation (thermoregulation), excretion, absorption, perception, pigment formation (melanocytes) and keratinization.

Anatomically, the skin consists of epidermis, dermis and hypodermis layers, therefore, both ill-health and well-life conditions can be reflected from the skin condition. (we medical doctors, especially dermatologists, can tell a smoker and a non-smoker by the appearance of the facial skin).

Skin Aging Process

The skin aging process consists of two categories: Intrinsic and extrinsic aging. Intrinsic aging is characterized by skin atrophy with loss of slow elasticity metabolic activity.

UVB Damages Collagen Synthesis

Extrinsic aging is caused by environmental factors, such the long-term effect of repeated exposure to ultraviolet light commonly. This type of aging is referred to as referred as photo aging. Here, UV light energy, especially UVB which is loaded with free radicals, damages collagen synthesis, which in turn decreases the collagen number. These changes make the skin surface sag and reduce its elasticity, eventually causing wrinkling. In the stratum corneum layer exposure to this UVB can change the mechanical barrier characteristic and function, resulting in the increased of trans-epidermal water content loss in the stratum corneum, leading to dehydration.

Natural Aging: Oestrogen, a hormone, decreases with advancement of age. As we know, Oestrogen converts fibroblasts into collagen and therefore with old age setting, this gradual decrease in Oestrogen means reduced collagen number.

What is Collagen?

Collagen is a protein! Collagen is the main component of connective tissues that make up several body parts, including tendons, ligaments, skin, and muscles. being the most abundant protein in the body, Collagen plays important functions, including providing your skin with structure and strengthening your bones. Collagen enables wounds to heal.

There are 28 types of collagen, and type lll is the main component of reticular fibers, which are found in your skin and blood vessels. In the absence of collagen, skin dries and wrinkles form.

Replenishing Collagen

Replenishing collagen, especially Collagen Type III is the hallmark of maintaining healthy skin and apart from slowing down the aging process, adequate maintenance of collagen in body tissues, combination with Vitamin A can reverse aging significantly.

Replenishing collagen can be through topical skin application (Lotions, Creams and Serums) and ingestion (oral route). The latter can be through Foods that contain gelatin, such as bone broth, provide collagen. (Gelatin itself is a protein substance derived from collagen after it’s cooked). Collagen is found in the connective tissues of animals. Thus, foods such as chicken skin, pork skin, beef, and fish are sources of collagen.

Reversal of Skin Aging Signs

As a Skilled Cosmetologist, reversing the aging process and removing tell-tale signs of aging can be achieved through a combination of interventions namely hydration, protecting the skin from free radical damage (well achieved by antioxidants), blocking the UV radiation, treating minor and major skin ailments that hasten aging (such as Acne and Rosacea), promoting cellular metabolism (excretion of metabolic wastes) and collagen repair.  

Replenishing Collagen through Topical Applications

Besides incorporating strong antioxidants, strong humectants and UV blockers, Lotions, Creams and Serums can be good vehicles for lab-synthesized collagen and several other pharmacological agents that can prevent or cure Acne and Promote Cellular Metabolism. All the above included in one pack, we can confidently say that our products, especially creams (due to the nature of formulation) can cure of reverse or slow aging. Without incorporating all the above, or leaving out some of the discussed agents, then the cream is said to be more cosmetic or placebo-because it will not achieve any significantly noticeable changes on the user.

Mode of Working for a Typical Anti-Aging Cream

Let us analyse the mode of working for each anti-aging components in a typical anti-aging cream (not serums or lotions) can accommodate

Vitamin A: Vitamin A (also known as Retinol) has a complex pharmacodynamics which we won’t discuss here because I want to be brief to the point and facilitate easy understanding of this vital component in Cosmetics. Used as a Topical retinol, it improves fine wrinkles associated with natural aging, by significantly inducing the cellular synthesis of glycosaminoglycan, which is known to retain substantial water, and increased collagen production. Vitamin A also promotes cellular respiratory processes including excretion of metabolites.

Vitamin A is most likely responsible for wrinkle effacement. With greater skin matrix synthesis, retinol-treated aged skin is more likely to withstand skin injury and ulcer formation along with improved appearance. Sources of Vitamin A include pharmaceutically manufactured Retinyl Acetate or Locally (home-based) extracted Retinyl Palmitate from Ripe Paw paw, Palm Oil etc.

Collagen: Collagen helps the skin cells renew and repair themselves. Collagen also plays a role in strengthening skin, as well as in elasticity and hydration. It should be noted that both the levels and quality of collagen affect the skin. Sources of Collagen can be commercially prepared plant extacts through Hydrolysis (i.e. lab-synthesis). Stimulation of collagen in the tissue cells underlying the skin can be achieved by black coffee extract which also increases hydration levels of the epidermal layer. The black coffee extract is actually an Alkaloid that stimulates fat degradation during lipolysis by inhibiting phosphoesterase activity with strong antioxidant activity, often protecting the skin against UV radiation and inhibiting the aging skin process. Caffeic Acid from the Coffee Extract can be used to treat skin infection such as Acne and Rosacea

Hyaluronic Acid: to start with, Hyaluronic acid (HA) is a polysaccharide found in the extracellular matrix of vertebrate epithelial, neural and connective tissues. It is therefore, a  substance that’s naturally found in our body, including the eyes, skin, and joints. It holds onto moisture and keeps tissues and joints lubricated.

Intrinsically, hyaluronic acid helps with soft tissue growth, prompts your body to make more collagen and elastin, keeps your skin moisturized, prevents tightness, boots elasticity, and reduces scarring. Hyaluronic acid is available from commercially synthesized endotoxin-free microorganisms such as Bacilli and Escherichia coli.

Other ingredients of concern in an anti-aging cream include Zinc Oxide that acts as a UV blocker and Vitamin C & E that act as strong anti-oxidants, effectively reducing the fine wrinkling that appear on fatigued face, aging skin and sickly individuals.

For those who can join our Lotion & Cream Classes, a newly introduced special Course Unit “Pharmacology & Physiology of Skin Actives in Cosmetic Formulations” will help the learner to understand in greater detail the Skin Aging Process in Old and Young People, Premature Aging, The role of contraceptives in Skin Aging Process, Endocrinology in Tissue Cell rejuvenation, Common Illnesses that induce premature skin aging and the cure, Nutrition and Skin Aging. The course will also address inter alia the issues of Special non-cosmetic skin preparations for aging skin among many more.

To book cosmetology classes, Please text us on WhatsApp +254 723 4242 40

For the starters, the heavy commitments that come in the form of Startup financing for equipment, space, time, and labor are always the cause of delays for what is deemed to be the brightest opportunity to sell your finished products

Over the years, we have been able to handle such burdens with ease, given our vast experience and expertise in manufacturing as well as teaching. Further, the Creams and Lotions are custom – made to suit the client’s requirements. We also guide the clients in terms of quality, texture and feel, color, perfume, Active Ingredients and shelf life of their products.

Have you felt that you can sell a product (if it is already packaged) and yet you do not have it? If yes, this is the opportunity for you to have your dreams fulfilled. We can handle quantities of your preference and once we make the bulk production, yours is just to put the Lotion or Cream in your preferred jars and sell them

For contract Manufacturing of Lotions and Creams, please do not hesitate to contact us on WhatsApp 0721264147 to negotiate on charges and other arrangements. We are also the contract manufacturers for clients like Vasson, AVI, Clario etc. Ask for the samples

The recent surge in the retail price of laundry bar soaps, thanks to the Ukraine War that has compounded the post-COVID-19 economic crisis, has led to consumer shift to alternative sources of cleaning agents: Detergents.

Detergents, by definition, are cleaning products that utilise surfactants as the principle ingredients. Detergents contrast sharply with soaps (Bathing, Laundry, Organic etc.) in that the latter are made up of oils (saponified oils) while the former are purely synthetic. Being synthetic in nature, detergents are made up of chemicals that are synthesised in laboratory, making their availability and affordability fairer when compared to oils (used in soap making)

It is noteworthy that about 99% of the laundry detergent (powder and liquid) ingredients share a vast industrial usage, further making their availability in the market a no-option. For example, Sodium Metasilicate, a flow agent that doubles as pH buffer is also found in engine degreasers, petrol (as a detergent and anti-corrosion agent etc.), while Sodium Carbonate has numerous industrial applications both in food and building (paints etc.) industry. Sodium Lauryl Ether sulphate has uses in Cosmetic (lotion and creams), Mouthwashes, Liquid Soap, etc. Those and many other examples build up a strong and an irrefutable case of co-usage of synthetic raw materials

With the current marked rise in the laundry soaps, the consumer is feeling the burden of regular use of the commodity that is touted as a ‘basic need’ and a shift in consumer preference for suitable alternatives can be seen from far. This accurately predicts that in the very near future, powder detergents will be the preferred alternatives for the bar soaps.

What this spells is that Detergent (especially powder) manufacturers are in for a big reap. This also serves as an encouragement for new industry entrants as the manufacturing of detergents carry the lowest risks compared to soaps. Also, the start-up capital is less demanding while the availability of raw material is 100% assured

The future of Laundry Bar Soap

Both post Covid-19 economic melt-down and the Russia-Ukraine combined factors have played a major role in the recent phenomenal rise in the soap commodity. But the return to normalcy, however long it may take will not influence the prices of soap to come down. This means that, with a rebound sustained supply of raw materials at normal global prices, the manufacturers of soap will make superfluous profits. If, for example, the palm oil will be retailing at 100 Shillings (from the current Ksh. 70) making a 1kg bar will, according to our calculations, cost Ksh. 95. The current average retail price for a 1 Kilogram Bar Soap is 215 Shillings. This is a whopping 100% profit for a medium scale manufacturer who has not enlisted the services of wholesalers and distributors who take about 15% of the total cost of production.

What it Means to Manufacturers-to-be

Wannabe manufacturers will agree with me that the market trends will favour them greatly. Plans to start early arrangements are

 

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One of the major huddles faced by newbie manufacturers for Paints and food products is Branding or printing the packaging material

After considering our trainees’ concern for Paint Buckets and metal Tins branding, we set out to find long lasting solutions to their predicament. Firstly, we should acknowledge that, Kenya, being a developing economy where multinationals have colonized domestic businesses, companies that offer packaging solutions such as plastic container manufacturing, metal tins, plastic bucket branding or printing etc. to such multinationals have focused on mass production, equitably edging out small scale producers who cannot afford huge seed capital to finance their branding. Where the small scale manufacturers of, say paint, are required to brand their plastic and Metal Tin containers, huge capital requirements overstretch their limits and, are forced to scale down their production. It is notable that, small scale paint and food manufacturers often brand their containers with printed self-adhesive label papers that are themselves very expensive and marred with waste, especially after the label paper wrinkles during mounting

In light of the above situation, we set out, firstly to identify potential businesses that can offer bucket and metal tin container printing. And to our surprise, only two companies, who, by coincidence, are plastic products manufactures, offer the container printing services. On enquiring whether they can do 10 or 20 buckets (label printing) they said the minimum they can print is 300 pieces per product. Obviously, their biggest customers are the giant paint manufacturers who place orders in their thousands, efficiently booking out many days of production. This means a small scale producer willing to engage their services will have to que for weeks waiting for their turn!

We never gave up. Our quest to see small business owners’ equitably represented in the service industry bore fruits.

Mehta Plastic & Metal Can Printers

Our long, tedious day long search came to a happy ending, after we found out that Mehta Plastic & Metal Can Printers are at Beck and call for the service to the small and developing paint industries. Their specialty, according to the C. E. O., is printing of 4 Liter and 20L plastic and Metal cans for all, regardless of the size of the enterprise. They have 4 outlets in Nairobi and actively engaged in printing cups, bottles, tomato Paste cans and even paint cans. According to their marketing manager, they have invested in top of the rage expensive, modern printing machinery with 0.01% error margin, high luminacy and high speed printing configurations. We agreed to refer many of our clients to them and in turn they assured us that they won’t discriminate our referrals.

Aren’t you sorted out now?

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The dynamism observed in the world of product manufacturing has sparked a keen interest among Kenyans whose curiosity has led to the discovery of few industrial training firms that offer entrepreneurial training and mentorship programs that can enable them try a hand in a handful of more complex product manufacturing.  

Specifically, medium industrial undertakings for more complex end products such as Foam Mattress manufacturing, Architectural and Automotive Paints, Animal Feeds, Plastic Technology, etc. have seen heightened interest by local small-scale investors who have approached us for the second opinion as well as reassurances of the success of such undertakings.

And not letting them down neither acting the motivational speakers, we have demonstrated to them that such skills can be acquired and implemented without fail, provided they can set aside a sizeable budget for the whole process, starting from training, raw material and machinery acquisition and official paperwork-in that order.

Newest Course

Our latest industrial training rollout is the Plastic Moulding & Injection Technology that is aimed at churning out few Plastic Tanks Manufactures as well as Roofing and Machinery Part design and fabrication.

With a well-laid curriculum of 140 pages on Plastic and Rubber Technology, with a bias on Polymer technology and by extension Molding and Injection Techniques, our learners will have a wide choice of products that they want to learn about without necessarily spending weeks on the whole curriculum. However, the basics in polymer chemistry will apply in all sub units.

The Future of Plastic Industry in Kenya

East Africa, being a circular economy has traditionally embraced Plastics as the ubiquitous workhorse material of the modern economy – combining unrivalled functional properties with low cost. According to a report by the World Economic Forum spearheaded by (Dominic Waughray Head of Public Private Partnership World Economic Forum), the use of plastics has increased twentyfold in the past half-century and is expected to double again in the next 20 years. Today nearly everyone, everywhere, every day comes into contact with plastics –and in Kenya, Uganda and Tanzania where water conservancy has become the culture, every household has a budget for the plastic water storage tank. Therefore, plastic tanks alone can afford a local medium scale manufacturer a platform to build wealth while serving the inhabitants of the country. Elsewhere, the packaging industry, furniture and roofing avails a sure bet for the local manufacturer.     

Raw Material Availability

Numerous Local and international firms dealing with importation of raw materials for the construction industry come in handy for local manufacturers who are capable of making bulk purchases. However, local material suppliers such as Betty Industrial Chemicals, B&K Holding Ltd etc. have come in handy for people whose budgets for manufacturing is low and therefore they can purchase the ingredients in small packaging.

Manufacturing of Rotoplastic Tanks    

Rotoplastics molding is flexible enough for both small, intricate products and large, complex assemblies, and while Part design and tooling costs are important, our unique delivery method in training guarantees no hitch, especially on the side of machine fabrication and local assembly for the more bigger complex finished products.

Team with us for more enquiries and guidance on the subject. Invest in knowledge as the first important step towards implementation of articulated economic undertakings that add value to family’s income generation activities.

 

Foaming in  Handwash

Foaming in products based on micellar solutions such as hand soap has considerable importance in various consumer products. It is considered aesthetical. Foaming liquid Hand soaps are more pricy and fetches the manufacturer over 600% profit margin

How do We make Foam Handwash?

Understanding the process and familiarising ourselves the key physicochemical and hydrodynamic factors which control the foaming process is very important from both scientific and practical viewpoints.

 Foamability of surfactant solutions, based on the processes of air entrapment and bubble coalescence

The hand wash’s foam volume increases when a newly entrapped air -during mechanical agitation or gas incorporation (via bubbling or from chemical reaction)- is unable to coalesce with the large air-water interface. On the opposite, the coalescence between entrapped air bubbles and this large interface removes the trapped air and keeps the foam volume low

Influence of Salt on Foam generation

The addition of salt to a foaming solution increases the rate of surfactant adsorption at the air-water interface and reduces electrostatic double layer repulsion between the surfactants as well as the surface tension. Herman our senior director and technical training says that, at this juncture, increased adsorption enables more surfactant molecules to trap air, thus increasing foamability.

Of importance to know is that The size of foam bubbles tends to depend on the concentrations of salt and the surfactant

 The stability of the foam in the presence of oil (dirty oly hands) is extensively addressed in the study and understanding of the co-efficient qualitatively entering, spreading and bridging

Team with our teaching staff for professional industrial training for the foam wash. Course takes 8 hrs of pure industrial chemistry theory and unlimited time for practicals.

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We all by now know and appreciate the importance of quality products as a tool of marketing in the overcrowded market, which also offers the biggest opportunities for specialized types of Hair Shampoos.

Quality control in manufacturing is paramount because it offers the consumer safety assurance and helps to ensure that the product looks and behaves the same from batch to batch.

However, challenges abound, especially in products whose part of the aesthetic features involve clarity and viscosity. The color tint also plays a crucial role in how consumers judge the quality of the product even before using it

Shampoo belongs to a class of liquid Detergents, just like its counterpart Handwash, Shower gels, multi purpose Detergents etc. These products use a common ingredient, Sodium Lauryl Ether Sulfate (SLES) which comes in two grades (35% & 70% Conc.). SLES, as we know it, exhibits natural polymeric properties that are initiated by reaction with sodium chloride (common Salt). It polymerises into a gelatinous substance (becomes a gel) and this improves the rheology (viscosity and flow properties).

Since the ‘swelling’ of SLES into a gel is through Ionic interference, the amount of salt used can result into over thickening or thinning. This calls for proper knowledge in Ionic balancing in viscosity control of Sodium Lauryl Ether Sulfate based Detergents, a course unit in our industrial chemistry and compounding techniques

Generally, shampoos must be viscous and clear, as the primary focus by the formulist. Color stability, Foam and lather generation comes second. These two properties can be a nightmare especially if one is compounding specialized shampoos.

What are specialized shampoos?

Specialized shampoos are Detergent systems formulated to perform a secondary role other than just cleansing. Examples of special shampoos include Two in one Shampoos, anti dandruff shampoos, clarifying shampoos etc. These shampoos use additives that may present solubility challenges for the manufacturers because they interfere with viscosity and clarity of the final product.

Understanding various solubilzers for such additives and their proper use will equip the Formulator with adequate knowledge in finding long lasting solutions to products with poor clarity and viscosity. For Example, an anti-dandruff shampoo (a standard product has 15 ingredients) may use salicylic acid as part of the additive ingredient (salicylic acid is a keratolytic agent). However, we know that once it is incorporated into the shampoo without a Suitable solubilzer, the shampoo developes phase dissociation (separates into 2 layers) and loses viscosity (partly due to pH imbalance). Therefore, identifying the best solubilzer that does not interfere with overall product formulation performance characteristics can help you achieve a world class standard product.

Specialty Shampoos are the game changer in the market that is already inundated with cheap hair Shampoo brands and these special products serve the larger customer bracket of high spenders.

Team with our able staff members to identify the area of your challenge and we shall offer impromptu assistance. You can reach us on WhatsApp +254723 42 42 40. You can also request our senior directors email address for further consultation. He’s currently overseeing the establishment of Internal Standards Committee for B & K HOLDINGS LTD, a national manufacturing corporate for assortment of industrial consumables.

According to 2020 Kenya Association Manufacturers’ report on Automobile Industry’s statistical report christened ‘Kenya Automobile Sector Profile‘ there are 3.16 million Motor vehicles registered in Kenya as at 2019. This translates to 6.6% of the human population occupancy, a big source of income for the sector’s service providers. Among the biggest beneficiary of this erstwhile lucrative market is the automobile repair kits manufacturers. Fuel dealers, and the spare parts importers top the list.

Speaking of body repair kit manufacturers, the automobile paint and Filler manufacturers smile all the way to the bank in enviable proportions. In this case, let us discus the Body Fillers business in Kenya.

Body Filler is one of the fast moving automotive repair products in Kenya, if the number of repair garages in every town is anything to go by. The few brands in the Kenyan market are manufactured by the multinational paint manufacturing corporates, however, a number of them are famous brands from Egypt, Germany and China.

Curious to know which body Filler most garages prefer, A car panel beating specialist in Kariobangi Light Industry, a Mr. Gerald once confided to me why Henkel, a German brand and a more expensive Mido, an Egyptian brand are most popular with panel beaters besides the Kenyan one Sweco. In his own words, he said that the three brands are easy to sand and more durable. Not far away, grogon, a popular car repair yard in the backstreet of the city with more than 40 garages, hundreds of kilograms of Filler putty are consumed daily. Hundreds of spare part shops lining this street stock all the 8 brands produced both locally and from outside . So, what makes Filler manufacturing business a worthwhile undertaking?

Ease of Manufacturing

Unlike paint that requires time running the mill and a little sophistication for specialized coatings, Body Filler needs a constant speed agitator, not specialized in any format but just a geared motor and stirrer blades. The process of compounding Filler putty is straightforward and minimal risks are involved.

Good Profitability

The automotive Filler putty is a well priced product. The average retail price of 4L can goes for Ksh. 1,500. The cost of producing the 4L, metallic tin included is Kshs. 880. This is if the raw materials are sourced at Wholesale prices. The actual price of the raw materials, with that of the Hardener included is 780 shillings. Overheads account for 6% of the initial cost of production. They cover labour, electricity, transport, rent and levies. Branded tin costs Ksh 85. Therefore, a producer is able to make close to 70% profits if he supplies his merchandise directly to the retail shops and 60% if he channels his product through distributors and wholesalers.

Low Initial Capital Investment

The limiting factor to many business startups is the capital and statutory demands. Not so with the body Filler. While an individual can manually mix up to 50kg, mechanized production may require use of simple electric stirrers with a capacity of mixing 50kg batch. These mechanical implements can be fabricated locally at a cost less than 30,000 shillings. This is according to a specialized construction equipment fabricator, Gilead Auto Machinery Workshop based in Kariobangi. Raw materials needed for a 50kg batch is 10,000. That is to say a 4L tin fits Raw material worth 800 Bob! It is noteworthy that all raw materials are available locally, with some mined locally from Kajiando District.

Ksh. 52k Daily Profits

A 50kg batch, mixable manually with a long wooden ladle, can produce twelve 4-Litre tins. Breaks in between, a well fed individual can run 5 batches in a single day. That’s about 62 tins worth 87,000 shillings. Assuming the manufacturer is selling 2 tins in every County daily, the daily factory production volume can be sold by the sunset. A 60% profits of the total daily sale volumes translates into 52,200 net worth income.

Getting Started

A wise way of venturing the market is to familiarize yourself with the environment and field of operation. Conducting a detailed survey, analyzing pros and cons, getting as much information as possible and getting a professional training and guidance, form adequate preparation for the challenge. As I noted earlier, the putty business does not need heavy capital investments, apart from the professional training or consultation with serious Consultancy Firms. Raising and setting aside 60k for the project is not risking too much for an undertaking that can turn around your family fortunes.

Overcoming Obvious Challenges

Since factory-branded tins may require capital commitment close to 100k, one can opt to purchase plain tins and brand them with printed labels. After all, the labels appearing in a well branded international brand from Egypt is a printed paper applied on the tin with a glue. You may not realize it unless you take a keen look at the tin! Lack training fee? Do not take shortcuts. Dealing with polymers is the trickiest part of the product manufacturing. Avoid Juakali considerations. Just purchase formulations from Cosmetics and Detergents Kenya Institute, Betty Industrial Chemicals Ltd or team up with a partner and purchase a book for Industrial Coatings formulations from accredited institutions.

The factory need not be formal. Start from the backyard of your rural home. You can also do it in your house provided children and expectant wife is not around.

Remember that KEBS certification is mandatory. It protects you and your customers. Plan for it and get help from consultants on how to manoeuvre through the process.

Important Advice

Remember that starting a business is a babystep process. Do not rush or anticipate to become a millionaire overnight. Nurture the newborn and seek advice from seniors. Do not do business as a revenge mission to outdo your former employer, or to overtake your agemates and business colleagues. Accept ups and downs as part of the learning curve. Always seek wisdom from God and walk a straight path. No short cuts. YOU WILL SUCCEED.

During a recent training of our most ardent client, who has so far learned over 9 products, she posed a question: Why do companies sell 5L shampoo at 250 Shillings…Is it not very cheap? My answer was yes. Hair Shampoo for Salons, usually sold in 5L gallons is among the few cheapest beauty care products in the market.

In sharp contrast, the same hair shampoo, usually sold in stylish 500ml bottles, sachets sell over 20 times costlier than the bulk 5L salon shampoo. For example, UNILEVER’S SUAVE Shampoo sells Ksh. 2,200 for a 800ml pack, while another brand TRESEMME sells their 828ml for 1,700 Shillings. Similar numerous high-end brands costing a tooth and nail can be spotted along Nairobi’s Dubois Road where we have over 2,000 shops stocking cosmetics

Few explanations can be fronted to satisfy the curiosity of this observation:

Consumer Satisfaction

Companies with a line of products in the market need to cash in from budget-conscious (low-end) consumeship albeit little net profits. This, they achieve by producing the lowest quality ever hair shampoos, provided they meet the KEBS’ mandatory minimum standards of 5% Active Matter. By this, it means that SLES, the mainstay functional ingredient in shampoos is utilised at its least amount of 7.2%. Co-surfactants that double as lather generators will be struck out of the formulation because they’re a value-adding ingredients. Therefore, this idea of getting the littlest of the poor spender’s coin is win-win situation since the customer will access the products and services while the manufacturer will gain, however little it will be

Maintenance Brand:

Companies will make cheap shampoos with very little net profits that cannot, on their own, support or maintain a functional industrial process. This, they do for various reasons: To provide continuity of their presence in the market. This has the advantage of creating market dominance. Secondly, the small net profits accrued from the shampoos they sell will take care of company overheads such as transport, electricity and oftentimes, rent.

Market Dominance

Big companies with moderately priced line of products in shopping malls, retail shops and supermarkets will want to be seen everywhere. This satisfies the ‘Dominance hierarchy’ psychology which is an animalistic behavioural expression of dominance. In our entrepreneurship lessons our learners get to understand that these dominance hierarchies can be despotic or linear. (Let’s leave this for another day). Now, with their low-priced Shampoo brands in the market, not only do they create presence all-over, but the little margin profits generated can be used to sustain that line of cheap products on their own independent accounts.

High Volume Sales Strategy

The high volume strategy allows a corporate to sell products in large volume quickly, relying on the smaller profit per item to add up due to volume. This strategy works perfectly if one’s product is relatively below the market price for similar competing items and you have a large inventory to sell.

The key with high volume sales is lowering the price (because your cost was low) to sell rapidly. For High Volume Sales strategy to work, your price needs to be below usual competitive pricing but include enough cushion so that you cover your costs and achieve profitability. Strangely, this is the practice that works very well with bigger corporates manufacturing fighter brands, e.g. Kibuyu Laundry Soap, Popcorn brand of Laundry soap etc. In some situations, fighter brands often have their lifespan and you don’t get to hear about them after some time (a story for another day)

Expensive Shampoos

While we have known the reasons why we have 5L shampoos going for Ksh. 250, often scaring and badly discouraging beginners of cottage industry, shouldn’t we explore why similar versions, or better, same products from same companies sell more as is the case with Unilever’s Suave brand or TRESEMME brand? Please save this number +25472342420 and send us a ‘Hi’ in order for us to send you full article alert.

 

The science of polymer reactivity and characterisation of paints is the mainstay in competitive manufacturing of paints-both Automotive and Architectural.

Our classes that last an average of 29 days enable the Trainee to understand how chemicals in Paint interact and behave in different combinations and proportions in order to bring the desired quality and performance of the paint. This is one aspect many manufacturers overlook and therefore, lack of basic understanding of the chemical reactivity will limit them in designing paint products with either better quality and performance or lower costing but better quality.

The Paint industry is awash with brands with a variety of different prices, performance and quality. This enables manufacturers of such paints compete favorably and survive in the market, especially with bigger companies preferring to have cheaper types of Paints as their fighter brands. However, it should not worry a small scale manufacturer given that in the face of stiff competition, the said small starter can vary his or her formulation to lower the costs and provide unmatchable competition with such low cost varieties.

Take for example the Matte Paint (variously going by the names Covermatt, VinyMatt etc.). The lowest costing 20L types go for Ksh. 2,500, while the highest quality goes for, 4000. A “clueless” manufacturer may find it difficult competing with the well educated manufacturer who makes the two types. But understanding the the formulation aspects of the two types of paint can enable one to design formulations with high binder capacity and low volume premium pigments. This is possible if the manufacturer understands the basics in pigment volume concentration, volume solids and sheen level adjustments. Therefore, Knowledge on basic polymer reactivity and characterisation of the different types of binders can help one manipulate and substitute the costly ingredients with cheaper ones while maintaining a better quality.

To reach us, kindly text us or call us on WhatsApp +254723 42 42 40. Books are also available for self training.

We have launched a new detailed and thoroughly revised 2121 edition of Paints and Coatings formulation manual that will offer local and international paint manufacturers a reference material for their manufacturing factories

The 120 page Manual is well edited with basic theory touching on introducing each paint in its rightful category, functions and their binder systems. The second part discusses the raw materials used in making paints in their rightful categories and grades and enables the paint manufacturer to understand quality attributes for each paint based on the raw materials, binder systems and Pigment Volume Concentrations as well as Volume solids.

The third chapter focuses on individual paint formulations for over 50 types categorized as Architectural, Motor vehicle coatings, Metal and wood surfaces. The chapter also incorporates Varnishes, Thinners and Fillers (Car repair body Filler, wood Filler, wall fillers and Hardeners. Further, Printing ink technology and formulations are featured as well as Adhesives.

Pigment Concentrates, very useful in Paint tinting is featured and the leaner is is updated on raw material sourcing, grading and use of the machinery. A free 22 page Business Plan on Architectural Paints manufacturing accompanies the book to help the owner of the manual to plan and strategize the paint factory set up, including sales projection and profits management.

Authorship

The 2021 Manual is co-authored by a team of top educationists, raw material importers, paint manufacturers and polymer chemists. The piece work in the manual has been edited and re-edited, with reviews on the accuracy in the formulary values as appears in some of selected local brands such as PolyPaint, DABCO, Dalwatt etc.

Aim of Publishing the Manual

As an educational institution, our main aim to publish the book is for educational purposes and promotion of local entrepreneurship, with focus to promoting local material stockists, mentoring of TOTs, entrenching professionalism in product manufacturing among cottage industry players and promoting local business entrepreneurship spirit among the local manufacturing enthusiasts

We hope the Manual will be a standard resource and reference book for students doing their thesis on industrial chemistry, local TVETs training on paint manufacturing and paint companies wanting to diversify their product portfolio.

Special thanks to all the collaborative team and particularly the directors of the Cosmetics and Detergents Kenya Ltd Institute

Machines are mechanical implements designed to take up tasks that humans do manually. Besides cutting down the cost of production and waste of human energy, machines go an extra mile optimizing finesse of the finished product.

Homogenizers

These machines are electric devices that stir or mix ingredients. They’re however, designed to rotate at both very high speed and very low speed (speed variable). Modern homogenizers are geared to increase torque (energy). The high torque helps in swirling high viscous materials such as pastes, Creams, soaps, colloidal products such as hair foods etc. without ceasing or breaking. Power consumption is lowest for geared motors because the mechanical advantages are achieved by the gears.

Since homogenizer machines can vary speeds during production, products needing high shear mixing such as emulsions, carbomer based products e.g. Hand sanitizers, hair gels and products needing low but constant speed such as grease, glues, etc. can all be done by the same machine.

Liquid Detergent systems such as Hair Shampoos, Handwash, multi purpose Detergents, Shower gels etc. often need initial high speed to disperse surfactants and lower speed during the second phase of mixing. During the last stage, these Detergent systems need lowest speed possible to avoid aeration or bubble formation. Homogenizers find home here.

Quality Homogenizer Machines

More often than not, the choice of machine to replace human labour needs forethought and thorough selection criteria.

Cheap is Expensive

Homogenizers that cost less come with a price attached while the most expensive ones come with financial burdens that may slacken funding and progress. As a good planner, choosing a middle priced machine can be likened to killing the proverbial two birds with one stone: Securing both future and immediate expenses.

Quality Work

A better competing product is the envy of every manufacturer and eye catcher to prospective customers. Suffice to say that, the texture of the final Detergent products, whether hand wash, Surface disinfectants, multi purpose liquid Detergents, etc. are defined by how well they are mixed. Some important ingredients such as EDTA, which we cannot do without, Salt which is used as an Ionic thickener and few other additives may pose initial solubility challenges. When a Homogenizer is employed in mixing the ingredients, the particle size reduction of these low-solubility ingredients can be enhanced by the shear dispersion force generated by the high speed rotations. In the final stages of mixing, low speed agitation encourages nucleation of bubbles formed by Anionic Surfactants. This ensures that less time will be taken to pass the product through the final stages of Quality control such as measuring the pH and pigment incorporation. Remember that pH stabilization is the third last procedure to making Detergents. After ensuring the pH is stable, color pigments and fragrances are next in that order. Assuming one used conventional stirrers or hand mixing, the settling of bubbles ( to allow the two last procedures) may take hours especially if the desired thickness of the product is above 2000cps. This delays processing and loss of time.

We recommend machines that add value to the work of the manufacturer. Pay keen attention to the nitty gritty details of the machines that you want them work for you, and don’t feel overburdened spending on them. It will eventually pay a thousand fold and save you money

Among the few challenges a local powder Detergent manufacturer is likely to face is sourcing of the color Speckles.

While it is likely to get NO local reliable source for the additive ingredient, many overseas dealers are willing to export it, but the cost and logistics complicate the process.

Few things can explain why nobody wants to sell the color Speckles. Firstly, the ingredient is very light and therefore bulky to handle. Secondly, it is cheap. For a manufacturer to realize good returns, they will look for a customer buying tons and tons. This huge bulk takes excess space and cargo transporters won’t ferry it at normal charges. It therefore becomes extremely expensive for the end user

Like any other product made from scratch, local cottage manufacturers can make the Speckles from the backyard of their home. It is plainly simple, convenient and affordable.

With locally available materials for the manufacture of the Speckles, it is a simple process, however, a small hand-operated machine for Extrusion of the Speckles will come in handy. The gadget can be sourced from Express Marine Engineering Corporation or Gilead Machinery

Team with us for the knowledge in making of the Speckles that will add colorful value to your powder Detergent. Our senior technician’s contact is +254723424240

Without over-emphasizing, the cleaning industry is the biggest consumer of Industrial consumables, after the food industry. Therefore, manufacturers find a haven of ready market for their products without breaking a sweat.

Not every cleaning product though promises good returns since the market is segmented through the stratum of dire needs.

The following categories of cleaning products are known to have the highest market consumption regardless of consumer buying power while at the same time serving as highest net income earners

Chlorine Bleach.

We all grew up using “Jik”, a brand that has not only dominated the laundry industry but has popularized the Culture of laundry bleaching and disinfection. Since the industrial revolution in Kenya came knocking, many brands in the same category have sprouted. The Juakali sector has caught up with the popular demand of the product that has seen chemical shops busy stocking and selling the raw materials used in making it. The numerous informal manufacturers of the bleach serve the neglected (and possibly the biggest) class of low income ‘afforders’- a group of consumers whose taste of quality comes last in light of the lower prices the backstreet concoctions fetch.

The high demand for the substandard, yet medium priced chlorine bleach is a positive economic indicator that the market is ripe and ready for more and more professional manufacturers of well branded products that serve the same purpose, irrigardless of the 4 major brands whose spirited advertising rule the media airwaves.

Cost of Production

Chlorine bleach, like many other industrial consumables, has a cost of production profile. Of importance is knowing that the net profits are way above 800%. E.g. Making a 5L of chlorine bleach costs anything between 30-40 shillings. The lowest priced is 500 shillings with an average cost of branded 750ml going for Ksh 150. Ready, stable market exists with learning institutions, hotels and middle income Estates.

Liquid Antiseptic

The advent of Corona Virus Disease has heightened the popularity of hygiene practice in boarding schools, which now serve as an emerging market for the product since most schools demand that each pupil reports with the 1L of dettol Antiseptic. Elsewhere, individual home users, hospitals serve as a continuity consumer. While the average cost of making 1L of the product is about Ksh. 300, the retail value is almost 5 times. Few professional brands like Dettol, Robert’s, Famarsi etc. have had blissful business for the past 18 months, thanks to the institutional demands and heightened hygiene needs. We have noted that part of the reason why we have very few manufacturers of the product is due to lack of manufacturing skills and awareness among Kenyans who like trying a hand on anything that promises quick income. The complexity surrounding the chemical characteristics of the product (forming a white cloud upon mixing with water) deters many would-be makers of the ‘Dettol’, who are, ironically, merchants of Detergents and soaps, fearing that once concocted the casual way of mixing multipurpose Detergents, it won’t produce the ouzo effect. Worthy of note is that 4 other brands joined the market recently after their manufacturers passed through our training Institute. One of them, a Mr. Theuri, whose brand we cannot reveal for professional ethics, is overstretched with supply of his Antiseptic brand to a number of boarding schools.

Toilet Cleaner

Over 88% of bedsitters have a toilet inside them. In a related feature story, we enumerated the cost of producing an equivalent of 500ml of a common brand in the market and stated that the profit margins are a good motivation for someone willing to make Ksh 100k per month from the comfort of his home.

Big brands like Harpic, Duck, Mongoose etc. are waking up to the fact that Juakali manufacturers are inching closer to their territory however, they are not bothered since their internal market surveillance systems have not sounded any alarms of market takeover (by Juakalists) in the next few decades.

Liquid Antiseptic Disinfectant

For the general information, Disinfectants and Antiseptics are two different products when it comes to individual formulation and use. Liquid Antiseptics such as Dettol are for use on skin and they form uzo effect (clouding in water). Disinfectants do not form cloud effects in water, and are used for sanitizing benches, floors, etc.

However, a new class (combo) of a product that performs both roles was invented by Reckitt Benckiser (the owners of,Dettol brand). The good news is that this combo does not necessarily have to form white cloud on water, making it a cheaper version of the original dettol disinfectant. Even the material for its manufacture are cheaper and user friendly to the manufacturer, with not special skills to mix them up. What is required by the new manufacturer is to learn the specifics in formulation and KEBS requirements for eventual certification.

Market for Antiseptic Disinfectants

A newfound market for the hybrid product, that occasionally spots the golden yellow color and the trademark Pine smell is in the hair Salons. Since coronavirus pandemic trimmed spending power for many people, Salons, which are frequented by majority of working class women, wealthy business ladies and men are increasingly finding its use as the alternative to Dettol. The cost of producing a 500ml fully packaged and branded product is Ksh 50. It is retailing at 150 shillings for the same amount.

Conclusion

One common thing with the discussed products is that they are very popular and fast moving, fetch high margin profits, do not require a space larger than a a standard bedsitter in Nairobi, have lowest cost of production and do not need advertisements since the ready market is already sensitized by the predecessors.

The cons is that special skills are needed to formulate a a stable, KEBS certifiable product. We at Cosmetics and Detergents Kenya Ltd Institute are dedicated in providing exceptionally highest industrial skills that enable the learner in designing own formulations that fit a particular budget needs for the target consumers without compromising the Kenya National Bureau of Standards. You can reach the chief trainer on this No. +254723424240