AN EDUCATIONAL TRIP TO SASINI COFFEE FACTORY REPORT

Introduction

Sasini is one of Kenyas major tea and coffee producers, and is one of the country's "Big 6" tea producers. The company's headquarters are located in Nairobi and the company's stock is listed on the Nairobi stock exchange. It is a member of the Sameer group of companies also located in Kenya. Their history begins in 1952, in what was then known as the Kenya Colony. Sasini was originally incorporated as Doondu Estates Ltd, with one coffee farm in Kiambu. They acquired three more coffee farms in Kiambu in 1959. The following year they went public. They therefore pride themselves as being one of the oldest firms to be listed on the stock market. On the threshold of the republic in 1964, they acquired a significant stake in Kipkebe Ltd in Sotik, Bomet District. This marked their entry into the tea sub-sector. By 1965 they had acquired 100% shareholding in the Kipkebe firm. They also continued to consolidate their position in the coffee arena by purchasing part of Mweiga Estate Ltd, in Nyeri. In the same year they adopted the name Sasini Tea and Coffee Ltd. To underscore their move toward diversification in investment portfolio, they changed the name to Sasini Ltd in 2007. Currently Sasini Ltd has implemented systems that improve the quality, quantity and value of their products for the future, in line with their strategic plan for the years 2004 to 2006. These plans will go a long way to ensure that their products remain right at the top in these important agricultural sectors. Through various wholly owned subsidiary companies their operations cover tea, coffee, dairy livestock, horticulture, tourism and export activities. These operations are spread all over the country. Tea is grown by a Sasini subsidiary, Kipkebe limited which operates two major CTC factories (Kipkebe and Keritor) serving four estates in Western Kenya, with a combined production capacity of over 8.5 million kilograms of tea annually. Tea is exported by Sasini to Egypt and the United Kingdom. Coffee The Companys coffee plantations are located at altitude in central Kenya with facilities in Kiambu District and Nyeri District. Sasini's Mweiga Estate in Nyeri District has an airstrip capable of transshipment of planeloads of not less than 5,700 bags of coffee. Sasini's timing and vast resources has made it possible for it to capitalize on the gross mismanagement by Kenya planters coffee union (K.P.C.U). Dairy and Horticulture Sasini's dairy division produces milk and flavored yogurts, as well as producing milk for sale to the food industry in general. Its horticulture division is growing, producing such vegetables as peas and corn. Retail coffee shops Sasini has recently started rolling out coffee shops in Nairobi, with aim to spread outside Kenya. This is seen as value addition for shareholders. COFFEE GROWING Sasini coffee estates are located on the scenic cool highlands of Central Kenya and forms part of the leading Kenyan coffee growers. The total acreage under coffee establishment for Sasini is 2300 acres (930Ha) distributed in Central Kenya and lies at an altitude range of 1630 1935

Meters above Sea Level. The annual average rainfall is 1000 1500mm. Several rivers whose sources are Mt. Kenya, the second highest mountain in Africa, and the Aberdare ridges irrigate the estates. Their coffee operations are the oldest in their line of business. Over the years, they have acquired a great deal of experience in coffee growing. They have continued producing quality coffee by ensuring that only the red ripe berries are picked from the trees, coming from the original coffee variety of SL. 28,(Scottish lab) French mission, SL. 34, K7 and Blue Mountain. These varieties were introduced into the country early in the 20th Century. With the benefit of good volcanic soil and sunshine they have maintained the fuller, redder and heavier quality than any other place. The main varieties include the SL (Scottish lab) and the ruiru11.the SL has low weight and vast root system compared to the ruiru 11.low sulphur fertilizer is used to improve the soil fertility in the coffee farms. Coffee picking is done by hand, by the employed labourers, when the berries are fully red. The picked coffee undergoes several steps before being processed, they include; Pulping; The coffee is left overnight in fermentation tanks. Pulping refers to the removal of the outer coating of the coffee berries. Constant supply of water is required during pulping. Grading channel; after pulping, the coffee is passed to a grading channel with a 2% gradient, to separate various grades of coffee based on their weights as they pass through the channel. The main grades of coffee processed in Sasini are; AA, AB, C, PB, TT, T, E, MH, ML, and SB. Drying; the beans are dried mainly in the sun (sun drying).the UV reaction with the content of coffee beans results in high quality of coffee. However, mechanical driers are used, but less often, since these driers require large amount of tonnes of coffee daily which cannot be met. These driers are the Wilken skin driers, which use kerosene or diesel as source of energy hence an expensive mode of drying. These skin driers remove water by convective method, (hot air is the drying agent). Drum driers are also used, they can dry up to 3.5 tonnes of coffee daily, and often the temperature is controlled electronically. Roasting; when the coffee beans are fully dry to a moisture content of 10.5-11%, the green beans are roasted in a coffee roaster and cooled to room temperature by motors which suck atmospheric air, and pass over the coffee beans. Instant coffee can be produced at this stage and packed. MILLING The roasted product is packed in sacks and transported to the main processing factory. Weighing is done at the weigh bridge and the weight of the product obtained after subtracting the tare weight of the vehicle. Sasini factory also processes coffee for farmers willing to supply it. However the farmer must be registered, has a movement permit, weigh bridge ticket and must make a booking at the factory. The coffee beans waiting processing are stored in designated bays and rows, for easy identification of the suppliers and avoid mixing varieties. The store is highly ventilated and the roof is such that theres enough light inside it. Milling is done through the following chambers in order;

1. Pre-cleaner; this is where the beans are cleaned of any dust or other foreign matter. This ensures that high quality is achieved at the end product. They are fitted with dual aspiration system. Light impurities are removed at inlet and before discharge and are collected in the aspiration chamber. After passing through pre- aspiration the material falls on vibrating deck. Big impurities such as clay lumps and bags material are removed. The material then falls on the second screen where the fine powder like small impurities are removed along with broken coffee beans the material then falls into the aspiration chamber where again the light impurities are removed. The magnet fitted removes all the ferrous impurities. The mill is fitted with blower and cyclone for collection of fine impurities. 2. De-stoner; the most important part of the destoner is the deck, because it is the main separating surface. It consists of carefully constructed wooden frame to counteract false vibrations with a screen or cloth over cover that is the surface on which the separation takes place. What occurs on a destoners stoner deck is that compressed air is forced through the mesh of the deck cover lifts the lighter particles upward, while the heavier particles sink against the air currents and come to rest on the deck surface, providing the air is properly adjusted. The heavier particles are forced to travel uphill by mechanical action, while lighter particles float downhill on a film of air, in these case the coffee beans is separated from foreign matter. 3. Huller and polisher; this chamber determines the size of the mill. It can process 4-6 tonnes of coffee per hour. It is made up of two compartments for hulling and polishing. Hulling involves the removal of husks while polishing helps to bring forth the beautiful deep colour of the coffee beans. This chamber is ideal for treating both dry parchment and cherry coffee of any kind. The huller special feature is the fluted broad hulling cheeks, and completed by friction under pressure of the coffee inside the cylinder, in this manner polishing effect is also achieved. The rotating roller inside the cylinder is equipped with exchangeable conveying and hulling ribs made of tool steel, and arranged in an oblique pattern. Coffee is squeezed by friction hence forming a thin layer of oil to preserve its contents. 4. Graders; this is used to grade coffee by virtue of their size. It is a double- decked chamber consisting of several sections with different perforations or sieves. The various grades drop into corresponding partitioned bins with outlet slides. These sieves are kept clean by fitted brushes. This is where the different grades are achieved. 5. Bins; the different grades from the graders are achieved they are passed onto the bins then to the conveyors which carry them to the bucket elevators. 6. Bucket elevator; this is a mechanism for hauling flow able bulk materials vertically. It consists of buckets to contain the material, a belt to drive to carry the buckets and transmit the pull.These elevators carry the coffee into the gravity separator.
7. Gravity separator; The term gravity separator is a contraction of the proper name specific gravity separator which means a separator of particles differing in their specific gravities. All gravity separators have five variable adjustments that must be properly adjusted and balanced to obtain optimum separations these are: feed rate, end raise, side tilt, eccentric speed, and air control. The feed rate control is located on the feeder and governs the amount fed onto the separating deck. For optimum separation, the feed rate should be as low as possible without falling below the minimum federate at which the deck can be kept completely covered. End raise is the slope from the free end of the deck to the discharge end. Side tilt is the difference in

elevation between the high side of the deck and the low side of the deck. Eccentric speed and side tilt are closely related. Increasing eccentric speed will cause material to be shifted toward the high side of the deck. Air regulation is the most important adjustment to be made in a gravity separator. All gravity separators use air as a standard reference medium rather than water, the relative difference between particles of differing weights is increased. For this reason a gravity separator is a very sensitive machine and when operated correctly, can produce very precise separation. 8. Grade mixing; this is where blending of the different grades is done to achieve different flavours. After this done the coffee is weighed in a weighing scale and packed in sacks and stored. Storage; after mixing, the packing is done in 60kilograms sacks, an international mode of packing. A clean coffee store must be well ventilated with a uniform air flow rate, a water proof floor; normally the foundation should be 1.2 metres high. QUALITY CONTROL The varieties of coffee, that is AA, AB, C, PB, TT, T, E, MH, ML, SB, are tested by an experienced liquorer or taster. The main things tasted include, acidity, body (viscosity, aroma) and the flavor or the after taste. Here, a small huller is used to grind the green beans based on classification after roasting. Tasting is normally done in the morning based on experience. The grade AB is the medium of main tasting of the other grades. The PB grade has a high level of acidity and is normally produced from monocot seeds. The TT grade is from lighter beans and is separated from the AA grade in the gravity separator. The E grade is huge but has little flavour. The AA grade is the most valuable grade. A liquorer must be person who neither drinks nor smokes and must be certified by the coffee board of Kenya to become a liquorer.

Through the years, Sasini has continued to be a major contributor to the growth of the Kenyan economy and they endeavor to continue in this trend. Currently they directly and indirectly employ over 5,000 employees. Sasini also has major interests in the tourism sector and is part owner of the Aberdare Country Club and the Ark, two of Kenyas premier tourist attractions located on the Aberdare Ridges in the Mt. Kenya region. Coffee is still Kenyas major foreign exchange earner. REFERENCES www.google.com Sasinis website.

Jomo Kenyatta University of Agriculture and Technology College: Engineering and technology School: Mechanical, manufacturing and materials Department: Biomechanical & environmental engineering Course; Biomechanical & processing engineering Unit: Drying of biological materials Code: ABE 2306 Title: Report on trip to Sasini coffee factory 1/11/2010 Name: Rotich Vincent Reg no: AG211-0006/06 Lecturer: Mr. E. Ronoh