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 .. ',-:
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2 / L/-SS
MALAWI INDUSTRIAL RESEARCH AND
TECHNOLOGY DEVELOPMENT CENTRE
P.O. Box 357, B/1111~ Malawi Td: 623 805 Fax: 623 831

SALT TECHNOLOGY
DEVELOPMENT

DP/MLW/88t033 - ESTABLISHMENT OF AN INDUSTRIAL

RESEARCH AND TECHNOLOGY DEVELOPMENT CENTRE

FINAL REPORT

K. KAFATIA SEPTEMBER 1995

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I I I I I I II
INDEX
SECTION DESCRIPTION PAGES

1.0 SCOPE 1

PART A - SALT TECHNOLOGY

DEVELOPMENT 1

2.0 BACKGROUND 1

3.0 METHODOLOGY 1

3.1 Community Participation 1

3.2 Salt Harvest
2
3.3 Salt Extraction 2
3.4 Sources of Energy 2
3.5 Material Storage 3
3.6 Market Study 3
3.7 Laboratory Tests 4
4.0 RESULTS AND DISCUSSIONS 4

4.1 Community Participation 4

4.2 Salt Harvesting 4
4.3 Salt Extraction 4
4.4 Sources of Energy 5
4.5 Solar Still 5

5.C SUMMARY AND RECOMMENDATIONS 5

INDEX
SECTION DESCRIPTION PAGES

PART B - DESIGN FOR A 60 TONNE

SALT PER ANNUM PILOT PLANT 6

6.0 PRINCIPAL ASSUMPTIONS 6

6.1 Capital Budget 6

6.2 Revenue 6
6.3 Process Technology 6
6.4 The Product 7
6.5 Waste Disposal 7
6.6 Plant capacity 7
6.7 Staff 7

7.0 PROCESS CALCULATIONS 8

7.1 Salt Harvesting 8

7.2 Solar Still Performance 8
7.3 Number of Filters required 9
7.4 Number of Filtrations required 9

8.0 BUDGET CA LC ULA TIONS 10

8.1 Fixed Capital 10
8.2 Working Capital 11

II
1.0 SCOPE

This is the final report of the Salt Technology Development Project. The project
was carried out by the Malawi Industrial Research and Technology
Development Centre (MIRTDC) with the financial support from the United
Nations Industrial Development Organisation (UNIDO).

Part A of the report presents the results of the project which was conducted
in Chigweshe Village, Chikwawa District, during 1994/95. Part B gives a
proposal for a pilot plant designed to produce 60 tonnes of salt per annum
based on the developed technology.

PART A - SALT TECHNOLOGY DEVELOPMENT

2.0 BACKGROUND

The project was initiated in October 1994 after the signing of a contract
between UNIDO and MIRTDC. Under this contract. UNIDO provided funds for
rhe project whose scope of the contracting activities was as follows:

1- Fabrication of an improved salt extractor and the demonstration of its

use.

2- Development and demonstration of controlled salt harvesting techniques.

3- Design and construction of a solar still and a preliminary study of its

performance

4- Investigation of appropriate sources of energy

5- Study of material storage structures

6- Chemical analysis

7- Product marketing

3.0 METHODOLOGY

3.1 Communitv Particioation

The salt technology development project was designed for high

community participation in order to ensure maximum benefit to the
people of Chigweshe village. These people have been producing low

1
 grade salt through traditional methods since early eighties (see
photographs 1-3). The project therefore, focusses at improving the
indigenous methods in order to enhance the income generating capacity
of those already engaged or interested in the salt production activity.
In line with this thinking, a team of six traditional salt producers was
identified through meetings held with the villagers. This team was used
for the project activities.

3.2 Salt Harvesting

A twenty meter square area was identified and protected from people,
animals and wind by fencing with reeds. This area was used for
controlled salt harvesting.

The soil in the protected area was carefully observed and areas of high
salt concentration (identified by the conspicuous grey colour) were
scraped. The scraped soil was weighed and the area where it was
scraped from measured.

3.3 ~alt Extraction

An improved salt extractor was fabricated from timber and hessian cloth
(see drawing No. 1-3 and photograph 4).

Special features of the extractor were a two stage filtration system and
the use of sand as an additional filtering medium in the secondary (final)
filter. The minimum thickness for the sand, which was washed clean
before being used was 50 mm. The sand weighed approximately 40 kg
per charge.

The filters were filled with weighed amounts of salt soil. Water, in the
ratio of 2 kilograms of soil for every litre of water, was added to the soil
and allowed to percolate through. At the end of filtration, the amount
of filtrate was measured.

3.4 Sources of Energy

Sources of energy investigated inr.luded firewood, solar and biogas.

Visits were made to surrounding areas to locate sources of firewood.

Two temporary solar stills of 4050 mm by 3600 mm and 4050 mm by

1800 mm were constructed using bricks, cement, timber and plastic
sheets (see drawing No. 4 and photographs 6-8).

2
•

The floor of the still was constructed of hard core and cement screed.
A black polythene sheet was laid on the floor to absorb the solar
radiation for brine evaporation. 150 mm high walls were constructed
around the floor, using bricks, to form a trough to hold the brine as it
evaporated for crystallization. The trough was plastered inside with
cement mortar.

A roof was constructed over the trough using tr?nslucent plastic

sheeting supported on a timber structure. A trap door was provided for
salt removal.

Before charging the solar still, the filtrate was boiled for approximately
thirty minutes to facilitate the removal of scum and other impurities.
Small amounts of water treatment grade Aluminium Sulphate (half a
teaspoonful per 80 litres) were added to enhance flocculation and
sedimentction.

The boiled filtrate was p~ured into the still and the initial filtrate
temperature and fill level recorded. Temperatures and liquid levels were
recorded daily at selected times. Daily ambient temperatures were also
recorded (see Table 1 and 2 for typical data).

An estimate was made for the number oi cattle available in Chigweshe

village to support a biogas plant. This was done through selected
interviews with cattle owners and other people. A six cubic meter
biogas digester is currently under construction.

3.5 Material Storage

Material storage structures were investigated. Places where bricks,

sand, stone and fiber-cement roofing sheets could be obtained were
identified and visited within a distance of thirty kilometres of the project
site.

3.6 Market Study

A marketing study was conducted by the Technology Assessment and

Transfer Department cf the Centre. A report is included in appendix 1.

3.7 laboratory Tests

The Malawi Bureau of Standards conducted chemical tests for the salt.
Results are given in appendix 2.

3
 4.0 RESULTS AND DISCUSSION

4.1 Community Particioation

Community participation was highly successful in this project. The main

reason being that the participants acknowledged the fact that they
would benefit directly from the results of the technology development
project.

The project started with six people (three men and three women; see
photograph 4-5). Others joined in as the solar technology became more
promising. The number increased to seven women and five men by the
time of writing this report. More people are showing interest. It is
anticipated that the group will grow larger after the biogas plant starts
operating.

4.2 Salt Harvesting

Controlled salt harvesting was affected by drought. However, the study

established that amounts of salt ranging from 2. 7 to 11 . 1 kg could be
recovered from 100 kg of soil. The wide variation in these figures is
explained in part by non uniformity in soil mo~sture content and texture.
Earlier studies and laboratory tests by Malawi Bureau of Standards report
salt concentration levels of 10 percent.

The amount of salt soil scraped from withir. the controlled area ranged
2
from 13 to 27 kg/m with an average value of 22. Typical results of
salt harvesting are shown in tabh::s 3 and 4. The wide range in the
results may again be explained by the difference in capillary rise by the
salt water from the ground due to variations in soil type texture and
moisture content.

4.3 Salt Extraction

The improved salt extractor worked very well; improving the

concentration of salt in the saline solution by at least 100%. Hence
from the traditionally achievable 10% salt solution concentration, the
new filters produced solutions whose concentration ranged from 20 to
32% m/m. This was mainly due to the double filtration (counter-current)
principle introduced.

4.4 Sources of Energy

Firewood is not available within Chigweshe village and very scarce in the
neighbouring areas due to severe deforestation. The small amounts of
firewood that were found were very expensive. Prices were turther

I
 inflated due to high costs to transport the firewood on bicycles over
distances generally not less than thirty kilometres.

Chigweshe village has abundant cattle which provide large amounts of

cow dung to support biogas plants. It is estimated that there are more
than 2000 cattle.

4.5 Solar Still

Salt of high purity (consumption grade) was produced by solar

evaporation. Chemical analysis by the Malawi Bureau of Standards
supported this (see Appendix 2).

5.0 CONCLUSIONS AND RECOMMENDATIONS

The work done so far has proved that it is possible to produce better quality
salt at higher yields using the improved filtration process. It has also shown
that solar energy can be utilised to produce better quality salt and that in doing
so, problems of deforestation and severe shortages of fuel for making salt will
be overcome. Most important it has been demonstrated that it is possible to
produce more and high quality salt while maintaining low levels of technology
sophistication in order to ensure that the villagers benefit directly.

Arising from the study therefore, it is recommended that the salt making
process be scaled up into a larger pilot plant combining the tested unit
processes of filtration, boiling and evaporation.

The following section of the report therefore gives details of a proposed pilot
plant with a scaled-up production capacity of at least one tonne of salt per
week.

The development of this pilot plant combining all the processes together will
form the basis for the transfer of the technology to other districts and areas in
Malawi where saline soils or brine solutions exist. Some of these areas are
around Lake Chirwa, in Chikwawa, Mzimba and Kasungu Districts. The
transfer of the technology to other parts of Malawi will gradually substitute salt
imports and provide sources of income to many Malawians.

5
 PART B - DESIGN FOR A 60 TONNE SALT PER ANNUM PILOT PLANT

6.0 PRINCIPAL ASSUMPTIONS

6.1 Capital Budget

The capital budget has been based on a plant producing 60 tonnes of

salt and operating for 300 days per annum. It assumes the plant would
be integrated with a biogas digester which will provide the energy for
boiling the salt solution to remove scum (impurities) before charging the
solar still. The biogas plant is currently under construction through
assistance from the Ministry of Women and Children Affairs.

The budget also includes a batch salt iodisation machine capable of

processing up to 60 kilograms of salt per batch and up to 2000
kilograms salt per hour.

The budget is reasonably accurate with respect to the process elements.

However, it has been necessary to provide lump sums for items which
can be more accurately estimated for once firm indications for funding
are obtained. This is necessary because of the continuously rising costs
of materials and transport.

6.2 Revenue

Calculation of revenue has been based on the current price of K5.90 per
kg for imported salt. Indicative cash flows are shown in tables 5 and 6.

6.3 Process Technology

The process on which the budget is based comprises three stages.

The first stage is simple filtration. The second stage is boiling the filtrate
for 30 minutes or less in order to remove scum and impuritiP.s. Small
amounts of aluminium sulphate will be added to enhance the removal of
impurities. The final stage is the solar evaporation of water to crystallize
the salt. lodization will be necessary for the high grade salt for
consumption.

For boiling the solution, biogas will be used and a 6m:i digrJster is already
under construction.

Solar evaporation and crystallization will be done using solar stills made
of wood and glass for rig her durability and efficiency.
 The process technology chosen is very simple. This was done in order
to keep production at cottage level to benefit the poor people directly.

The project is to be considered a pilot project from which .1erification of

process parameters will continue. Thereafter, technology dissemination
will take place to other districts of Malawi which have saline soils or
brines.

6.4 The Product

Two grades of salt will be producP.d. These will be the grade suitable
for human consumption, and that for industrial use. The calculations
assume the prices for the two products to be the same.

6.5 Waste Disposal

Attempts will be made to find suitable waste disposal methods

6.6 Plant Capacity

The design is for initial production of 1 tonne per week (60 tonnes per
annum) which represents approximately 0.2% per cent of the imported
salt at 1 994 import quantity. This is indeed a very small proportion of
the national salt demand. Product quantities will become significant
once the t&chnology spreads to other potential areas of salt production.

The production capacity can easily be increased by uprating the units of

the plant or by constructing additional parallel units.

6.7 Staff

Staff costs are for temporary staff who will be employed for a period of
not more than 3 years after which they may be absorbed by the project
or laid off. Direct labour will be provided by the people who wlll work
as a co-operative. ThP. product will be sold by th~ co-operative for their
sustenance and operating costs.

7 .0 PROCESS CALCULATIONS

7. 1 Salt Harvesting

From salt harvesting:

1 m 2 of ground gives 27 kg salt soil.

7
 From solar still results

27 kg of soil gives 0. 72 kg of salt

Therefore to produce 1 tonne (ie 1 000 kg) of salt per week, amount of
soil required is:

37.5 tonne

Ground area required:

Since 1 m 2 of ground gives 27 kg of soil and the same gives 0. 72

kg of salt,

1 389 m 2 of ground is required for 1 tonne of salt

i.e. an area of approximately 37 m x 37 m

However, the salt regenerates.

7 .2 Solar Still Performance

22 kg salt was produced from a 4.6 m 2 solar still in 14 days.

i.e. 0.34 kg Salt produced per square meter per day.

or 1 . 71 kg salt produced per square meter per week of five days

To produce 1 tonne of salt per week, the area of solar still required, m 2 ,
is:
m2 == ( 1 000 kg) m2 == 585 m2
(1.71 kg)

i.e. a still of 24 m x 24 m

or 39 stills of 1.5 m x 10 m covering 585 m 2

7 .3 Number of Filters Required:

From filtration results:

Average filtrate produced per day = 70 litres

Average salt produced per litre filtrate = 0.20 kg.

8
 70 litres of filtrate will have:

70 Ix 0.20 kg = 14 kg salt
1I

1 tonne of salt will comP. from 1 000 kg x 70 I

14 kg
i.e. 5 000 I filtrate

7 .4 Number 'lf filtrations required for this amount of filtrate is:

5 000 = 71 per week of five days

70

i.e. 15 filtrations to be done per day

One filter takes 8 to 10 hours to produce 70 litres

Therefore 15 filters are required

9
8.0 BUDGET CALCULATIONS

8.1 Fixed Capital

Batch lodization Plant

Available through UNICEF, a rotary salt

iodization machine, capable of processing
60 kg salt per charge. The machine can
iodize 600 to 2 000 kg salt per hour.
Powered by 5HP petrol engine or a
diesel Gen Set.
MK

US$ 2 000 31 000

Diesel Gen set 5KVA

(EX-UNICEF) US$ 4 000 62 000

lnstal!ation sum 10 000

Quality Control equipme:lt

(EX UNICEF) US$ 368.67 6 000

Motor Vehicle (Pick/up) 400 000

Buildings

Working area 30 000

Storage shed 50 000

Office/Toilets 60 000

Equipment shed (see 8.1) 30 000

Filters 1 5 x 1000 15 000

Solar stills 40 x 5000 200 000

Total Fixed Capital MK 894 000

NOTE: US'$1 = MK15

10
8.2 Working capital
MK

Wages for six months (500 x 6 x 10) 30 000

2 supervisors ( 1000 x 6 x 2) 12 000

Replacement glass (sum) 5 000

Timber and nails (sum) 4 500

Process material

Soil @ K1O/tonne soil (three months) 4 320

One month's product (stock) 5 900

Al 2 S0 4 @ K25/tonne salt 380

(three months)

Tools & Equipment (three months) 10 000

Fuel (three months) 10 000

Other (Paint, Plat•~s Sacks etc) 10 000

(three months)

Total workin9 capital 92100

TOTAL WORKING CAPITAL PLUS

FIXED CAPITAL MK 986 100

11
BIBLIOGRAPHY

1 J A Sonia, 1985 Salt Project Report No. 1

2 MIDAS Consulting ltd Salt Mining at Chikwawa

3 Intermediate Technology
Publications, i 992 Energy Options

4 IDRC TS8E Compost, Fertilizer and Biogas

Production from Wastes in the Republic
of China.
5 World Bank & Indian
Institute of Technology Solar Distillation. A practical study of
a Wide Range of stills and their
designs.

12
 ..

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PHOTOGRAPH 1. TRADITIONAL SALT Fil TER
WOODEii Fil H<ATE COLLECTOR SHOWN UNDER TlfE FILTER BETWEEN
THE TWO POLES TO THE FAR RIGliT OF THE FIL HR
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PHOTOGRAPH 2. BOILING THE SOLUTION

THE LAOY IS StlOWN , SCOOPING SOME SALT CRYS TA LS

POORQUAUn
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ORIGINAL

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· FOUR . FILTER· COMPARTMENTS StlOWU

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PHOTOGRAPH 4.
AN IMPROVED SALT EXTRACTOR
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PHOTOGRAPH ';: PART or TH[ T£CHNOLOGY R£C[PJ[NT GROUP

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APPENDIX 1

MALAWI INDUSTRIAL RESEARCH AND TECHNOLOGY

DEVELOPMENT CENTRE

•
'"

MARKET RESEARCH REPORT FOR SALT PROJECT

PREPARED BY
JR KAMANGA

RESEARCH OFFICER (MARKETING)

TAT DEPARTMENT

DATE
SEPTEMBER 1995
1 INTRODUCTION

The project is carried out at Chigweshe Village, T/A Ngabu, Chikwawa District.
It is located in the outskir~s of Nchalo Trading Centre within one kilometre to the
South of the Sugar Corporation. Access road to the village is from Nchalo Trading
Centre. The main product of the project is salt which is produced at cottage
industrial level using solar and biogas energies. The production process is
currently being operated by a functional group of seven people who have been
imparted with local technological production processes by Malawi Industrial
Research and Technology Development Centre so as to improve the quality of salt
such that it complies with local standards. In view of complementing the technical
support given to the functional group, a market research for the product was
undertaken by Mr J R Kamanga under the supervision of Mr S Kachale.
I
2 BACKGROUND TO SALT MINING AT CHIGWESHE

It is believed that Chigweshe Village has for a long time been regarded as a sacred
place due to the existence of salt soil which was thought to be a divine
concession to the area. Historically, the area is reknowed for offerings which
tribesmen made to their gods to plead for rains, death, misfortune etc. In view of
this, the soil was left untouched.

With the passage of time, the tribesmen gradually developed an interest in the
extraction of salt in smaller quantities for home consumption. This was
rationalised as consumption of divine soil for the purification of the body.

Through the 1970s to th~ end ot the decade, saw the immigration of people into
the village after having perceived the commercial potential of salt. Chigweshe
Village, originally with a population of less than 200 became gradually flooded
with over 500 families who sought a piece of land where they could undertake
salt mining.

It is worthy reporting that the history of the occurrence of geological salt cannot
be remembered clearly although there is evidence that it '1as been the subject of
oral tradition for more than 80 years. It can therefore be said that the exact
history of salt eruption is estimated from time immemorial.

2
3 OBJECTIVE

The objective behind the market survey was to assess the product market share
as well as establishing onto the village the pricing strategies for the product so as
to penetrate into the market. The identification and assessment of the product
market will be based on both industrial and domestic usage.

4 METHODOLOGY

The survey was carried out as per the underlisted:

Analysis of the Business environment and target market.

Assess the existing channels of distribution.

Assessment and analysis of competitors.

Quantification of annual data on supply and prices and ascertain current and
future demand.

Computation of opportunities and threats of the project.

5.0 MARKET & MARKETING ASPECTS

5. 1 Demand Analysis

Salt is ~sed for domestic as well as ir.dustrial applications. At the domestic

level, salt is used to almost every dish which it is applied during cooking or
on the table. It is also used in the preservation of food such as fish or
meat. Further to the highlighted uses, :t is generally applied to traditional
herb medicines. Following to this domestic use, c!emand analysis for the
product has been derived on the locational basis and based on the
population of Chigweshe Village, Ngabu Traditional Authority and other
neighbouring villages such as Makhuwira Traditional Authority and part of
Nsanje District. The highlighted places register the total population of
149,862 with an average growth rate of 4. 7% per annum and this
ascertains the strength of the immediate local market. However, it is of
worth noting that it is somehow difficl'lt to quantify the level of demand
based on the population statistics as the cons~1mption pattern per an
individual during a specific period of time is not uniform. On an estimation
basis, holding all other factors constant, an individual annual salt
consumption is estimated at 4 kg and this put the quantity demanded by
the market of 3,644 people of Chigweshe Village at 14.6 to:ines while with

3
 the inclusion of the neighbouring villages that register a population of
149,862 put an annual consumption at 599 tonnes.

As rP.gards to industrial usage, below is a highlight of potential consumers:-

Lever Brothers = 50 tonnes per month

(600 t/annum)

Cold Storage = 20 tonnes per month

(240 t/annum)

l.irangwe Women
Working Group = 20 kg per month
(0.24 t/annum)

MACOHA (Tie and

Die Centre) = 250 kg per month
(3 t/annum)

Total annual demand for the product is 1 442.24 tonnes. This demand will
be increasing annually due to the increase in population as well as economic
activities which are now moving from Agro to manufacturing.

4.2 Market Size and Projections

The historical salt imports statistics published in the statement of Externa!

Trade by the National Statistical Office in Zomba, showed the following
import figures:-

Year Ouantit'{ (tonnes) Value CKwachaJ

1989 24 445.93 10 259 692

1990 21 883.00 9 950 044

1991 22 977.15 10 400 000

1992 14 566.47 4 394 200

1993 21 120.70 8 000 000

1994 39 268.00 15 158 040

4
 The import figures shew the potentiality of the marl<..et size and thereforr-
the prospects of getting a market share are very high though the sites
inspected were all small and probably would not contain sufficient reserves
to produce the volume of salt necessary to significantly reduce the
importation of salt.

It is a worthy noting that from 1989 to 1994, importation of salt has

increased by 60.63% due to an increase in population and economic
activities. In view of this rising trend it is therefore predicted that import
of salt will continue to rise at not less than 10% per annJm.

Currently salt production by the functional group is at an average of 1 5 kg

per day which is 2.52 tonnes per month. This puts annual production at
30.2 tonnes with the assumption that all other factors are held constant.
This shows that there is 15.6 tonres in excess of the demand by thk village
but a shortfall of 568.8 tonnes if taken into account the demand of the
neighbouring locations.

As regards to industrial usage, to meet Lever Brothers' demand for the

product, the current production capacity needs to be increased by 20 times.

4.3 Product

The produced salt is course and compares favourably with imported one.
It has undergone quality improvement such that moisture content has been
reduced to standard level of 2.3% m/m while that of MBS specification,
required maximum moisture content is 4.0% m/m, and this makes it look
more whiter than it used to be. As regards to insoluble residues, the
sample registers a figure of 0.4% m/m while the required maximum
standard is 0.2% m/m. In view of this therefore, it can be said that the
product has attained the standard 'eye and oral appeal' where it meets the
needs and preferences of the customers. This has been evidenced by the
comments put forward by the visited customers during the market research.

The salt as produced at Chigweshe is not iodised. There is a legal

requirement in Malawi that salt intended for human consumption should be
iodised. The salt produced at Chigweshe should te sold to iodisation plants
if it is to be used for human consumption. Otherwise it is suitable for
industrial use.

5
4.4 Pricing Policy for the Product

The market for the product is not price controlled. The price is determined
by market forces of demand and supply. Currently. the product is sold at
a ruling market price of K3.30 per kg while imported salt is sold at a ruling
market price of K5.90 per kg. During the period of high product supply. the
product price tends to go down and picks up during low supply. With the
objective of penetrating the market. it is necessary to use a price
penetration strategy where the sale price should be lower than the ruling
price of the competing product.

Based on the existing project inputs. the break even price of the product is
K 1 . 5 7 /kg on the assumption that cowdung will be free of charge. In light
to the stipulated break even price. the current price or K3.30 per J<g need
to be analysed such that it should reflect production costs.

The established break even price will have to be compared to the ruling
market price and the selection of a competitive price is a must.

4.5 Competition

It is worthy reporting that currently there is no factory in the country which

produces salt. Thus ali the salt found in the designated market area is
imported. It can therefore be assumed that if the project gets off the
grour"~• the imported salt might be subst.ituted for by the :ocal salt since it
can hardly be distinguished from the imported one. The substitution of the
imported salt would help the country in saving foreign exchange. To
successfully substitute the imported product, the current product quality
needs to be maintained and be priced at lower than the competing product.

Following the shop survey which was carried out. it was found out that
21.3 tonnes was and would be distributed at Nchalo Trading Centre. In line
with the population of the area. it can therefore be said that competitors do
meet the demand for the product. During the same survey. it was found
out that the majority of customers preferred unprepacked as this could be
sold in small quantities in order to conform with the income levels of the
targeted customers.

In view of this observation therefore. if the product is sold through the

intermediaries it has to be sold in bags of 20 kg and the intermediaries shall
sell it in small quantities. This strategy would ease competition since the
large proportion of the competing product is sold in packets which is being
viewed by the customers as expensive.

6
 4.6 Distribution

Distribution of the product needs to be through the existing distribution

channels such as wholesalers, retaileis and market vendors. The existing
distribution agents s~ll the imported salt to final customers at recommended
price by the suppliers as well as at market determined product price. The
agents are well knowledgeable in the Marketing of the product and
therefore use of the existing ones will facilitate the distribution of the
product to the targeted customers. Following the survey which was
conducted, it was found out that about 21,300 kg of salt was and would
be sold out through the existing distribution agents at Nchalo Trading
Centre. In conside;aticn of the financial base of the producers, use of the
existing distribution channels need be strengthened ano intensified as this
will save transport costs since the hiring cost from project sit~ to the
trading centre is K50.00 per trip.

4.7 Promotion

Promotional measures will be required for the product for entering tile
market as it has shown that the product seem not to be known to the
would be customers.

5.0 OPPORTUNITIES AND THREATS OF THE PROJECT

5.1 Raw Materials

The salt processing uses soil and water as its raw materials and these are
locally found within the project area. In view of the location as well as the
abund~nce of the said raw materials, the project faces no incremental costs
in terms of transportation and procurement of raw materials. This therefore
is seen to be a financial advantage to the production processes of the
product as the production costs are kept at minimum. However, it i~ of
worth r, ting that raw materials sustainability seem to IJe uncertain and this
has been manifested by the non-establishment of the salt production
capability. Nevertheless, the project has potential signs of continuity due
to the reserves which have been identified in other localities such as Lake
Chirwa in Zomba District, Phalombe in Mulanje District, Kazuni in Mzimba
District, Kachu!u and Kasungu.

7
 5.2 location

As highlighted in the introductory part cf the report. the project is located

in the outskirts of Nchalo Trading Centre within one km to the south of the
sugar plantation. "The project has the advantage of being close to the raw
materials site which means that there are no transportathn costs in the
shipment of the raw materials. The proje.ct site is also easily accessible to
the target market which is Nchalo Trading Centre and other neighbouring
locations.

5.3 Environmental Impact

With the intrcduction of the new technological means of production. the

use of firewood as the main source of energy has been substitute~ by the
usage of biogas which is complimented by solar energy. T:1e usage of
biogas and solar energy has brought in environmental advantages to the site
as this will reduce the deforestation. This calls for the strengthening of the
usage of the newly introduced sources of energy through the dissemination
of the information to other micro entrepreneurs who are also involved in salt
production.

It is worth pointing that there are no organised waste handling methods.

The sp13nt soil is left out in unsightly soil heaps. This therefore calls for a
mechanism where spent soil would be properly spread and levelled on the
ground for salt regeneration and for land preservation.

The land in the project site has no vegetation. Therefore, there is a strong
and urgent need to grow some veg~tation to prevent soil erosion.

5 .4 Business Threat

It is worth reporting that if the project gets on well off the ground,
scrupulous dealers may force themselves into the manufacturing industry
thereby depriving the community from enjoying the benefits of the
investments.

6.0 RECOMMENDATIONS

6. 1 The survey has shown that there is potential market for the product
however the product seem not to be known to the would be customers and
therefore this calls for a promotional campaign for the product so as to
stimulate demand for the product.

6.2 As regards to the product packaging format, the survey has revealed that

8
 44% of the visited distribution agents preferred the product to be
distributed in 20 kg bags which in turn can be sc!d out in small quantities
to meet the purchasing power of the community. 36% of the distribution
agents pref erred the product to be sold out in 20 kg bales of packets
ranging from 1oo· grammes to 250 grammes. This therefore calls for the
impartment of packaging skills onto the micro entrepreneurs involved in the
salt manufacturing industry.

6.3 MIRTDC should establish through its research the source of the raw material
underground and estimate its sustainability.

9
 APPENDIX 2

MALAWI BUREAU OF STANDARDS

OUI' file code: DS/LAB/35/4 Our d~te: 1'194-08-16

1~1
Your file code: Your d~te:

Miii'tDC ~
P O Box 357 ~1'>~:
BLANTYRE
' .
........ ..... sfl"M., ~ ~-'! \4-\JI H !..JJ·.
REPORT NO. 354/N 572 - ~·fl-· i l\ I)~ a ~
•
SJ\KPLE Common Salt
- dt'~rk-~ I'\'tlO I ll ~J-

MDS HO. w 1408 to w 1412

-¥.r'~ \\f-" I\ Q{r..);:
- ~~~-
IDENTIFICATION NO lP • W 1408: NO lR .. W 1409 '~' l.. JS ~
t~~
NO 2? e W 1410. NO :!r = w 1411 ..
NO illL ,. \i l "12

CONDITIONS See overleaf

TEST REQUIRED

According to HBS 188 1988

\I' 2. TEST KETDOD

HBS 188 : 1988

'.·· ./J. RESULTS

If I (l lf Jf Ill
ff 140A ff 1409 ff 1410 ff 1411 "' 1412

Sodium Chloride \m/111 · s 96, 7. 96,0 97,J 21,7 33,1

Alkalinity \m/m .. : 0,01 !),lll 5 0,014
Impurities \m/m 0,03 o,o.a ci,02
~ Moisture \m/m ll,3 ~ 13., 5
Iodine, mg/kg 2,1 J,2 1,1

ehJJv~~
E G Chinangwa
Senior Assistant Labo.atory Hana9er
for: GEHERAL MANAGER

,,..

A STATUTORY BODY BSTABUSRBD IN 1911

'.·
:·ro1i.I Addrcu Office Addrcu . ·'. tblioMI Tel: (26J) 670 411 Tclu: 44J2S "Mso· Ml
'P.O. Box 946 Moi11 Rood lni.mal10111I Tel: 1+:Z6S 670 411 Tclc1nm1: ·sund1,.J1"
{lltnlyrc Dl1nl7N Fu: 670 7.H

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.•
l

MALAWI BUREAU OF STANDARDS I

I
l

'
Our file CodeBS/LAB/35/4 Our d8tel 995/08/ 16
I
Your Fiie Code: YOU! d•le: I

Malawi Industrial Research and

T@chnolo9y Development Centre
P 0 Box 357
BLANTYRE

REPORT NO. : 354/X 588

•

SAMPLE : Salt f
MBS NC. : x 1564

CONDITIONS : See overleaf

• l. TEST REQUIRED

Acccrdin9 to MBS 188

2. TEST METDOD

HBS 188

3. RESULTS (on Wet basis)

Sample H&S 188 specification

.•
-.~
-·- Insoluble matter, \ m/m 0,4 0,-2 maximum
Alkalinity as CO~\ m/lll 0,01 0,1 maximum
Chloride as Nacl m/a . 98,8 97,0 Minimum
Iodine as KIO}' m9/k9 Nil 50,0 Minimum
Moisture, \ m m 2,3 4,0 Maximum
4. R~S

4.1 The salt is not iodized. Insoluble matter is above maximum

requirement.

It,~~/
~ c chinan9wa· CJ - -
Scientific Officer
for: GENERAL HANACEK

A STATUTORY •ODY ESTAaLISHED IN 1'11

...
I
Otr.cr Addrnt l'111ior11I UtSI '10 411 Ttlu 44JJJ 'M!\lt" MJ
............. +1., t10 ... ,,.,,,._ 'll•••r••
"'" '~
I • ·, ~_, • I .J
 ..
MALAWI BUREAU Of STANDARDS
Our file code: BS/LAB/45/3 Our d11e: 1994-12-12
- . Yout file cod~: Your d11e:

..,.
Ttae General Manager
H.IRTDC
P d Box 357
BLANTYRE ..
REPORT NO. 354/W 770

SAMPLE Salt

HBS NO. w 2035, w 2036, w 2243 ,,r

IDENTIFICATION Residue Salt, Product salt, Commercial Salt

CONDITIONS See overleaf

., .

1. TESTS REQUIRED

·':...:,. Appearance, Iodine, Iron

2. TEST METHOD

Appearance Visual
Iodine Titrimetric
Iron AAS

3. TEST RESULTS

w 2035 w 2036 2243

Appearance Yellowish brown Whitish brown Crystalline White

Iodine as KI0 ,mq/kg 9,8 5,4 58,l
3
Iron,mg/kg 0,0297 0,0099 0,0099

4. REMARKS
! ..•. -----
The degree of browning of salt from saline salts seems to correlate

¥:·- with levels of iron and not iodine.

d--

~ w fl Huyila
Scientific Officer
for: GENERAL Hl\NAGRR

A STATUTPIY •OD.Y iSTA•LISHJf' IN 1•11

.• I
Pu111I AdJru1 OIJ'1n A44NH N11i-1 T1I: ('HJ) 670 411 Tele': ..,.,u "Mso· Ml
P.O. Bo1 946 Moin Road lllwnwdoMI T•I: • 265 no 411 T•l•1,.111e: "ltatllbr4•"
lltntyN llllll)'rt F.. : 610lH
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I - , '
DRAWING N° I FILTER TABLE. ! ~-. ;·
I ~ -· : .:. ~ -
NOTE: CROSS BRACE AS NEEDED FOR STABrt.:ITY. ·.:.
LEGS 100 x 100.
DIMENSIONS IN MILLIMETRES ..

1 l - - Ill ~
r- - r -
I
I 1 I I

.
I

I
!
i
'
'
0
.
;

'° ! "°'
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0.

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PLAN

DRIP TRAY
I :
I I
' I
/FINAL FILTER
•••fF========'=•1
I ••· I IC 1

,_-BRINE ~EC El VER

ELEVATION
r
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- ~ECTION A-A

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910
.....
·I
DRAWING N° 2 FILTER FRAME
NOTE"
FILTER FRAME APPROX 910•910, 150• 25.
INNER FRAME ANO WEDGES SO" 100 BE VE LEO
AS INDICATED.
DIMENSIONS IN MILLIMETRES
~t~~I:f2~ ~ ·:~~,:~-.~~·\:;.~~~~
~· ... . ... ·.. :' :, .:·· ',. ·i':... i-
... .. -:. - :~ ··:. '. ' '.. <J". :-:. ---:.-:~:·::~.::· 't.
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DEFLECTOR
50 COARSE SAND

INNER FILTER FRAME)

I
BRINE
I
I
, BURLAP FILTER
/ CLOTH

~
I

DRAWING N° 3 FINAL FILTER (SCHEMATIC)

.. NOTE: DIMENSIONS IN MILLIMETRES
.:_- -_;_·::---::- . - '~~~: I,' •.• : ..--.·.~.'~:..·: .. ' ...··.4.
•.• r'
-
.
't .,_

I••
.:
¥

.. : ':. :' --= ::-..'7" .

: I ·i : ..
: CLEAR PLASTIC SHEET
. .'
. . . .-.

' ....
BRICKWORK

GROUHD L [ VEL
\1
ELEVATION SCALE 1~ .r.o
.. - - . ·---- - - -
' . . ... - ELEVATION s·cALE 1:.r.o

ARE A COVERED
WITH PLASTIC 4'.lULAR FOAH

PLASTIC SHE ET
LAID ON PLOOR SI.AB
•

MA~AWI .INDUSTRIAL RESEARCH AND

"'
0
0
TECHNOLOGY.. D,EVELOPMENT CENTRE
N ~ O. Box 3 5 7
BLANTYRE Tel. 623805 Fax 623631

SOLAR STILL
I £ £ <£ £ £ £ L £ , < , , < )5,J

·I
0

DRAWN: HJ HFUNE
I 2 00
1- I,
DATE: OCT 199S
PLAN SCALE 1: l,O
SCALE: AS SHOWN
DRAWING N°
 -
~f~~~:~~~:~~~; :t;: ::;-,:~~;fr'! ·~ . ·•· ". . ., . , ,·' .,_, ·: '.' ".:y: ·. ~~'.~t~''-~f:? :'.:f.: C-"''~2 .
r
- . --• ~-. -· ·...7•.• :~: .•·· .

... . ..

:.· ':
T;.aLE 1 SOLAR STILL OPTIMIZATION - .FILTRATE LEVEL AND· ·TEMPERATURE DETAILS
STILL DIMENSIONS 4050mmic3600mm
_.. --· ...... ·-- .7

-· ··--·· . ----------

1,
-
l DATI: FILT
RAn:
mnA.n: U:\"EL l\' nn: STILL M\11 SALT
RE.'tlO \''E.D
RESmut DAil..Y TEMPEAAXVRES (°C)
·-
II TUvIE Ciel
(lu.l Ciel TIME ..
II ..._,, 8.00 I 10.00 ! 12.00 14.00 16.00
I -
8.00 10.00 12.00 14.00 16.. 00__
I - -
I
I ' I I - I -
-.
CN ·OUT IN OUT IN OUT IN OUT IN _OUT
I 9.s-.9.s - -- - I- - - I- . . ..
- 30 25 36 26 40 29 so 30 40' 29

l 10.8.95 - . I. I - . . . . 29 23 40 27 45 29 57 31.5 49 30

h
r l!.8.95 128 17 !7 I 16.9 16.5 16.2 . - 27 22 •.S 3.S 27 42 29 ..S 48.5 30 40 29.s I
,j i5.8.95 - 6 6 :'.8 5.2 5 10 - I 21 ~2 45 26 so 30 57 30 : 4.: I ;.J
.
,,
,, 16.8.95 - 4 4 I 3.9 3.4 3.3 - - 25 21 36 27 .SS 31 40 2.S ' 35 I 24

17 .8.95 - 3 3 2.5 2 1.7 7 . 27 .,~

-J 40 26.:; SS 30 51 29.'=> 49 30

is.8.95 I- I 1 II - - - - - 27 22 40 27 57 31 45 30 45 30

23.8.95 - I- I- l.
I I- - s . I I I
'
2s.s.9s I - I. I
i. I. - I- . s I I I I I

NOTE: IN : INSIDE STILL (VAPOUR TEMPErlATURE)

..
...... . OUT: OUTSIDE STILL
 .--- - .. -...•... •
.
.
- ..
..:~
-~-

'
...
_. ·~..
..·.<',~!Ji~ ;., ' >·-·~ •. ... •. ::·:.
. :~ . . ..
,.
.. :.
.
:· :~·
-··
'.: .. ' r ..·,._,

-
-:-~' •·•.M :.·.1: ·~;
- ..
.' ~ ...~ .. ;,
p

- .
TABLE 2 SOLAR STILL · OPTIMIZATJON --~iiLTRAT( LEVEL . ·····. . ..
AND
~TILL OIMENS-IONS. . 4050mmxl800mm .. TEMPERA
- TU RE ·. DE TAl LS
.I

"'•
------·--
DATE
......
FtLT
- - -·· ..
- --JU::SmLC: - ...
.
.. - .. ,
nl.nATE LEVEL L"I TB:t STILL i:\t\O SALT I
'
RATE

(lbJ
.. .
TL\1E
--
RL'IOVED

(lcC)
Cliif
DAil.. Y TEMPERA TURES (°C)
-.
... _.TIME '.
. ...... _. I
-·_j

• 8.00 10.00 12.00

'

14.00
. ·- --- .. I.

.
16.00
--
8.00 10.00 f 2.00 14.00 . - 16.00 I
I - IN OUT IN OUT .IN .OUT IN OUT IN I.our I
12.9.95 64 . .. ,-... 10 10 .. - -
. -
- - - - -. .. . ..: 60 3.S 40- I -- J ..: .>
. --
- - ..
-13. 9.95
14.9.95 120
10
30
9.5
29
9
27
. 8
25
8
24 -.
. ' - -- .
-
30
35
2.S . .. :
2.S
40
4.S
-
32
3l.
.SQ . 38
.SS 32
35
so
.29__
32
--· I -o I.
'J.l_

4.s.. In I
,1

15.9.95 - 23 23 22 20 20 . - 35 2.S 45 29 .52 31 .)2 -., 45 I 32 I

18.9.95 - . . . - J-

jQ I 2.5
35 24 40 30 50 35 40 30 I
19.9.95 - • 13 . 12 10 9 9 - - 30 24 45 30 52 35 so 30 47 I 35 I
20.9.95 - I 9 8.5 8
. ..:. -7·--· -r - - .. - ...
- - 32 2.S 48 30 so 33 SS 34 46 I 31 I
21.9.95 - 6 - - 45 I 33
6.5 5 3 3 17 - 35 25 50 30 55 33 60 36 I
22.9.95 - 3 2 - - -- I
J 3
I 30 2.S 47 29 56 JJ

I I
lNJTIAL BRINE TU\1PERA TUR.E = 63' C
NOTE· IN : INSIDE STILL (VAPOUR>·ffMPERATURESJ
OUT : OUTSIDE STILL
 .
~;:~3~~~.;~

--:;~~~~:~]:-·
·- -_--_..:.·
- \, -.~=-: -..,,_:
.• . .·
-~ .; )~H:~;r·':' . . ., , ~~; .::'~~'.~(!'~f\~-;~:,~n :::~ff!/?<:;~::r.~~~ .
.. -·
-. /
.··· - ,- ·" --..:~ ...
~

..
TABLE 3 SALT HARVESTIN.G :. -
BOILING TO CRYSTALIZATION . SALT RECOVERY PROCESS ... ···
-
.,_, ------·-------- -~--·-·- ---
.....
Date I
·-----.--··-- .
..Batch No.
.
Arca (nT) Soil (kg)
-
Water Oitres) Filtrate Residue Cki)

!
Operator Salt (k:) Salt {ke/m2) ·
- (litres)
09-08-95 Mr Chatafa 1 20.15
..
403 201 80 16 - 0.79
I
I 10-08-95
. . . l . 33.3 666 333 . ·80 24 . -0.12
I 10-os.95 · _ . - ... 2 33.3 - 666 333 80 22 - 0.666
·- .
. 11-10-95 I. •. l . 20.15 403
.

201 80 18 - 0.89
12--08-95 . 1 33.3 666 I 333 80 - ~s - 0.84
 :- ;:....:;_;:_;\-.'--....
-~ - -- -~~··~~- ---= -:
it~l~l f~~'- ~· . .·_;;./ : . •.. . .... ... :.. - \

-·.
.
;
- ., .. ~
··.· ....
..:...:
• ...... o;.
~ .

TABLE 4 SALT H:~;R.vfs~T.'fNG :.=-.;

•. SOLAR SALT CRYSTA~iZATION . PROCESS '.

Date Oper:itor I Batch No. Area (m:) Soil (kg} ,Water (litres) Filtrate j Salt (k&) IR~ldue Salt (k&fm1
I (litres)
Ck&)

10-08-95 Mr Cbatata 14.92 1403 .208 80 11 2.5 - 0.74

10-08-95 ?
... I is.44 417 ··208 .·:• I 80 11 . 2.5 b. 71
12-09-95 Mrs Chatata 1 .. 20.83 417 ;208 80 12.46 .: 2.83 0.59 ..
12-09-95 Mrs Banda 2 15.44 417 208 80 12.46 2.83 0.81
~ 12-09-95 . I Mrs Bramu I3 I ll'. •4 444 224 80 I 12.46 2.83 0.76

I\OTE: Dau for I.he salt and residue ~mounts for th: month of Sc:pten1ber ob1.1ioed thrcu~b simple proponion.

..
.

:.-.
 :- -· ·-·•.:.._-
':5t:=.z;.-.,-;_'!::';:.>:-:=-·-~~
d-;..~------,~~.-
.....~Jo.lok - · !::::> ·' '--"' .. " · r .., ... "
~~:~~~~~.:~;..:·.- .~·-:;,-._ - ~ .· ·.. .. . -~
-:':..- _: ;;~-.;.~;-~
- -·

CASH FLOll ........

~~nu•l salt prod~cticn (kg.) 6000ll.\)0
Price of salt (K•ac~a per kg.) 5.90
Fiie~ c•pi til 894000.00 ·-:::. --··..
Find costs 90000.00
Sross ull!S 5.90 -· ! ~~ ··-;..
Cost of u!es 1.50 ·"
·.
Fixed production for 10 years . ;::. -

· YEAR o.oo 1.00 2.00"' 3.00 4.00 s·;oo .. , .=:: 6.~oo 7.00 a.oo 9.00 10~00

Sales Kg. 60000. 00 60000. 00 60000. 00 60000. 00 b0(100. 00 60000. 00 60000. 00 60000. 00 60000. co 60000. 00

Gress salas K'OOO 354.00 354.00 354.00 354.00 354.00 354. ~'0 m.oo 354.00 354.00 354.00

Sross sales K/kg 5.90 5.90 5.90 S.90 S.90 5.90 5.90 5.90 5.90 5. 90
Cost of sales K/kq 1.50 1.50 1. 50 1.50 1. 50 1.50 1.50 1. 50 1. 50 1. 50
-------------- -- -
Contribution K/(g 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40
Sross traoing profit K'OOO 264.00 2b4.00 264.00 m.oo 264.00 264.00 m.oo 264.00 264.00 264.00
Fixed costs K'OOO qo.oo 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00

Traoing proii t ('000 m.oo 174.00 FUO m.oo 174.00 m.oo m.oo 17 4,1)0 174. 00 174.00
Cepreciahon K 44700.00 22~S.OO 111.75 5.59 0.28 0.01 o.oo o.oo o.oo o.oo
Talable inc~ee ,;·ooo 174.00 liUO 174.00 174. 00 1i4 .oo 174. 00 m.oo 17UO 17 4. (10 174 .co
l:ico1e tu ('\100 6.:1 6.2! 6.21 6.21 6.21 6.21 /:, ~l 6.21 b.21 0.:1
.. -
Profit after tax K'ilOO 167.79 m. n 167.79 167.79 167. 79 167. 79 167.79 167.79 167.79 lb7.79
Marking caplt al K'OOO -92.10
Find capital K'OOO -894.00

Cuil flow K'OOO -906.10 167.79 167.79 167.79 167.79 167.79 167.79 w. 79 167. 79 167.79 167. i9
Ac~. Cuh flo11 K'OOO -906.10 -918.31 -650.52 -402.73 -314.94 ·147.15 20.64 169. 43 m.22 524.01 691. 00
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PHOTOGRAPH 7: INSID[ TEMPORARY SOLAR ST Ill

THE MAN IS SHOWING SOM[ or THE CRYSTAL SALT
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··, .. ' PHOTOGRAPll 8: IN510[ T[HPORARY SOLAR STILL