From Powder to Pellet: Mbuyu Farms Ltd. Enhances Value and Market Reach with Roller Press Granulation

Client: Mbuyu Farms Ltd.
Sector: Mineral & Agricultural Product Processing
Emplacement: Kenya
Solution: Roller Press Granulator

Executive Summary

Mbuyu Farms Ltd., a leading Kenyan producer of mineral and agricultural powders, sought to overcome the limitations of selling fine-powder products. By investing in a state-of-the-art roller press granulation system, they successfully transformed their Calcium Carbonate, Gypse, and other powders into durable, dust-free pellets. This strategic upgrade resolved key handling and application issues, unlocked new market opportunities, and significantly increased product value and revenue.

Le défi

Mbuyu Farms produced a high-quality range of powdered products, y compris:

• Calcium Carbonate Powder
• Coral Lime Powder
• Gypsum Powder
• Vermiculite
• Boma Rhodes Hay (finely cut)

While the powders were effective, their physical form presented significant commercial and logistical challenges:

• Dust and Handling Issues: Powders are difficult to handle, creating dust that poses health risks to workers, causes product loss, and leads to a messy application.
• Transportation and Storage: Powdered goods are less dense, leading to higher shipping volumes, and are prone to caking and spoilage in humid conditions.
• Limited Application Methods: Fine powders are not suitable for precise mechanical spreading in large-scale agriculture, limiting their appeal to major farming operations.
• Product Differentiation: The market for powdered minerals is highly competitive, often competing on price rather than value.

La solution

Mbuyu Farms Ltd. integrated an industrial roller press granulator (also known as a compacting granulator) into their production line. This dry process technology mechanically compresses fine powders into uniform, high-density granules or pellets without the need for binders or water.

Key Advantages of the Adopted Solution:

• Dust-Free Production: The process eliminates dust, creating a cleaner and safer working environment.
• Improved Physical Properties: The resulting granules are easy to bag, store, transport, and apply via mechanical spreaders.
• Product Integrity: The dry granulation process preserves the chemical composition of the original minerals without adding moisture or binders.
• Efficacité & Versatility: The same machine can be easily adjusted to produce different pellet sizes from various raw materials, making it perfect for Mbuyu Farms’ diverse product portfolio.

Results and Benefits

The installation of the roller press granulator delivered transformative outcomes for Mbuyu Farms:

1. Premium Product Offering: The ability to sell pellets allowed Mbuyu Farms to command a higher price per ton, moving from a commodity powder market to a value-added specialty product market.
2. Access to New Markets: Granulated products are preferred by large-scale commercial farms that use mechanical spreaders, opening up a significant new customer segment previously inaccessible.
3. Enhanced Operational Efficiency: Granules offered improved flowability, leading to faster bagging, reduced storage space, and lower transportation costs per unit of nutrient.
4. Superior Customer Value: End-users benefit from cleaner, easier, and more precise application, leading to increased customer satisfaction and loyalty.
5. Stronger Brand Identity: Mbuyu Farms is now recognized as an innovative processor offering advanced, user-friendly solutions, distinguishing itself from competitors.

Conclusion

The investment in roller press granulation technology was a strategic masterstroke for Mbuyu Farms Ltd. It allowed them to solve inherent product challenges, dramatically enhance the value of their existing output, and strategically position themselves for growth in Kenya’s modern agricultural sector. This case demonstrates how a single processing innovation can fundamentally strengthen a company’s market proposition and profitability.

“Granulating our powders was the logical next step in our growth. This machine has not only solved our dust and handling problems but has fundamentally allowed us to offer a superior product that commands a premium. It’s the best investment we’ve made in years.”
-Production Manager, Mbuyu Farms Ltd.