INTRODUCTION
During my attachment at West Kenya Naitiri Sugar Factory, I had the opportunity
to immerse myself in the dynamic and intricate world of sugar production. This
experience was designed to bridge the gap between academic knowledge and
practical application, providing a comprehensive understanding of the entire
production process from field to factory. Over the course of my attachment, I
engaged with various departments including agronomy, production, quality
control, and machinery maintenance. This hands-on experience allowed me to
observe and participate in the day-to-day operations, gaining valuable insights
into the complexities of sugar manufacturing and the importance of sustainable
practices. My time at the factory not only enhanced my technical skills but also
deepened my appreciation for the collaborative efforts required to produce high-
quality sugar, and the significant impact this industry has on the local community
and economy.
1
OBJECTIVES
As an agricultural student pursuing a Diploma in General Agriculture, my field
attachment at West Kenya Naitiri Sugar Factory is guided by several key objectives:
1. Apply Theoretical Knowledge to Practical Situations: To translate the
theoretical concepts learned in the classroom into practical skills within a
real-world setting. This includes understanding the lifecycle of sugarcane
from planting to harvesting and processing.
2. Gain Hands-on Experience: To actively participate in and observe the
various stages of sugar production, including agronomy practices,
harvesting techniques, and factory operations. This hands-on experience is
crucial for developing practical skills and competencies in agricultural
production.
3. Understand Sustainable Agricultural Practices: To learn and evaluate the
sustainable practices employed by the factory in sugarcane cultivation and
production. This includes studying soil management, pest control, water
usage, and other eco-friendly techniques that contribute to sustainable
agriculture.
4. Enhance Technical Skills: To acquire and improve technical skills related to
modern agricultural machinery, quality control measures, and production
technologies used in the sugar industry. This exposure is vital for adapting
to technological advancements in agriculture.
2
5. Analyze Operational Challenges and Solutions: To identify common
operational challenges faced in the sugar industry and understand the
strategies and solutions implemented by the factory to address these
issues. This includes both agronomic and industrial challenges.
6. Develop Professional Competence: To build professional competencies
such as teamwork, communication, and problem-solving within a
structured industrial environment. This experience is essential for personal
and professional growth, preparing for future roles in the agricultural
sector.
7. Network with Industry Professionals: To establish connections with
professionals in the sugar industry, gaining insights from their expertise and
experiences. Networking is crucial for career development and
understanding industry trends and opportunities.
8. Contribute to Community and Economic Development To understand the
role of the sugar factory in the local community economy, and to
explore how agricultural practices can be optimized to support local farmers
and contribute to regional development.
Through these objectives, my field attachment aims to provide a well-rounded
and immersive experience, equipping me with the necessary skills and knowledge
to excel in the field of agriculture.
3
HOST INSITUTION DEPARTMENT
Naitiri sugar factory has many parts with different departments majorly due to
my specialization in agriculture I was assigned to my respective department of
agriculture.
Upon my arrival at the Naitiri Sugar Factory, I was warmly welcomed by Mr. Evans,
the head of the Agricultural Department. After being allocated by the Human
Resources and Agricultural departments, Mr. Evans greeted me with a friendly
smile and a firm handshake, making me feel instantly at ease.
Mr. Evans began by providing a brief overview of the factory’s operations and the
pivotal role played by the Agricultural Department. He then graciously offered to
take me on a comprehensive tour of the facility to gain a deeper understanding of
the entire sugar production process.
The Tour
Arrival and Cane Yard
We started our tour at the cane yard, where the harvested sugarcane from local
farms is brought in. Mr. Evans explained how the cane is meticulously weighed
and documented upon arrival to ensure accurate records. The sight of trucks lined
up, each filled with freshly cut sugarcane, was truly impressive. Mr. Evans pointed
out the efficient logistical operations that help maintain a smooth flow of cane
into the factory.
Initial Processing
From the cane yard, we moved to the initial processing area. Mr. Evans described
how the sugarcane is first washed to remove any dirt and debris. The cleaned
cane then goes through a series of crushing mills where it is shredded to extract
the juice. He emphasized the importance of this step, as extracting the maximum
amount of juice is crucial for high sugar yields.
4
Juice Clarification and Evaporation
Next, we visited the juice clarification section. Here, Mr. Evans showed me how
the extracted juice is treated to remove impurities. The clarified juice is then
heated and sent to the evaporation tanks, where excess water is removed.
Watching the transformation from raw juice to a concentrated syrup was
fascinating.
Crystallization and Centrifugation
The tour continued to the crystallization and centrifugation stages. Mr. Evans
explained how the concentrated syrup is seeded with sugar crystals and then
cooled to form larger sugar crystals. The mixture is then spun in centrifuges to
separate the sugar crystals from the molasses. I observed how precise and careful
control of temperature and timing is essential during these processes.
Drying and Packaging
Finally, we reached the drying and packaging area. The sugar crystals are dried to
reduce moisture content and then graded according to size and quality. Mr. Evans
pointed out the packaging machines that fill and seal bags of sugar, ready for
distribution. It was remarkable to see the end product, knowing the intricate
processes it had undergone.
By-products
During the tour, Mr. Evans also highlighted the by-products of sugar processing. He
explained how bagasse, the fibrous residue from crushed cane, is used as a biofuel
to power the factory’s boilers. Molasses, another by-product, is sold for use in
animal feed and fermentation industries. Mr. Evans emphasized the factory’s
commitment to sustainability by utilizing every part of the sugarcane.
Conclusion of the Tour As the tour concluded, Mr. Evans reiterated the factory’s
dedication to supporting local farmers and contributing to the regional economy.
His passion for the work and his deep knowledge of the sugar industry were
5
evident throughout the tour. I left with a profound appreciation for the complex
processes involved in sugar production and the significant impact of the Naitiri
Sugar Factory on the local community.
Mr. Evans’s warm welcome and the informative tour provided an excellent
introduction to the factory’s operations, setting the stage for a productive and
insightful experience at Naitiri Sugar Factory.
6
BACKGROUND OF WEST KENYA NAITIRI SUGAR FACTORY
It was found by Rai and his family in 1971 in kakamega county
It has engaged in production of sugar and other related products ever since
Its not the biggest company in kenya but it comes second when it comes to
Production
It has grown from 500tons crushed everyday to 5000tons
It has over 2000 workers
It has branches like Nasebwa- Busibwabo in busia and Naitiri in Bungoma
County
West Kenya Naitiri sugar factory has many sections with different departments.
Starting from the gate where we find our our right hand the weigh bridge and on
the left we find the 1st department which is the workshop
The Role and Functions of the Workshop at West Kenya Sugar Factory
Introduction
The workshop at the West Kenya Sugar Factory is a critical component of the
factory’s operations. It supports the maintenance and repair of machinery,
ensuring continuous and efficient production processes. This report provides an
overview of the workshop’s functions, its importance to the factory, and its
contributions to operational excellence.
Machinery
7
Functions of the Workshop
Maintenance The primary function of the workshop is the routine maintenance of
all factory machinery. This includes regular servicing, lubrication, and adjustment
of equipment to prevent breakdowns and ensure optimal performance. Scheduled
maintenance activities help in minimizing downtime and extending the lifespan of
the machinery.
Repair Services
The workshop is equipped to handle repairs of all types, from minor fixes to major
overhauls. Skilled technicians and engineers diagnose issues and perform
necessary repairs swiftly. This capability is crucial for addressing unexpected
breakdowns and maintaining the smooth operation of the factory.
Fabrication and Manufacturing
The workshop also undertakes the fabrication of custom parts and components
that may not be readily available in the market. This includes manufacturing spare
parts, creating specialized tools, and modifying existing machinery to meet
specific production needs. The ability to fabricate in-house reduces reliance on
external suppliers and speeds up the repair process.
Installation of New Equipment
When new machinery or equipment is procured, the workshop team is
responsible for its installation and commissioning. This involves setting up the
equipment, ensuring it is properly integrated into the existing systems, and testing
it to confirm it operates correctly and efficiently.
Upgrading and Retrofitting
To keep up with technological advancements and improve efficiency, the
workshop undertakes upgrading and retrofitting projects. This includes installing
new technology on older machines, improving automation, and enhancing safety
features.
8
Inventory Management
The workshop manages an inventory of spare parts and tools necessary for
maintenance and repair activities. Effective inventory management ensures that
parts are readily available when needed, preventing delays in repair work and
maintenance schedules.
Importance to the Factory
Operational Efficiency
The workshop’s activities are fundamental to maintaining high levels of
operational efficiency. Regular maintenance and timely repairs reduce the risk of
machinery failures and production stoppages, ensuring that the factory operates
smoothly and continuously.
Cost Savings
By performing maintenance and repairs in-house, the factory saves on costs
associated with hiring external service providers. Additionally, fabricating parts
internally can be more cost-effective than purchasing them from suppliers,
especially for custom or specialized components.
Safety and Compliance
The workshop plays a vital role in ensuring that all machinery and equipment
comply with safety standards and regulations. Regular inspections and
maintenance help identify potential hazards and address them before they lead to
accidents or violations.
Supporting Sustainability
Through efficient maintenance practices, the workshop helps in optimizing energy
use and reducing waste. Properly maintained machinery operates more efficiently,
consumes less energy, and has a lower environmental impact.
Contributions to Operational Excellence
Skilled Workforce
9
The workshop is staffed by skilled technicians and engineers who are trained in
various aspects of machinery maintenance and repair. Their expertise ensures that
the factory’s equipment is kept in peak condition, contributing to overall
productivity and quality.
Rapid Response
The ability of the workshop to quickly address machinery issues minimizes
downtime and keeps the production process on track. This rapid response
capability is essential for maintaining the factory’s production schedules and
meeting market demands.
WEIGHBRIGDE
The work of the weighbridge is to measure the weight of sugarcane and the
tractor in tons where the weight of the tractor is removed from the total tons
recorded
As we proceed on find offices that are respectively for different departments
For example :
Agricultural department: dealing with sugarcane planting and harvesting
Financial office: dealing with the salary of drivers and paying of farmers
Workshop: Dealing with machinery
Electrical department: Dealing with the electricity in the factory
Safety department: Dealing with PPE personal protection
After the offices where there is the cane yard where using gate B the sugarcane is
transported to the cane yard and carried up by machines where its cut into
smaller sizes and transported into the machines for sugar processing. The juice
from the sugarcane plant is collected in a juice tank as the by products are
separated. After that the juice undergoes another process where there is
10
separation of sugar and molasses later turned into the crystal and dried into fine
sugar. The material remained are turned into bagase and molasses
AREAS WHERE I HAVE WORKED
1.I have worked Mobile weighbridge on a field trip to Tulwet
I learned how to use a server a machine that detects the weight of a given tractor
when its loaded and not loaded…where you key in the number plate of the tractor
and a trailer. You also key in the name of the driver and the tractor and after
weigh the sugarcane with the tractor you minus with the weight of the when its
not loaded to find the weight of sugarcane and calculate the gross weight .
2.I have worked with the finance offices on records of farmers
Where in 2023 farmers were issued with planting materials majorly on fertilizer it
was either DAP, NPK or CAN
I was to identify:
Size of the land
Name of the farmer
The area where the farm is
Denote number
Field number
Type of fertilizer he/she was given
Identification number
3.I have worked in sugarcane plant in Saboat
I travelled to farm in field trip at saboat where we had a 25acre field where
farmers were planting sugarcane .we were to supervise and teach them on how to
plant sugarcane using the two methods which are:
Slanting method
11
Double method
We showed the how to plan and using NPK fertilizer that was applied in farrows
4.I have worked in agriculture office in fertilizer supply to farmers
Fertilizer was issued to all farmers who registered for it and it was to be added as
a debit during sugarcane harvesting. The fertilizer was issued according to the size
of the land.
5. I have travelled with my supervisor to Maliki office
The main theme was to teach farmers much about sugarcane and the importance
of planting sugarcane as a crop. We gave farmers advices on the fertilizers they
should use for exam DAP is suitable during planting when it is mixed with lime
6. I have also gone to field research on cane age at Lungai C for research
We were to determine the age cane using brix method
We counted the brix of a cane plant and we later we took them for research
Mr. Sifuna the agronomist also thought me on theories of sugarcane and varieties
where I learned we have varieties such as Brazilian and Spain variety
He also thought that the juice in sugarcane can determine the age of the plant
12
ACHIEVEMENT I HAVE ACQUIRED AT WEST KENYA NAITIRI SUGAR FACTORY
I have acquired skills
During my field attachments at the West Kenya Naitiri Sugar Factory, I had the
opportunity to gain hands-on experience and accomplish several important tasks.
Here are the key achievements:
1. Mobile Weighbridge Operations in Tulwet: I successfully managed and
operated the mobile weighbridge, ensuring accurate measurements of
sugarcane deliveries. This involved calibrating the equipment, recording
weights, and maintaining logs for each batch.
2. Sugarcane Planting in Saboat: I participated in planting sugarcane, learning
best practices for soil preparation, planting techniques, and crop
management. This experience deepened my understanding of the
agricultural aspects of sugar production.
3. Visiting the Caneyard and Observing Sugar Processing: I toured the
caneyard and observed the entire sugar processing workflow. This included
witnessing the stages of sugarcane crushing, juice extraction, purification,
crystallization, and packaging. It provided me with a comprehensive
overview of the industrial processes involved.
4. Finance and Record Keeping I assisted in the finance department, focusing
on maintaining accurate records concerning farmers. This included tracking
13
payments, managing accounts, and ensuring transparency in financial
transactions with the farmers.
These experiences have significantly enriched my understanding of the sugar
production industry, from fieldwork to processing and financial management.
14
CHALLENGES HAVE FACED AS A STUDENT DURING MY ATTACHMENT IN WEST
KENYA NAITIRI SUGAR FACTORY
During my attachment at West Kenya I have experienced the following problems
Bad weather: in rural area I have been experiencing heavy rainfall especially
when am assigned for Field work in different parts.
Illiterate farmers: In rural areas most farmers are unlearned and dealing with
them has been a challenge. Farmers may need more time for them to understand
and also challenge in language barrier some of them don’t understand Swahili or
English
Poor infrastructure: Roads in rural areas are poor as they are muddy and dust
during dry season it has been a challenge traveling to the factory and back as you
may meet trucks on a narrow road
Lack of electricity: some parts of Naitiri are lacking electricity and it has been a
challenge for me personally as a student during night times and checking on my
schedule.
15
CONCLUSION
In conclusion, incorporating organic manure and agroforestry practices in growing
sugarcane can have numerous benefits for both the crop and the environment.
Organic manure provides essential nutrients to the soil, improving soil health and
fertility while reducing the reliance on synthetic fertilizers. Agroforestry practices
help enhance biodiversity, promote soil conservation, and provide additional
income opportunities for farmers.
By combining these sustainable practices, sugarcane cultivation can become more
environmentally friendly, economically viable, and socially beneficial. It can
contribute to a more resilient and sustainable agricultural system that supports
long-term productivity while minimizing negative impacts on the environment.
Overall, integrating organic manure and agroforestry practices in sugarcane
production can lead to a more sustainable and holistic approach to farming
16
REFERENCES
Here are some references that you can use for further information on sugarcane
growing:
FAO. (2016). Sustainable Sugarcane Initiative. Food and Agriculture Organization of
the United
Nations. Retrieved from: http://www.fao.org/sustainable-sugarcane-initiative/en/
Rott, P., Bailey, R. A., & Comstock, J. C. (2000). Sugarcane: Research towards
efficient and
Sustainable production. CABI
Singh, A., & Singh, R. P. (2002). Sugarcane: Physiology, Biochemistry & Functional
Biology.
John Wiley & Sons.
Sugarcane.org. (n.d.). Sugarcane Planting and Harvesting. American Sugar Cane
League.
17
Retrieved from: https://www.sugarcane.org/sugarcane-101/planting-harvesting/
These references provide valuable information on sugarcane cultivation, including
planting, harvesting, physiology, and sustainable production practices.
18
