Agro-Tech Book - Agriculture Support Programme

Economic Expansion in Outlying Areas - (EEOA) 

Ministry of Agriculture Food and Fisheries - (MAFF) 

RWA International

2 

The Economic Expansion in Outlying Areas (EEOA) Programme is 

funded by Sida/Sweden and implemented by RWA International, 

United Kingdom in association with Terra Nova AB, Sweden and Moses 

Banda & Company, Zambia on the basis of a contract with the Ministry 

of Agriculture, Food & Fisheries, Zambia. 

This publication is one of a series of extension materials commissioned 

by EEOA and prepared by Mano/Arulussa. Other topics included in 

this series are: Farming Systems; Maize; Groundnuts; Beans; Sweet 

Potatoes, Tomatoes, Sunflower, Marketing and Agro-Processing. 

Copies of these publications may be obtained from: 

The National Coordinator, EEOA, P.O. Box 50181 RW Lusaka, Zambia 

Telephone: ##260-1-253523; Fax: 253532; e-mail: eeoa@zamnet.zm 

or 

E.E.O.A. 

RWA International, Beckets House, 34 Market Place, Ripon, 

North Yorkshire, HG4 1BZ, UK. 

Telephone: ##44 -1765-600455; Fax: 600344; 

e-mail: rwaripon@rwainternational.com 

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any 

form or by any means without the prior permission of the copyright owner. 

© EEOA Box 50181 RW, Lusaka, Zambia 

AGRO-TECHNOLOGY: Farming and Processing Equipment

Farming and Processing Equipment 

AGRO-TECHNOLOGY 

In this Information Pack some of the equipment that can be used for ploughing, cultivation, 

irrigation and processing is discussed. At the end there is a list summarising the equipment 

and showing where it can be bought. 

Irrigation Equipment 

Irrigation can be done in many different ways depending on where the water comes from, 

how the land is shaped, what sort of power is used and how much money is spent. 

If the water comes in a stream and can be diverted into a furrow, so that it �ows above 

the crop, then it can be directed into the �eld and used in “FLOOD” irrigation. This is the 

cheapest way to irrigate but it can be done only when the water can be put into a furrow 

above the crop. It is wasteful of water, particularly in sandy soils. 

If the water cannot be diverted to �ow by gravity above the crop then it must be pumped. 

It can then be diverted to the crops by furrows. Or, it can be pumped into a tank from which 

it can �ow to the crops by pipe, or directly to a basin dug around the crops. This is called 

a “HOSE AND BASIN” system. Such a system does not require pressure except to reach 

the tank. 

A “PIDDLE” system is one in which holes are drilled in pipes so that the water comes out 

next to the plants. It can be fed from a pump or a tank and does not waste the water. Such 

a system can cost $150 per hectare without the pump. 

A “DRIP” system has smaller outlets for the water by each planting station so that the 

water drips into the soil and wets only a small area at the surface so that weeds do not grow 

and there is little evaporation. The system requires a low pressure of 1 atmosphere (1 bar or 

15psi) and provides the most ef�cient use of water. Drum kits or bucket systems are drip 

lines attached to a drum or bucket that must be �lled to distribute the water to the plants. 

Drip lines cost about US$ 900 per ha. depending on the interrow spacing. Where drip lines 

are used with very low pressure, such as from a drum elevated only 2-3 metres, the drip 

lines must not be longer than 20m. 

E.E.O.A. 

“MICRO-JET” sprinkler systems give better distribution of water to the root zone but allow 

more weeds to grow. They are more expensive than drip and require a pressure of only 1 

atmosphere. They will cost about US$ 1,000 per ha. 

“SPRINKLERS” are more expensive to buy but fewer are required per hectare. They can 

be spaced up to 18 metres apart and require a pressure of at least 2.5 atmospheres at 

the sprinkler nozzle to work properly. The sprinklers are supplied from a pressurised 

pipe, usually aluminium (prone to theft!), thin walled galvanized iron (relatively heavy) or 

polyethylene/ aluminium combinations. The pipes and sprinklers are moved at regular 

intervals; e.g. every 8 hrs where the irrigation rate is 6mm of water/hr. This combination is 

AGRO-TECHNOLOGY: Farming and Processing Equipment 

3

fairly common in Zambia and applies 50mm water every week. 

PUMPS 

There are many different kinds of pumps, some are operated by human power, others by 

wind power and others by diesel, petrol or electric motors. 

Human powered pumps 

“DIAPHRAGM PUMPS” are made in Zambia using wood, and small amounts of metal with 

rubber/plastic parts. They are operated by a handle and can be used for low-lift situations. 

They cost US$117 and are available from TDAU at the University of Zambia. 

“TREADLE PUMPS” are operated by standing on one peddle and then the other alternately. 

There are models for high lift and others for low lift. High lift models do not pump as much 

water per step as low lift, so the height to which water is to be pumped is important in 

choosing a pump. Check how much pipe is supplied with the pump. A non-collapsible suction 

pipe is needed and a delivery pipe which can be collapsible. 

Pumps cannot suck water more than about 6 metres no matter how strong the operator is. 

The suction side of a pump is always more problematical than the delivery side because small 

leaks allow air to enter, which prevents the water from entering the pump. The pump should 

always be as close as possible to the water to avoid these problems. 

When dirt is allowed to enter the pump it will cause damage and stop the pump from working 

well. Make sure that the suction pipe does not pull 

mud, sand and dirt into the pump. It is best to 

have a foot valve with a sieve to protect the pump 

and keep it primed when not in use. 

Treadle pumps need to be pumped for 2 to 4 hours 

per day twice a week for one tenth of a lima of 

crop, depending on the maturity of the crop and 

the weather. 

ZEEOA HPRESS TREADLE PUMP 

4 

E.E.O.A. 


A “DEEP WELL PUMP” is a means of raising water from a well using rubber washers on a rope 

in a pipe. Turning the handle at the top of the well causes the rope with washers on it to 

pass up the pipe lifting the water with it. The out�ow can be diverted into a furrow. Do not 

try to put the water into a pipe on the surface since no pressure can be generated by this 

kind of pump at the outlet. 

The pump can deliver about 5,000 litres per hour to a head of 4 metres. 

Wind powered pumps - windmills 

Windmills cost around US$2,500 and will pump from a borehole or a well. They must be 

placed where there is enough wind and they will pump only when there is wind, so they should 

deliver into a tank so as to catch the water by night as well as by day. It is advisable to �t 

them with a manually operated handle to pump even small amounts of water to keep seedlings 

alive when there is calm weather. 

A large windmill could irrigate up to 5 hectares if it is well placed for wind and water 

source. 

Windmills can be damaged by high winds in storms and so should be “locked” to prevent 

rotation during storms. 

Motorised pumps 

Pumps with engines are usually “centrifugal” pumps using one or more “impellers” that spin 

very fast to give pressure. There are also “mono” pumps for boreholes that operate on a 

screw principle forcing water upwards through a pipe. 

There are many different speci�cations for these pumps so farmers must to describe to 

the sales agent what the needs are exactly in order to have the correct kind provided. The 

agent will need to know: 

the amount of money available to purchase the equipment 

the size of the area to be irrigated 

the type of soil (sandy-clay) 

the elevation of the top of the water supply in relation to the elevation of the �eld 

the �ow rate of the supply 

the topography (contours/slopes) of the �eld 

the range (rotations!) of crops to be grown 

the availability (and distances) of ZESCO 

E.E.O.A. 

When a competent agent has all the above information, he can make sensible proposals to 

the farmer who can then select a design which will suit him best. He can decide what kind 

of irrigation system is to be used. Will it be �ood or drip or sprinkler because the different 

pressure requirements will dictate what kind of pump is needed. 

Standard pumps with petrol or diesel engines are useful for �ood irrigation or �lling tanks. 

Check with neighbours to �nd their experience of pumps and see what is available in your 

area. All pumps require spares so it is important that there is an agent nearby. 


5

OX-Drawn Equipment 

ZEEOA PETROL PUMP 

Ploughs, rippers, cultivators, ridgers and planters. 

Ox drawn ploughs are all very similar although some are heavier and stronger than others 

are. They all need to have new “points” with nuts and bolts for �xing to the share as the 

share points become worn out with use. Ploughs have different sizes of shares ranging from 

8 inches (200mm) to 12 inches (300mm), depending on how deep you want to plough. The 

ploughing depth usually depends on how heavy the soil is. Heavier ploughs can plough more 

deeply but will require strong oxen or even more than two to pull them. 

Ploughs should be used with caution as their repeated use causes destruction of the land! 

ZEEOA PLOUGH 

The Magoye “Ripper” 

E.E.O.A. 

This is really a furrowing tool which is bolted onto most standard plough beams. It was 

developed in Zambia and is one of the best agricultural inventions from this region. It is 

particularly suited for “Conservation Tillage” where only the planting furrow is subject to 

deep cultivation. In lighter (sandy) soils it can be used in the dry season, even though more 

6 


than one “pass´may be required to achieve an acceptable depth. The furrows are made only 

at the chosen crop row spacing (usually from 70-90cm) and the interrow is NOT ploughed. 

Cultivators and ridgers are then used to control weeds and build up ridges around the crop. 

Where farmers use the Magoye Ripper they can “dry plant” before the rains or make a 

planting furrow in even heavy soil immediately after the �rst rains. A strong pair of well 

trained oxen in one day can “rip” suf�cient furrows to plant a hectare. The yield losses due 

to the customary delays in planting have been well documented as costing the farmer the 

equivalent of 50kg of maize/ha for each day late after the �rst planting rain!! 

Wing Extension attachments for the Magoye Ripper can serve as ef�cient weeding and 

ridging accessories 

Ridging Bodies can be attached to most ploughs. Check what attachments are available for 

the plough you choose. There are also b attachments available though the technology has 

not yet been fully proven in the �eld. 

ZEEOA RIPPER 

Planters that can be pulled by oxen are also available. These allow for faster planting and 

fertilser application so long as they are operating properly. Check that they can plant the 

seed that you want to use. Sometimes different planter plates have to be bought to allow 

certain seeds to be planted. 

ZEEOA SEED PLANTER 

E.E.O.A. 


7

Cultivators should be adjustable to cover more or less of the inter-row space according to 

which crop is grown and how mature it is when the cultivator is used. Hiller blades can be 

attached to outer tines to cover the weeds in the crop lines. 

Processing equipment 

E.E.O.A. 


ZEEOA CULTIVATOR OR 

CULTIVATOR 2 

Lifters are attachments with 

a blade for under-cutting 

groundnuts so they can be easily 

separated from the soil. 

Oil expellers 

Machines for expelling oil from sun�ower, groundnuts or sesame can be operated by hand. 

Screw presses have greater capacity but need electric or diesel motors and are more 

expensive to operate and therefore can be justi�ed only when a large amount of seed can 

be bought and a large market for oil exists. 

A comparison of costs is attached. 

Ram Press and Oil Press 2 

8

Shellers 

There are many devices used for shelling maize from simple hand held collars for one cob 

at a time to motorised machines which can shell several tons per hour. Some machines can 

also shell groundnuts and some will shell only groundnuts. Do not buy machines with a higher 

capacity than you need unless you think the business will de�nitely expand. 

A comparison of the prices and capacity of available machines is attached. 

Mills 

There are hand-operated mills and motorised mills. Do not forget the cost of maintenance 

of machinery and specially of diesel engines if thinking about buying a motorised mill. 

ELECT MILL 

HIPPO MILL 

E.E.O.A. 


9

SUNFLOWER PROCESSING 

Introduction 

Processing Sun�ower oil provides a good opportunity for increasing income from Sun�ower 

production. 

Between 10-18 litres of oil can be expressed from 50kgs of clean seed. As a rule of thumb, 

Improved varieties and hybrids should yield at least 15 kgs of oil. 

Many farmers, particularly in Eastern and Central Provinces operate the Yenga hand press 

to express and sell oil locally. These farmers express oil from their own sun�ower and that 

of farmers who have grown the crop, usually in exchange for the cake which is a valuable 

stock feed. 

press 

The Yenga Press 

The Yenga Press is operated by hand and can be pro�table if there is a supply of good seed 

and a reliable market for the oil. 

Before investing in a Yenga press, farmers should check out the availability and price 

of commercially and locally expressed cooking oil being sold by traders and marketeers. 

E.E.O.A. 

They should also �nd out whether many other farmers are expressing oil and have already 

satis�ed local demand. A good local supply of clean improved seed with a high oil content is 

essential. 

Farmers investing in a Yenga press should therefore consider growing their own Sun�ower 

to ensure they have adequate supplies. Africare provides a detailed owner’s manual for the 

Yenga Press and any farmer considering investing in a press should obtain this lea�et to �nd 

out what is involved. 

Important facts about operating the press: 

* It takes 5-7 hours to press 50 kgs of seed. A reasonable average from clean soft-shelled 

seed of improved varieties is 12 litres of oil from each 50kg bag. 

10 


* Dirt, dust and all waste matter must be removed from the seed by winnowing it. Dirt 

particles will wear out the piston. If seed from other farmers is being purchased for 

expelling, it should be carefully checked �rst. Some local varieties have a very low oil 

content and hard shells. A good test is to see how much oil can be expressed from a 5 litre 

tin of seed. Seed with acceptable oil yield will 1/2 �ll a 750ml saladi bottle and good seed 

will 3/4 �ll it. 

* It is best for 2 people to work the press. One prepares the seed and the second operates 

the press. Before pressing seed should be warmed in the sun for 15 minutes as this will 

increase the extraction rate. If there is no sun the seed can be warmed over a �re in a �at 

metal container. Seed should be warm to touch and not hot or burnt. 

* The press should be properly set before operation commences, and as regularly as 

required, by adjusting the restrictor. The press should only be operated by 1 person and the 

handle should be moved up and down smoothly. 

* The press should be lubricated twice a week with clari�ed oil and should be cleaned each 

time 10 bags has been crushed. Boiling water is poured over the cage cylinder, and then 

scrubbed with a brush. A knife is then used to remove residues caught between the cage 

bars and the cage is rinsed again with boiling water. 

* Oil coming out of the press will be grey. Oil can be clari�ed by allowing it to settle for 72 

hours. The particles settle and the clear oil is carefully decanted off. This is the best and 

most simple method of clari�cation. 

• Simple daily records should be kept of: 

• the amount of seed bought; from whom and how much paid (or contractually committed) 

• the amount of seed crushed 

• the source of the seed 

• the quantity of oil (and colour) 

• the labour used (cost) 

• the quantity of oil sold – and income (credit or cash or barter) 

• quantity of cake produced 

E.E.O.A. 

• the quantity of cake sold – and income (credit or cash or barter) 

• Balances of Seed; oil; cake; cash 

• Any problems and what action taken 

The Sundhara Press, available from Jung & Co Kitwe ( tel 02 212851; 02 210476) extracts 

18 litres of oil from 50 kgs of hybrid seed and is run by a 10 hp diesel or electric motor. 

The expeller costs $5,150 ( 3 phase electric motor) and has an output of 200 litres of crude 

oil a day. The screw worm wears out after 50-70 tons of sun�ower has been expelled. This 

reduces extraction rates and the worms then have to be re-faced by the manufacturer. 

Operators should have 2 spare worms so processing is not delayed during re-facing. 

The business is really only suited to entrepreneurs who have large retail outlets and who 


11

are used to operating machinery. Electric motors are cheaper and more ef�cient than diesel 

engines for providing power. 

Cake 

Cake is the remainder of the seed after it has been crushed and the oil extracted. It still 

contains small amounts of oil and is a valuable feed for animals. It can be broken into small 

particles and fed to chickens or mixed with meal and fed to pigs and cattle. Meal is valuable 

and can be sold to other farmers. 

SUNFLOWER PROCESSING BUDGETS 

Cost of running the press. 

The cost of buying the machine is the biggest hurdle in running an oil pressing business. 

The cost of the press must be covered by sales of oil before the press stops working from 

being too old. A Yenga should be able to process 15 tons (300 bags) of sun�ower in its life. 

If the owner has borrowed money to buy the press, and is paying interest, it should be paid 

off as soon as possible. Here we assume that no money was borrowed. 

If the press costs K540,000, and processes 15 tons before it is useless, it means that 

K1,800 (15TX20bags=300bags --– K540,000/300=K1,800) is needed from each bag to pay 

for the press. 

It also costs money to keep it maintained and repaired. This may be K75 per bag. 

The running cost of the press is then K1,875 per bag without counting interest. 

Interest may be 60% per year and if we assume the life of the machine is 2 years, then the 

interest payable will be approximately 60% if repayments are spread over the 2 years. This 

would amount to (0.6X540,000)=K324,000 

Thus, the cost of interest, per bag processed = K1,080 --- (324,000/300= 1,080) 

In addition the owner may be paying a worker to operate the press. This may be K3,000 per 

day during which one bag can be processed. 

Therefore the cost of operating the press to process one 50 kg bag will be K5,955 

(1,800+75+1080+3000=5,955) 

Cost of the seed 

E.E.O.A. 

A press owner may process his own seed or buy it from someone else; either way it has a 

cost. It will be cheaper at harvest than later in the year and may range from K15,000 to 

more than K25,000. Assuming that it cost K20,000 per bag the total cost of processing the 

oil and cake will be it will now be K25,955 --- (20,000+5,955) 

How much oil will be produced? 

The Yenga press is not as ef�cient as a mechanical screw press at extracting oil and the oil 

content of the seed is also variable. You can expect about 10 to 13 litres (13 to 17 bottles 

of 750 mls) from a bag of seed. 

The sale of this oil must cover the cost of processing the bag. 

12 

• If 13 bottles are produced for sale, then the selling price per bottle must be at least 

(zero pro�t) K1,996.54 (K25,955/13 bottles) 






Oil sales 

The price of oil will change through the year depending on the cost of seed, the amount of 

oil that others are trying to sell and the amount of money that customers have. 

At a selling price of K2,700 per bottle, a bag producing 15 bottles, will produce K40,500 

worth of oil and therefore give a margin of K14,545 (40,500-25,955) per bag. 

The margin is K969.67 per bottle (K14,545/15 bottles) 

Value of Cake 

The cake is very valuable provided there is a market! Cake can be valued at K400/kg and 

as approximately 30Kg are produced per 50kg of Sun�ower processed, the value of cake 

from one bag of seed can be K12,000 (30kgXK400). 

If the processor can sell his cake for K12,000 per bag processed, the total gross pro�t 

jumps to K26,545 (14,545+12,000). 

It is therefore most important to secure a regular market for the cake!!! 

Riskiness 

The business has its risks as explained above. 

The level of pro�t will depend on: 

• The selling price of the oil (who pays for the bottle? -- customers exchange bottles!) 

• The price paid for the seed delivered to the press 

• The extraction rate i.e. the number of bottles of saleable oil produced per bag 

• The amount paid for operating labour 

• The selling price of the cake – there may be no local market so the owner may have to 

transport the cake at a cost, or feed it to livestock! 

E.E.O.A. 

If we assume zero selling price for the cake, the 15 bottles of oil must sell for over K1,730 

per bottle in order to make a pro�t if seed is bought at K20,000 per bag. If oil is sold at 

K2,000 per bottle and only 13 bottles are produced, no more than K20,045 (13 bottlesX 

K2,000 – K5,955) must be paid for each 50kg of seed 

Keeping Records 

Make sure that press owners keep records so that they know if they are making or losing 

money. 

Make a cost and sales sheet like the form attached to keep records on. 

Examples of costs and returns are shown in the tables below. 

Oil Press Costs and Returns 

Press Owner’s name: Bwalya Mulenga Press type:Yenga 

Price paid:K540,000 Date purchased: 31 st February 2006 from Mafuta 


13

A - Cost of maintenance: 

Date Operation Cost Accum Cost 

1 st 

2 nd 

Etc. 

B - Cost of repairs 

Date Operation Cost Accum Cost 

1 st 

2 nd 

Etc. 

C - Monthly Processing Record for month of _____________2001 

Date Names of Workers Kwacha Bags Litres Accum Accum 

Cost pressed Oil Bags Litres 

1 st 

2 nd 

etc 

(Kwacha “cost” can be what is “paid “ to workers or, total cost e.g. to include food, leave pay 

etc. or, to include the value of family labour) 

D - Monthly Seed Movement for month of ________2001 

E.E.O.A. 

Opening balance ___ bags. Opening value K_______ Average Opening value/bag K_______ 

Date Bags Bags Bought from Cost Total Balance Balance Average 

Pressed Bought per Cost Value (bags) Value of 

Today Today bag of Seed Seed 

1 st 

2 nd 

etc 

31 st NB No1 – include owner produced S/F seed as “sales” from farm to the “business” 

14 

No. 2 - check totals and arithmetic! 


E - Monthly Oil Movement for month of ________2001 

Opening balance ____ litres =____ bottles. 

Date Bottles Bottles Total Value of Accum. Accum. Average 

produced Sold Bottles today’s Bottles Sales Value bottle price 

Stock sales sold 

1 st 

2 nd 

etc 

F - Monthly Cake Movement for month of ________2001 

Opening balance ____ Kg. 

Date Kgs Kgs Total Value of Accum. Accum. Average 

produced Sold Kgs today’s Kgs Sales Value price per Kg 

Stock sales sold 

1 st 

2 nd 

etc 

CALCULATION OF MARGIN 

The margin for the period is the difference between: the “value of sales plus stocks at 

the end of the period” and, the “operating costs plus purchases plus value of stocks at the 

beginning of the period”. 

CALCULATION OF MARGIN USING MONTHLY RECORDS 

(considering “July” as an example) 

E.E.O.A. 

Start with Oil Sales during the month (from Table “E” Accumulative sales value at end of 

month minus accumulative sales value at beginning of month - assume K720,600) 

K720,600 

ADD Cake Sales during the month (from Table “F” Accumulative sales value at end of 

month minus accumulative sales value at beginning of month - assume K298,600) 

K298,600 

ADD 

Value of oil stocks (from Table “E” = the total bottles remaining unsold in stock at the end 

of the month). (assume 42 bottles at the most recent selling price per bottle, say K2,800= 

K117,600) 

K117,600 


15

ADD 

Value of seed stocks (from table “D” = the balance of bags at the end of the month). (assume 

12 bags at the most recent buying price, say K26,500 = K318,000) 

K318,000 

ADD 

Value of cake stocks (from table “F” = total kgs stock at the end of the month). 

(assume 120kgs at the most recent selling price, sayK400 = K48,000) 

E.E.O.A. 


K48,000 

K720,600+K298,600+K117,600+K318,000+K48,000 = K1,502,800 

(consider this �gure as “x”) 

Now, 

SUBTRACT from “x”, the closing stock Balances for the previous month (= opening balances 

for present month; e.g. when calculating for July, the opening balance at beginning of July 

is equal to the closing balance at the end of June). Use Tables C,D,E & F (consider K154,800 

for calculation purposes) 

K1,502,800 – K154,800= K1,348,000 

NOW, SUBTRACT the following purchases and operating costs: 

Total Purchases in month (from Table “D”) – (assume K620,000) – K620,000 

Total Maintenance in month (from Table “A”) – (assume K26,200) – K 26,200 

Total Repairs in month (from Table “B”) - (assume K34,200) - K 34,200 

Total Labour cost in month (from Table “C”) - (assume K230,500) - K230,500 

K1,348,000-K910,900 = K437,100 (the “MARGIN”) 

Sub total = K910,900 

Each month take the margin away from the cost of the press and see how much is still 

remaining to cover the cost of it. 

When all the monthly margins have covered the full cost of the press, you are making real 

pro�t. 

16 

SAVE UP TO BUY A NEW ONE!

HAMMER MILL PROCESSING and COSTS 

Introduction 

Processing maize into Roller Meal provides a good opportunity for increasing income from 

maize production and from other people’s maize. 

Roller meal is the product obtained when whole maize grain is milled by any process. “Breakfast 

Meal” is the product obtained from maize after most of the germ and seed coat has 

been removed. This process requires a more sophisticated machine or set of machines. 

There are roller mills on the market which can produce a product very similar to commercial 

breakfast meal but they cost much more than a “Hammer Mill” and require a high standard 

of management for successful operation. 

The hammer mill is a simple robust machine which consists of a set of “hammers” which are 

attached to a steel shaft which rotates very fast so that it smashes the maize grains. The 

smashed pieces then pass through a “screen” or sieve. Eventually all the maize is smashed 

suf�ciently that all of it is able to pass through the screen. These particles after passing 

through the screen are called “roller meal”. 

Roller meal is more nutritious than breakfast meal as a signi�cant part of the protein and 

minerals is removed as “maize bran” during the processing of breakfast meal. 

DESIGNS of HAMMER MILLS 

Most hammer mills are based on the same simple principle – maize is fed into a chamber in 

which a row (or rows) of hammers rotate at approximately 3,600 rpm. This requires a motor 

of 5.6 kilowatt or 7.5 horse power (HP) for a throughput of 200kg/hr. The motor can be 

fuel driven – usually diesel (D), or electrically powered (E) which is cheaper to buy and to 

operate. 

Common hammer mill sizes and capacities are; 

OUTPUT MOTOR SIZE Litres of diesel/hr Cost of Mill($) 

200kg/hr 7.5HP 1.3 2,111(E); 2,328(D) 

E.E.O.A. 

400kg/hr 15-16HP 2.6 2,715(E); 5,563(D) 

600-700kg/hr 25HP 6.1 3,700(E);7,100(D) 

DECIDING TO BUY and OPERATE A HAMMER MILL 

The �rst consideration is: “is there suf�cient market?” This entails looking at the “competition”, 

the population and their ability/willingness to buy roller meal or milling services and 

for how much of the year. Normally it is not worthwhile buying maize, transporting it to the 

mill, processing it and then transporting any signi�cant distance to market. 

The next decision is the size (capacity of the mill) – this will depend on the expected market 

demand. The choice of motors is the next decision – electric motors are cheaper but there 

AGRO-TECHNOLOGY: Farming and Processing Equipment 17

may not be any ZESCO near the site for the mill. 

The mill will require a secure and rainproof room and it is advisable to have an adjacent 

rainproof store for storage of maize, meal, sacks, spares – fuel should be kept in the mill 

room to avoid it tainting the maize. 

SITING of the MILL 

The operator needs to consider the following when choosing a site for the mill: 

18 

Drainage during the rainy season 

Security – near the owner’s house? 

Accessibility by the customers and vehicles 

ZESCO supply 

COSTS OF OPERATING A HAMMER MILL 

CAPITAL COSTS 

Purchase of the Mill – this is the biggest expenditure and the operator should allow for: 

Transport to the site 

Installation e.g. concrete base 

Exhaust pipe 

Raised platform for easy loading of the mill 

Electrical installation ( a 3 phase supply would be necessary)– cables; switches and 

starter (may or may not be included in price and should have “protection” for Zesco 

power �uctuations) 

Buildings for the mill and storage facilities – these are variable and allowance should be 

made for construction, repair or rental 

OPERATING COSTS 

E.E.O.A. 

These comprise: fuel (or ZESCO charges); service parts; spares; maintenance charges; 

labour and sacks 

Fuel see the table above for fuel consumption (this will deteriorate with age) 

Engine oil allow for 15ml/hr 

Filters change the diesel and oil �lters after every 250 hours of operation – allow 

$29/change 

Change the air cleaner elements after every 500 hours – allow $55 

Change the hydraulic oil �lters after every 1,000 hours – allow $102 

Belts allow for $11/2,000hrs or every year (NB always change ALL the belts) 

Labour allow for a team of 2 people 

Mill Screens allow for $15/1,000hrs 

Sieving Screen ( for cleaning maize before milling) allow $50/2,000hrs 


OPERATING BUDGET 

This will be considered per hour of operation for a 400kg/hr mill using a diesel engine 

Note that the 400kg �gure is for a constant �ow of maize. In practice, a �gure of 300 kg/hr 

of product is a reasonable output and the following calculations are based on 300kg/hr: 

The costs are calculated in $US so that costs in Kwacha can be derived by converting at the 

current exchange rate. 

COST OF PROCESSING 300KG OF MAIZE (1 HOUR OF OPERATING) 

USING A DIESEL POWERED ENGINE 

$US 

Capital cost depreciated over 10,000 hrs ($5,563/10,000) 0.5563 

Cost of building dep.over 10,000 hrs ($1,600/10,000) 0.16 

Diesel (2.6litres @ 0.9$/l) 2.34 

Engine oil (.015litres@$3/l) 0.045 

Filters – diesel and oil ($29/250hrs) 0.1303 

- air cleaner elements ($55/500hrs) 0.11 

- hydraulic oil �lters ($102/1,000hrs) 0.102 

Belts ($11/2000hrs) 0.0055 

Labour ( 2 workers @ $1.5 each/7hrs working day) 0.4286 

Screens ($15/1,000hrs) 0.015 

Sieving screen ($50/2,000hrs) 0.025 

Total cost for 300kg = $3.9177 = $0.01306/kg = $0.235/Tin of 18kg 

At a Kwacha/dollar exchange rate of 3,500 this is K822=50 

KEEPING RECORDS and CONTROL! 

This is WITHOUT any PROFIT!!! 

E.E.O.A. 

A Daily Log Sheet is presented overleaf. 


BUNGA ENTERPRISES DAILY CONTROL SHEET 

For: Weekday_ / /02 Sign. of Supervisor@____hrsam Sign. of Supervisor@____hrspm 

STOCK CONTROL 

MAIZE brought forward from yeaterday ____ kgs@K__Kg =K_______ 

Add: ___kgs from___________ (Inv No--) total cost =K ______ 

Add: ___kgs from___________ (Receipt No--) total cost =K ______ 

Add: ___kgs from___________ (Inv No--) total cost =K ______ 

Add: ___kgs from___________ (Credit sale No--) total cost =K ______ 

Sub total(A)_____kgs Sub total (B) =K_______ 

Subtract ____Kgs processed @K____/kg =K_______ 

Subtract ____Kgs processed @K____/kg =K_______ 

Subtract ____Kgs sold @K____/kg =K_______ 

Subtract ____Kgs sold @K____/kg =K _______ 

Sub total(C) _____Kgs Sub total (D) =K_______ 

CLOSING BALANCES= ________Kg(=A-C) __________ K (=B-D) 

MEAL brought forward from yeaterday ____ kgs@K__/Kg =K_______ 

Add: ___kgs processed___________ (Inv No--) total value =K ______ 




Sub total(A)_____kgs Sub total(B) =K_______ 


Subtract ____Kgs processed @K____/kg processed =K_______ 


20 

E.E.O.A. 

Subtract ____Kgs processed @K____/kg processed =K_______ 

Subtract ____Kgs sold @K____/kg =K _______ 

Sub total(C) _____Kgs Sub total(D) =K_______ 

CLOSING BALANCES= ________Kg (=A-C) K__________ (=B-D) 


Hrs �nish_______ 

Hrs start_______ 

BUNGA ENTERPRISES DAILY OPERATIONS RECORD 

For: Weekday_ / /01 Sign of Supervisor____@___hrsam Sign of Supervisor____@___hrspm 

Next service (changing_______________________________) due on ___/__ 

Engine oil checked by ______ @_____hrs; ___litres oil added 

Belts, screen checked and nipples greased by_______ @_____htrs 

Hrs 

used 

OPERATION 

___kgs/client 

Receipt/Inv 

Ref No 

Litres fuel 

Added/by: 

E.E.O.A. 

Kgs of maize milled=________ Kg(E) - Fuel used to �ll up= ______litres(F) 

Total hrs = _____ (G) Total fuel used in day =________(H) 

Fuel consumption/hr for the day =____L(H/G) – Kgs per l fuel=___ Kgs(E/H) 

Supervisors comments 

Breakdowns 

Service 


Agro-Tech Equipment Suppliers 

22 

Category Item Make or Model Price * Power source Regular spares Weight Dimensions Capacity Life Supplier 

Guide (K) Kg LxWxH. mm Expectancy 

Irrigation 

Manpowered Treadle Pump River Pump ( Sams) 195,000 Treadle Valve rubbers 20-25 1000x350 3,300 l/hr 5-10yrs. Internatinal Development 

Enterprises 

Treadle Pump Pressure Pump ( Saro) 275,000 Treadle Valve rubbers 30-35 1000x255-356 3,000 l/hr 5-7yrs. Internatinal Development 

Enterprises 

Treadle Pump Modified Pump ( Sams) 195,000 Treadle Valve rubbers 15-20 1000x255-356 3,300 l/hr 5yrs. Internatinal Development 

Enterprises 

Deep well pump Forcelift Manual Rubber Cups and 1400x1200x1000 5,000 l/hr 4 years TDAU 

Nylon ropes 

Deep well pump Forcelift Manual Rubber Cups and 1200x300x1300 3,000 l/hr 3-4yrs AquaAgro Ltd. 

Nylon ropes 

Diaphragm pump TDAU Manual Inner tube 1500x350x1000 3,000 l/hr 5 years TDAU 

Drip Irrigation- Drum Kit ID-Drip system- 155,000 Manual None 100-120 sqr. Mts. 5yrs. Internatinal Development 

(Southn Africa) Enterprises 

Drip Irrigation-Bucket Kit ID-Drip system Manual None 104 plants 5yrs. Internatinal Development 

(South Africa) Enterprises 

Deep Well Hand Pump India MarkII Manual Repair Kit 15kg 1600x400x1400 .5lts/stroke 5-6yrs AquaAgro Ltd. 

and Valves 

E.E.O.A. 


Bucket Kit Bucket Kit Manual 104 plants/fill 3-4yrs AquaAgro Ltd. 

Cultivation 

Rippers Magoye Ripper 150,000 Animal Tines, Separators, 15 2000x800x1000 0.15-0.25ha/h 4-5yrs Saro Engineering 

Wheels, Nuts 

Ripper attachment to plough Saswaz 75,000 Animal Tines, Separators, 400x450x300 0.15-0.25ha/h 3-4yrs Saswaz 

Wheels, Nuts 

Magoye Ripper Sams 65,000 Animal Tines, Separators, 10 2000x1200x1199 .15-.25ha/h 4-5yrs Sams Co-op. Society 

Wheels, Nuts 

Ploughs Ploughing- Double Board Zimbambwe 720,000 Animal Shears and Nuts 120 2000x1200x1200 0.1-0.2ha/h 10yrs Handymans Paradise 

Plough MDM 350,000 Animal Shears and Nuts 25 1800x800x1200 0.05-0.1ha/h 5-7yrs MDM Engineering Co. 

Plough Saswaz 286,000 Animal Shears and Nuts 20-25 1800x800x1201 0.05-0.1ha/h 5-7yrs Saswaz 

Ridger Plough Zim 1,340,000 Animal Shears and Nuts 40-45 1800x800x1202 0.15-0.25ha/h 5-7yrs ZCF 

Plough Zim 345,000 Animal Shears and Nuts 40 1800x800x1203 0.05-0.1ha/h 5-7yrs ZCF




Ploughs Ridger-attachment only Saswaz 72,000 Animal Shears and Nuts 40-45 400x450x300 5-7yrs Saswaz 

Harrows Zig-zag Harrow-Clearing MDM 395,000 Animal Harrow Spikes 20 2000x1000x200 0.5-1ha/h 3-5yrs MDM Engineering Co. 

Cultivator- Weeding MDM 420,000 Animal Harrow Spikes 30 2000x900x1000 0.10-0.20ha/h 3-5yrs MDM Engineering Co. 

Zig-zag Harrow-Clearing Saswaz 176,000 Animal Harrow Spikes 20 2000x1000x200 0.5-1ha/h 10yrs Saswaz 

Cultivator- Weeding Saswaz 300,000 Animal Harrow Spikes 30 2000x900x1000 0.3-0.5ha/h 7yrs Saswaz 

Cultivation 

Planters Planter/Fertiliser Applicator Zim 2,952,000 Manual/Animal Shears,Nuts 20-25 2000x600x800 10kgfert/8kg seed 5-7yrs ZCF 

and wheels 

Planter/Fertiliser Applicator Zim 520,000 Animal Shears,Nuts 20-25 2000x600x801 10kgfert/8kg seed 5-7yrs Handymans Paradise 

and wheels 

Planter / attachment Saswaz 227,000 Animal Shears and Nuts 25-30 600x700x800 8-10kg Seed 5yrs Saswaz 

Lifters Groundnut Lifters Saro 550,000 Animal Sheni Agriculture Supplies 

Processing 

Oil expellers Ram Press Saro 672,000 Manual Piston 20 500x250x800 15lts/50kg-s/flower 2-4yrs Saro Engineering 

E.E.O.A. 

AGRO-TECHNOLOGY: Farming and Processing Equipment 23 

Yenga Press Yenga ( Sams) 650,000 Manual Restrictor 30-35 280x1650x450 100-150kg/day 3-5yrs Sheni Agriculture Supplies 

Oil Expeller Sams 9,000,000 Manual Worm screws 1500kg/day 5-7yrs. Sheni Agriculture Supplies 

Yenga Press Saswaz 520,000 Manual Barrels and Piston 30-35 280x1650x450 10kg/h 3-5yrs Saswaz 

Oil Expeller Zim 3,188,000 Manual Worm screws 5-7yrs. ZCF 

Oil Expeller Chinese 3,240,000 Electrical Belt, Shaft Bars, 140Kg. 998x520x660 1 tonne/24hrs. 5-7yrs. Camco Equipment 

Rings 

Oil Expeller Chinese 6,288,000 Electrical or Diesel Worm screws 140 660x520x998 50kg./h 10yrs AFE 

Shellers “crocodile” Maize Sheller Crocodile- (Saro) Manual None 10 200x100x350 20kg/h 4yrs Saro Engineering 

Maize sheller Sams 1,800,000 Manual Sieves 68kg 1400x860x500 200kg/h-output 4yrs Sams Co-op. Society


24 



Shellers Maize shelller Zim 2,392,000 Manual Sieves 60-70 250kg/h 5yrs ZCF 

Dehuller Turning and Metals 4,000,000 Diesel and Electrical Bearings, 450kg/h 5yrs Turning and Metals Ltd. 

Sieve and Filters 

Dehuller-Maize, Rice Sams 5,000,000 Electrical or Diesel Bearings, 145 1180x1460x930 200kg/h 5-7yrs Sams Co-op. Society 

and Sorghum Sieve and Filters 

Groundnut sheller Saro 620,000 Manual Seives and 40 600x300x700 300kg/h 5yrs. Saro Engineering 

Hammers 

Groundnut sheller Saro 950,000 Manual Seives and 39 600x300x699 300kg/h 5yrs Sheni Agriculture Supplies 

Hammers 

Groungnut sheller Sams 1,800,000 Manual Seives and 60 1320x570x600 60-85kg/h- 5yrs Sams Co-op. Society 

Hammers Output 

Maize and Rice Dehuller Kalonthoho 3,900,000 Diesel Bearings, Sieve 120 800Wx1000 H 380Kg./h 5-8yrs. Kalontho Engineering 

and Filters 

Rice and Maize Dehuller Saro 13,000,000 Electrical or Diesel Bearings, Sieve 400-500kg/h 5-7yrs Sheni Agriculture Supplies 

and Filters 

Mills Grinding Mill 400,000 Manual Hammers 100kg/h 5yrs ZCF 

E.E.O.A. 


Hand Grinding Mill Tamsa 2,116,000 Manual Roter and Starter 80 1200x750x1500 70kg./h 10yrs AFE 

Mills Domestic Mill Tamsa 1,200,000 Electrical Bar sieves 10 1000 high and 70kg./h 2-3yrs. AFE 

300 diametre 

Hammermill Sams Electrical Hammers and screens 5 400 Diametre 2-3yrs. Saro Engineering 

x1000high 

Hammermill Turning and Metals 4,800,000 Diesel or Electrical Filters and Various Variuoss 605kg/h 5yrs Turning and Metals Ltd. 

Hammers 

Maize Mill Saro 11,000,000 Diesel or Electrical Filter 1000high and 70kg./h 5yrs Sheni Agriculture Supplies 

300 diametre 

Hammermill Yamaha EHM300 16,096,000 Petrol Hammers 250 1200x500x1600 700kg/h 5yrs. Power Equipment 

and screens 

Peanut Butter Machine Tamsa Electrical 70kg 530x2602x800 25kg./h 4-5yrs AFE 

*Note: Prices can change at any time. These prices are approximate and assume an exchange rate of K4,000 to US$1.00.

Agro-Tech Equipment Suppliers - Branches 

Organisation Branch/ Outlet Town Province Comment 

AFE (African Farming Equipment) AFE Lusaka Lusaka Several outlets available in major districts of Zambia 

AFE Kabwe Central 

AFE Chipata Eastern 

Sams (Small-Scale Agric Mech Services) Sheni Agriculture Chipata Eastern Equipment Manufactured by Sams in Lusaka 

Brother Willys Petauke Eastern 

Bodmas Stores Sinda Eastern 

Sun Enterprises Katete Eastern 

Nyimba Farmers Association Nyimba Eastern 

Burley Farms Kabwe/ Mkushi Central 

M&D Enterprises Kapiri Mposhi Central 

Imatongo Marketing Senanga Western 

Kalabo Rice Promotion Kalabo Westerrn 

Mongu Nutrition Group Mongu Western 

Makondu Rural Development Trust Zambezi North Western 

Kabompo Farmers Association Kabompo North Western 

Saswaz AfriCare field offices act as Outlets for Saswaz Saswaz is an Association of small-scale rural workshop owners/ relailers 

AquaAgro Industrial Equipment Kitwe Copperbelt 

Handyman’s Paradise Handymans- Cha Cha Cha Rd. Lusaka Lusaka 

Handymans- Lumumba Rd. Lusaka Lusaka 

Handymans-Freedom Way Lusaka Lusaka 

Handymans- Northmead Lusaka Lusaka 

Handymans Ndola Copperbelt 

ZCF- Farmers Shop ZCF Lusaka Lusaka 

ZCF Mumbwa Central 

ZCF Kabwe Central 

International Development Enterprise IDE- Kapiri Kapiri Mposhi Central IDE has trained manufactures in Lusaka, Chipata, Mufulira 

and Kafue. 

IDE-Choma Choma Southern Among the major manufacturers are SAMS, Saro, Knight 

E.E.O.A. 

AGRO-TECHNOLOGY: Farming and Processing Equipment 25 

Engineering, Chokwadi and Mailo. 

IDE-Petauke Petauke Eastern 

IDE-Chipata Chipata Eastern 

IDE-Monze Monze Southern 

Saro Engineering Lutanda Kitwe C/bvelt 

Sheni Chipata Eastern 

Vandoma L/stone Southern

Agro-Tech Equipment Suppliers - Addresses 

26 

Supplier Physical Address Postal Address Town Tel. Fax 

AFE Freedom Way, South End Box 31505 Lusaka 228995-8 223361 

AquaAgro Ltd. Plot. 3134, Buyantanshi Rd, Heavy Industrial Area. Box 30457 Lusaka 244477 244464 

Camco Equipment Sentor Motors, Great North Road Box 39558 Lusaka 254799/ 702668 254799 

Handymans Paradise Freedom Way, City Centre Box 33518 Lusaka 224663/236181 225617 

Internatinal Development Enterprises Plot.211 Belvedere House, Katunjila Rd. Box 350040 Lusaka 223590 237685 

Kalontho Engineering Plot. 1541, kafulafuta Rd., Kitwe Box 22301, Kitwe 02-214106/224048 217168 

MDM Engineering Co. 1566, Miseshi Rd, Heavy Industrial Area Box 21997 Lusaka 214126 214146 

Power Equipment North End, Cairo Rd. Box 32699 Lusaka 228035-8 235021 

Sams Co-op. Society TBZ Building, Mungwi Rd- Opp. BP Private Bag.W47 Lusaka 233229 233229 

Saro Engineering Plot.8617,Los Angeles Rd. Box 35168 Lusaka 287412-5 287416 

288846 

Saswaz Mungwi Rd, Opposite BP Depot Lusaka 287678 287678 

Shepherd Agriculture Zambia Mungwi Rd (Parmalat Building) Box 39123 Lusaka 233202 286321 

293655 

E.E.O.A. 


Sheni Agriculture Supplies Second-Class area Box 510110 Chipata 21528 21529 

Turning and Metals Ltd. Plot. 3140, Buyantanshi Rd., Heavy Industrial Area Box 31609 Lusaka 244011 244789 

Technology Development and Advisory Unit (TDAU) University of Zambia. Great East Road. Box 32379 Lusaka 293869 293869 

ZCF North End, Cha Ccha cha Rd. Box 33579 Lusaka 238901/2 220521

NOTES 

E.E.O.A. 


27

Agro-Tech Book - Agriculture Support Programme

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