International Journal of Current Business and Social Sciences | IJCBSS Vol.

1, Issue 3, 2015

Exploitation of Agricultural By-products for Employment Creation: the case of

Trans-Nzoia County, Kenya

Wakasiaka, Mwichabe Eliud

Mount Kenya University
Kitale Campus
P.O. BOX 2963 – 30200, Kitale
E-mail: mwichabewakasiaka@yahoo.com

Authors: Wakasiaka Eliud Mwichabe 1 (Mount Kenya University, Kenya); Mbote,

Waweru Francis2 (Mount Kenya University, Kenya) Chelimo K. Kenneth 3 (University
of Eldoret, Kenya) Prof. Chegge Mungai Peter 4 ( Mount Kenya University, Kenya).

CITATION: Eliud, Wakasiaka, Mwichabe (2015): Exploitation of Agricultural By-

products for Employment Creation: the case of Trans-Nzoia County, Kenya.
International Journal of Current Business and Social Sciences, 1 (3), 79-89.

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ABSTRACT

Trans-Nzoia county covers an area 2,469.90 Km2 with a total Population of 818,757
(Male 50% , Female 50%) and a poverty index of 5.2% (KNBS, 2011).The main
economic activities in Tran-Nzoia county include horticulture, large and small scale
maize farming , wheat farming, Tea, Coffee and fish farming. Many farmers here focus
on production and sale of the main products as raw materials. A large part of residual
harvest is handled inappropriately, hence weakening the world’s food production
capacity and contributing to biosphere change. Such a malpractice is particularly
common in low income countries, where indaquate amounts of residues are recycled.
Unacceptable amounts of straw and stalks are burnt either in the fields or as house hold
fuel. No nation keeps statistics on production of residue. Most crop residues are wasted
or used for non-feed purposes in many smallholder crop and livestock systems in
developing countries. This opinion paper looks at how Trans- Nzoia residents who are
primarily agro-based income generators can make good of agro-by products from their
crop and livestock waste products to not only break-even, but also to provide sustainable
employment for the youth through processing the by-products from their farm output
with the overriding aim of making the county self-sustaining and generating a surplus of
the by-product for export as finished value-added products. This library-researched paper
looks at Value Addition on Maize grain and focuses on the utilization of Maize by-
products since it is the most easily-available crop in Trans-Nzoia County.

KEY WORDS: Value addition on Maize grains, Agricultural by-products (Crop residue
processing), Industrialization and Employment Opportunities.

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Introduction

Trans-Nzoia county is located at the Northern part of the Rift-Valley Province, at the
slopes of Mount Elgon, Kenya. The main economic activities in Tran-Nzoia county
include horticulture, large and small scale maize farming , wheat farming, Tea, Coffee,
and fish farming. Many farmers here focus on production and sale of the main products
as raw materials (KNBS, 2011). Of these economic acivities, production of maize tops
the list with the County listed as one of the largest maize producers in the country
(Uluma, 2011; Short et al, 2012 )

There are many other industrial uses of maize which may not have been exploited.
Some industrial uses of Maize (corn) include filler for plastics, packing materials,
insulation materials, adhesives, chemicals, explosives, paint, paste, abrasives, dyes,
insecticides, pharmaceuticals, organic acids, solvents, rayon, antifreeze, soaps, and
many more (Lance, 2002).

Besides the main maize products, many other products that can be processed from corn.
(Suszkiw, 2009) asserts that after the oil is extracted from corn germ meal, the corn
germ is typically fed to poultry and other livestock. But a new, value-added use could
be on tap for this “leftover.” Corn germ, Suszkiw adds, can be used as a protein
extender for plywood glues, potentially opening the door to a new market for the
agricultural byproduct. Studies done in Zimbabwe indicate that Maize cob powder
produced from maize cobs that can be effective in the control of maize weevils
(Gadzirayi et al 2006).

Furfural chemicals are made out of organic matter which is typically produced for
industrial purposes such as weed killer, fungicide, solvent; and others are used in further
manufacture of other products including pharmaceuticals, and stabilizers (Francisco et
al, 2007). Cellulosic ethanol, which is a biofuel produced from existing waste biomass
alone could create thousands of jobs and hundreds of millions of dollars for the average
maize farmer (Cohen, 2010).

Maize cobs can also be used for manufacture of cheaper lightweight concrete (Pinto, et
al (2012).

This paper looks at Value Addition on Maize grain and focuses on the utilization of
Maize by-products for possible job creation since it is the most abundant crop in Trans-
Nzoia County.

Value addition on Maize Grains

According to Short et al, (2012), Kenya produces around 3 million tons of maize per
year; about 15 percent is sold directly to the National Cereals and Produce Board
(NCPB) and large millers, most of which comes from medium and large farms in
surplus regions of western Kenya. Uluma (2011) puts it at between 2.3 and 3.3 million
metric tons per year. Parts of the Rift Valley Province, particularly the counties of Trans

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Nzoia and Uasin Gishu, produce a large maize surplus, primarily on medium and large
farms. Other regions are either self sufficient or face a maize deficit on annual basis.
However, much of Kenya is semi-arid and subject to significant production volatility.
Medium and large scale producers may be more motivated by income earned from
maize production (Short ibid).

Findings from the Moi University Agrishare survey of stake holders in maize value
chain indicate that maize is the most important cereal crop in Kenya It forms an
important part of the food and feed system, and contributes significantly to income
generation for rural households. It is the main, staple food for the people of Kenya,
providing more than a third of the caloric intake. In terms of land usage, maize accounts
for about 56% of cultivated land in Kenya. About 98% of the 3.5 million small-scale
farmers in Kenya are engaged in maize production. The small and medium scale sector
produces about 75% of the nation‘s maize crop, while the large-scale sector (farms of
over 25 acres) produce the other 25%. On average, 1.5 million hectares are used to plant
maize annually, with annual production ranging between 26 and 36 million bags (2.3
and 3.3 million metric tons (MT)) depending on weather and market conditions (Uluma,
2011).

Kenya’s maize consumption is about 37 million bags (2.9 million Metric tonnes)
annually. Yet, despite the centrality of maize to the Kenyan food system, the country
has for the last several decades been trending toward a structural deficit in maize
production. Coping effectively with recurrent maize deficits is critical for enhancing
food security in Kenya and promoting economic growth in the smallholder farmer
sector. The sector is however, both technologically and organizationally complex
mainly due to poor infrastructure, lack of rural finance and poorly developed markets.
The major constraints affecting growth of the maize sub-sector include low soil fertility,
unreliable rainfall, pest infestation, poor infrastructure, marketing and policy
bottlenecks and low profitability attributed to a combination of low yields and poor
marketing strategies (Uluma, ibid). This means that the motivating factor in the
production of maize in Trans-Nzoia is the price of the whole grain. Farmers here do not
add value to the grain which can yield a variety of products and by-products, besides
giving them higher financial returns and creating jobs.

Some industrial uses of Maize (corn) include filler for plastics, packing materials,
insulating materials, adhesives, chemicals, explosives, paint, paste, abrasives, dyes,
insecticides, pharmaceuticals, organic acids, solvents, rayon, antifreeze, soaps, and
many more.(Lance, ibid).

Ethanol is another important biofuel that can be extracted from miaze grain. According
to Glassner et al (1998), if corn grain is used to double ethanol production in the US, the
following disruptive effects ensue. According to studies by the Government Accounting
Office (USGAO, 1990) and The United States Department of Agriculture (USDA)
Economic Research Service (Petrulis et al, 1993): (1) higher corn prices, 9% to 15%; (2)
increased livestock costs; (3) reduced corn export market, 5%; and (4) reduced soybean
price, 6% to 11%. There are three drivers for increased ethanol in the transportation fuel

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market: (1) energy independence (2) Green House Gas (GHG) emissions offset of fossil
fuel; and (3) cleaner air from vehicle emissions (Glassner et al, 1998).

Kenya has a very high potential in the commercialization of ethanol not only from the
grain but also from the stover. As shown by Glassner (ibid), it implies that increased
ethanol production from maize will push up the market prices for maize grain.
According to Suszkiw (2009), after the oil is extracted from corn germ meal, the corn
germ is typically fed to poultry and other livestock. But a new, value-added use could
be on tap for this “leftover.” Corn germ can be used as a protein extender for plywood
glues, potentially opening the door to a new market for the agricultural byproduct. Glue
extenders reduce the amount of main binder, or resins used in such glues and enhance
their adhesive action.

These potential value addition industries may not have been exploited in Kenya. The
government is set to establish a maize milling company in Trans Nzoia County at a cost
of one billion shillings (Mutenyo, 2012). The move is a response to complaints by
farmers in the region over middlemen who extort them by regulating market prices for
their maize before transporting to other counties for processing. Farmers have also
expressed concern over transporting the commodity to Mombasa and Nairobi counties
yet value addition could be done from the region (Mutenyo, ibid).

This plan only focuses on maize milling for flour; yet there are many other products that
can be processed from raw maize. One reference lists over 500 different uses for corn
(Lance, 2002). Corn is a component of canned corn, baby food, hominy, mush,
puddings, tamales, and many more human foods. Table 2.1 summarizes Kenya’s total
maize production within a span of six years.

Table 2.1 Maize Production, 2005 – 2010 in million tones.

Year 2005 2006 2007 2008 2009 2010

Production 2,916 3,249 2,925 2,367 2,439 3,222
Sources: Economic Survey 2011(Table 8.9 & 8.11), Statistical Abstract 2010 (Table
60), and Ministry of Agriculture, Economic Review of Agriculture 2010 (Table 5.2) as
cited by Short C., Mulinge W. & Witwer M. (2012.).

Agricultural by-Products (Crop residues)

Agricultural by-products referred to here include; Maize stalks, cobs and leaves, rice
husks, rice straw, wheat straw and hulls, coffee husks awns, chaff, bagasse, cotton
stalks, sunflower hulls and stalks, banana stalks, coconut coir, bamboo, durian peel, oil
palm leaves among others (Owen, 1989). This paper focuses on maize stover because it
is easily available in Trans-Nzoia County.
Corn stover’s potential applications range from an input in bio or thermo chemical
conversion processes for the production of liquid fuels to a direct energy source in
biomass cofiring applications (Klingenfeld, 2008).

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As a cellulosic or second-generation feedstock, corn stover can be used in bioenergy

applications without directly affecting food production. This contrasts with corn grain,
the feedstock currently used for the bulk of U.S. ethanol supply (Klingenfeld, ibid).
Klingenfeld (2008) describes stover as the residue left on the soil surface after corn
grain has been harvested. It consists of cob, husks, leaves and stalk fractions.
Crop residues has become the term used in tropical research and development circles
for describing the fibrous by-products of cereals, sugarcane, roots and tubers, pulses, oil
seeds, oil plants, vegetables and fruits. With notable exceptions such as sugar beet pulp
and citrus pulp, other crop residues are of low nutritive value as feed for ruminants and
have little or no feed value for non-herbivores (Owen, ibid). Most crop residues in
Kenya have limited uses. Latham (1997) observes that crop residue is mainly used for
soil mulch and animal feed. These are the two major competing uses of crop residues.

Table 2.2 Annual global harvest of crops and crop residues in the mid-1990 (all
figures are x 106 tonnes)
Crop Harvested Crops Crop residues
Fresh Weight Dry Matter
(Dry Matter)
Cereals 1900 1670 2500
Sugar Crops 1450 450 350
Roots, tubers 650 130 200
Vegetables 600 60 100
Fruits 400 60 100
Legumes 200 190 200
Oil Crops 150 110 100
Other crops 100 80 200
Total 5450 2750 3750

Adapted from FAO (1997a); dry matter calculated by using average moisture values in
NRC (1971) and Bath et al (1997) as quoted by Smil (1999).

From table 2.2 above, it can be observed that there is a huge amount of crop residue that
is treated as waste by most farmers the world over. This paper targets crop residues
from cereals and specifically maize which is grown in abundance in Trans-Nzoia
County.

Studies done by Gadzirayi et al (2006) in Zimbabwe indicate that Maize cob powder
can be effective in the control of maize weevils. This is an area that can be explored
with the aim of commercializing the production of this maize by-product to provide
sustainable income to farmers and the youth in Trans-Nzoia County, a product which
hitherto has been used for a long time as domestic fuel after harvesting the grain (Smil,
1999).

Francisco et al (2007) describe Furfural as a chemical made out of organic matter which
is typically produced for industrial purposes. It is primarily composed of agricultural
byproducts such as oat husks, bran, corncobs, and sawdust. Some of the products it is
used to make include weed killer, fungicide and solvent. It is also a familiar element in
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the production of transportation fuels and in the process of refining lubricating oils. The
chemical is an element in the production of several other industrial agents as well
(Francisco, ibid).

When mass-produced, the chemical is made by putting pentosan polysaccharides

through the process of acid hydrolysis, meaning that the cellulose and starches of the
base material are converted to sugar using acid. In an airtight container, furfural is
viscous, colorless, and oily, and has an almond-like scent. Exposure to air can colour
the liquid in shades from yellow to brown.

Furfural is somewhat water soluble and completely soluble in ether and ethanol. In
addition to its uses as a solitary chemical, it is used in the production of chemicals such
as furan, furfuyl, nitro furans, and methyl furan. These chemicals are also used in the
further manufacture of products, including agricultural chemicals, pharmaceuticals, and
stabilizers (Francisco, ibid). This is a product that can be of high commercial value to
Kenyan maize farmers, giving further potential for employment opportunities for the
un-employed through off-farm activities.

According to Cohen (2010), cellulosic ethanol, which is made from crop waste and non
food plants instead of edible plant sugars and starches, is the future of smart biofuels.
Missouri produces usable crop residues sufficient to produce 500 million gallons of
transportation fuel each year and has enormous potential to grow dedicated energy crops
on marginal or unused land. Biofuel produced from existing waste biomass alone could
create thousands of jobs, hundreds of millions of dollars of economic activity, and
$13,000 annually in gross income for the average Missouri corn farmer (Cohen ibid).

Lignocellulosic biomass could produce up to 442 GL (Gigalitres) per year, of

bioethanol. Thus, the total potential of bioethanol production from crop residues and
wasted crops is 491 GL per year, about 16 times higher than the current world ethanol
production. The potential bioethanol production could replace 353 GL of gasoline (32%
of the global gasoline consumption) (Kim, 2003). This is technology that could be
carefully domesticated, environmental impact assessment withstanding, to benefit most
Kenyan farmers and specifically Trans-Nzoia farmers who are predominantly cereal
growers and specifically Maize growers.

It is also possible to use maize cobs as a useful ingredient in the making of cheaper
lightweight concrete. Recent studies by Pinto et al (2012) indicate that granulate of corn
cob is proposed as an alternative organic aggregate of lightweight concrete. Generally,
corn cob is considered an agricultural waste. Using it as an alternative to expanded clay,
cork, expanded polystyrene (EPS) among other possibilities may have an interesting
economic and sustainable benefit.

Experimental results indicate that corn cob concrete processed according to a ratio of
6:1:1 (corn cob granulate : Portland cement : water) may have acceptable material
properties (Pinto, ibid). Domestication of this technology in Kenya and specifically
Trans-Nzoia might give high potential for maximum utilization of the hitherto waste
product from maize.

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Industrialization and Employment Opportunities

From the literature review above, it can be deduced that Kenya and Trans-Nzoia County
in particular, has great potential for creating many employment opportunities through
the following off-farm industrial activities targeting maize crop by-products in the
following areas:
I. Establishment of micro-industries dealing in the production of Maize (corn) products
which include filler for plastics, packing materials, insulating materials, adhesives,
chemicals, explosives, paint, paste, abrasives, dyes, insecticides, pharmaceuticals,
organic acids, solvents, rayon, antifreeze, soaps, and many more.(Lance, ibid).
II. Manufacture of protein extender for plywood glues from maize germ instead of limiting
its use to making chicken and livestock feed alone (Pinto et al, 2012).
III. III Production of Maize cob powder from maize cobs that can be effective in the control
of maize weevils (Gadzirayi et al, 2006).
IV. IV Manufacture of Furfural chemical made out of organic matter which is typically
produced for industrial purposes such as; weed killer, fungicide, and solvent. Other
chemicals include furan, furfuyl, nitro furans, and methyl furan which are also used in
the further manufacture of products, including pharmaceuticals, and stabilizers
(Francisco et al, 2007).
V. V Cellulosic ethanol, which is a biofuel produced from existing waste biomass alone
could create thousands of jobs, perhaps worth hundreds of millions of dollars for the
average maize farmer (Kim, 2003) and (Cohen, 2010).
VI. VI Manufacture of lightweight concrete (Pinto, et al, 2012).

These are just but a few examples of what Trans-Nzoia farmers can contribute to the
county and country in job creation and earn extra income from off-farm activities
accruing from their most popular crop.

Conclusion
From the above findings, it can be concluded that the poverty index of 5.2% in Trans-
Nzoia County can be substantially reduced, the maize prices stabilized and the living
standards improved if crop waste management technigues are embraced. Corn product
industries for production of a variety of corn products will enhance off-farm activities,
and create employment. Production of maize cob powder will provide a viable
alternative to expensive agro-chemicals used in the control of maize weevils while
building materials involving plywood and light weight concrete will be more affordable,
hence making housing affordable especially to those people who have been left out of
Kenya’s current real estate market. Furfural and related chemicals will be a major
export earner while ehanol will greatly reduce the reliance on the expensive gasohol.
These activities will transform the county into an industrial hub with a spiral effect in
job creation and enhance other developments that come with industrialization such as;
better healthcare, housing, infrastructure, access to quality education and retention of
learners in school and tourism.

Recommendations
This paper makes the following recommendations, which Trans-Nzoia County
Government and other Maize-growing areas in low-income countries may adopt to
manage maize-related waste and thereby, enhance job creation:

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I. There is need for deliberate and systematic establishment of value addition industries
for maize in Trans-Nzoia County by farmers through mobilization of funds through
farmers’ cooperative movement and interested local and foreign partners to tap the huge
potential of direct maize products for sale locally and for export to boost the farmers’
direct benefit from their crop.
II. The processing of maize by-products should be given a critical analysis with the view of
enabling the farmers to reduce residue wastage through maximization of the processing
of the various possible products from the residue to create employment.
III. Curriculum developers should come up with tailored programmes in higher and middle
level institutions to train the necessary man-power in the specific maize product and by-
product processing industries.

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