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18 line items in process order, each with its tag, specification, quantity, power and an indicative unit price.
18 m deck · 60 t · 20 kg division · ticket printer & software
Weighs every inbound raw-material truck and every outbound finished-goods load.
3 t rated load · 1.8 m³ bucket · diesel · rubber cutting edge
Reclaims straights from the bulk bays and feeds the Line A weigher and Line B hoppers.
4 × 8 m³ hoppers · micro-doser · 2 t batch · ± 0.2 % · PLC recipes
Weighs DAP, urea, MOP, CAN and micronutrients to each blend recipe.
2 t batch · 3–4 min cycle · internal flights · 6 t/h
Tumbles the weighed straights into a uniform bulk blend without breaking granules.
Ø 2.0 × 8 m · 5 t/h · steam & water spray · rubber lining
Rolls fine powders and recycled fines with steam into 2–4 mm compound NPK granules.
Ø 2.2 × 20 m · 1.2 MW biomass furnace · outlet < 1.5 % moisture
Dries wet granules in co-current hot air so they stay hard and free-flowing.
Ø 2.0 × 18 m · ambient counter-flow air · outlet < 45 °C
Cools dried granules before screening so they do not cake in the bag.
Double-deck 2 mm / 4 mm trommel · chain mill for oversize
Splits on-size granules from fines and oversize, which is crushed and recycled.
Ø 1.6 × 6 m · anti-caking oil spray · talc/clay powder feeder
Coats granules with anti-caking agent so they flow freely after months in store.
Twin cyclones · 240 m² polyester bags · < 30 mg/Nm³ outlet
Captures dryer, cooler and screen dust and returns it to the granulator.
3 m working width · 1.2 m pile height · 800 m³/h · diesel
Turns and aerates manure and crop-residue windrows to hold 55–65 °C composting.
Chain-blade crusher 3 t/h · twin-shaft paddle mixer · mineral feeder
Crushes mature compost and blends it with rock phosphate, lime and minerals.
Ø 2.8 m tilting pan · 1 t/h each · water spray · 3–5 mm pellets
Rolls the compost-mineral mix into round organic pellets.
Ø 1.6 × 14 m dryer + cooler · 0.8 MW furnace · < 90 °C product
Dries pellets gently from about 30 % to 12 % moisture to keep microbes alive.
1,500 L SS316 · high-shear agitator · 25 µm bag filter on transfer
Dissolve soluble salts, add chelated micronutrients and hold the batch for filling.
4-head piston filler 1–20 L · capper · labeller · 1,200 × 1 L/h
Fills, caps, labels and batch-codes 1 L and 5 L bottles and 20 L jerrycans.
Kjeldahl N · UV-vis (P) · flame photometer (K) · sieves · EC/pH
Tests nutrient guarantee, moisture, granule size, crush strength, EC and pH on every lot.
25–50 kg · 6 bags/min · ± 0.2 % · belt + sewing head · big-bag frame
Weighs, fills and sews 50 kg bags and fills 1 t big bags for bulk buyers.
Indicative ex-works prices (US$, 2026) for budgeting a sample project, not quotations. Photos are illustrative of each machine class.
12 unit operations in order, with the equipment that performs each and its control point.
| Step | Operation | Equipment | Control point |
|---|---|---|---|
| 01 | Receiving & weighbridgeTrucks of DAP, urea, MOP, CAN, manure and crop waste are weighed, sampled and logged. | WB-101 Pit-less Weighbridge (60 t) |
Net weight · supplier CoA · intake moisture |
| 02 | Bulk store & reclaim to linesStraights go to separate covered bays and are reclaimed by loader to each line's hopper. | FL-102 Wheel Loader (1.8 m³ Bucket) |
One product per bay · FIFO · incompatible pairs apart |
| 03 | Line A: Batch weighing & bulk blendingStraights are weighed to a crop recipe and tumbled; bulk blends go straight to bagging. | BW-201 Multi-Hopper Batch Weighing SystemRB-202 Rotary Drum Blender (2 t Batch) |
Recipe weights ± 0.2 % · 3–4 min mix time |
| 04 | Line A: Drum granulationPowder feeds and recycle fines are granulated with steam into compound NPK granules. | GR-301 Rotary Drum Granulator |
Recycle ratio 1.5–2 : 1 · bed temperature 60–70 °C |
| 05 | Line A: Drying & coolingGranules are dried in hot air, then cooled; exhaust air passes the cyclone and bag filter.Dust → bag filter | DR-302 Rotary Drum Dryer & Hot-Air FurnaceCL-303 Rotary Drum CoolerDC-306 Cyclone & Pulse-Jet Bag Filter |
Moisture < 1.5 % · product < 45 °C |
| 06 | Line A: Screening & coatingOn-size 2–4 mm granules are coated with anti-caking agent; off-size returns to the granulator.Fines → granulator | SC-304 Rotary Screen & Chain CrusherCD-305 Coating Drum with Oil & Powder Dosing |
≥ 90 % in 2–4 mm · crush strength ≥ 30 N |
| 07 | Line B: Windrow compostingManure and crop residues are composted in turned windrows on a sealed slab for 45–60 days.Leachate → windrow | WT-401 Self-Propelled Windrow Turner |
55–65 °C for ≥ 15 days · C:N 25–30 : 1 |
| 08 | Line B: Crushing & mineral blendingMature compost is crushed and blended with rock phosphate, lime and trace minerals. | CR-402 Semi-Wet Crusher & Paddle Mixer |
Mix moisture 28–32 % · mineral dose ± 2 % |
| 09 | Line B: Pan granulation & dryingThe blend is pelletised on disc pans and gently dried and cooled.Fines → disc pan | PG-403 Disc Pan GranulatorDR-404 Organic Pellet Dryer & Cooler Set |
Moisture ≤ 15 % · product ≤ 90 °C |
| 10 | Line C: Dissolving & chelate mixingSoluble salts are dissolved in treated water, then EDTA-chelated micronutrients are added. | MT-501 SS Dissolving & Mixing Tanks |
EC and pH 5.5–6.5 · specific gravity per recipe |
| 11 | Line C: Filter, fill & capFiltered batches are filled into 1 L, 5 L and 20 L packs, capped, labelled and coded. | LF-502 Liquid Filling, Capping & Labelling Line |
Fill volume ± 1 % · clear, sediment-free |
| 12 | QC release, bagging & dispatchLots are released against lab results, bagged into 50 kg or 1 t bags, palletised and dispatched. | QC-601 QC Laboratory (NPK & Physical)BG-602 Open-Mouth Bagging Scale & Sewer |
N-P-K within tolerance · bag weight ± 0.5 % |
6 zones arranged for one-way material flow, with every item of equipment placed by tag.
A shared weighbridge, store and loader feed NPK, organic and liquid lines from one site.
Line A switches between fast bulk blends and fully granulated compound NPK.
PLC-stored recipes turn county soil-test results into crop-specific blends in minutes.
Fines, oversize and captured dust go back to the granulator; compost leachate goes back to the windrows.
Line C adds foliar and fertigation products that earn more per kilogram of nutrient.
An in-house lab checks N-P-K, moisture and granule size before any lot is released.
The core routines operators follow, from start-up to batch release.
8 sections: open any one to read it, or download the whole document.
Mavuno Blend Fertilizers Ltd is a fertilizer plant in Nakuru's industrial area, on the A104 highway between Mombasa's import terminals and the maize and wheat farms of the North Rift. Imported straights and local organic waste arrive through one shared intake (weighbridge, covered bulk bays and a wheel loader), which then branches into three production lines: Line A bulk-blends and granulates crop-specific NPK at 5 t/h, Line B composts manure and crop residues into 2 t/h of organic pellets, and Line C makes 3,000 L/day of liquid and foliar fertilizers. All three lines share one QC laboratory, one bagging area and one dispatch bay.
| Metric | Value |
|---|---|
| Line A: Blended & Granulated NPK | 5 t/h · ≈ 22,000 t/yr capacity (2 shifts) |
| Line B: Organic / Bio-fertilizer | 2 t/h · ≈ 5,000 t/yr capacity |
| Line C: Liquid & Foliar | 3,000 L/day · ≈ 840,000 L/yr capacity |
| Annual Revenue (Year 1) | KES 912,000,000 (~$7.0M) |
| Initial Investment (capex) | KES 130,000,000 (~$1.0M) + KES 220M working-capital facility |
| Operating Break-even | Month 9 |
| Payback Period | ≈ 3 years on capex and working capital |
| Employees | 72 (plus 8 field agronomists) |
The plant is built around three product categories that share raw-material intake, QC and dispatch but run on their own equipment, so each line can be scheduled around its own season and customers.
| Line | Products | Target Crops | Pack Sizes | Ex-factory Price |
|---|---|---|---|---|
| Line A: Blended & Granulated NPK | 17:17:17, 23:23:0, 10:26:10 + Zn/B, maize/wheat planting and top-dress blends, custom soil-test blends | Maize, wheat, potatoes, tea, horticulture | 50 kg bags · 1 t big bags | KES 4,700/50 kg (~$36) · KES 94,000/t |
| Line B: Organic / Bio-fertilizer | Compost pellets, phosphate-enriched organic, lime-fortified soil conditioner | Horticulture, coffee, avocado, acidic maize soils | 25 kg · 50 kg bags | KES 2,000/50 kg (~$15) · KES 40,000/t |
| Line C: Liquid & Foliar | NPK foliar feeds, chelated micronutrient mixes, calcium-boron, fertigation concentrates | Vegetables, flowers, fruit, greenhouses | 1 L · 5 L bottles · 20 L jerrycans | Average KES 380/L (~$2.90) |
| Ingredient | Analysis | Quantity | Cost/kg (KES) | Total (KES) |
|---|---|---|---|---|
| DAP | 18-46-0 | 370 kg | 105 | 38,850 |
| Urea | 46-0-0 | 225 kg | 65 | 14,625 |
| MOP (muriate of potash) | 0-0-60 | 283 kg | 55 | 15,565 |
| Zinc sulphate | Zn 33% | 12 kg | 180 | 2,160 |
| Borate | B 15% | 3 kg | 350 | 1,050 |
| Dolomitic lime (filler) | Ca/Mg | 107 kg | 10 | 1,070 |
| Total | 17-17-17 + Zn, B | 1,000 kg | 73,320 |
Nutrient check: N = 66.6 kg (DAP) + 103.5 kg (urea) = 170 kg; P₂O₅ = 170 kg from DAP; K₂O = 170 kg from MOP. Urea–DAP blends pick up moisture quickly, so they are bagged within 24 hours and sold within one season.
| Input | Line | Annual Quantity (Year 3) | Source |
|---|---|---|---|
| DAP, MAP, urea, MOP, CAN, SOP | A, C | ≈ 13,000 t | Imported via Mombasa; railed to Naivasha ICD or trucked |
| Zinc, boron, sulphur, magnesium sources | A, C | ≈ 250 t | Importers and regional traders |
| Cattle and poultry manure, crop residues | B | ≈ 11,000 t (wet) | Dairy farms, poultry units, flower farms around Nakuru |
| Rock phosphate and agricultural lime | B | ≈ 900 t | Regional quarries and importers |
| EDTA chelates, MKP, potassium nitrate | C | ≈ 120 t | Specialty chemical importers |
| Woven PP bags, big bags, bottles, jerrycans | All | ≈ 420,000 bags · 400,000 packs | Nairobi and Thika packaging converters |
Every bag carries a nutrient guarantee, so the lab tests each lot before release and keeps retained samples for inspectors. The label shows the N-P₂O₅-K₂O guarantee (for example 17-17-17), declared secondary nutrients and micronutrients, net weight, batch number, date of manufacture, the manufacturer's address and the registration number.
| Requirement | Authority | Scope |
|---|---|---|
| Registration of premises and each fertilizer product | Fertilizer and Animal Foodstuffs Board (FAFB), Fertilizers and Animal Foodstuffs Act (Cap 345) | Before sale; renewed annually |
| Product standards and Standardisation Mark | KEBS (Kenya and EAC fertilizer specifications) | NPK, organic and foliar products; periodic surveillance sampling |
| Inspection, sampling and phytosanitary checks | KEPHIS | Market and import sampling; organic feedstock and export consignments |
| EIA licence, air emission and effluent licences | NEMA | Dryer stacks, compost leachate, waste handling |
| Net-quantity verification of scales and packs | Weights & Measures Department | Weighbridge, bagging scales, liquid fill volumes |
| Workplace safety, fire and chemical storage | DOSHS and county fire department | Annual audit, fire certificate, CAN storage |
| Organic claims (optional) | Certification body under the East African Organic Products Standard | Line B "organic" labelling |
| Line | Year 1 | Year 2 | Year 3 |
|---|---|---|---|
| Line A: NPK (7,500 · 11,000 · 13,500 t at KES 94,000/t) | 705,000,000 | 1,034,000,000 | 1,269,000,000 |
| Line B: Organic (2,800 · 4,000 · 5,000 t at KES 40,000/t) | 112,000,000 | 160,000,000 | 200,000,000 |
| Line C: Liquid (250,000 · 400,000 · 550,000 L at KES 380/L) | 95,000,000 | 152,000,000 | 209,000,000 |
| Total Revenue | 912,000,000 (~$7.0M) | 1,346,000,000 (~$10.4M) | 1,678,000,000 (~$12.9M) |
| Metric | Year 1 | Year 2 | Year 3 |
|---|---|---|---|
| Raw materials & packaging (A 82%, B 35%, C 45%) | 660,000,000 | 972,000,000 | 1,205,000,000 |
| Gross Margin | 252,000,000 | 374,000,000 | 473,000,000 |
| Labour | 52,000,000 | 60,000,000 | 68,000,000 |
| Energy, biomass & diesel | 38,000,000 | 52,000,000 | 62,000,000 |
| Distribution, agronomy & soil testing | 45,000,000 | 62,000,000 | 76,000,000 |
| Admin, licences & insurance | 30,000,000 | 36,000,000 | 42,000,000 |
| Depreciation & interest | 25,000,000 | 24,000,000 | 22,000,000 |
| Profit Before Tax | 62,000,000 (~$0.48M) | 140,000,000 (~$1.08M) | 203,000,000 (~$1.56M) |
| Margin | 6.8% | 10.4% | 12.1% |
Equipment (all three lines plus shared intake, lab and bagging): about KES 76M (~$585,000). Conveyors, bucket elevators and installation: KES 16M. Civil adaptation of a leased warehouse, compost slab and leachate pond: KES 22M. Permits, product registration, lab set-up and pre-operating costs: KES 16M. Total capex: KES 130M (~$1.0M). Seasonal raw-material stock is financed through a KES 220M trade-finance facility, drawn before each planting season.
Line A earns a thin margin on a large volume, while Lines B and C earn 55–65% gross margins on smaller volumes. That is why the plan pushes custom blends and liquids once the NPK line has built the dealer network.
Kenya uses about 700,000 tonnes of fertilizer a year, and almost all of it is imported as finished products or straights. Since 2022 the National Fertilizer Subsidy Programme has sold 50 kg bags to registered farmers at about KES 2,500 through NCPB depots and e-vouchers, and it increasingly includes locally blended NPK and organic fertilizers. That creates a large institutional buyer alongside commercial agro-dealers.
| Segment | Demand Driver | Mavuno Offer |
|---|---|---|
| Subsidy programme (NCPB / county) | Tenders for planting and top-dress fertilizer | Line A blends in 50 kg bags, delivered to depots |
| Commercial agro-dealers | Farmers buying outside the subsidy window | Branded NPK, organic pellets and foliar feeds |
| Large farms & cooperatives | Wheat, maize, tea and sugarcane estates | Soil-test-led custom blends in 1 t big bags |
| Horticulture & greenhouses | Export flowers, vegetables, avocado | Liquid fertigation feeds, chelates, organic conditioners |
| Month | Milestone | Owner | Dependency |
|---|---|---|---|
| M1 | Lease 1.2 ha site with warehouse, submit EIA study report | MD | 3-phase power and road access for trailers |
| M2 | Order equipment (30% deposit), apply for transformer upgrade | MD | Capex financing closed |
| M2–M5 | Civil works: bulk bays, compost slab, leachate pond, liquid room, lab | Plant Manager | NEMA EIA licence |
| M4 | Line B windrows started with first manure contracts | Operations Lead | Compost slab complete |
| M5–M6 | Equipment arrives; installation with supplier engineers | Plant Manager | Transformer energised |
| M6 | Commissioning; FAFB premises and product registration; KEBS sampling | QA Manager | Trial lots and lab results |
| M7 | Commercial launch of Line A and Line B, aimed at short-rains planting | Sales Lead | Trade-finance line for straights |
| M9 | Line C liquids launched to horticulture customers | Sales Lead | Product registration |
| M12 | Subsidy programme tender qualification; two-shift operation on Line A | MD | A full season of quality records |
| Risk | Impact | Mitigation |
|---|---|---|
| Swings in world urea, DAP and potash prices | High | Buy against confirmed orders, keep limited stock, quote price bands to dealers |
| Currency depreciation on imported straights | High | USD-matched trade finance and forward cover for large shipments |
| Changes to subsidy policy or late government payments | High | Keep subsidy sales below 40% of volume and grow commercial and estate sales |
| Off-spec or counterfeit claims damaging the brand | High | Lot release, retained samples, tamper-evident sewn bags, QR batch codes |
| Caking and moisture pick-up in store | Medium | Coating, dry covered bays, compatibility rules, FIFO dispatch |
| Dust, odour and leachate complaints | Medium | Bag filters, covered windrows, lined leachate pond, buffer planting |
| Fire or explosion risk in ammonium-nitrate storage | High | Segregated CAN bay, no hot work, fire-fighting equipment and DOSHS training |
Equipment specifications, process flow diagrams, recipes and the business plan, bundled as one download.
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