11/20/2012

Our visit to Zamsugar a.k.a. Zambia Sugar, Whitespoon brandname, Nakambala Factory


At the beginning of the month we had the opportunity to travel south with Martin again. He and his wife Elsa live next door to us. He is the Dutch Reform church minister and he travels to Livingstone once a month to meet with a congregation there. He has graciously offered for us to travel with him when he goes and we spend the first night in Mazabuka visiting with some of his parishioners (and now our new friends!) Hans and Daisy. The following morning he drops us off at Kalomo so we can spend a weekend with friends at Namwianga. We did this last month too and both visits have been such a wonderful blessing to us and just filled our souls up!
Traveling south on the tarmac from Lusaka.
Kafue flats.

 Hans works for Zambia Sugar and they live in the employee village on the plantation. On our last visit we expressed interest in a tour and Hans kindly arranged it for us. It was so interesting – but also extremely hot. I seriously thought I might pass out. Most of the machines are steam driven so as if the heat of the day, the multiple huge machines, and climbing lots of steam stairs wasn’t enough heat generation – there were also occasional bursts of steam! Wowzers. The tour was about 2.5 hours and our guide was excellent – he was a Chemist. We saw the whole process: cane growing in fields, arriving by truck to the factory, mulching the cane, several rounds through diffusion tanks using water to extract sugar from the cane, heating and evaporation, separation of juice and mud, crystal formation, drying of sugar, packaging, stacking, and storing ready for shipment. It was so interesting! 

Following are excerpts from the Matthew’s journal that he emails to family and friends while we are here combined with pictures. Hope this portrays a little of what we experienced that day!

--> Nakambala sugar plantation has been operating for a few decades now and employees 6000 employees during the harvest season. They cease production from December through April as this is the wet season here. Instead of producing sugar, they use these months for annual maintenance and thus their employee numbers decrease significantly. Our tour was led by a chemist who has worked there for 20 years and could we ever tell. He was extremely knowledgeable, sometimes to the point of information overload. 


We began by watching the semis drive in and have a sample taken so the independent farmers could be paid according to the quality of their cane sugar.
To determine the amount to pay farmers, each truck must pull through here, then that big arm at the top takes a cross section sample in 3 places. The sample is them mulched and sent to the lab to determine how much sugar is in this cane or the quality of the cane. Then price is set accordingly. This factory grows a lot of its own cane but it also purchases from 15 commercial farmers - of that total, 1 farm is a cooperative formed by medium-scale farmers.
Taking the sample.
The mulch to go to the lab.
 After this we watched as a crane offloaded the canes into a massive shredder which broke the canes into a mulch type consistency. After this the “mulch” travelled up a conveyor belt to a series of other tanks some of which used water to diffuse the sugar from the more solid particles. Flocculent was used once the sugar was in more liquid form to help settle the larger particles to the bottom and then the sugar water was filtered off to be sent to huge dryer machines where the sugar crystals grew in size. As you can likely tell, this is a large process most of which I am still unclear on. What was clear to me was that I felt like an Umpalumpa in Willy Wonka’s factory with bells and whistles ringing off and steam rising from various moving mechanical parts.  It was a great tour but I was conscious the entire time of the act that I couldn’t be sure how well maintained everything was or if we would survive the intense heat. 
Cane dumping from trucks into the shredder.
 
Mulch going from the shredder to the diffuser.
Yikes!
Mulch going into diffusers. It goes through 6 rounds of this to get the most amount of sugar out.

During the tour I was amazed by the scale of the operation but also by the working conditions of the warehouse. Things are done differently in Africa, this is true but the heat in some of the rooms people had to work in was unbearable. There was no air conditioning and all of the employees had to wear coveralls. I can’t be sure but I do know that if I had to wear those in that work environment, I would not be wearing another stitch of clothing. The entire process from sugar cane to the point of having sugar used for baking, etc. takes only 4 hours but with the drying time added to that the process takes around 12-14 hours. Pretty amazing really!

This is the nice brown sugar that we sell at home but they don't actually sell it here, rather it gets reprocessed to grow more crystals that makes white sugar.
After spinning the damp sugar crystals through a machine that uses centrifugal force to separate crystals from liquid, the crystals are sent to drying machines for about 10 hours.
The warehouses were probably what interested me most. We saw paper and poly bags being filled anywhere from 2 kg to 1 ton. As you can imagine Coca Cola and Pepsi as large customers for the factory and they are very particular in the quality of sugar they will accept. We saw how individual table size packets are filled as well as how they fill and seal the larger packets. In the warehouses for export we saw 20 young men acting as a human ladder moving 50kg bags to the top of the 60 foot tall pyramid of sugar. I was in awe and disgust at all of the sugar produced. I think we both swore off ever drinking another Coke. The rail system is used as well as semis for shipping the sugar.

These are the packages we see in grocery stores and most roadside tuckshops!
Here are the large bags being filled. Different coloured bags indicate the  destination - i.e. domestic or export. I think these are domestic use.
See the spool of thread? After is is filled is is sewed shut!
This 'Maple Syrup' tastes nothing like maple syrup from Canada - but it is much cheaper!
I was stoked to see this machine - I've always wondered how little tiny restaurant sugar packets are filled! Now I know. ;)
Human conveyor belt - 50kgs, 2-by-2, up and up and up.
These are for export to large industry. This sugar is literally loaded by front end loader off the warehouse floor...
There was at least 12 warehouses loaded from floor to ceiling with mountains of sugar and about 8 warehouse sized mountains outside covered in tarps waiting to be shipped. We were stunned. And our guid said that these piles don't stay for long - the mountains are quickly replaced though so one might think they are always there, but they piles are continually being shipped out and then piled high again with new bags of sugar daily.
An interesting thing about this factory is that they use burn the left over fiber from the cane to drive a turbine to create electricity. They have 2 smaller and one bigger turbine. (I think.) The bigger one is broken now, so there is more fiber than can be burned daily - so this mountain has grown. It is a fire hazard so they have started trucking it out to put on fields. 
Burning the fiber to create electricity. Currently they create enough electricity to run the factory and the employee village on the plantation for 10 months of the year; the other months they use Zesco.


Of course, I'm sure some of our details are slightly off - there was a lot of information to take in at once! But hopefully we got most of the details correct! 

11/17/2012

Zambus evangelisms


A couple posts ago I noted my love of Zamwords or Zambianisms that we enjoy as we wander around this place—like products named Zamthis or Zamthat. Another of my favourite scouting pastimes is to read the words often inscribed on the many minibuses that zoom by hooting and yelling ‘taxi! taxi!’ They can be completely nonsensical (at least to us), quirky, and funny—but they are often encouraging little phrases or even statements of faith that shed a little ray of sunshine upon those who behold it. And whether encouraging or just humorous they have often brightened our days and brought many smiles.



I now present a sampling of the goodness found on the classic blue and white Zambuses:
God’s divine favour
It happens
Never recovered
Joe Gospel
By His Stripes
Leza Wamaka (this means God is power)
Flash for the people on the move
My charm is in Jesus
Let them say
Vin Diesel
Persian chariot
God’s ambassador
Blood of Jesus
Behold I come quickly
Man u 4 life
The eagle has landed
Ave Maria
God is good all the time
Young Joe
Try your best
Ask God
Man of God
Fighting temptation
You can’t see me! (front of bus) My time is now! (back of bus!)

And my personal favourite is the bus that said - "Pray for us!" I am pretty sure I’d beg for prayers too if I was jammed in minibus zooming down Lusaka streets on a +35C day.

Oh yes, and there were mud flaps on a big lorry that said “Holy ghost fire of God” and a another lorry that proudly proclaimed "God knows!".

So there you have it: some evangelisms and the just plain ol’ awesomeness of Zambia’s mini buses!

Random musings on blessings and recent happenings


What do they say about the best-laid plans? Well, whatever it is I’m sure it can also be said of my intentions to blog regularly. Clearly, I have not succeeded in this. The truth is though that I actually spend quite a bit of time on the computer for research doing things like for reading articles, sending emails to contacts, looking up places to go, organizing/creating research questions for an upcoming interview or transcribing interview recordings. By the time I’m done tasks like that I’d just rather not type any more! Plus I haven’t felt a lot of pressure to post regularly because Matthew has been incredibly diligent about sending regular journal-style emails to a big list of family and friends—so at least our parents know that we are alive and well. My lack of posting does not, however, mean that I haven’t thought of a zillion things I could write about. There are plenty of things on my list—or ‘plent’ as is often said here! ;) Unfortunately, when the list piles up, my post ends up being quite long and I’m sure a bit tedious to read. So, here I will just share some random thoughts of our journey thus far and then over the next week or so I will post pictures and few words to highlight specific happenings as time and internet connection speed permits.

We have now called Lusaka home for about 6 weeks. Our initial feeling towards this place were a bit neutral as we didn’t know many people and were unsure what this research-thing would look like. It is a pretty big city—at least as far as our limited urban experiences go and, of course, it was unfamiliar. But we like Lusaka more now. Not nearly as much as being in a rural location, but Lusaka has its advantages—such as its proximity to delicious Indian food.

We are kind of in a suburb, so most things are kind of far away. We walk where we can in this neighbourhood and take a taxi for further away places. We have a regular guy named Max. He’s been a blessing.  I do love to walk though; I always think that is the best way to know a place. I especially became a fan of walking in Halifax last year. I feel like I really see a place when I walk and get a sense of its atmosphere when I’m walking: for example I notice the way people either attempt or avoid eye contact as you pass one another, the smell of diesel zooming by, the carefully piled stacks of tomatoes–some for 3 pin and others for 5 (a pin = a thousand kwacha; 5,000 kwacha = approx. $1), the broad smile of the gentleman selling talk time when you call him over to buy cell phone minutes, the way the little cloud of dust caused by each step of my feet makes my toes and ankles filthy in under 30 seconds, the hopeful expression of a street vendor saying “madam, madam, avocado, nice price”, the surprise and smile of the veggie lady when I greet her with “muulishani”, and—most difficult to miss—the heat of the sun beating down on my bronzing shoulders.

The first few weeks into the research we were quite discouraged because I had several contacts but very few responses for interviews. I started to doubt coming here and spending so much money for a ‘silly’ thesis. I don’t really think it is silly—but I’ve had my moments. In fact, the further into this I get the more I love my topic: Decision-making processes of Customary Land in Zambia. It is timely, relevant, and incredibly important to Zambian farmers, identity, and future. Anyway, the first few weeks were slow: it took me 12 days to get my first interview and then another 14 days to get a second one. At that pace we’d need a year to reach the target of 30 interviews! But then momentum started to build, in the next 2 weeks I did 5 interviews. This past week we traveled a few hours south and I did 10 interviews plus a focus group—in ONE week. The grand total is now 18. Phew! It would have been 20 today but I had two cancellations. I was relieved though because I was pretty wiped after this past week and we just returned home on the bus at 20h30 last night. We were grateful for the break and quickly declared today a Sabbath day. This rest day included some walking, a little reading, some wandering around a neat shop and café we’d heard about, chatting and giggling about nothing and some lounging around home. Oh yes, and a sweet ABBA dance party for me - so great! It also included feasting on some yummy things like litchis, naartjes (basically a mandarin orange), a bush fruit that grows in a gourd-type thing, fresh greens with basil and parsley mixed in (so wonderful!), crepes with cinnamon, banana, and ice cream—enjoyed with an Irish coffee. Lovely.

This past week was unique because we traveled out of town to meet with a contact who had arranged some interviews for us with chiefs and farmers. It was so interesting and we learned a lot. We took one of the super buses down—it even had air conditioning! Matthew was in heaven. We stayed at a little lodge just off the tarmac called the Golden Pillow and it is on the same property as the Tooters take-away food place—famous for their friend chicken. Alisha, Matthew and I have an inside joke about that place from 2006. And the chicken is exceptional. I mostly just love the names they come up with here though, I mean seriously, Tooters?! Anyway, the trip was extremely fruitful and totally worth the expense. I just love to sit under a tree and learn from others as cows and goats wander by. One of my best memories from 2003 is sitting under a tree talking to a mudala (old man) for along time about polygamy. Such a unique opportunity to learn about different life experiences. I am extremely grateful for the people that we have met here that have gone out of their way to help us with this project and genuinely appreciate the topic because it in an area that they are passionate about. This type of research absolutely cannot happen without energetic and motivated people like this. I am astounded by those who work tirelessly for community organizations with extremely lean budgets and they just keep charging ahead with a zeal that inspires. Compassion for the vulnerable lived out in action. Amazing.

I am also so thankful for the family and friends that been praying this project forward. I reached a point in the first few weeks when I was almost panicked that all this effort and expense was going to be a total waste and that I would fail. And that I had wasted the resources we’ve been blessed with. Of course I realize that this stemmed from my attempt to trust in my own weak self. I was looking inward instead of upward. I wrote to dear ones to request prayers for contacts to respond and for our efforts here to be blessed. Within a day interview responses began to trickle in and interviews began happening more regularly—culminating in quite a rapid pace over the past 2 weeks. Indeed, we did more interviews this week than we did in the whole first month! Abundant blessings indeed! I am humbled and reminded again that it is not by my own strength that I succeed.

Now, this might go without saying, but I must state here and now that I truly have the best husband on earth. Honestly. He is just the best partner I could ever ask or hope for. I have always known that he is a gem and I have often marveled at his diligence, patience and thoughtfulness. And I am often grateful for how well we work as a team, but this experience has reminded me anew. Perhaps I am so amazed because we were apart for most of last year while I was at school but now little things like finding my purse, sunglasses and water lined up ready for me to go out the door astound me. Or perhaps it is how he carefully rolls a towel to put at the bottom of the door each night so no creepy crawlies come in. Or how he diligently checks under my bed for snakes each night. Now that’s love, baby! (Although I’m not too sure what he would do if he actually found one…;) Speaking of true love, our relationship has gone to a whole new level living in this little house because we have no bathroom door! That has been quite the experience. Perhaps this means our relationship has gone to a whole new low?! Ha! I can now hear my mom’s voice in my head telling me that bathroom talk is inappropriate, so I best move on. This guy is seriously incredible though. He comes to each interview with me, listens intently, sweats through hours of talking in often very stuffy rooms, enthusiastically shares the points he found most intriguing as we chat about it afterwards, and is also genuinely excited by this work. He carries groceries and that darn backpack everywhere we go. And he insists on constantly asking me where the house key is—just planning ahead you know. We always joke about this, because he will always dig the key out when we get in the taxi to go home - 40 minutes in advance - whereas I might think to dig it out when I am two steps away from hitting my nose on the door of our cottage! In any case, for sure now when somebody asks Matthew what my topic is he will be able to answer quite thoroughly. I am just so thankful to have this unique experience with him. It is amazing to have a constant companion and partner throughout this project, because research can often feel isolating or overwhelming because it rests solely on your own shoulders. I am blessed to have such a beautiful soul and wonderful man to help me carry this load!

So, things are definitely moving forward with research and I am sad to say that our days here are already half over. So sad. We often wish that we could just live and work here for a few few years or indefinitely. Oh the things we could grow in this climate! I wish you see the orchard I have already planted in my imagination! [sigh] Perhaps someday. For now though I'll just be thankful for the days and experiences we have had in the beautiful place.