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TANZANIA
SMALJOLDER WTOBACCO CURING EFFICIENCY PROJECT
NAY 1989
ABBREVIATIONS AND ACRONYMS
ACCS Assistant Commissioner for Crop ServicesCRDB Cooperatives and Rural Development BankCSS Crop Services SectionDADO District Agricultural Development OfficerDEO District Extension OfficerMALD Ministry of Agricultural and Livestock DevelopmentMEM Ministry of Energy and MineralsMFEA Ministry of Finance and Economic AffairsMNRT Ministry of Natural Resources and TourismNALERP National Agriculture and Livestock Extension
Rehabilitation ProjectPPMB Project Planning and Monitoring BureauRCSO Regional Crop Services OfficerSHTCA Southern Highlands Tobacco Growers AssociationSMS Subject Matter SpecialistTARECU Tabora Regional Cooperative UnionTAT Tobacco Authority of TanzaniaTCS Tobacco Curing SpecialistT & V System Training and Visit System of Agricultural ExtensionTTPMB Tanzania Tobacco Processing and Marketing BoardVEW Village Extension Worker
CURRENCY EQUIVALENTS
Currency Equivalents are Tanzanian Shillings (TSh)Rate as of June 1988TSh 90.0 = 1 US$1 TSh = US$O.O11
TANZANIAN FISCAL YEAR
July 1 - June 30
TABLE OF CONTENTS
Page
EXECUTIVE SUMMARY ............. i
I. THE PRODUCTION OF FLUE-CURED TOBACCO IN TANZANIA......... 1
Extension Services for Tobacco...s...........e.o........ 3Supply of Inputs ....... 4Marketing Arrangementsa ng............em e n ts... o.. .e. . 5Credit Arrangementsa n8oo.....oe m enot so....... o.... ee.... 6Existing Tobacco Curing Barns and Furnaces************** 6Fuelwood and Tobacco Curing u rooi ng...oo....o..o.o.o.... 9
II. PROPOSED MEASURES TO IMPROVE THE EFFICIENCY OFTOBACCO CURING .......... .... 12Introductiono .. ooooo....... ,ooooooooos 12Measures for Fuelwood Conservation.servati.... on.... o.. 13Barn Modifications. ... o...................o. ...... 13Barn V e n t i l a t i o n 14Furnace Retrofit.. oooootooooooe*t** 15Flue-Pipe and Chimney Systemo...o...s t em.............. 15
Improving Management of the Curing Processc*.e sso*...... 19Assessment of Impact of Proposed Measures..o............ 21
III. STRATEGY FOR PROPOSED DISSEMINATION PROJECTo.oo..oo....... 24Overview.........o.o...o..o......o............o...... 24Objetb js.oec t i v es.,o*.Oo..0*.000*o 25The Dissemination Strategyor a t e gy. .... ..... .... .... o 25Proposed Project Componentsm p o.. n e nt.s .. o ...... .o.. 29
Technical Assistance to Crop Services Sectionof MAALD....o .... ooo..o....o.o........ oo.... .... 29Training for Tobacco Extension Staff. a ff*..o........ 29Procurement and Distribution of Special Inputs...... 30Credit for Upgrading Bar n s 30
Project Implementationo........ ooo. oo... oo...o....... 31Role of MAADLD.. ... oo...o.oo..... ...... o.o.....o.. 31Role of TTPMB.oM....B... 31Credit Administrationo..oo.. .o.........o....... . 32Annual Implementation Planoo.**o...o.....o...,o.o..o 32Project Monitoring and Evaluation...................e 32
Schedule for Project Implementationo........o.e.e....... 33Project Cost Estimatesoo i m a t es. .. o o.o.. o. ooooo....... 34
IV. PROJECT BENEFITS, JUSTIFICATION, AND RISKS...........K.S.. 36Project Benefits....n e f i ts...... . .... o.....ooo........ 36
Fuelwood Savings...a v i n gsoo..o..oo.......o.e......e.. 36Increased Tobacco Leaf Output t p uto*9e*9eeo9o9...oo..o 36Total Savnso. v i n gso*ooo****oooooo 37
Project Justification .... . .............. . . . .*....... .... 39Financial Perspective. * * o .. . . . . . . . . . *. * * * * * * *.e 39Financial Rate of Return............................. 40Economic Perspective. . ** *.. . . . . . . . . .. . . . . .. .. .. 41Economic Rate of Return ...... .......... ...... ........ 42Sensitivity Analysis................................. 43
Project Risks.... 44
TABLES
1.1 Tanzania Flue-Cured Tobacco Production ........... , ............ 21.2 Barn Inventory of Top Tobacco Producing Districts#............. 71.3 1986/87 Production of Flue-Cured Tobacco and
Fuelwood Requireients. 444444404440444404444444444 4444444o444444 112.1 Estimates of Benefitso..........................................o 233.1 Breakdown of Project Target Group. ........ .......... .oo..o..o. 263.2 Tentative Schedule for Barn Modification by Districtooo.. o....4 343.3 Project Cost Estimates ........................................0 354.1 Project Benefit Analysis: With and Without Scenarioss.o e.....oo 374.2 Estimates of Annual Benefits from Projecto .................. 384.3 Fuelwood Savings Versus Production Costs....................... 394.4 Financial Cost of Fuelwoodo ......................o.............. 404.5 Farmers' Payback Schedule Per Barn.............................. . 414.6 Economic Value of Fuelwoods ............................. *....ooo o 414.7 Economic Values for Tobacco.................................... 424.8 Sensitivity Analysis of Project Economic Rate of Return..o..4.. 44
FIGURES
1 Traditional Medium Sized Growers' Barn a rn.o.oooooooooooo*.o 82 Grower's Medium Sized Barn. o.ooo.o.........o..o. o...oo..o.... 173 Low-Profile Barn (24 4)l6' x 1 6'x 13.o..............)..00 184 Wet- and Dry-Bulb Hygrr o m et..o.............o.. ooooo44444044. 205 A Guide for Successful Curing.................................o 28
ANNEXES
1 Terms of Reference for Tobacco Curing Specialistoo,.......... 462 Project Costs Estimates and Analysesoooool y se.o.o.ooo.oo.oo.s. 483 Barn Census and Inventory.4.....o4.4.4...o.. .o..ooooo.ooo.. .. 554 The Tobacco Curing Trials. ro.i aol....... o 444s44444 67
MAPS
IBRD 20998 Dissemination Project: Tabora RegionIBRD 20999 Dissemination Project: Iringa and ChunyaIBRD 20794 Tobacco Producing Areas of Tanzania
EXECUTIVE SUMKARY
About This Activity
Purpose
1. The purpose of this preinvestment study is to formulate atechnically and economically viable project to assist smallholder farmersin Tanzania to upgrade tobacco curing efficiency, thereby reducing postharvest losses (i.e., damages to tobacco during curing) and minimizingthe impact on the worsening fuelwood supply/demand imbalances in tobaccoproducing areas. The study has been conducted by the WorldBank/UNDP/Bilateral Aid Energy Management Assistance Program (ESMAP) incooperation with a Steering Committee on ESMAP activities which wasestablished by the Government of Tanzania and comprises representativesof the Ministries of Finance and Economic Affairs (MFEA), of Agricultureand Livestock Development (MALD), of Energy and Minerals (MEM), and ofNatural Resources and Tourism (MNRT). 1/
Background
2. In 1984, the joint UNDP/World Bank Energy Assessment Report onTanzania estimated that, in several regions of the country, there was agrowing gap between the level of fuelwood consumption and the sustainablesupply from the natural woodlands. 2/ The report noted that thefuelwood supply/demand imbalances were particularly acute in areassurrounding the main urban centers, and in the tobacco producingdistricts. A consensus developed between the Government of Tanzania andinterested multilateral and bilateral organizations that the increasingrate at which the country's natural woodland resources were beingdepleted for charcoal production and tobacco curing was among the mostpressing energy sector issues; hence, there was a need to formulate andimplement comprehensive strategies for both woodfuel supply developmentand demand management aspects.
3. In 1986, the Government's Steering Committee and ESMAP agreedon a program of technical assistance which would address three separate
1/ The ESMAP team comprised Mr. Amarquaye Armar (Energy Planner) asteam leader, Mr. Mohammed A. Wahid (Consultant-Tobacco CuringSpecialist), Ms. Deborah Hines (Consultant-Economist), and Messrs.A.S. Nawab, H. Megeri, A. Rajack (Field Assistants-Tobacco CuringTechnicians). The report was authored by Mr. Armar with secretarialsupport from Ms. Morrissa Young. The report was discussed with theGovernment in March 1989.
2/ "Tanzania: Issues and Options in the Energy Sector," Report No.4649-TA, November 1984.
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but complementary aspects of the woodfuels strategy. One activityfocused on a two-phased approach to examining Lte issues and options withrespect to woodfuel supply to the major urban centers of Dar es Salaam,Arusha, and Mwanza. The activity has led to the preparation by ESMAP ofa US$37.6 million project proposal which incorporates the development ofsustainable woodfuel supply schemes based on: (a) improving themanagement of the natural woodlands; and (b) intensifying village woodlotschemes in catchment areas serving the above urban centers and tobaccoproducing areas in the Tabora region. A second activity, the output ofwhich is this report, addresses preinvestment requirements leading to aproject to upgrade tobacco curing efficiency by smallholder farmers. Athird activity, which is ongoing, aims at applying remote sensing methodsto upgrade and update the information about biomass supply potential inthe critically affected woodlands. The end product will be SPOTsatellite image maps and overlays depicting the different types ofvegetation and biomass densities, and providing estimates of the relativelevels of biomass stocks in the natural woodlands surrounding the majorurban areas and the tobacco producing zones. It is envisaged that theoutputs would be used to design a more comprehensive biomass inventory inthe context of the proposed woodfuel supply development project. 3/
Scope of Study
4. This preinvestment study has been executed in two phases.During the first phase, which extended from September through November1987, an ESMAP Identification Mission visited Tanzania to review previousefforts by the erstwhile Tobacco Authority of Tanzania (TAT) to assistfarmers on tobacco curing efficiency aspects under the unsuccessful"Smallholders Tobacco Improvement Project. 4/ The ESMAP mission alsoexplored the option of substituting fuelwood with coal which is producedat the Ilima Colliery in a remote part of southern Tanzania. Thepreliminary investigations made it apparent that coal was not a practicalfuel option for the majority of smallholder farmers in the country. Themain potential beneficiaries of a coal substitution effort are likely tobe the 20 or more members of the Southern Highlands Tobacco Growers Asso-ciation (SHTGA), who own and cultivate relatively larger farms (about 100ha each). However, the SHTGA are already benefitting from a line of
3/ The UNDP/World Bank ESMAP Activity Completion Report No. 068/88,"Tanzania: Woodfuel/Forestry Supply Development Project," datedApril 4, 1988, incorporates measures and investments to augmentfuelwood supply for charcoal production and tobacco curing in theTabora region.
4/ The TAT's Smallholder Tobacco Improvement Project was entirelylocally funded. It was designed in part to implement measures toimprove curing practices, based on the report "Technical Package ofPractices to Improve the Efficiency of Fuelwood Use in the TobaccoIndustry of Tanzania," by M.A. Wahid (Tobacco Specialist), for theTobacco Authority of Tanzania, dated 1985 (updated in 1986).
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credit to rehabilitate their operations (i.e., part of an IDA financedTanzania Agricultural Export Crop Rehabilitation Project). Given thelimited ESMAP resources for this activity, it was more appropriate toconcentrate on the requirements of smallholder farmers.
5. Objectives. The findings of the identification mission led tothe conclusion that the primary focus of the activity would be onsmallholders, and also that a pilot demonstration project was a necessarystep to comprehensively address the following specific objectives of thepreinvestment study:
(a) identifying the key elements of a "technical package" toupgrade the efficiency of fuelwood use for tobacco curing bysmallholder farmers;
(b) preparing an inventory of existing barns by size/dimensions,type of furnace, configuration of the flue-pipe and chimneysystem etc., in the principal flue-cured tobacco producingvillages;
(c) obtaining quantitative assessments of the relative andincremental impacts of the application of the "technicalpackage" i.e., in terms of fuelwood savings and reduction incuring losses, etc.;
(d) defining the scope and requirements of an extension effort tosupport the dissemination of the "technical package" to farmersin the principal producing villages;
(e) demonstrating and explaining the different components of the"technical package," including the use of innovative aids suchas curing charts, newsletters, etc., and obtaining feedbackfrom smallholder farmers and extension agents;
(f) designing and field testing low-cost measures to structurallyupgrade existing barns, improve the combustion efficiency offurnaces, and improve the heat transfer efficiency of flue-pipes and chimneys; and
(g) combining the above elements of tobacco curing efficiencystrategy into a financially and economically viable dissemi-nation project which would be targeted at the more productivesegments of the flue-cured tobacco sector in Tanzania.
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6. The Pilot Demonstration Project. 5/ Accordingly, the mainassignment for the second phase involved curing trials at the village ofUfuluma in the Tabora district during the 1987/88 curing season i.e.,December 1987 through the end of May 1988, and other survey and fielddemonstration activities as follows: 6/
(a) Curing Trials. The aim was to establish, under fieldconditions in Tabora, the specific fuelwood consumption levelsin existing smallholder barns, and also to investigate therelative and incremental benefits (i.e., savings in fuelwoodand reduction in curing losses) that would be realized with theapplication of the main components of the "technicalpackage." The curing trials would therefore establish a betterquantitative basis for assessing the relative costs andbenefits associated with the proposed strategy;
(b) Barn Census. The aim was to conduct a survey of smallholderbarns in the top producing villages of the Tabora, Urambo,Iringa, and Chunya districts respectively, to establish an up-to-date inventory (i.e., by size of barn, type of furnace,configuration of flue-pipe and chimney systems) whichsubsequently has been used by ESMAP to estimate the size of theprospective target groups, and establish some guidelines forfuture monitoring and evaluation requirements; and
(c) Demonstrations and Workshops for Farmers. The aim was to begincreating greater awareness about the proposed measures forimproving the efficiency of tobacco curing, and to obtainfeedback from the farmers about specific aspects of theproposed "technical package". During the pilot project, twoworkshops were organized to demonstrate the construction andoperation of an improved slot-type furnace (i.e., the"Malakisi" furnace). Also, an exhibition was organized forover a thousand farmers during "Farmers' Day" (April 15, 1988)to demonstrate the use of the "Malakisi' furnace, to explainthe use of wet- and dry-bulb hygrometers to monitor the curingprocess, and to publicize the results of the curing trials. Anewsletter in Swahili language, "Habari Za Tumbaku", whichexplained the proposed measures, was also inaugurated onFarmers' Day.
5/ The ESMAP Field Director for the pilot demonstration project was Mr.Mohammed A. Wahid. His principal counterpart was Mr. C.O.Mwambanga, a District Subject Matter Specialist with the RegionalAgriculture Office in Tabora. The barns used in the curing trialsbelong to Mr. J. Mongono, a farmer in Ufuluma Village, TaboraDistrict.
6/ Refer to Annexes for details on and results of the curing trials,and barn census/inventory, respectively.
Structure of Report
7. The main text of this report is structured as follows. ChapterI reviews the origins and present structure of the flue-cured tobaccosector in Tanzania, and presents an assessment of the fuelwood supply anddemand situation in the four main tobacco producing districts. ChapterII reviews some shortcomings of existing tobacco barns and outlinesmeasures that need to be introduced as a "technical package" to improvethe efficiency of fuelwood use in tobacco curing by smallholders inTanzania. The chapter ends with an assessment of the potential benefitsof the proposed measures, based on the results achieved during the curingtrials. Chapter III defines the principal objectives and strategy fordisseminating the proposed "technical package" to the more productivetobacco farmers, and identifies the scope and components of a project totranslate the strategy into action over a six-year period, beginning in1989. The estimates of project costs are also presented in ChapterIII. The project justification in financial and eionomic terms ispresented in Chapter IV. Other details pertaining to the curing trials,the census of barns, guidelines for effective curing of tobacco, etc.,are presented in several annexes and a technical supplement to thereport.
Proposed Measures to Improve Tobacco Curing Efficiency
8. The inefficiency of tobacco curing by farmers in Tanzania canbe attributed to four factors:
(a) poor management and control of the curing process, particularlythe uneven loading of barns and the inadequate regulation ofhumidity levels inside the barns;
(b) the lack of proper furnaces or major deficiencies in the open-hearth furnaces that are used by some farmers, resulting ininefficient combustion;
(c) major deficiencies in the design and installation of flue-pipeand chimney systems that are vital for the effective exchangeof heat within the barn; and
(d) poor construction and maintenance of barns, including lack ofproper insulation and ventilation mechanisms on walls, therebyincreasing heat losses.
9. The "technical package" incorporates measures that have beensuccessfully tested during the ESMAP curing trials. The measures aredesigned to address the above deficiencies at least-cost, given thatincomes earned by smallholder tobacco farmers in Tanzania are stilllow. Because of scarcity of foreign currency in Tanzania, the "technical
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package" is also designed so that a minimum of imported materials andequipment is required for implementation. The "technical package"comprises the following two main components.
10. Upgrading Traditional Barns. This component covers barnmodification and improvement, and also includes retrofitting of existingopen-hearth furnaces with an improved slot-type furnace which has beenproven in use elsewhere in East Africa (in Kenya, Malawi, and Uganda).The 'Malakisi' furnace design, with some adaptations to improve perfor-mance, and incorporating materials which are available in Tanzania (i.e.,railway sleepers converted to furnace grate), has been selected. Ratherthan require the farmers to incur relatively high investments toconstruct improved barns, as was the case under TAT's Smallholder TobaccoImprovement Project, the "technical package" emphasizes a number ofspecific measures to: (i) improve the existing barns (i.e., replasteringand sealing cracks in the walls, rethatching roofs with reed grass,etc.); and (ii) improve the flue-pipe and chimney systems by graduallymoving from 11 inch to 8 inch diameter flue-pipes, and ensuring that inall cases, the chimneys extend above the roof level.
11. Improving Curing Methods. The other principal component of the"technical package," essentially would aim to upgrade farmer know-how andskills about the curing process. Emphasis has been placed on vitalaspects of the tobacco curing process such as optimum loading of thebarns, and use of wet- and dry-bulb hygrometers to facilitate themonitoring and control of humidity levels in the barn. The entireprocess has been encoded into a visual aid which, judging by feedbackfrom farmers during the workshops under the pilot demonstration project,will be a very useful tool for the dissemination phase. As indicatedabove, a field assessment of the relative impact of the "technicalpackage" on improving tobacco curing efficiency was made during thecuring trials. The results are shown in Table 1 below.
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Table 1: SUMMARY OF RESULTS OF CURING TRIALS 8/
Specific Incremental Yield of
Barn Type Fuelwood Consumption b/ Cured Tobacco c/
Traditional Barns
cured by farmers (control) 20.1 195
Traditional Barns with
Improved Curing Methods 15.3 233
Upgraded Barns with
Improved Curing Methods 9.7 290
a/ For medium-sized barns of 16 ft. x 16 ft. x 14 ft. dimensions,
b/ In m3 stacked wood per tonne of cured tobacco.
ci Based on 195 kg. of tobacco leaf produced per curing cycle in
traditional barns.
Source: ESMAP Pilot Project.
Rationale for Dissemination of the "Technical Package"
12. From the broader perspective of national economic recovery in
Tanzania, the proposed dissemination of the "technical package" for
tobacco curing efficiency will make very significant contributions
towards reversing the decline in export crop production. The overall
developmental objectives for disseminating the "technical package"
include: (a) reinforcing Tanzania's efforts to rehabilitate agricultural
export crop production, with particular focus on addressing current
inefficiencies associated with post harvest processing (curing)
activities in the tobacco sector; (b) supplementing efforts in the
country to alleviate the growing pressure on natural woodlands for the
supply of fuelwood, especially in tobacco producing areas; (c) supporting
ongoing efforts in the country to rehabilitate and strengthen agricul-
tural extension services and infrastructure; and (d) enhancing the
economic viability of the tobacco sector.
13. From the perspective of increasing the productivity of the
tobacco sector in Tanzania, the proposed project, which in the medium
term, will be the main framework for disseminating the "technical
package," will contribute substantively to reducing post harvest losses,
particularly losses due to leaf damage during curing (e.g., scalding,
excessive drying, etc.). Presently, post harvest losses, particularly
curing losses, are known to account for the loss of between 35-40% of the
tobacco harvests. By promoting greater efficiency in tobacco curing, the
leaf output per cure would increase by between 20-50% as indicated in
Table 1 above, and leaf quality would also improve. The result would be
much higher financial returns to the farmers than is presently the case;
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at the 1987/88 producer price of TSh75.6 per kg., farmers using medium-sized barns would realize between TShl4,000-36,000 in additional earningsper barn for the season.
14. From the energy perspective, the most significant contributionof the proposed project is the alleviation of fuelwood supply/demanddeficits in the tobacco producing districts. The results of the curingtrials demonstrate that the potential is good for reducing by 20-50% thespecific fuelwood consumption for tobacco curing. This again would leadto higher financial returns to smallholder farmers; during the 1987/88curing seasoy, farmers in the Tabora region paid an average of aboutTSh260 per m (stacked) for fuelwood, and hence could have saved betweenTShl,200-2,600 by adopting the "technical package." From the viewpointof controlling deforestation, the greater efficiency of tobacco curingwould reduce the pressure on accessible woodlands in tobacco curingareas, thereby facilitating the introduction of other measures andprograms to effect a transition to levels of woodland exploitation thatare within sustainable yield limits, as is envisaged under the proposedwoodfuel supply development project.
15. The need for improving the efficiency of tobacco curing byfarmers in Tanzania was first given prominence in 1983 at the Governmentlevel during the review of rehabilitation requirements and priorities forexport crops (i.e., the Export Crop Rehabilitation Packages). Despiteits failure for lack of funds, overemphasis on rebuilding of barns, andinadequate organizational support, the TAT initiative to promote tobaccocuring efficiency measures under the "Smallholder Tobacco ImprovementProject" helped to increase awareness within the Government and amongtobacco farmers about the potential to reduce the impact of tobaccocuring on depletion of the natural woodlands.
The Proposed Project
16. As a result of the ESMAP pilot demonstration project, a strongimpetus has been created for disseminating nationwide the "technicalpackage" of measures to upgrade the energy efficiency of tobaccocuring. To do so effectively requires systematic planning and executionof a dissemination strategy which would combine activities to: (i) createand maintain awareness among large numbers of tobacco farmers about thebenefits of the tobacco curing efficiency program; (ii) mobilize andtrain a core group of Subject Matter Specialists (SMSs) to lead thedissemination effort; and (iii) develop and strengthen the necessaryhuman resources and infrastructure to ensure that the disseminationeffort evolves, over the medium term, into a self-sustaining and fullyintegrated component of the agricultural extension systems servingtobacco producing areas.
Project Design
17. The proposed smallholder tobacco curing efficiency project isbased on the following principles that underlie the training and visit (T
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& V) system of agricultural extension. First, the project will aim toincrease awareness among tobacco farmers about the benefits of adoptingthe "technical package," both in terms of the fuelwood savings and theincreased quality and quantity of cured leaf output (i.e., reduction incuring losses). To achieve a strong demonstration effect, the projectwill put emphasis on mobilizing relatively small groups of farmers toserve as "role models" or "contact groups" in the target area.
18. Second, the project, through the provision of .direct technicalassistance and training, would aim to develop a strong cadre of SMSs whowould gain more specialized knowledge and skills relating to extensionfor tobacco curing and related post-harvest activities (e.g., grading).The cadre of SMSs would be deployed in direct support of the RegionalCrop Services Officers (RCSO) responsible for the Tabora, Urambo, Chunya,and Iringa districts respectively, thereby ensuring their full inte-gration into the existing extension systems. The extension program ontobacco curing efficiency will emphasize the use of workshops, exhibi-tions, and regularly scheduled field visits to monitor curing activities,and it is envisaged that contact groups will be used as the primaryagents for disseminating the "technical package" and transferring know-how about improved curing techniques to other farmers at the ward andvillage levels (i.e., through existing farmer groups.
19. Third, the project will aim to introduce a "technical package"that will be simple and practical from a farmer's perspective. The feed-back received from farmers who participated in the curing trials andspecial demonstrations, workshops, and exhibitions on "Farmers' Day"indicate that the extension program in the proposed project should incor-porate: (a) random surveys and interviews to test farmer awareness aboutthe links between inefficient curing methods, curing losses, and growingdifficulties in obtaining fuelwood supplies; (b) continuation of thepublication in Swahili of the newsletter ("Habari Za Tumbaku");(c) regular pre-season workshops on the construction, operation andmaintenance of the improved slot-type 'Malakisi' furnace; and (d) demon-strations, displays, and exhibitions at special functions such as theannual Farmers' Day celebrations, which would highlight important aspectsof the "technical package," and contrast the impact achieved with the"technical package" with that using the "business-as-usual" or tradi-tional methods.
Project Components
20. The above dissemination strategy translates into a threecomponent project design covering some 50 villages in the Tabora, Urambo,Chunya, and Iringa districts respectively.
(a) a technical assistance component which would strengthen theCrop Services Section of the MALD and the Regional CropServices Officers in tobacco producing areas (especially inTabora) to implement the project. Under this component,project related training would be provided to SMSs covering
tobacco producing districts. The technical assistance wouldprimarily be in the form of an expatriate Tobacco CuringSpecialist (TCS) who would be deployed on a full-time basis indirect support of the RCSOs and SMSs serving the tobaccoproducing districts;
(b) a specialized inputs production, procurement, and distributioncomponent under which the TTPMB would on behalf of the MALD,coordinate arrangements to ensure that participating farmerswould be supplied in a timely fashion with all key inputsrequired for the tobacco curing efficiency improvementprogram. Funds would be provided under the proposed project toprocure machine tools for the TTPMB's factories at Morogoro andUrambo (i.e., for fabrication of flue-pipes, etc.), and forlocal production of wooden shutters/vents and iron grates forfurnaces (i.e., conversion of old railway lines). Wherenecessary to ensure cost competitiveness, the TTPMB wouldorganize local tenders for the production of the inputs, andfor the transportation of such inputs to the districts; and
(c) a credit component under which the proposed project wouldcollaborate with the Cooperative and Rural Development Bank ofTanzania (CRDB) to ensure timely provision of credit (prefer-ably on a three-year repayment schedule) to enable partici-pating farmers to bear the costs of upgrading their barns andfurnaces.
21. The project related training activities would be supplementaryto the training program under the ongoing National Agricultural andLivestock Extension Rehabilitation Project (NALERP) which is financedjointly by the IDA and the African Development Bank (ADB). Under theproposed project, study tours would be arranged for the SMSs and theRCSOs to visit organizations in other developing countries such asMalawi, Zimbabwe, and possibly India, where major advances to improvetobacco curing efficiency have been made. The TCS would play a leadingrole in developing training materials to be used locally by SMSs (i.e.,in monthly workshops or refresher courses) and other field extensionpersonnel (i.e., in-service workshops for Divisional Extension Officersand Village Extension Workers).
Project Implementation
22. The proposed project would be implemented by the Crop ServicesSection of the MALD on behalf of the Government of Tanzania. The Assis-tant Commissioner for Crop Services (ACCS) would be responsible for theoverall supervision of the project. The day-to-day responsibilities forimplementing the proposed project would be assigned as follows:
(a) the Regional Crop Services Officers in the Tabora and SouthernHighlands Zones would be the principal counterparts for theTCS. It is expected that the TCS would devote about 80% of his
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services in the Tabora and Urambo districts, and 20% in theSouthern Highlands area. Accordingly, the TCS would be basedin Tabora, and operate out of the offices of the RCSO for theTabora region. For field extension activities, the principalcounterparts for the TCS would be the District SMSs for Tabora,Urambo, Chunya, and Iringa respectively, and the Regional SMSfor Industrial Crops for Tabora;
(b) the TTPMB would be responsible on behalf of the MALD forcoordinating the production, procurement, and distribution ofkey inputs required by participating farmers for the tobaccocuring efficiency program. It is expected that with theretooling of the TTPMB factories at Morogoro and Uramborespectively, the TTPMB would be able to produce 8" diameterflue-pipes, and also convert the old railway lines into irongrates for furnace retrofits. However, for other items such asthe fabrication of cast iron flue-pipe sections to be insertedinto furnace outlets, the production of wooden shutters forbarn ventilation, etc., the TTPMB would arrange local tenders;and
(c) the CRDB would be responsible for administering credit to thefarmers through the Farmer's Societies. For this, it isexpected that the CRDB would retain arrangements similar tothose established recently under an ongoing IDA financedTanzania Agricultural Export Rehabilitation Project (Credit1981-TA).
23. The above assignments would be compatible with arrangementsmade by MALD for other major extension projects in the same regions,particularly the National Agricultural and Livestock ExtensionRehabilitation Project (NALERP) in the Tabora region. However, therewill be the need during project appraisal by prospective donor/fundingagencies to ascertain once more that the proposed organizationalstructure for the project would be a workable one and would notcritically hamper the achievement of results with respect to tobaccocuring efficiency improvements.
24. The implementation of the project will be monitored andevaluated by the Project Planning and Monitoring Bureau (PPMB) of theMALD. At least two such evaluations have been programmed into theproject schedule; the first would be at the end of the second season ofproject implementation, and the second at the end of the fifth season ofthe six-year project.
Project Costs
25. The estimated total costs of the proposed project is TSh340million, including price and physical contingencies. About 47% of thetotal project cost will be for capital expenditures which will beincurred for the procurement of vehicles, equipment (e.g., machine tools)
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for the TTPMB factories at Morogoro and Urambo, and materials for thefabrication of key inputs required by farmers to modify and upgrade 6,810barns and furnaces. The total cost of the project is equivalent toUS$3.6 million, and about 22% of the total cost will be in foreigncurrency.
Project Benefits
26. The proposed project to improve tobacco curing efficiency bysmallholder farmers in Tanzania will yield direct benefits in tworespects: (a) increased outputs of cured tobacco leaf as a result ofsignificant reduction in curing losses with improved management of thecuring process; and (b) saving in fuelwood as a result of reduction inspecific fuelwood consumption levels. Because of shorter curing cycles,labor which would otherwise be "tied up" with curing would be availablefor redeployment to other tasks such as picking and tying up green leavesfor curing. This is considered to be an indirect benefit. An additionalbenefit would be the higher quality of cured tobacco leaves, but for thepurposes of this analysis, such improvements have been counted as anindirect benefit.
27. Over the life of the project, the total benefits would cumula-tively amount to: (a) about 206,000 m3 of fuelwood savings or about 3,400ha of natural woodlands which would be saved from clearfelling; and(b) the reduction in curing losses, yielding about 8,100 tonnes ofadditional cured leaf for export. In financial terms, the total value ofthe benefits (in constant 1988 TSh) for the project's lifetime would beon the order of TSh665 million: TSh54 million due to fuelwood savings,and TSh6ll million due to increased output of cured tobacco.
Project Justification
28. In financial terms, the project is justified from the perspec-tive of participating farmers. Each farmer would realize full payback intwo years on his investments associated with the "technical package."For the project overall, the financial rate of return is slightly over23% due to the additional costs associated with project management andextension services.
29. The economic rate of return for the project, indicatingincremental returns to the country, is estimated to be 32.5%, which ishighly favorable. This indicates ample justification for the projectwhich would convert relatively small investments in tobacco curingefficiency measures into large fuelwood savings and significant reductionin curing losses. The results of the sensitivity analyses confirms thatthe results of the economic rate of return analyses are also robust(Table 2).
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Table 2: SENSITIVITY ANALYSIS OF PROJECT ECONOMIC RATE OF RETURN
Rate of Return
Scenario (%)
Base Case 32.5
Decrease Export Price of Tobacco
- By 20% 27.7
- By 40% 22.5
Decrease Project Benefits a/
- By 20% 2405
- By 40% 15.1
Decrease Project Benefits and Increase Project Costs b/
- Both by 10% 25.3- Both by 20% 18.5
Decrease Total Number of Barns Retrofitted
- By 40% 20.7
a/ Value of additional tobacco leaf, and of fuelwood saved.
b/ Total project costs Inciuding extension support.
Project Financing
30. The Government requires financing from external multilateral
and/or bilateral sources to implement the proposed project. The ongoing
NALERP has already begun with the rehabilitation of extension services in
the Tabora region, and hence provides funds for some activities and
facilities which are similar to those defined under the proposed project
(e.g., training and provision of vehicles for SMSs and other extension
personnel). Also it is envisaged that the CRDB may not require external
financing to maintain a line of credit for participating farmers.
31. The additional funds required for the proposed project would
most likely amount to about US$2.2 million of the estimated
US$3.6 million total cost of the project. Of this amount, about US$0.7
million would be required to finance the technical assistance component,
and US$1.5 million to finance the procurement of machine tools and the
materials and the production and distribution of the key inputs required
for modifying the curing barns. The exact financing arrangements for the
proposed project would need to be determined through direct negotiations
between prospective donors and the Government, taking into account the
possibility for cofinancing with the NALERP.
Project Risks
32. The major risks associated with the proposed project rest
primarily with the failure to achieve expected benefits within the six
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year time frame. Delays or failure to reach the expected savings targetswould most likely result from: (a) failure to generate interest in theproject resulting in low farmer participation; (b) lower than envisionedsavings in fuelwood and curing losses resulting from discrepanciesbetween test conditions and actual on-farm implementation of the curingtechniques; (c) farmers failing to follow technical advice or implementnew techniques properly. The above risks have been greatly minimizedthrough the successful completion of the pilot project. This project canbe considered as a second phase that has incorporated lessons learnedfrom a first phase. Particular attention should nevertheless be paidduring the next step of project appraisal to reviewing the proposedorganizational set-up for the project. It is especially critical thatthe organizational framework for project implementation should be fullycompatible with the revamped system for agricultural extension in thecountry. Also, clear-cut arrangements should be made to coordinateproposed project activities in the Tabora and Urambo districts with thoseof the IDA and ADB financed NALERP in the Tabora region.
I. THE PRODUCTION OF FLUE-CURED TOBACCO IN TANZANIA
Introduction
1.1 Tobacco is one of Tanzania's major agricultural export crops.It is a principal target of the Government's ongoing export croprehabilitation program which, in large part, is supported by the IDAfinanced Tanzania Agricultural Export Crop Rehabilitation Project. 7/ Theexport crop rehabilitation program was designed to reverse the preci-pitous decline in tobacco production from a peak of 15,000 tonnes in1974/75, to a low of 9,000 tonnes in 1983/84. In this chapter, theevolution of flue-cured (Virginia) tobacco production in Tanzania intothe present structure with respect to the cultivation, processing, andmarketing of flue-cured tobacco is reviewed. The chapter concludes withan assessment of current flue-cured tobacco production, and fuelwoodsupply and demand for curing in the principal tobacco producingdistricts.
Background
1.2 In Tanzania, the administrative regions of Iringa, Tabora, andMbeya are the principal areas for flue-cured tobacco production. Theorigin of the industry is in Iringa, where in the early 1940s, settlersfrom Greece, and some religious missions established relatively largeplantations. Cultivation of flue-cured tobacco spread to smallholderfarmers, and by 1963, significant numbers of smallholder farmers hadorganized themselves into village cooperatives and settlement schemes tocultivate flue-cured tobacco. 8/ In the Tabora region, flue-curedtobacco production was introduced on a large scale to smallholder farmersin 1957 after the collapse of a major Groundnut Scheme that had beeninitiated by colonial authorities. During the same period, efforts weremade in the Mbeya region (mainly the Chunya district) to establish flue-cured tobacco as a cash crop for smallholder farmers. Eventually,production spread to other districts in the Mbeya region, although not aswidespread as has occurred in the Tabora and Iringa regions. Thedistribution of flue-cured tobacco producing areas relative to those forthe production of the fire-cured and burley (air-cured) varieties oftobacco is shown on IBRD Map 20794.
7/ "Tanzania Agricultural Export Rehabilitation Project," StaffAppraisal Report No. 6958-TA, Southern Africa Department, WorldBank, March 1988.
8/ "The 'Success Story' of Peasant Tobacco Production in Tanzania," byJ. Boesen and A.T. Mohele, Publication No. 2, Center for DevelopmentResearch, Scandinavian Institute of African Studies, 1979.
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1.3 In Tanzania today, flue-cured production is dominated bysmallholder farmers who account for about 90% of annual output. Theremaining 10% of the output is produced by large scale farms located inthe Iringa district. These larger farms are owned and cultivated by some20 farmers, most of whom are Greek settlers, and belong to the SouthernHighlands Tobacco Growers Association (SHTGA). Up to 75% of flue-curedtobacco production is obtained from the Tabora region; and between 20-25%from the Southern Highland Zone (i.e., Iringa and Mbeya regions). Themost productive areas from the standpoint of smallholder farmers are infour districts; Tabora and Urambo in the Tabora Region, and Iringa andChunya in the Southern Highland Zone.
Table 1.1: TANZANIA FLUE-CURED TOBACCO PRODUCTION
MARKETING YEAR AREA PRODUCTION YIELD(ha) (tonnes) (kg/ha)
1973/74 16,264 10,278 6321974/75 20,024 15,292 7641975/76 20,447 11,939 5841976/77 19,863 14,229 716197?/78 21,542 14,670 6811978/79 24,565 14,403 5861979/80 25,248 13,005 5151980/8 23,006 12,972 5641981/82 22,239 12,164 5471982/83 14,511 9,579 6601983/84 15,847 9,007 5681984/85 20,346 10,720 5271985/86 16,250 12,113 733
Source: TTPMB
1.4 Statistics on the total number of active smallholder tobaccofarmers are not reliable; estimates range from 20,000 to 50,000. Forexample, although some 150 villages in the Tabora region produce tobacco,90% of the crop originates from about 100 villages. During the 1987/88season, an estimated 15,000 farmers in the region were organized into 189Primary Societies; 106 serving the Tabora district, and 73 the Urambodistrict. The average size of tobacco farms is between 0.4 to 0.6hectares, but the more successful smallholder farmers cultivate over twohectares. Productivity is low; most cultivation is by hand tools andyields of cured tobacco per hectare planted are reported to be of theorder of 450-700 kgs., compared to about 1,000 kg/ha in neighboringcountries such as Malawi and Kenya, where smallholder production is alsoimportant. One factor in the low yields is the high post harvest losses(i.e., curing losses and handling/baling losses from the barns to themarketing centers). It is estimated that post harvest losses are on
average 35-40% of the harvested crop. 9/ Other losses in the fieldthrough poor crop husbandry are equally high, about 25-30%. A majorcootributing factor to the high curing losses is that the farmers havevery rudimentary knowledge of curing principles, and most barns arestructurally in very bad condition.
1.5 Major constraints for flue-cured tobacco production by thesmallholder farmers are well documented. 10/ They include lack ofproducer price incentives, the high costs of inputs and recurringdisruptions in the supply of key inputs for production (i.e., farmimplements, fertilizer, spare parts, etc.); poor extension support; andregional shortages and/or difficulties in obtaining fuelwood for curingtobacco. The ongoing export crop rehabilitation program, which issupported by the IDA Tanzania Agricultural Export Crop RehabilitationCredit, is designed to address some of these constraints. A number ofmajor reforms have recently been introduced by the Government to supportthe tobacco industry, including higher producer prices for flue-curedtobacco, and a major restructuring of agricultural extension services, asreviewed below.
Extension Services for Tobacco
1.6 Prior to 1984, a separate extension service for tobacco wasmaintained by the TAT. As part of a major restructuring of agriculturalextension services nationwide, all tobacco extension services were mergedunder the direct supervision of the Assistant Commissioner of Agriculture(Extension Services) in the Ministry of Agriculture and Livestock Devel-opment. The extension services are based on the Training and Visit (T &V) system, which is coordinated at the regional and district levels byRegional Agricultural Development Officers (RADOs) and District Agricul-tural Development Officers (DADOs), respectively. Crop specificextension support is provided by Subject Matter Specialists (SMS), alsobased at the regional and district levels. At the ward level, theservices are coordinated by Agricultural Field Officers, who in turnsupervise extension workers assigned to the villages.
1.7 The existing extension system is not effectively dealing withtobacco production, especially the tobacco curing aspects of post harvest
9/ Post harvest crop losses or spoilage are normally due to impropercuring; poor storage conditions on the farms, at baling centers, andat transport terminals; improper conditioning for packing and inade-quate presses for baling.
10/ Refer to "Export Crop Packages - National Tobacco Program." Reportof the Agricultural Planning and Marketing Division, Ministry ofAgriculture and Livestock Development (December 1984); see also"Annual Review of Tobacco by the Marketing Development Bureau,Ministry of Agriculture and Livestock (August 1986).
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treatment of tobacco. Some factors underlying the poor performance ofextension support for tobacco can be discerned as follows. First,because of logistical constraints, the coverage of extension workers intobacco producing villages is thin. The practice whereby each extensionworker is required to cover all food and cash crops grown in a given areaalso dilutes the impact of tobacco extension efforts. In the Taboraregion, for example, some 110 extension workers were deployed during the1987/88 season. Of these, 41 were assigned to villages in the Taboradistrict, and 57 to the Urambo district. Each extension worker had tocover tobacco and maize farming activities. Second, support in terms ofmaterial and information on tobacco production is weak. There are onlythree SMSs serving the region, and although they each have someexperience with tobacco agronomy, none has had any specific training orexperience in tobacco curing activities such as barn and furnaceconstruction and maintenance, and techniques for loading barns andmanaging the curing process. Third, although some training on tobacco isprovided to extension workers as part of general agricultural certificatecourses by the Ministry of Agriculture Training Institute (MATI), tobaccocuring techniques are not covered. The Tumbi Agricultural ResearchStation has also severely curtailed its tobacco research and demon-stration activities, and hence is unable to effectively support theextension effort. The local expertise on tobacco curing is currentlylimited to a few personnel within the TTPMB.
1.8 The Agricultural Extension Systems serving the four principeltobacco growing districts are being overhauled and strengthened byexternally funded projects: the Tabora and Urambo districts will becovered by the IDA and ADB financed National Agricultural and LivestockRehabilitation Project (NALERP); and the Iringa and Chunga districts bythe IFAD financed Southern Highlands Food Support Project.
Supply of Inputs
1.9 The main inputs for tobacco production are the seeds,fertilizer, insecticides, fuelwood, and the flue-pipes. The principalinputs for tobacco curing (i.e., fuelwood and the flue-pipes) areprocured by farmers with direct assistance from the Cooperative Unionsand TTPMB as follows. For fuelwood, the Cooperative Unions providetransportation in the form of tractor-trailers or trucks as discussedbelow (para 1.20). The TTPMB produces the flue-pipes at two locations;the main factory is at Morogora, and a second machine tool factory is atUrambo. The TTPMB fabricates the fluepipes using imported 22" gauge ironsheets and delivers the flue-pipes by truck to Cooperative Unions andPrimary Societies. Currently, the TTPMB's machine tools are fairly oldand need to be overhauled and/or replaced. The TTPMB plant at Morogorois well equipped to handle specialized tasks associated with the proposedproject, particularly the cutting of old railway lines for use as gratesin the "Malakisi" slot-type furnaces (para 2.12).
Marketing Arrangements
1.10 Until 1976, all flue-cured tobacco in Tanzania was purchasedand transported to the processing factory in Morogoro by the CooperativeUnions. However, as a result of sharply rising costs which was attri-buted to inefficient marketing, the cooperatives were dissolved in 1976and replaced by the Tobacco Authority of Tanzania (TAT). The TAT wasgiven the responsibility of advising, supervising, and regulating alldevelopment of the tobacco industry in Tanzania, and performing allactivities pertaining to extension, procurement and distribution ofinputs, and transportation, processing and marketing of cured leaf.
1.11 By 1984, it had become apparent that the dissolution of thecooperatives had not solved the problem of rising marketing costs, andhence the government decided to reintroduce the cooperatives. TheRegional Cooperative Unions in Tabora, Mbeya (Chunya), and Iringacurrently handle all tobacco related procurement activities; supply ofinputs and marketing of flue-cured tobacco produced in the Tabora region,for example, is controlled by the Tabora Regional Cooperative Union(TARECU). In 1985, the government replaced TAT with the TanzanianTobacco Processing and Marketing Board (TTPMB), whose activities werefurther restricted to processing cured tobacco leaves at the Morogorofactory and marketing all flue-cured tobacco to domestic and inter-national markets. About two-thirds of the production is exported and theremainder is sold to two domestic cigarette manufacturers. ll/
1.12 During the purchasing season, running from March to August,farmers place their tobacco in bales of 21 to 100 kilos before it isdelivered to sales floors or marketing centers for sale. 12/ Thisgrading and baling takes place at village baling sheds operated by thePrimary Societies. Two controllers are responsible for the supervisionof grading and baling activities (i.e., an extension worker and a PrimarySociety member). The Primary Society sells the tobacco on behalf of thefarmers to the Cooperative Union at the Government announced price. 13/
11/ The domestic cigarette manufacturers currently pay a 20% premiumabove the export prices for the tobacco.
12/ After curing, flue-cured tobacco is graded into 12-16 standardgrades by individual farmers, tied into hands and finally pressedinto bales of 70/80 Kgs with tar-lined (Bituminized) paper andhessian cloth.
13/ The Cooperative Unions buy tobacco from farmers through the PrimarySocieties at GOT announced producer prices. TTPMB pays the unions"into-store'@ prices for the tobacco, which includes the producerprices and agreed costs for transporting tobacco from the villagebaling center to the marketing center.
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Credit Arrangements
1.13 Tobacco farmers annually receive production inputs through acredit account with their primary society. The inputs are purchased bythe Cooperative Union with credit obtained from the Cooperative and RuralDevelopment Bank (CRDB) and delivered to the primary society. 14/ TheCRDB credit to the cooperatives also covers their requirements forpurchasing and handling the crop until delivered to TTPMB. Inputsrequiring foreign exchange are purchased by the TTPMB and delivered tothe cooperative unions. TTPMB receives credit from the National Bank ofCommerce to cover its operating costs including the costs of purchasingtobacco from the cooperative unions.
1.14 The dual source of credit for producing and marketing tobaccohas contributed to higher credit costs than necessary. This arises whenthere is a delay between the sale of tobacco to TTPMB and payments to thecooperatives or a delay in the cooperatives clearing their overdraft withCRDB. This is said to occur sometimes due to administrative delays atthe primary societies in updating farmers' accounts and paying forcrops. The payment to farmers is the net value of their crop afterdeducting the input credit received, their share of primary society costsand levy, and their share of cooperative union costs and levy.
Existing Tobacco Curing Barns and Furnaces
1.15 The barn census conducted by ESMAP has revealed considerablevariations in the size, materials, and layout of existing tobacco barnsin the four main producing districts. The barn inventory produced duringthe pilot demonstration project is shown in Table 1.2 below. Most small-holder farmers use the small-sized barns with dimensions of 12'x12'x12'or smaller; or medium-sized barns with dimensions of 16'x16'x14'. A fewwho participated in the TAT "Smallholder Tobacco Improvement Project"have constructed larger "Low Profile" barns with dimensions of24'x16'x13'. Most of the large-scale farmers of the SHTGA use largerbarns, with dimensions of either 20'x20'x20', or 24'x16'x20'.
1.16 Most medium-sized smallholder barns are made with mud brickwalls, usually 9 to 12 inches thick (23-30 cms.). The small-sized barnsare generally in worse shape, and have walls which are built of polesthat are firmly planted in the ground, strapped together with tree barktwine, and sealed in mud (Figure 1). The roofs in both small- andmedium-sized barns have a frame made out of local poles (Brachystegia!.), and thatched with reed grass (Hyparrhenia filipendula).
14/ On behalf of farmers, the Cooperative Unions negotiate input loansfrom the Cooperative and Rural Development Bank (CRDB) and ensuretheir reimbursement during the crop's marketing season. Input loansare recovered by deductions from proceeds of each grower at the timehe sells his tobacco and are remitted to the CRDB.
1.17 The furnaces and flue-pipe systems also vary considerably amongfarmers. Typically, each barn is fitted with one open-hearth furnace,which is located either externally or partially embedded in the barnwall. The furnace is usually built of brick and mud, consists of wallswhich are 10-12 inches thick, and have an arched top. Most furnaces areapproximately four feet long, and about 2.5 feet high. None of thefurnaces surveyed had an ash pit or grate.
1.18 One of the major disadvantages of open-furnaces, in addition tohigh radiation heat losses, is that, depending on the direction of theprevailing wind, the flames can be sucked out of the furnace, resultingin heavier heat losses. When the wind blows directly into the furnace,burning is rapid and uncontrolled, and results in a carry-over of ashinto the flue-pipes. Relatively simple changes such as the use offurnace doors, could force air to pass through the fire bed, control airentry into the furnace, and reduce heat losses. Further details aboutmodifications in the barns and furnaces to improve overall efficiency offuelwood are discussed in the next chapter.
Table 1,2: BARN INVENTORY OF TOP TOBACCO PRODUCING DISTRICTS
NUMBER NUMBER NUMBEROF OF OF
REGION DISTRICT WARDS VILLAGES a/ FARMERS 12x12 16x16 16x20 24x16x13 b/ 20x20 24x16x20A B
Tabora Tabora 16 15 12 7,630 6,095 2,827 566 5Urambo 5 5 7 2,556 4,385 2,765 954 --
Iringa Iringa 2 2 4 1,885 520 253 332 -- 475 c/ 66Mbeya Chunya 9 4 5 3,606 5,661 379 -- 2 -- --
Total 32 26 28 15,677 16,661 6,224 1,852 2 475 66
a/ Group A villages produced over 100,000 kg cured tobacco in 1984/85 and 1985/86 seasons; andGroup B villages, between 50,000-100,000 kg.
b/ Special "Low Profilet barns established durlng pilot TAT project.c/ Large barns operated by farmers in the SHTGA.
Source: ESMAP Census (1988); Annex 2.
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Figure 1: TRADITIONAL MEDIUM SIZED GROWERS' BARN
Thatched roof
Either poston I or 2 Wall of mud and buh pols
Fuheood -
FRONT
Zhimney,
Mud joints (Circular)
Opening In theppeswall for fumjye
Intemai furnace
FLUE PIPES LAYOUT
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Fuelwood and Tobacco Curing
1.19 The tobacco industry in Tanzania relies on wood for a varietyof purposes, the most important being as an energy source for curingtobacco. Relatively small but significant amounts of wood in the form ofpoles and sticks are used in constructing the barns.
1.20 Fuelwood requirements for tobacco curing have been identifiedas one of the principal causes of deforestation in the Tabora and Iringaregions, but the full extent of the fuelwood supply/demand imbalances ineach of the four main tobacco districts, and the adverse environmentalimpact of tobacco curing activity is not well documented. 15/ However,it is generally agreed that the worst affected areas with regard todepletion of natural woodlands occur in the Tabora, Urambo, and Iringadistricts. 16/ The Chunya district is relatively much better endowedwith woodland resources. The assessment below puts the fuelwoodsupply/demand situation in the Tabora, Urambo, and Iringa districts intofocus.
1.21 Fuelwood Supply Potential. ESMAP has commissioned a team ofspecialists from the Institute of Resource Assessment (IRA), Universityof Dar es Salaam, Tanzania, and the Swedish Space Corporation-SATIMAGE,to conduct an assessment of the biomass cover in the Tabora and Iringaregions. Under this activity, remote sensing images from the SPOTsatellite are being combined with field surveys (i.e., "ground truthing")as the first stage to inter alia assess the standing stock of fuelwood inthe woodlands (i.e., m wood per ha) that surround the main urban centersand the tobacco producing regions. Preliminary results for the Taboraand Iringa regions were obtained in 1987 which indicate that for naturalwoodlands areas that currently supply the bulk of fuelwood for tobfccocuring, fuelwood yields from clear felling would be between 57-99 m ofwood (stacked) per ha.
1.22 Fuelwood Supply Arrangements. Most smallholder farmers are nolonger able to obtain fuelwood for tobacco curing within walking distancefrom their respective villages. The fuelwood usually has to be obtainedfrom accessible woodlands that are several kilometers away. In theTabora and Iringa areas, farmers rely on seasonal labor to cut, extract,and pile the fuelwood in stacks along the access roads or tracks in thewoodlands. The farmers also hire trucks or tractor-trailers to haul thefuelwood to the barns. The costs involved are as follows for the 1987/88
15/ "Agricultural Development versus Environmental Protection inTanzania: The Case of Tobacco Production," by S.K. Marshalla,University of Dar-es-Salaam (December 1986).
16/ "Fuelwood Scarcity and Other Problems Associated with TobaccoProduction in Tabora Region, Tanzania," by A.B. Temu. Report No. 12of Division of Forestry, Sokoine University of Agriculture (October1979).
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season in the Tabora region. Laborers who cut, extract, and pile t~efuelwood into stacks charge farmers about TShlOO-150 per stack of 1 m .Haulage charges vary depending on type of vehicle used and pqymentarrangements. For trucks, the charge was TSh 800 per load of 5 m on acash payment basis; and TSh95O per load on a deferred payment basis withthe Cooperative Union (TARECU). The Cooperative Union also charged TSh900 per tractor-trailer load of 4 m3 on a deferred payment basis. Thecost of haulage was therefore of the order of TSh 160-225 per m . A fewof the larger farmers own trucks, and hence their costs of haulingfuelwood may be lower.
1.23 Specific Fuelwood Consumption. On the demand side, the basisfor estimation usually is the specific fuelwood consumption (SFC) statedin terms of weight (or volume) of fuelwood used to cure a tonne oftobacco. In the F3ast Africa region, estimates of SFC are commonly in therange of 20-30 m stacked wood per tonne of cured leaf. There are,however, very wide varinations in She estimates. In Tanzania, estimatesof SFC range from 20 m to 64 m of stacked wood per tonne of curedleaf. Tests carried out under the UK-ODA funded Tabora Land Use PlanningProject (LUPP found that on average, sma3llholder farmers in the regionrequired 30 mJ of solid wood (about 45 m stacked wood) to cure a tonneof tobacco leaf.
1.24 Against this background, ESMAP, during the pilot project,conducted systematic measurements of a group of 16 "control" barns todetermine SFC levels. Qn average, the "control" barns achieved SFClevels of between 17-28 mi stacked wood per tonne of cured lea. Henceit appears that previously reported levels of the order of 40 m stackedwood per tonne cured leaf and higher are overestimates.
1.25 Labor Input for Tobacco Curing. It is estimated that thetypical smallholder in Tanzania requires annually to mobilize some 420-530 mandays of labor per hectare of tobacco cultivated. These estimatesassume that yields vary between 450 kgs/ha to 700 kgs/ha of tobaccorespectively, and that farmers rely to a large extent on family membersfor the work, especially during curing. Of these total mandays, about28-32% is accounted for by tobacco curing chores, principally cutting andhauling of fuelwood to the barns, building and maintenance of barns, andthe process of curing itself. In overall terms, the curing stagerequires the largest proportion of labor-days in tobacco curing, usuallysome 75-110 mandays per annum for each hectare cultivated.
1.26 Impact of 1986/87 Tobacco Curing Season. The estimated totalfuelwood consumption in the three main districts for flue-cured tobaccoproduction is of the order of 167,000 m3 (stacked) for the 1986/87 seasonalone (Table 4.3). assuming conservatively that the average SFC in theseareas is 20 m wood (stacked) per tonne cured leaf. Since, for the mostpart, fuelwood requirements for tobacco curing are obtained by clear-felling parts of the surrounding Miombo woodlands, the implication isthat in 1986/87 alone, just over 3,000 ha of woodlands may have been
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severely degraded to provide wood for tobacco curing, ass uing optimis-tically that each hectare of woodland could yield 60 mU of tackedwood. 17/
1.27 With increasing production of flue-cured tobacco under therehabilitation programs, the demand for fuelwood is expected to risesignificantly. Given that farmers already have to travel longerdistances, and pay higher costs for cutting and hauling the fuelwood totheir respective barns, it is likely that regional fuelwood supply demandimbalances will worsen considerably, perhaps eventually leading onceagain to a marked reduction in output. Alternatively, the fuelwoodscarcity in the Tabora, Urambo, and Iringa districts will compelproducers of flue-cured tobacco to migrate to areas with more accessiblewoodlands, particularly the Chunya district.
Table 1.3: 1986/87 PRODUCTION OF FLUE-CURED TOBACCO
AND FUELWOOD REQUIREMENTS
Tobacco Fuelwood WoodlandRegion District Production Consumed a/ Cleared
(tonnes) (m ) (ha)
Tabora Tabora 3,396.6 67,732 1,129Urambo 3,226.6 64.532 1,076
Iringa iringa 417.7 8,354 140SHTGA b/ 1,272.6 25,452 424
Mbeya Chunya 858.4 17,168 286
Total 9,161.9 183,238 3,055
a/ Assumes specific fuelwod consumption of 20 m) wood (stacked) pertonne cured tobacco.
b/ Members of the Southern Highlands Tobacco Growers Association.c/ Average 60 m3/ha by clearfelling natural woodlands.
Source: Mission estimates; TTPMB.
17/ There is still a strong selectivity in the types of tree speciesfelled for various purposes. For tobacco curing, the preferredspecie appears to be "Mtundu" Brachystegia sp., Jurbenadia sp., andAcacia sp..
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II. PROPOSED MEASURES TO IMPROVE THE EFFICIENCY OP TOBACCO CURING
Introduction
2.1 The Government has, since the early 1980s, been concerned aboutthe relatively high levels of fuelwood consumed for tobacco curing in theproducing regions, and the impact of tobacco curing in aggravatingregional fuelwood supply/demand imbalances. Several surveys have alsoidentified the growing shortages of fuelwood as a major constraint onproduction in the flue-cured tobacco sector. In 1984, the erstwhileTobacco Authority of Tanzania (TAT) began investigating ways of reducingfuelwood requirements for tobacco curing, and identified several measuresthat were later incorporated into the unsuccessful "Smallholder TobaccoImprovement Project."
2.2 In this chapter, measures considered necessary for improvingthe efficiency of fuelwood use in tobacco curing in Tanzania areredefined and reviewed, based on the work of the ESMAP team during thepilot demonstration project. The measures are, to some extent, drawnfrom previous experiences gained in other Eastern Africa countries (e.g.,Malawi, Uganda, Kenya). The chapter concludes with the assessment of thepotential impact and benefits that would accrue to farmers who implementthe measures. The assessment is based on the results achieved by ESMAPduring curing trials with medium sized barns which were conducted atUfuluma Village in the Tabora district during the 1987/88 curing season.
2.3 The ESMAP investigations have confirmed that the following arethe main factors that currently contribute to inefficiencies in fuelwooduse and accentuate energy losses for tobacco curing by smallholders inTanzania:
(a) poor management and control of the curing process;
(b) lack of proper furnaces or major deficiencies in the open-hearth furnaces used for heating;
(c) deficiencies in various aspects of the flue-pipe and chimneysystems; and
(d) poor construction and maintenance of barns, includinginsulation and ventilation mechanisms.
2.4 Because the earning power of smallholder tobacco farmers inTanzania is still relatively low, greater emphasis has to be given tomeasures that are both relatively simple to implement, and would notplace undue financial burdens on the smallholder farmers. Similarly,because there is a scarcity of foreign exchange in Tanzania, measuresthat would require a minimum of imported materials and equipment toimplement in the country have been favored by ESMAP. Based on theresults achieved by ESMAP during the curing trials, the potential impacts
- 13 -
and benefits are assessed in quantitative terms (i.e., m3 of fuelwoodsaved, reduction of curing losses in kgs. of cured leaf, and laborsavings in man-days for each curing cycle).
Measures for Puelwood Conservation
Barn Modifications
2.5 Most of the existing smallholder barns surveyed during thecensus are structurally in bad shape. In most cases, the doors to thebarns do not fit properly, large gaps exist between the side walls androofs, and cracks had developed in walls after the original clay mortarhad dried, crumbled, and fallen off. The cumulative effect of suchdamage is significant in terms of reducing the efficiency of fuelwood useduring curing, because heat loss by convection increases through thegaps; hot air leaking out of the barn is more pronounced during the earlystages of curing; and conversely, cold air leaking into the barn is morepronounced during the final stages of stem drying. Ideally, the barnsshould be completely rebuilt using burnt bricks with better insulationproperties, improved construction methods for the walls, door frames, androofs. However, this would appear to be a longer term objective becausethe costs involved may be too high relative to the present earnings ofsmallholder tobacco farmers. The more practical approach in the short-term, would appear to involve barn rehabilitation, primarily:(i) resealing the walls; and (ii) rethatching the roofs.
2.6 Sealing of Walls. As a minimum measure, the farmers would needto replace the clay mortar, and also patch-up any cracks in the walls.Doors would be refitted to ensure that existing gaps are eliminated. Iffeasible, the farmers would be encouraged to use a cement-sand slurry toseal and/or paint the outside of the walls.
2.7 Rethatching of Roofs. Also as a minimum measure, farmers wouldneed to rethatch the roofs of their respective barns prior to each curingseason. Although the existing traditional thatched roofs have beendemonstrated to have fairly high insulation properties, they arepermeable, thereby allowing air to flow into and out of the barn. Thismakes difficult the process of controlling humidity and temperaturelevels within the barn during curing. Farmers need to be instructed asto how to improve the construction of their thatched roofs, especially tomake them as dense and compact as possible, using reed grass, and toeliminate unnecessary gaps, etc. Most smallholders in the main producingareas of Tanzania presently cannot afford the cost of replacing thethatched roofs on the barns with corrugated iron roof sheeting.
- 14 -
Barn Ventilation
2.8 The traditional smallholder barns rely on natural convectionwith air. Vents, which usually are located at the bottom and top of eachbarn, allow cooler air to enter the base of the barn, gain heat from theflue-pipes, and rise up towards the roof while picking up moisture fromthe tobacco leaves; the top vents allow the hotter and moisture laden airto leave the barn. During curing, the vents need to be operated (closedand opened) by farmers in a manner that regulates the air flow throughthe barn. The rate of heat loss by convection can be regulated byadjusting the vents. At present, since most smallholder barns inTanzania are fitted with permanently open vents, it is almost impossibleto control ventilation rates at different stages of the curing cycle.During the final stages of curing in existing barns, for example, theventilation rate cannot be reduced because top vents always remainopen. Even when the bottom vents are closed (blocked), air leakage intothe barns can be substantial i.e., through cracks in the wall, and aroundthe poorly fitted doors. In general, most of the bottom vents on thebarns are poorly located for air distribution purposes.
2.9 In order to improve the farmers' control of ventilation inexisting barns, the following relatively simple but practical measuresshould be introduced in conjunction with better schedules for managingventilation rates during curing:
(a) Top Vents. The open vents should be replaced by woodenshutters which are designed to close within tightly fittingwooden frames. Hinges made out of rubber instead of metalshould be used to hold the shutters to the frames. For easyoperation by the farmers, new shutters were designed byESMAP. 18/ The shutters can be opened in various degrees bydrawing on a cord attached to the rudimentary pulley system(i.e., a looped nail embedded in the barn wall). The shutterswould be able to close under their own weight because the framewould be canted slightly to the inside of the barn. For mostof the existing smallholder barns, four such self-closingshutters would need to be installed as top vents, one each atthe two gable ends, and one each above the top tiers on thefront and back walls, respectively.
(b) Bottom Vents. Similar self-closing shutters should beinstalled near the base of the barn. The proposed location ofthe bottom vents would facilitate a more even distribution ofair entering the barn.
18/ The ESMAP Field Director (Mr. Wahid) in consultation with themanager of a local wood processing company, the Tabora Msitu PoductsLtd.
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Furnace Retrofit
2.10 Most smallholder tobacco barns in Tanzania are fitted withpoorly constructed open-hearth furnaces, which do not provide any meansfor controlling air required for combustion. This increases heat lossesby radiation and convection, leading to significant wastage of fuel-wood. In order to improve the efficiency of fuelwood use in thiscontext, there is the need to introduce a new type of furnace. Theimproved slot-type furnace, which is being disseminated elsewhere in EastAfrica, notably Kenya, Malawi, and Uganda, may be the most appropriateand cost-effective design to minimize heat losses and also to improvecombustion efficiency.
2.11 Design Changes. Typically, furnaces in smallholder barns inTanzania usually are embedded in a barn wall. In most cases, the furnaceis simply a shell with an opening in one end into which fuelwood isfed. Where there is an arch encasing the furnace, it usually isconstructed of burnt brick and mud of 10" (25 cm) to 12" (30 cm)thickness. Part of the furnace extends about two feet within the barnwall. This section of the open hearth furnace is shaped in the form of abox 4 feet (1.2 cm) long and 2.5 feet (0.76 cm) high. Among the manyshortcomings of this type of furnace are: (i) the lack of any provisionfor ash removal except by clearing out the entire furnace; and (ii) thelack of a mechanism for air flow regulation. Charcoal is usually formedin such furnaces, indicating that combustion is somewhat incomplete.Also, depending on the direction and strength of prevailing winds, flamescan be blown into or sucked out of the furnace, thereby aggravating theheat loss problem.
2.12 In order to comprehensively address these problems, the 'slot-type' furnace is recommended for this purpose. The basic design of the'slot-type' furnace originates from the Malakisi Research Station inKenya, and hence is usually referred to as the 'Malakisi' furnace. Themain features of the particular version for Tanzania, which incorporatessignificant modifications made by the ESMAP team during the pilot projectat Ufuluma Village, are presented in Annex 6, together with sometechnical drawings.
2.13 The furnace was successfully tested and demonstrated during theESMAP pilot project at Ufuluma Village during the 1988 curing season;also a local capability to build the Malakisi furnace (Ufuluma Type) hasbeen created in the Tabora region. Such capability can be replicated inall other flue-cured tobacco growing areas of Tanzania.
Flue-Pipe and Chimney System
2.14 The design and configuration of the flue-pipe and chimneysystem in a tobacco curing barn is an important factor in achievingenergy efficiency. The more effective the transfer of heat from theflue-pipes into the barn, the lower the heat loss through the exhaustgases. Most of the flue-pipes and chimneys of barns that were inspectedduring the ESMAP survey were found to be defective and poorlyinstalled. Heat loss through exhaust gases are likely to be much higherthan should be the case. Hence, there is significant scope for improving
- 16 -
the efficiency of fuelwood use by introducing the measures below toupgrade flue-pipe and chimney systems in the smallholder barns.
2.15 The flue-pipe systems in the existing barns are not suitablefrom the energy efficiency standpoint and need to be changed. Such flue-pipes are made of 22- and 24-gauge sheets of galvanized iron and arefabricated as an 11" diameter pipe of either 3 foot or 6 foot length.There are several shortcomings in the way they are installed. In most ofthe barns operated by smallholders, flue-pipes extend out of the furnaceand circle the inside perimeter of the barn; an allowance of about onefoot away from the barn wall is given, and because of regular damagethrough overheating and ash deposits, the section of the flue-pipe thatextends out of the furnace has to be replaced several times a season.
2.16 A majority of the barns surveyed did not have any chimneys.The chimneys in other barns were ineffective because they were too short(i.e., do not even clear the roof level); this undermines the mainfunction of the chimney, which is to create a draught, thereby improvingboth the combustion efficiency in the furnace, and heat transfer from theflue-pipes into the barn.
2.17 During the ESMAP pilot project described below, two differentconfigurations to improve the effectiveness of flue-pipes were success-fully tested: (i) the U-type of layout which is most suitable for thesmallholder farmers who use conventional medium-size barn of 16' x 13'dimensions (Figure 2); and (ii) the T-section layout which is mostsuitable for conversion of larger barns (e.g., by SHTCA members into lowprofile barns of 24' x 16' x 13' dimensions (Figure 3). Also, flue-pipesof 8" diameter, rather than those of 11" diameter, were used with goodresults.
2.18 Besides increasing the efficiency of the hot-air circulationand heat transfer system of the barn, the proposal to retrofit 11" flue-pipes with 8-inch ones would significantly reduce the cost of piping bysome 27-30%, because three pipes of 8" diameter can be made out of asheet which presently provides only two pipes of 11" diameter. Also, inorder to reduce the recurring heat damage to the section of the flue-pipes that extends out of the furnace, a cast iron pipe (3-feet long)should be used instead of 22" or 24" gauge sheets for that section offlue-pipe. Such cast iron pipes can be fabricated locally by foundriesin Morogoro.
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Figure 2: GROWER'S IEDIUM SIZED BARN1
GROWER'S UARNI-UAYOUT
V V I
V
Malakisi
V V V
GROWERS BARN (16' x 14') FITTED WITH MALISI FURNACE 8" DIAMETER FLUES & CHIMNEY(Diagramotic)
, h.t,ched roo
Chinamwn's hat&
4 3'D 0 0 0
0
- 4.-- 4'. Dt-4--
G.L
hatcIecn roo I D/ /
21/ Ash 16'
33Da t C
- 18 -
Fiture 3: LOW-PROFILE BARN (24' x 16' x 13')
Elbow Wlzt Z M ~ ~ ~~,Ebwiln
Ebowjdrit Elb~~~~~~~~~~~~Stow worg Ben rlght
LOW~PROLE CURING BARN T-IAYOUT(Dkgramoft. Not to scab) 16 h
O 111!!! 2ihll'we CIIJ/II fl/Il/
ol SAto 0 o
O O o o 0S 4' -0_
o o 0 0 0 1 0 RES H
LOW-PROFILE BARN24x 16V x 13) IED WITH MALAXIS FURNACE & V"DIAMETER FLUES & CHIMNEY(DlgamaCtc. Not to scale)
- 19 -
Improving Management of the Curing Process
2.19 Techniques for loading barns and for managing and controllinghumidity levels in the barns during curing have been demonstrated asbeing at least as important as the above measures for achieving greaterlevels of energy efficiency in tobacco curing. They also contribute in avery significant way to reducing curing losses, thereby increasing thenet yields and quality of cured leaf produced per cycle. The followingtechniques were successfully demonstrated during the pilot project andhence are strongly recommended as forming the core of the requiredtraining and extension program to upgrade farmer skills in respect oftobacco curing.
2.20 Use of Wet- and Dry-Bulb Hygrometers/Thermometers. Mostfarmers in Tanzania understand the curing process primarily in terms oftemperature cycles, rather than as a drying process in which convectionheating is largely a means of varying the rate of air flow over thetobacco leaves, so that the air gradually picks up the moisture in theleaves, and the humid air is vented out. Indeed, the farmers have littleelse with which to monitor the curing process except for the traditionalcurometer, which is essentially a form of thermometer. Most of thetobacco produced in Tanzania shows signs of the color loss and barn rotwhich are typical of the damage due to "scalding" and high humiditylevels in the barns during the curing process.
2.21 In order to improve farmer capability to control humiditylevels during the curing process, the use of Wet- and Dry-Bulb Hygro-meters should be introduced, and their application comprehensivelydemonstrated. During the field demonstrations and workshops that wereorganized as part of the pilot project and attended by over 500 farmersin the major tobacco districts, the feedback received indicated thattheir awareness had been raised about effective ways and means ofimproving tobacco curing efficiency, particularly with the use of wet anddry hygrometers (Figure 4) to assist in managing and controlling thecuring process.
- 20 -
Fi&ure 4: WET AND DRY BULB HYGROMETER
GI Q
Eie
B BMAWERLALS2 pcs 1" PVC pipe 7' long (one piece with 1/4" hole ddiled
1 1/2" ffom one end)I pc 1' PC pipe 2" bnog290° 1" PVC elbo#2 End caps 1" PC1 pc Athltic shoe srng r lon (wick)1 TobOcco Curing eRmometer with bulb guards cut
out wlde rubber band- i 1 pc of thrad (not hn) 4 longo btie wik to themor bulb
Wet bj ulb themome
- 21 -
2.22 Barn Loading Guidelines. Most smallholder farmers in Tanzaniaregularly overload their barns during curing, i.e., in terms of thenumber of sticks and the spacing between the successive tiers. The netresult is poor and uneven ventilation of barns, unnecessarily long curingcycles, and relatively low teperatures in the barn, usually below thecritical range between 122-140 F (50-60 C). Such problems lead to markedreductions in leaf quality, high curing losses, 19/ and greater wastageof fuelwood.
2.23 There is the need for a major effort as part of the follow-upextension strategy to inculcate in the farmers the know-how about correctmethods and practical guidelines for loading barns. Ideally, the sticksthat hold the packs of tobacco leaf should not be so tightly placed as toblock the flow of air by natural convection through the barn. Sticksshould therefore be far enough apart so as not to touch each other beforewilting occurs in the leaves (i.e., sticks should not be less than 6inches apart). Some guidelines for loading smallholder barns of the typeand sizes commonly used in Tanzania are shown in the technical supple-ment, and should be incorporated into the proposed extension program.
Assessment of Impact of Proposed Measures
2.24 Indicative Fuelwood Savings. For smallholder farmers that usemedium size barns for curing (i.e., 16'x16'x14'), the results of thecuring trials indicate that on average, they achieve SFCs of just over20 m of stacked wood per tonne of cured tobacco leaf. This level of SFCis significantly les s than the previously reported estimates which wereon the order of 40 m stacked wood per tonne of cured tobacco leaf. Thecuring trials demonstrate clearly that even with the more conservativeestimate of SCF in existing barns, there still is considerable scope forimproving the energy efficiency of the barns. The following are theestimates of potential fuelwood savings that can be achieved over thebaseline level of 20 m (i.e., for the medium sized barns):
(a) about 25% savings in fuelwood use (close to 5.0 m3 per tonne oftobacco cured) can be achieved with the existing medium sizedsmallholder barns by upgrading farmer skills and technicalknow-how of farmers about the management and control of thecuring process. This would apply especially to improvingfarmer skills in respect of using the wet and dry hydrogrometerfor monitoring humidity levels in the barn, as well as forloading the barn, etc. No savings due to investments inmodifying and/or retrofitting the barn are taken into account;and
19/ Curing losses are incurred when the leaves are picked and tied-uponto sticks for loading into the barn. Further losses occur duringcuring due to scalding, "dry-out," etc., and breakage. Post-curinglosses are a result of leaf damage during grading and baling beforeshipment to marketing centers.
- 22 -
(b) when such improvements in farmer skills (i.e., on managementand control of the curing process) are combined with relativelylow-cost investments to upgrade the barn, the projected impactin terms of savings in fuelwood use, increase to 3just over 50%,thereby reducing SFC levels by just over 10 m per tonne ofcured tobacco.
2.25 Reduction in Curing Losses. The results of the curing trialshave confirmed that in addition to the fuelwood savings, there would bemuch more significant reductions in curing losses (i.e., damage totobacco leaves due to scalding, excessive drying, etc.). Such curinglosses are usually high because of poor management of the curing process,and as indicated above, sub-optimal loading of the barns. By carefullymonitoring the output of each control and demonstration barn during thecuring trials, the following estimates of the potential increases in theoutput of cured tobacco leaf per cycle due to reduction in leaf damagecan be made:
(a) the application of improved techniques for managing andcontrolling the curing process could lead to a 20% increase inbarn output of cured tobacco per cycle, i.e., 233 kg of tobaccowould, on average, be produced as against the average of about195 kg of tobacco produced in the control barns;
(b) by combining the low-cost investments to upgrade the barns withimprovements in farmer skills for curing, the potentialreduction in curing losses would lead to a 50% increase intobacco output per cycle i.e., 290 kg of tobacco would beproduced against the baseline of about 195 kg of tobacco forthe control barns.
2.26 Other Significant Benefits. Other benefits that arise from theapplication of the recommended measures include: (a) improvements in thequality of cured leaf are which significant, and should translate intohigher prices obtained by the farmers. On average, the tobacco cured bythe ESMAP team fetched a price some 5-10% higher than the average tobaccoprice recorded for smallholder farmers in the Tabora Region during the1988 purchasing season; and (b) reduction by at least one day of thelength of each curing cycle. This should also translate into a saving ofabout one man-day of labor for the typical smallholder farmer, which issignificant because such labor would usually be needed urgently for othertasks on the farm, such as picking the next batch of mature leaf andpreparing (tying and hanging on sticks) for the curing.
- 23 -
Table 2.1: ESTIMATES OF BENEFITS c/
Barn Configuration Incremental Fuelwood a/ Additional Tobacco b/
Savings Output
(m ) (kg)Improved Management Only 4.8 38
Improved Management plus
Investment In Barn
Modification 10.4 95
a/ In m' of stacked wood.
b/ In kg cured tobacco per cycle, reflecting reduction in curing
losses.
c/ Based on results of curing trials for medium-sized barns only.
Control barns with SFC of 20.1 m3 wood (stacked) per tonne cured
tobacco and average output of 195 kg cured leaf per cycle.
Source: Mission estimates (Annex 1).
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III. STRATEGY FOR PROPOSED DISSEKINATION PROJECT
Overview
3.1 With the successful completion of the ESMAP pilot demonstrationproject, which included an exhibition and two field workshops for farmersin the Tabora and Iringa regions, a strong impetus has been created fordisseminating nationwide the "technical package" of measures to upgradethe energy efficiency of tobacco curing. To do so effectively requiressystematic planning and execution of a dissemination strategy which wouldcombine activities: (a) to create and maintain awareness among tobaccofarmers about the benefits of the tobacco curing efficiency program;(b) to mobilize and train a core group of Subject Matter Specialists(SMSs) to lead the dissemination effort; and (c) to develop and strengthenthe necessary human resources and infrastructure to ensure that thedissemination effort on tobacco curing efficiency evolves, over the mediumterm, into a fully integrated component of the agricultural extensionsystems serving all tobacco producing areas.
3.2 This proposed strategy embodies a phased approach which would bea follow up to the demonstrations, awareness campaigns, and other pre-investment activities that were conducted by ESMAP during the 1988 curingseason i.e., January through May 1988. The proposed project as definedbelow, will aim to disseminate the "technical package" to the moreprogressive and productive smallholder tobacco farmers in the four majorflue-cured tobacco districts of Tabora, Urambo, Iringa, and Chunya; thedissemination activities in the Tabora and Urambo districts would beintegrated into the activities of the IDA financed National Agriculturaland Livestock Extension Rehabilitation Project (NALERP), and theactivities in the Iringa and Chunya districts would be coordinated withother programs to revamp the extension systems in the Southern HighlandsZone Support Project. A separate line of credit which recently has beenestablished under the IDA financed "Tanzania Agricultural ExportRehabilitation Project," can be used by the large-scale farmers of theSHTGA to cover the costs of upgrading their barns according to thespecifications given in the Technical Supplement. For the medium term, itis expected that the momentum generated, and extension materials createdand tested during the proposed project should be able to sustain anexpanded dissemination effort to all other tobacco farmers in Tanzania.
3.3 In this chapter, the objectives of the proposed disseminationproject are presented. The main project components, the principal targetgroup, the recommended organizational framework, and the tentativeimplementation schedule for the project are also outlined.
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Objectives
3.4 The following are the overall developmental objectives for theproposed dissemination project: (a) reinforcing Tanzania's efforts torehabilitate agricultural export crop production, with particular focus onaddressing current inefficiencies associated with post harvest processing(curing) activities in the tobacco sector; (b) supplementing efforts inthe country to alleviate the growing pressure on natural woodlands for thesupply of woodfuels, especially in tobacco producing areas; (c) supportingongoing efforts in the country to rehabilitate and strengthen agriculturalresearch and extension services and infrastructure; and (d) enhancing theeconomic viability of the tobacco sector.
3.5 For the short to medium term, the direct objectives of theproposed dissemination project include: (a) upgrading the capabilities andskills of smallholder tobacco farmers to manage and control tobacco curingprocesses; (b) upgrading tobacco curing barns by retrofitting withimproved slot-type furnaces, better layouts of flue-pipe and chimneysystems, and improved ventilation systems; (c) reducing average specificfuel consumption levels for tobacco curing in major producing areas bysome 50%, thereby minimizing the impact of tobacco curing activities onthe unsustainable exploitation of natural woodlands; (d) curtailing curinglosses, thereby increasing productivity and the rate of recovery ofproduction levels for flue-cured tobacco in the country; and(e) developing the knowledge and skills of a cadre of Subject MatterSpecialists (SMSs) on tobacco curing efficiency measures who wouldinitially be deployed in each of the major tobacco districts, andeventually would be the basis for extending the coverage to all tobaccoextension workers and producers of flue-cured tobacco nationwide.
The Dissemination Strategy
3.6 The dissemination strategy, which forms the basis for the designof the proposed smallholder tobacco curing efficiency project, emphasizesthe following principles that underlie the training and visit (T & V)system of agricultural extension. First, the project will aim to increaseawareness among tobacco farmers about the benefits of adopting thetechnical package, both in terms of the fuelwood savings and the increasedquality and quantity of cured leaf output (i.e., reduction in curinglosses). To achieve a strong demonstration effect, the project will putemphasis on mobilizing relatively small groups of farmers to serve as"role models" or "contact groups" in the target areas. A furtherconcentration of project resources will be achieved by covering onlyfarmers with medium-sized barns in the 54 villages that consistently havemaintained high tobacco production levels (i.e., over 50,000 kgs curedleaf per season), as judged by the records from the 1984/85 and 1985/86seasons. The results of the barn census indicates that there currentlyare about 7,700 medium-sized barns (i.e, dimensions 16'x16'x13') in these
- 26 -
54 villages, over 90% of which are in the Tabora and Urambo districts(Table 3.1). The project will aim at rehabilitating and modifying about6,810 barns in all four districts.
Table 3.1: BREAKDOWN OF PROJECT TARGET GROUP
No.No. of No. ofof Villages Medium Sized
District Wards Group A Group B Barns
Tabora 16 15 12 3,393Urambo 5 5 7 3,717iringa 2 2 4 58Chunya 9 4 5 377
Totals 32 26 28 7,645
a/ Dimensions are (121x12'x13').
Source: TTPI4; ESMAP Census, 1988; Annex 2.
3.7 Second, the project would, through direct technical assistanceand training, aim to develop a strong cadre of SMSs who would gain morespecialized know-how and skills relating to extension for tobacco curingand related post-harvest activities (e.g., grading). The cadre of SMSswould be deployed in direct support of the Regional and District Exten-sion Officers and Crop Services Officers responsible for the Tabora,Urambo, Chunya, and Iringa districts, respectively. The technicalassistance under the program will take the form of the services of anexperienced expatriate Tobacco Curing Specialist (TCS) who would bedeployed to work directly with the SMSs serving the four targetdistricts. The extension program on tobacco curing will emphasize theuse of workshops, exhibitions, and regularly scheduled field visits tomonitor curing activities, and it is envisaged that the contact groupswill be the primary agents for disseminating the "technical package" andtransferring know-how about curing techniques to other farmers at theward and village levels (i.e., through existing farmer groups). The roleof the TCS will also be to assist the SMSs to develop and maintain astrong field monitoring system covering all aspects of the technicalpackage (i.e., barn and furnace construction and maintenance, loading ofbarns, use of wet- and dry-bulb hygrometer, etc.), thereby ensuringregular and timely feedback from all participating contact groups.
3.8 Third, the project will aim to introduce a "technical package"that will be simple and practical from a farmer's perspective. The"technical package" would be adapted as necessary based on feedback fromthe participating farmers. Some progress has been achieved in thisregard during the pilot project, under which a number of field demon-strations and workshops were organized for farmers in the Tabora
- 27 -
district. The feedback received from farmers who participated in thecuring trials, special demonstrations, workshops, and exhibitions on"Farmers' Day" indicate that the following activities should be anintegral part of the extension program in the proposed project:(a) random surveys and interviews to test farmer awareness about thelinks between inefficient curing methods, curing losses, and growingdifficulties in obtaining fuelwood supplies; (b) publication anddistribution of a Swahili language newsletter which would explain tofarmers and technical extension workers the benefits accruing from themeasures in the "technical package" for tobacco curing; (c) workshops onthe construction and operation of the improved slot-type 'Malakisi'furnace (Ufuluma type); and (d) demonstrations, displays, and exhibitionsat special functions by the farmers (e.g., Farmers' Day celebrations),which would highlight important aspects of the "technical package," andcontrast the impact achieved with the "technical package" with that usingthe "business-as-usual" or traditional methods. A sample of the "Guidefor Successful Tobacco Curing" is shown as Figure 5.
KIELELEZO CHAUKAUSfAJI BORA WA TUMBAKU/A GUIDE FOR SUCCESSFUL CURING
^ MUD/ WKWA NJANO/ KUKOMAZA RANGI/ KUK"SA A1 KUXAUSHA MGONGQ/HOURSS YELblONG COLOR FIXING DRING OF LEAF DRYING OF MIDRIB>tJ 3540 S-81 253~~~3&0 2543 V
t.UNYEVU/ 90 90 9090 80 57 4 4 37 35 32 33 32 30 29 29 20 1.e 1411#V _ II | |1 _ II I I I I I I I l
YELLOWING ' COLOR FDtNG' DRYING OF LEAF... DRYING OF MIDR18... PDIRA 8s 90 95 10 102 105 108 110 112 114 118 120 123 125 130 135 140 *45 130 155 160
DRY BULB I I I I I I I I I I I I I I IKoepvwnldtc tokopuphtMldltinbwn fots t temapotae 5 every 2/4 hour Hd todo 1237. tl IoT*1a dya Is Wahgwe T oenPtdoto 140-fct3 per hot Rto I0% Ut hewtthouln to ncreshridrlty Moinnm ventialaotion neede at thiF gtage Wd# lfltatisdyandrotoI10WFat37Apeshow Wart at 140F htthom ebs D 00tI necdd Do not wet moor and do not place Open aft vet as shon below o0ecampletetydy ChectWkyb.eo ngbetvwenthuntondadOffingrt Check
KUINGIZA teulaf an oUnlce PO 0oo Lto ot b ot corne and top t to It tW o I4EW Pondhtho Jaot nvuzl 5' klbo tooda Va suo 2/4JjWbtd 13 ta MktoPnshja
HMA HE WA ffh dW* yWo kutx*kWo urvu MoMdtsha Vate vow. wwl kwo waitaal t lkh M2r ffoko kn ekoulco P__*hO o onlyabornlroslimlomlct OrgeouWetu kom oayeshrs hod Pt 140F nttt 3 ktl bOodo yc too rvtr*oa kW limlka c hatu En
Top wrst kwo kuhuirtl mogunlo yottyoewonWvwa podsho pto hod nluhl 160°F kwdtnoon cho nyzl 3/4' kilo o00 &*__kbdt. U*swo nol Itn o1t no u*weke kotikonlutz 140 vpxomitgonoalkoiWaWiob ka ll o4lhaioko%kwa*
Bottom vent mo4gwunYenMo i - o boto*fb u mIrn kuno WObgkkuunnovkdaIo KatuakonaaenneziaborltlhOluu£ku0nio OA* kasso krun miganlogo ai
VENLATION J-/ -, Gs
* eloIg_ ________________ ____ COlOrfhlWlg CI4INI/~~TO RO1 CGEr-ARJOPENOS
DivIn aft CHNoro V-_ _**DrInd V BOTTOM hnt n I t - -sa t iun
Drying* o! rn*tb M>MIJ secde ios not cLuQ nrto.t ",on corull the dattr tUn kouYUI hoknId twwo mfworo now Shnomloo
- 29 -
Proposed Project Components
3.9 The above dissemination strategy has been programmed into aproject with the following components which should be implemented inparallel.
Technical Assistance to Crop Services Section of MALD
3.10 This component would strengthen the capabilities of theAssistant Commissioner for C1op Services (ACCS), and the MALD's CropServices Section, and the Regional Crop Services Officers responsible forthe Tabora, Urambo, Chunya, and Iringa districts to develop the fluecured tobacco sector. The project would cover the costs of the full-timeservices of an expatriate Tobacco Curing Specialist (TCS) who would beresponsible for developing the "technical package" for extension ontobacco curing efficiency, for developing and coordinating projectrelated training for the extension personnel, designing a fieldmonitoring system, and providing all necessary support to the ExtensionUnit of the MALD on dissemination activities (e.g., the Farmers Trainingand Information Unit). The draft terms of reference for the TobaccoCuring Specialist is presented as Annex 1. This component would alsoprovide for vehicles and other necessary office equipment and suppliesrequired for the activities of the TCS and the principal counterparts(i.e., the RCSOs).
Training for Tobacco Extension Staff
3.11 The proposed project would support a comprehensive trainingprogram for all levels of tobacco extension personnel within the overallguidelines of the NALERP as follows.
3.12 Subject Matter Specialists. Under the ongoing NALERP,extensive training activities are being organized locally for the SMSs inthe four primary tobacco producing districts. The local training programinvolves an orientation workshop at the beginning of the project,followed regularly by monthly workshops and refresher courses. The TCSwould assist in the development of the training program for SMSs assignedto tobacco producing districts. In addition, funds would be providedunder the proposed project for supplementary training activities such asstudy tours by SMSs and RCSOs to other developing countries such asMalawi, Zimbabwe, and possibly India, where major advances to improvetobacco curing efficiency are being made.
3.13 Divisional and Village Extension Personnel. In addition to theorientation workshops that would be held to initiate the implementationof the proposed project, the TCS with the assistance of the SMSs wouldconduct regular training activities for the DEOs and VEWs. Theseactivities would include regular In-Service Training Workshops onimportant techniques, complemented by Fortnightly Courses. The workshopswould for example cover aspects such as the barn, furnace, flue systemconstruction and maintenance, guidelines for curing control, and gradingand baling of cured tobacco to protect quality.
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3.14 The full details of the above training component would need tobe finalized in consultation with senior MALD officials responsible forthe NALERP.
Procurement and Distribution of Special Inputs
3.15 The project would assist the MALD to establish and coordinatethe following arrangements to ensure the timely production, procurement,and distribution to farmers of the key inputs required to upgrade curingfacilities.
(a) retooling of TTPMB facilities at Morogoro and Urambo so that 8-inch diameter flues would be available on a large scale forretrofitting of flue pipes and chimney systems (Annex 2);
(b) conversion of old discarded railway lines into grates for the'Malakisi' slot-type furnaces;
(c) fabrication of cast iron flue pipe sections (3-feet long, 8-inch diameter) to be inserted at the furnace outlets. Suchcast iron sections would be fabricated locally;
(d) production of wooden shutters for use as vents in the upgradedbarns; and
(e) importation of wet and dry bulb hygrometers for use withcurometers in the project areas.
3.16 The TTPMB would on behalf of the MALD be responsible forcoordination of the production and delivery of these inputs, and ensuringtheir delivery to farmers' societies and Cooperative Unions. It isexpected that the TTPMB would be able to handle (a) and (b) using thefacilities at Morogoro and Urambo (see Annex 2), but would organize localtenders for the production and/or procurement of the other items. Forexample, local foundries in Morogoro could be sub-contracted to produceitem (c) above. Also, to ensure cost competitiveness, tenders would beplaced with local firms for the transportation of the items to therespective districts.
Credit for Upgrading Barns
3.17 In order to encourage farmers to participate fully in theproject, it may be necessary to provide credit to supplement their ownresources. The project would therefore collaborate with the Cooperativeand Rural Development Bank (CRDB) to ensure the timely provision ofcredit (preferably on a three-year repayment schedule) to participatingfarmers through the respective farmers' societies. The followingcategories of expenditures would be covered under the proposed lines ofcredit:
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(a) purchase of 8-inch diameter sections for retrofit of flue pipesand chimneys;
(b) purchase of a cast iron flue pipe, a few iron rail grates, andother materials for construction of 'Malakisi' furnaces (Annex2);
(c) purchase of wooden shutters for barn ventilation system; and
(d) purchase of wet and dry bulb hygrometers.
Project Implementation
Role of MALD
3.18 The proposed project would be implemented by the MALD on behalfof the Government. The Crop Services Section of the MALD will beresponsible for the project. The expatriate TCS would be recruited on atwo-to-three year contract with the MALD, and deployed in Tabora tooperate from the offices of the Regional Crop Services Officer (RCSO).During project implementation, especially the curing season annually, theTCS would be deployed almost full-time in the Tabora and SouthernHighlands regions to directly suport the work of the district SMSs andother extension personnel (about 80X in the Tabora region). In theextension services, the principal counterparts for the TCS will be theRegional SMS for Industrial Crops in Tabora, and the District SMSs forthe Tabora, Urambo, Iringa, and Chunya districts respectively.
Role of TTPMB
3.19 The TTPMB would, under MALD supervision, be responsible forcoordinating the production, procurement, and distribution of the specialproject inputs to the four tobacco districts to be covered by theproject. The TTPMB already undertakes this responsibility with regard tothe fabrication and distribution of flue pipes from the machine toolfactories at Morogoro and Urambo. During the preparation of the project,both the MALD and TTPMB confirmed that such an arrangement would be themost practical means of executing that component of the proposedproject. The TTPMB would also arrange with the Tanzania RailwaysCorporation (TRC) for the collection of old and discarded railway lineswhich would then be converted into iron grates at the Morogoro factory.The TTPMB, with funds from the project, would be required to arrangelocal tenders for the production of wooden shutters (vents) and the castiron flue pipe section to be inserted into the furnace outlet. The TTPMB
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may be able with its existing fleet of trucks to distribute the inputs tothe farmers' cooperatives in the districts. Local tenders would be usedwhen necessary for transporting the inputs to the farmers.
Credit Administration
3.20 The CRDB would be responsible for administering credit to thefarmers through the farmers' societies. With regards to lending terms,the CRDB would maintain for this project similar arrangements to thosethat have reently been established under the IDA financed TanzaniaAgricultural Export Rehabilitation Project (Credit 1981-TA), forproviding credit to the export oriented sector, including tobaccoproducers. Participating farmers could be allowed two to three seasonsto repay the loans for approved investments to upgrade curing barns andfurnaces.
Annual Implementation Plan
3.21 The Tobacco Curing Specialist and the RCSO(s) will jointly beresponsible for preparing draft annual plans which will set targets foreach season's activities and credit requirements. The plans will beprepared in consultation with SMSs in the Tabora region and the SouthernHighlands Zone respectively. The plans would include: (a) numbers ofcontact groups, villages, and curing barns to be serviced by the projectin a given season; (b) requirements in terms of material and equipmentinputs for the barn modifications; (c) schedules for workshops,exhibitions, and training activities; (d) estimates of creditrequirements and budgets for extension activities; and (e) a discussionof specific measures to be taken to alleviate the bottlenecks and otherproblems encountered in preceeding seasons. The annual plans should besubmitted for review to the ACCS in the MALD, before being incorporatedthrough the ACES into the overall Annual Work Program for the NALERP.
Project Monitoring and Evaluation
3.22 In order to keep track of performance, the project will besubject to annual reviews as follows. At the end of each curing season,a meeting would be convened by the TCS for all project personnel,including the key SMSs and RCSO responsible for the target districts.The experiences from the dissemination and extension efforts of theseason would be reviewed, especially on aspects such as farmer acceptanceof and assimilation of different components of the technical package,etc. Based on the findings, plans for the next season would be preparedand revised. Any shortcomings identified in preceding seasons would becorrected and incorporated in successive workshops and training programsfor the extension personnel.
3.23 Concurrently with the above in-house evaluations, the TCS, withthe assistance of the RCSOs and SMSs concerned, will be required toconduct a series of sample surveys during the curing season to monitorthe impact of the tobacco curing efficiency technical package on barns
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modified by farmers participating in the project. Such barns will beselected on a random basis, and the performance i.e., in terms ofspecific fuelwood consumption, reduction in curing losses, will beevaluated and compared with projections. The types of data which will becollected routinely by extension agents, and later checked independentlyin the sample surveys, are shown on the sample "Monitoring Sheet for theProposed Project" (Technical Supplement).
3.24 Additional provision has been made in the project for two majorexternal evaluations which, as indicated above, should be conductedindependently by the Project Planning and Monitoring Bureau (PPMB) of theMALD. The first would be scheduled for the end of the second season ofproject implementation, and the second at the end of the fifth season.The results of these evaluations would be incorporated into the overallMonitoring and Evaluation System being developed by the MALD for theNALERP.
Schedule for Project Implementation
3.25 Subject to the overall schedule for implementing the NALERP, itis recommended that the implementation of the proposed efficiency programshould proceed in three phases as follows:
(a) Phase One will extend from before the 1989/90 curing season,possibly in September 1989 through the end of July 1990, duringwhich the Tobacco Curing Specialist would be recruited. Also,the Subject Matter Specialists (SMSs) would be identified ineach of the four districts to work as counterparts on theproject. A detailed workplan for the project would be preparedin consultation with the ACCS and the PPMB, and the program oftraining and orientation/study tours would be arranged andconducted for the SMSs). Also, arrangements for credit supportto participating farmers would be firmed up, most likely inconsultation with the Cooperative and Rural Development (CRDB)and the concerned Regional Cooperative Unions (e.g., TARECU).
(b) Phase Two from the beginning of August 1990 through the end ofthe 1993/94 curing season, during which over 6,000 barns inabout 49 of the 54 target villages (90% coverage) would bemodified according to the technical package, and extensionsupport from the project would be applied and maintainedthrough the respective SMSs. The tentative schedules forincorporating villages into the project and for modifying thebarns are shown in Table 3.2 below. These would be subject torevisions as necessary during Phase One, when the detailedworkplan for the project would be prepared.
(c) Phase Three which will extend from the beginning or the 1994/95curing season through the end of the 1995/96 curing season,
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during which extension support will be maintained by SMSs toall farmers who have had their barns modified. However,project funds and/or credit under the project would no longerbe made available under the project for new barn modifica-tions. The main emphasis of the TCS during this phase would beto evaluate the impact of the measures, and prepare plans forcontinuing the dissemination program beyond the project.
3.26 As indicated above, annual workplans would in all cases beprepared by the TCS in consultation with the respective RCSOs, andapproved by the ACCS. The PPMB would also establish the scope and timingof the planned evaluations. Altogether the project would extend for sixcuring seasons, beginning in the 1989/90 season.
Table 3.2: TENTATIVE SCHEDULE FOR BARN MODIFICATION BY DISTRICT a/
Tabora Urambo Iringa/ChunyaProject Year Barns Barns Barns
1 225 225
2 850 850 1003 1,000 1,000 2504 1,030 1,030 250
3,105 3,105 600
a/ About 24 villages in Tabora district will be covered; 12 villages inthe Urambo district; and 13 villages In the Southern Highland Zone.
Source: Mission projections.
Project Cost Estimates
3.27 Total project costs are estimated to be about TSh340 million(US$3.6 million), including physical and price contingencies, taxes, andduties. Foreign exchange costs amount to about US$0.8 million (22%) ofthe total. Project costs are summarized in Table 3.3, and are given indetail in Annex 2.
3.28 Project base costs were estimated from prices as of mid-1988,and were increased by estimated inflation rates to reflect project costsin each year of implementation. There is a high degree of uncertaintyabout prices in Tanzania because the ongoing exchange rate adjustmentshave contributed to relatively high inflation levels. For local costs,prices were escalated assuming an annualized average inflation rate of12Z from 1989 to the end of the project. For foreign costs, an inflationrate of 2.5% was applied for the years 1989-1993, and 5X thereafter.Assuming that the ongoing exchange rate adjustment process continuesthroughout the six-year life of the project, and constant purchasingparity exchange rates are maintained, the value of the TSh would fallfrom TSh92/US$ in 1988 to about TShl5O/US$ by 1995.
Table 3.3: PROJECT COST ESTIMATES
('000 TSh)
(OOOTSh) (000' US$)Local Foreign Totals Local Foreign Totals
Investment Costs
a. Materials for i3arn Modi-fication 133,898 -- 133,898 1,455 -- 1,455
b. Machine Tools (TTPMB) -- 13,800 13,800 -- 150 150c. Project Vehicles -- 6,260 6,260 -- 68 68d. Project Office Equipment 864 864 -- 9 9
133,898 20,924 154,822 1,455 227 1,682
Recurrent Costs
a. Personnel Payroll 10,200 28,500 38,700 111 310 421b. Lodging (Rent Allowance) 9,240 -- 9,240 101 -- 101c. Office Supplies 450 -- 450 5 -- 5d. Training 7,667 17,000 24,667 120 185 305 ene. Extension Materials 3,900 -- 3,900 42 -- 42f. External Evaluations 5,000 -- 5,000 54 -- 54g. Vehicle Operation and Maintenance 2,130 2,130 23 _ 23
38,587 45,500 84,087 456 495 951
Total Base Costs 172,485 66,424 238,909 1,911 722 2,633
Contingencies (Physical) 17,249 6,642 23,891 191 72 263Taxes and Duties 95 690 785 1 8 9Contingencies (Price) 73,345 2.820 76,615 688 3 691
Total Project Costs 263,174 76,576 339,750 2,791 805 3,596
Source: Mission estimates.
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IV. PROJECT BENEFITS, JUSTIFICATIONg, AND RISKS
Project Benefits
4.1 As indicated in Chapter III, the proposed project to improvethe efficiency of fuelwood use for tobacco curing by smallholder farmersin Tanzania will yield direct benefits in two respects: (i) saving infuelwood as a result of reduction in specific fuelwood consumptionlevels; and (ii) increased outputs of cured tobacco leaf as a result ofsignificant reduction in curing losses with improved management of thecuring process. Because of shorter curing cycles, labor which wouldotherwise be "tied up" with curing would be available for redeployment toother tasks such as picking and tying up green leaves for the nextcure. Such labor savings are treated as an indirect benefit for theanalyses below. An additional benefit would be realized in terms ofhigher quality cured tobacco leaves, but for the purposes of thisanalysis, such improvements in leaf quality have not been quantified.The analysis below therefore translates the results of the curing trialsinto specific targets and estimates of each of the direct benefits.
Fuelwood Savings
4.2 In this analysis, it is assumed that the level of fuelwoodsavings achieve by ESMAP during the curing trials (10.4 m3 wood stackedper tonne tobacco) represents a maximum or upper limit for the typicalsmallholder farmer who will participate in the project. The analysisbelow is more conservative because it is assumed that a "learning curve"phenomenon will better reflect the process through which each farmer willgain proficiency in the use of the "technical package," thereby achievingprogressively the proposed fuelwood savings. For each barn that ismodified according to the technical package, it is projected that thefarmer will achieve 25% of the maximum fuelwood savings after one year,due mainly to the impact of the new "Malakisi" slot-type furnace. Afterthe second year, the farmer's skills with respect to the management ofthe curing process (i.e., use of wet and dry bulb hygrometer, etc.) wouldshow a marked improvement, which in turn will result in his achieving 60%of the maximum fuelwood savings. By the end of the third year of thefarmer's participation in the project, fuelwood savings would increase to75% of the maximum achieved in the ESMAP curing trials. The level offuelwood savings would stabilize at 75% of the maximum; however, it hasbeen assumed in the analyses that the fuelwood saved in the fourth tosixth years would be equivalent to the level achieved during the ESMAPcuring trials without barn improvements i.e., 4.8 m3 wood per tonnetobacco. The impact of the above scenario for the attainment of eachfarmer of fuelwood savings per barn is shown in Table 4.1 below.
Increased Tobacco Leaf Output
4.3 The results achieved in the ESMAP curing trials confirmed thatan equally important benefit of the "technical package" and the improve-ment in farmer skills in managing the curing process was the reduction incuring losses, which translates into higher outputs of cured tobacco leaf
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per curing cycle. In the trials, an increase in output of 95 kg percuring cycle was achieved versus the "control" average of 195 kg. Againthe "learning curve" effect is used as a basis for translating theprojected improvements in farmer proficiency into direct benefits. Inthis case however, only 15% of the potential maximum reduction in curinglosses is achieved after the first year. Although this is conservative,it assumes a delayed response to extension efforts. By the end of thesecond year, curing losses would have been reduced to 60% of the maximumachieved by ESMAP; and by the end of the third season, 75% of thepotential maximum would be realized. For the fourth to sixth year afterbarn modification, it is assumed conservatively that reduction in curinglosses will be of the order of 38 kg/tonne of cured leaf (i.e., the levelachieved during the curing trials without barn improvements). The impactin terms of with and without project scenarios is also shown in Table4.1.
Table 4.1: PROJECT BENEFIT ANALYSIS: WITH AND WITHOUT SCENARIOS(Single Barn Basis) a/
Project YearBenefit 1 2 3 4 5 6 Totals
Fuelwood ConsumptionWith Project (m') 17.1 13.5 12.0 12.0 12.0 12.0 78.5Without Project (m3) 19.6 19.6 19,5 16.8 16.8 16.8 108.8
Total Saved (m3) 2.5 6.1 7.4 4.8 4.8 4.8 30.5
Tobacco ProductionWith Project (kg) 1,046.3 1,165.0 1,331.3 1,331.3 1,331.3 1,331.3 7,536.3Without Project (kg) 975.0 975.0 975.0 1,141.3 1,141.3 1,141.3 6,348.8
Additional Production 71.3 190.0 356.3 190.0 190.0 190.0 1,187.5
a/ Medium sized barns only.
Source: Mission estimates.
Total Savings
4.4 The total benefits extend four years over the project's six-year life, as shown in Table 4.2 below (i.e., barns converted in thefourth year will also yield benefits for six years). These benefits arethen converted into (TSh) values using estimates of the financial valueof fuelwood savings (TSh/m3 stacked wood), and additional tobacco output(TSh/kg), as discussed in the sections below. Altogether, the projectbenefits are as follows: (a) close to 206,000 m3 of fuelwood savings orabout 3,400 ha of natural woodlands would be saved from clearfelling andsevere degradation; and (b) the reduction in curing losses would amountto about 8,100 tonnes of cured leaf. In financial terms, the total valueof the benefits (in constant 1988 TSh) would be on the order of TSh665million: TSh54 million due to fuelwood savings, and TSh611 million due toincreased output of cured tobacco (Table 4.2).
Table 4.2: ESTIMATES OF ANNUAL BENEFITS FROM PROJECT
Project Year
Benefits Project
Category 1 2 3 4 5 6 7 8 9 10 Totals
Benefits
Fuelwood Savings 0.0 1.1 7.3 20.1 35.3 41.7 38.6 29.8 21.3 10.8 206.1
(S000 *3)Additional Tobacco
Produced (tonnes) 0.0 32.1 213.8 662.6 1318.8 1668.0 1677.9 1208.4 866.4 438.9 8086.9
Value of Benefits
('000 TSh) oD
Fuelwood Savings 0.0 296.6 1898.2 5220.1 9188.4 10840.8 10043.2 7738.8 5548.6 2810.8 53585.4 t
Additional Tobacco
Produced (tonnes) 0.0 2423.9 16159.5 50094.5 99704.1 126098.0 126852.1 91355.0 65499.8 33180.8 611367.8
Total Benefits 0.0 2720.5 18057.7 55314.5 108892.5 136938.7 136895.2 99093.9 71048.4 35991.6 664953.2
Source: Mission estimates.
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4.5 The costs of achieving the projected fuelwood savings (i.e.,39.3m3 stacked wood per barn) over the six-year life of the proposedproject is compared in Table 4.3 with the alternative of growing the sameamount of fuelwood on a woodlot. The estimated costs of fuelwoodproduction on the woodlot is based on estimates prepared for the Taboraregion as part of the ESMAP prepared Woodfuels Supply DevelopmentProject. The results confirm that the fuelwood conservation route is themore cost-effective approach, given that the equivalent cost per m3 offuelwood saved with the tobacco curing efficiency measures is equal orless than that for producing the fuelwood on woodlots. Another benefitfrom the fuelwood conservation approach relates to the environment, butdue to the difficulty in estimating environmental benefits in thatcontext, they have not been dealt with quantitatively in this analysis.
Table 4.3: FUELWOOD SAVINGS VERSUS PRODUCTION COSTS
Production withWith Project/barn Woodlot/ha
Wood saved orproduced m) a/Yr 1-3 16.0Yr 4-6 14.11 rotatio 30.3 40
Solid Volume m3 b/ 19.7 40Incremental Costs (TSh)d/ 19,662 42,000c/To Farmer
Cost/m3 (TSh) 990 1,050
a/ This is based on a per barn basis for fuelwood saved and a perhectare basis for woodlots.
b/ A conservative conversion factor of 0.66 was used to convert fromstacked to solid volume.
c/ Establishment costs are based on estimates derived by ESMAP for theTanzania Woodfuel Supply Development Project.
d/ For barn modification package only.Source: Mission estimates.
Project Justification
Financial Perspective
4.6 From the point of view of an individual tobacco producer theadditional investment required to improve operational efficiency wouldyield financial benefits of: (a) approximately 27% savings in fuelwood
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resulting in less expenditure for fuelwood in terms of time and transpor-tation cost; and (b) additional cash income generated from increasedcured tobacco yields. This reduction allows the farmer to spend addi-tional time harvesting the crop and preparing the leaf for curing, (tyingto stakes etc.) reducing wastage of tobacco leaf. Additional cash incomemay accrue to the farmer due to increased quality or grade of curedtobacco.
4.7 Also for the financial analysis, the fuelwood value is based onthe actual charges for cutting and extracting wood from accessible partsof the woodlands, for loading onto trucks, and for transporting the woodto the curing site (Table 4.4). Tobacco is valued in terms of the marketprice at the farm gate or the price the farmer sells to the TanzanianTobacco Processing and Marketing Board. This price is announced by thegovernment a year in advance enabling the farmer to plan the comingyear's production. The 1988 product prices are presented below in Table4.7.
Table 4.4: FINANCIAL COST OF FUELWOOD
Component TSh/m" (Stacked)
Cutting and Extraction Charges a/ 100.00Loading and Transport b/ 160.00
Total 260.00
a/ Based on TSh per m5 (stacked).u/ Based on TSh 800 per truck of 5 m) for loading and transport,Source: Mission surveys and estimates.
Financial Rate of Return
4.8 The financial analysis indicates that from the farmer'sperspective, participating in the project and acquiring the technologicalpackage of energy efficient hardware and improved curing techniques isfinancially sound, and in fact offers attractive returns on suchinvestment, yielding a simple payback of less than two years (Table4.5). Rates of return exceed 60X even for all farmers who join theproject for three years. These rates represent the incremental returnsto the farmer when all costs of production are incurred by the farmer.For the project overall, the financial rate of return is slightly over28% because the additional expenditures due to project management andextension services are also incorporated into the analysis.
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Table 4.5: FARMER'S PAYBACK SCHEDULE PKR BARN
(in TSh)
Cash CashYear Investment a/ Benefits b/ Profit
0 19,662 0 0
1 0 6,046 0
2 0 15,946 2,330
3 0 28,910 28,91019,662 50,902 31,240
a/ Incremental expenditure for barn modification package only,
b/ Incremental revenues due to barn modification package plus extension.
Source: Mission estimates.
Economic Perspective
4.9 Economic Value of Fuelwood. The economic values of fuelwood
should represent the opportunity cost to the country of one unit of
woodfuel consumption. In the project areas this cost can be approximated
by estimating the marginal cost of production for the most likely
alternative. Hence, the marginal cost of woodlot establishment in
Tanzania (TShl9O per m 3) is used for the analysis. 20/ To this cost,
the charges for felling, extracting, and loading the fuelwood onto
trucks, and transport costs to the point of consumption were added. The
economic costs of felling, extracting, and loading the fuelwood was
shadow priced at 75% of the market price as shown in Table 4.6.
Table 4.6: ECONOMIC VALUE OF FUELWOOD
Component TSh/m5 Stacked
Marginal Production Cost a/ 190.0
Cutting and Extraction Charges b/ 100.0
Loading and Transport b/ 160.0
Total 450.0
a/ Based on estimates for Woodfuel Supply Development Project.
b/ Refer to Table 4.4.
Source: Mission estimates.
4.10 Economic Values of Tobacco. In Tanzania, the tobacco export
market price is determined by members of the Tobacco Board. The price is
based on an analysis of world market information and a detailed study of
201 See ESMAP Completion Report No. 068/88 on the proposed "TanzaniaWoodfuel/Forestry Supply Development Project, dated December 1988.
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the tobacco auction prices in Malawi. Prices are constant for a givenyear. The assumption that 66.5% of production is exported and theremainder is sold to domestic cigarette manufactures was used throughoutthe economic analysis. The economic value for exported tobacco wascalculated by shadow-pricing the 1988 US$/kg price for Tanzanian tobacco(US$1.56/kg) to account for the economic benefit derived from foreignexchange earnings (TSh234/kg) and subtracting (a) transportation chargesfrom the buying centers to Morogoro processing plant and from the plantto Dar es Salaam, (b) repackaging charges, and (c) and losses to redryingto meet international standards (about 12%). The resultant value,TShll7/kg is the economic price at the buying center.
Table 4.7: ECONOMIC VALUES FOR TOBACCO
Basis TSh/kg
Producer Price a/ 75.6Domestic Sale b/ 108Exports 117
a/ Price set by Government for 1987-88 curing season.b/ Mainly to cigarette factory.
Source: TTPMB; Mission estimates.
4.11 The economic value for tobacco consumed domestically is108 TSh/kg. This price reflects government policy aimed at maximizingexports and equating the local price with the export price in order topromote the addition of value to products within the country. Forpurposes of this analysis, the 1987 domestic sales prices less transportcosts from the buying centers to the processing plant and redrying costs,was used for the economic value of domestically sold tobacco.
Economic Rate of Return
4.12 The economic rate of return for the project was calculatedby comparing the aggregate economic costs with the aggregate economicbenefits. The benefit-cost streams were derived from the one barnfinancial model that excluded interest payments. Costs which include allproject overheads, are almost identical to those used in the financialanalysis except for the valuation of items requiring foreign exchange.To these items (vehicles, equipment, salaries for expatriates, and studytours) a shadow price for foreign exchange was added to the base cost.The other changes include the use of: (a) a shadow-priced value for fuel-wood, based on the cost of substituting sources of supply; (b) a shadow-priced value for foreign exchange (TSh150 - US$ 1) earned throughexporting 66.5% of domestically produced tobacco; and (c) the full costof all project overheads including management/extension assistance andthe full cost of barn modifications, excluding taxes.
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4.13 The economic rate of return for the project, indicatingincremental returns to the country, is estimated to be approximately32.5X. This high rate is mainly due to relatively small investments inenergy efficient measures combined with large savings in the major factorof production (fuelwood) and a high economic price for tobacco.
Sensitivity Analysis
4.14 The responsiveness of the rates of return to variations inkey assumptions was tested through sensitivity analysis. The stability ofthe project economic rate of return was analyzed by decreasing benefits,increasing costs, altering the assumptions regarding the realization ofproduction efficiencies, and by reducing the number of barns modified.These results (summarized in Table 4.8) indicate that a sound rate ofreturn is maintained even when more conservative assumptions for theaboVe mentioned parameters are employed. A 24.5% rate of return isrealized if, simultaneously benefits are decreased by 20% and costs areincreased by 20%. If project participation is 50% lower than antici-pated, and only 3,405 barns are modified, (over which total projectoverheads would be spread) the rate of return is still sound at 20.7%.In the unlikely event that the extension system is not as effective asenvisioned, or if farmers are not as proficient in acquiring curingtechniques as anticipated, and the rate at which benefits are realizedare 40% less than those assumed in the base case respectively forfuelwood savings and reductions in curing losses, a return of approxi-mately 15.1% is maintained. These results indicate that the major priceand cost assumptions on which the project is based are conservative andcan undergo a moderate change without affecting the financial soundnessof the project.
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Table 4.8: SENSITIVITY ANALYSIS OF PROJECT
ECONOMIC RATE OF RETURN
Rate of Return
Scenario (%)
Base Case 32.5
Decrease Export Price of Tobacco
- By 20% 27.7
- By 40% 22.5
Decrease Project Benefits
- By 20% 24.5
- By 40% 15.1
Decrease Project Benefits and Increase Project Costs
- both by 10% 25.3
- Both by 20% 18.5
Decrease Number of Barns Retrofitted
- By 40% 20.7
4.15 A variation of sensitivity analysis, the switching value, wasalso calculated to test by what proportion the total benefits would haveto fall before the net present worth would fall to zero (i.e., theeconomic rate of return would equal exactly 11.5%, the opportunity costof capital in Tanzania, and the net investment ratio would equal exactlyone). Based on the project economic benefit/cost stream, benefits wouldhave to suffer a shortfall of 29.5% before the rate of return fell to theopportunity cost of capital (refer to Annex 2).
Project Risks
4.16 The major risks associated with the proposed project restprimarily with the failure to achieve expected energy savings within thetime frame proposed. Delays or failure to reach the expected savingstargets would most likely result from : (a) failure to generate interestin the project resulting in low farmer participation; (b) lower thanenvisioned savings in fuelwood and curing losses resulting from discrep-ancies between test conditions and actual on farm implementation of thecuring techniques; and (c) farmers failing to follow technical advice orimplement new techniques properly.
4.17 The above risks have been greatly minimized through thesuccessful completion of the pilot project. This project can beconsidered as a second phase that has incorporated lessons learned fromthe first phase. The project has been carefully designed to ensure that
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the technical assistance and training support for the dissemination ofthe tobacco curing efficiency measures would be provided to fieldextension personnel in a manner which would be compatible with the aimsand objectives of larger, ongoing efforts to rehabilitate extensionsystems. In addition, the midterm evaluation has been scheduled at theend of year two, and the final in year five, in order to allow forreadjustments in dissemination strategies early in the project ifnecessary.
4.18 The risk to an individual farmer is minimal due to the smallincremental investment required, relative to other expenditure for flue-pipes, etc., especially since arrangements will be made to stretch therepayment over three years. The risk would be further reduced if thefarmer is given an interest free loan.
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Page 1 of 2
TERMS OF REFERENCEFOR
TOBACCO CURING SPECIALIST
Job Description
The primary responsibility of the Tobacco Curing Specialist(TCS) under the proposed Tanzania Smallholder Tobacco Curing EfficiencyProject is to provide and coordinate all specialist technical support onmethods of improving tobacco curing efficiency to the Crop ServicesSection of the Ministry of Agriculture and Livestock Development.
Specific elements of the assignment for the TCS include:
(a) completing the preparation of a comprehensive "technicalpackage" or "extension kit" comprising critical information ontechniques, inputs, and training materials that would beapplied for the benefit of the RCSOs, the SMSs, other fieldextension personnel, and participating farmer groups within theoverall framework of the project;
(b) developing specialized training materials on tobacco curing forthe SMSs and other extension personnel, and coordinating theimplementation of training activities with senior officials inMALD responsible for the ongoing National Agriculture andLivestock Extension Rehabilitation Project (NALERP). Alsoassisting in planning for the study tour by SMSs and possiblyan RCSO to Malawi, Zimbabwe, and India;
(c) liaising closely with the management of TTPMB on all aspects ofthe production, procurement, and delivery of special inputs forthe modification of tobacco barns and furnaces according toguidelines in the "technical package;"
(d) providing all necessary support to the Extension Unit of MALDon dissemination of tobacco curing efficiency improvementmeasures, including assisting the MALD's Farmers Training andInformation Unit to prepare extension newsletters and radioprograms on tobacco curing;
(e) designing and implementing a field monitoring system for theproject's extension activities. This would be compatible withthe overall extension monitoring system that is being intro-duced throughout Tanzania under the NALERP.
The role of the TCS will be crucial in coordinating activitiesunder each of the project components, as well as ensuring that from atechnical standpoint, the project maintains uniformly high standards.
- 47 - Annex 1Page 2 of 2
Counterparts
The overall supervisor of the TCS will be the AssistantCommissioner for Crop Services in the MALD. The TCS will be deployed inTabora working out of the offices of the Regional Agriculture and Live-,stock Development Office. On a day-to-day basis, the counterpart of theTCS will be the Regional Crop Services Officer for Tabora. In the curingand marketing season, the TCS will provide direct support to SubjectMatter Specialists (SMSs) responsible for extension activities in each ofthe four principal flue cured tobacco producing districts (i.e., Tabora,Urambo, Iringa, and Chunya). In all, it is expected that the TCS willdevote about 80Z of the field support activities to the Tabora region(i.e., Tabora and Urambo districts), and the balance in the Chunya andIringa districts. For the annual reviews and preparation of implemen-tation plans, the main counterparts for the TCS will include other keyofficials in the MALD headquarters.
Duration of Assignments
The assignment has a two to three year duration. Accordingly,the TCS will be appointed on a two to three year contract with theMALD. The conditions for the assignment, including remuneration etc.,will be negotiable depending on the source of financing for the project.
Qualifications and Experience
The TCS would have an advanced degree(s) in agriculturalextension and/or agronomy, and at least five years experience in atechnical and/or managerial position related to production of flue curedtobacco in a developing country, preferably an international tobaccocompany. Knowledge and understanding of agricultural extension under theT&V system, as well as of smallholder production of flue cured tobacco inthe Eastern and Southern Africa Region would be an advantage.
- 48 - Annex 2Page 1 of 7
COST OF INPUTS FOR BARN MODIFICATION a/
MEDIUM-SIZED BARNS 016X14X13; 4X3 TIERS) COVERED WITH REEDOR
COST COSTITEM QUANITY INCL. LABOR EXCL. LAB
FURNANCEbricks 700 pieces 1890 1890railway Lines (20") 5 pieces 400 400time 1 bag 280 280farmer's labor I MD 30mason charges 2MD 400construction labor 3 MD 90
... ----- ...... ...
subtotal 3090 2570FLUESspecial ex-furnace flue pipe 1 piece 10000 10000(cast iron - 3'long x 8" dia.)
VENTILATORStop and bottom withshutter and frame (lxl') 9 pieces 1170 1170farmer's labor 4 MD 120
......--- .........
subtotal 1290 1170
EXTERNAL SHED COVERED WITH REEDGRASSjungle poles 8 pieces 240 240bush poles and 9 piecesjungle purtins 200 pieces 270 270reedgrass 12 bundle 420 420rope (jungle fiber) 50 bundle 100 100farmer's labor 4 MD 120
------- .........
subtotal 1150 1030
MISCELLANEOUScurometerandwet and dry hydrometer 2000 2000
.......--- ........... ....
MODIFICATION COSTS 17530 16770CONTINGENCIES 3106 2892
TOTAL MODIFICATION COSTS 20636 19662
a/ in 1988 prices.Source: Mission estimates.
Annex 2Page 2 of 7
MACHINE TOOLS FOR REVAMPING TTPMB FACTORIES a/
USE/TYPE OF EQUIPMENT EQUIPMENT SPECIFICATIONSNo. Req'd Working Length Max. Working Sheet Remarks
(mm) Thickness (mm)
A. PRODUCTION OF FLUE PIPES/CHIMNEYSGuillotines:-for shearing metal sheets
1. Power Guillotine 1 2050 3.0 for Morogoro factory2. Treadle Guillotine 1 1250 1.5 for Urambo factory
Bending Rollers:-for bending metal sheets
1. Power Operated Roller 1 2025 1.6 for Morogoro factory2. Hand Operated Roller 1 2025 1.6 for Urambo factory
Plain Folders:-for folding metal sheets to make angles or joinery
1. Power Operated Folder 1 2040 2.5 for Morogoro factory2. Hand Operated Folder 1 2050 2.0 for Urambo factory
Circular Cutting Machines:-for cutting curved and circular artic(es from metal sheets
1. Power Operated Cutter 1 650 dia. 2.0 for Morogoro factory2. Hand Operated Cutter 1 650 dia. 1.5 for Urambo factory
Universal Swaging, Wiring,Jennying, and Folding Machine:-for fitting wires, ridging flues, etc.
1. Power Operated Machine 1 400 depth 2.0 for Morogoro factory2. Hand Operated Machine 1 400 depth 2.0 for Urambo factory
Universal LockForming Machine:-for sealing flue pipe joints
1
B. PRODUCTION OF FURNACE GRATESHeavy Duty Power Hack Saw:- for cutting iron rails to make furnace grates.
C. PRODUCTION OF WOODEN SHUTTERS/VENTS
Universal Wood-worker:-for planing, surfacing, drilling, moticing, and sawingBand Saw:-for sawing timber for shuuters/barn ventilatorsSanding Machine:-for cleaning and smoothening wood for shutters
- 50 - Annex 2
.......................................................................................................... Page 3 of 7TANZANIA TOBACCO CURING EFFICItExCY PROJEtl
PtOJECT COST ESTIMAtES
(N1 p000 TSI)......................................................................... .........................................................................................
PROJECt rEAtS
UliMt Cost 1 2 3 4 $ 6 TOTAL
I. INVESTMENTS:VEMICLRS............ ....
LtO Bover 2 2500.0 SOOO.O 5000.0Motorcycles 6 200.0 1200.o 1200.0
Bicycle 6 10.0 60.0 60.0........................................................................
Subtotal 6260.0 6260.0
11. BECURRENT COSTS.............. ..........
A. VERICLIEStand Rov t 2 95.0 190.0 190.0 190.0 19. 190.0 190.0 1140.0
MotorcycLes 5 25.0 125.0 123.0 125.0 125.0 12S.0 125.0 hO0.0BieTcls 20 2.0 40.0 40.0 40.0 40.0 40.0 40.0 2S0.0
........................................................................
Stbtotal 3SS.0 35.0 355.0 355.0 315.0 353.0 2130.0
B. OFFICE EWIPIENTSquplies 3 25.0 n5.0 n.e 15.0 n5.0 n3.0 n3.0 450.0
Eqzipmnt 3 48.0 144.0 14.0 144.0 144.0 144.0 144.0 864.0........................................................................
Subtotat 219.0 219.0 219.0 219.0 Z19.0 219.0 0 1314.0
C. STAFF*Tobtcco Specialist 1 9500.0 9500.0 9500.0 9500.0 0.0 0.0 0.0 26SOO.O
Crop Services Officer 1 250.0 250.0 250.0 250.0 250.0 250.0 250.0 1500.0
Project SRS* 4 250.0 1000.0 1000.0 1000.0 1000.0 1000.0 1000.0 6000.0-Curing Technielcan 0 2000.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Project Accoultant 1 150.0 150.0 150.0 150.0 150.0 150.0 150.0 900.0
Driver/Nedhmnics 2 75.0 150.0 150.0 150.0 150.0 1SO.0 150.O 900.0
SecretarIes 2 h3.0 150.0 150.0 150.0 150.0 150.0 150.0 900.0=........................................................................
SubtotaL 11200.0 11200.0 11200.0 1700.0 1700.0 1700.0 38700.0
0. LODGINGRentat ALosonces 11 140.0 1540.0 1540.0 1540.0 1540.0 1540.0 1540.0 9240.0
E. TtAININGfietd Workshops 1000.0 1000.0 1000.0 1000.0 1000.0 1000.0 1000.0 6000.0
Study TOur 2 8500.0 17OO0.0 17000.0
orientatian Courses 1000.0 1000.0 333.3 333.3 1666.7
Subtotal 19000.0 1333.3 1333.3 1000.0 1000.0 1000.0 24665.?
F. EXTENSION SUPORT
Phlicity materials 650.0 '.0 650.0 650.0 650.0 650.0 650.0 3900.0
G. 1DlITORINO/VWAUATIONInitiaLtMid-te7 1 2500.0 2500.0 2500.0
final 1 2500.0 2500.0 2500.0
Ill. INWESTMENTS FOB BARN1 IlIFICATION...........................................
Irputs to Farsers 8847.9 35391.6 44239.5 45419.2 133898.2
Machine Tools 13100.0 13800.0
............................................................................................................................
BASE PROJECT COSTS 61871.9 5318t.9 59536.8 S083.2 7964.0 5464.0 238908.9
PHTSICAL COITIOE"NCIES * 102 6187.2 5318.9 5953.7 5088.3 796.4 546.4 23890.9
PRICE CONTINGENCIES 3001.4 11595.4 20991.8 29182.5 6071.3 5321.0 76163.4
TAXES/DUTIES 705.8 15.8 15.8 15.8 15.8 15.8 784.5
tOTAL PROJECT COSTS 71766.3 70119.0 86498.0 S5169.8 14847.4 11347.1 339747.6
............................................................................................................................
0.0
COST CATEGORY COST ITEMS AS A PERCENT OF TOTAL BASE COSTSTOTAL
2 BARNI/LUE MODIFICAtIOt 36.6U 66.52 74.32 89.32 0.0 0.02 61.8X
2 TRAININGITECN ASSISTANCE 30.72 2.52 2.22 2.02 12.62 18.3X 10.32
2 AOMINISTRATION 18.12 21.12 18.82 3.32 21.3X 31.12 16.22
2 TRANSPONATION 10.72 0.7x 0.62 0.12 4.52 6.52 3.5X
2 RENTAL ALLOWANCE 2.5X 2.9X 2.62 3.02 19.32 28.22 3.92
2 EXTENSION MATERIALS 1.12 1.2X 1.12 1.32 8.22 11.9X 1.6S
2 OfFICE EQUIPMENT 0.42 0.42 0.42 0.42 2.7S 4.02 0.62
S MllTORING 0.02 4.12 0.02 0.02 31.42 O.OX 2.12
CTAL l:0.O ICO.0D 100.02 100.02 100.02 100.02 100.02
............................................................................ ................................................................................
Annex 2Page 4 of 7
............... ........................................ ...........................................................................
TANZANIA TOEACCO CURING EFFICIENCY PROJECT
PROJECT COST ESTIMATES(IN '000 US$)
..........................................................................................................
PROJECT YEARSUNIT COST 1 2 3 4 5 6 TOTAL
I. I1VESTHEHTS:VENICLES................
Land Rover 2 27.2 54.3 54.3
motorcycles 6 2.2 13.0 13.0
Bicycles 6 0.1 0.7 0.7........................................................................
Subtotal 68.0 68.0
I1. RECURRENT COSTS................
A. VEHICLESLand Rover 2 1.0 2.1 2.1 2.1 2.1 2.1 2.1 12.4
Motorcycles 5 0.3 1.4 1.4 1.4 1.4 1.4 1.4 8.2
Bicycles 20 0.0 0.4 0.4 0.4 0.4 0.4 0.4 2.6
Subtotal 3.9 3.9 3.9 3.9 3.9 3.9 23.2
B. OfFICE EQUIPMENTSupplies 3 0.3 0.8 0.8 0.8 0.8 0.8 0.8 4.9
Equipnent 3 0.5 1.6 1.6 1.6 1.6 1.6 1.6 9.4.........................................................................
Subtotat 2.4 2.4 2.4 2.4 2.4 2.4 0 14.3
C. STAFF*Tobacco Specialist 1 103.3 103.3 103.3 103.3 0.0 0.0 0.0 309.8
Crop Services Officer 1 2.7 2.7 2.7 2.7 2.7 2.7 2.7 16.3
Project SlSs 4 2.7 10.9 10.9 10.9 10.9 10.9 10.9 65.2
'Curing Technicians 0 21.7 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Project Accountant 1 1.6 1.6 1.6 1.6 1.6 1.6 1.6 9.8
Oriver/Mechanics 2 0.8 1.6 1.6 1.6 1.6 1.6 1.6 9.8
secretaries 2 0.8 1.6 1.6 1.6 1.6 1.6 1.6 9.8........................................................................
Subtotal 121.7 121.7 121.7 18.5 18.5 18.5 0.0 420.7
0. LOOGING
Rentat Atowances 11 1.5 16.7 16.7 16.7 16.7 16.7 16.7 100.4
E. TRAININGField Workshops 10.9 10.9 10.9 10.9 10.9 10.9 10.9 65.2
Study Tour 2.0 92.4 184.8 184.8
Orientation Course 10.9 32.6 10.9 10.9 $4.3.............................. ....................................................................
Subtotat 228.3 21.7 21.7 10.9 10.9 10.9 304.3
F. EXTENSION SUPPORTPublicity Materiats 7.1 7.1 7.1 7.1 7.1 7.1 7.1 42.4
G. MONITORING/EVALUATIONInitial/Mid-term 1.0 27.2 27.2 27.2
Final 1.0 27.2 27.2 27.2
III. 1NVESTMENtS FOR BARM I4CIFICATION........................... ................
Materials to Farmers 96.2 384.7 480.9 493.7 1455.4
Equipment (flue-piPe fabr.) 150.0 150.0
................................. I............................................................................................ ..... ......................................
BASE PROJECT COSTS 694.3 585.4 654.4 553.1 86.6 59.4 2633.1
PHYSICAL CONTINGENCIES - 10S 69.4 $8.5 65.4 55.3 8.7 5.9 263.3
PRICE CONTINGENCIES 10.9 102.6 198.7 283.3 52.6 43.0 691.1
TAXES/DUTIES 7.7 0.2 0.2 0.2 0.2 0.2 8.5. ............................................................... .... .. ... .. ......... . .................................................. ................
TOTAL PROJECT COSTS 782.3 746.7 918.7 891.9 148.0 108.5 3596.0S… - z2=:: ::S=:::::S :::s:=::=::::: S:::n: ::=::=x-2 s-= .z:..t. s.... .:.:.:: ... s...=S ..S ... s...s.....
- 52 - Annex 2
TANZANIA TOBACCO CURING EFFICIENCY PROJECT Page 5 of 7
PROJECT FINANCIAL BENEFIT/COST STREAM
(in '000 TSh.)
YEARS 1 2 3 4 5 6 7 8 9 10
PROJECT COSTS
A. VEHICLES
Capital costs 6260.0 0.0 0.0 0.0 0.0 0.0
Recurent costs 355.0 355.0 355.0 355.0 355.0 355.0
B. OFFICE EQUIPMENT
Supplies 219.0 219.0 219.0 219.0 219.0 219.0
C. STAFF
Salaries 11200.0 11200.0 11200.0 1700.0 1700.0 1700.0
D. LODGING
Rental Allowance 1540.0 1540.0 1540.0 1540.0 1540.0 1540.0
E. TRAINING
Training costs 19000.0 1333.3 1333.3 1000.0 1000.0 1000.0
F. EXTENSION SUPPORT
Publicity Materials 650.0 650.0 650.0 650.0 650.0 650.0
G. MONITORING/EVALUATION
Surveys, etc. 2500.0 2500.0
H. BARN/FLUE MODIFICATION
Materials for Farmers 8847.9 35391.6 44239.5 45419.2
Equipment (flue-pipes) 13800.0 0.0 0.0 0.0
BASE COSTS 61871.9 53188.9 59536.8 50883.2 7964.0 5464.0
PHYSICAL CONTINGEN.(10%) 6187.2 5318.9 5953.7 5088.3 796.4 546.4
TOTAL COSTS 68059.09 58507.82 65490.51 55971.54 8760.4 6010.4
PROJECT BENEFITS
WITH YR 1 0.0 2720.5 10882.1 13602.6 13965.3 0.0 0.0 0.0 0.0 0.0
WITH YR 2 7175.6 28702.5 35878.1 36834.9 0.0 0.0 0.0 0.0
WITH YR 3 13009.4 52037.6 65047.0 66781.6 0.0 0.0 0.0
WITH YR 4 7011.4 35056.8 70113.6 106105.2 78059.8 43003.0
TOTAL BENEFITS 0.0 2720.5 18057.7 55314.5 108892.5 136938.7 136895.2 106105.2 78059.8 43003.0
PROJECT COSTS/BENEFITS STREAM
PROJECT YEARS 1 2 3 4 5 6 7 8 9 10
TOTAL BENEFITS 0.0 2720.5 18057.7 55314.5 108892.5 136938.7 136895.2 106105.2 78059.8 43003.0
TOTAL COSTS 68059.1 58507.8 65490.5 55971.5 8760.4 6010.4 0.0 0.0 0.0 0.0
NET BENEFITS -68059.0 -55787.3 -47432.8 -657.0 100132.1 130928.3 136895.2 106105.2 78059.8 43003.0
196019.4
PROJECT FINANCIAL
RATE OF RETURN >>>> 28.0%
- 53 - Annex 2Page 6 of 7
PROJECT ECONOMIC BENEFIT/COST ANALYSES
(in 'OOOTSh.)
YEARS 1 2 3 4 5 6 7 8 9~~~~~~~~~~~~~~~~~. .... ...... ...................................... ............................................................................ ................
PROJECT COSTS
A. VEHICLES
Capital costs 10168.7 0.0 0.0 0.0 0.0 0.0
Recurrent costs 352.0 352.0 352.0 352.0 352.0 352.0
8. OFFICE EQUIPMENT
Supplies 309.0 309.0 309.0 309.0 309.0 309.0
C. STAFF
Salaries 17189.1 17189.1 17189.1 17189.1 17189.1 17189.1
0. LODGING
Rental Allowance 1540.0 1540.0 1540.0 1540.0 1540.0 1540.0
TRAINING
Training costs 29517.4 1133.3 1133.3 800.0 800.0 800.0
F. EXTENSION SUPPORT
Publicity materials 650.0 650.0 650.0 650.0 650.0 650.0
G. MONITORING/EVALUATION
Surveys, etc. 2500.0 2500.0
H. BARN MODIFICATION
Materials for Farmers 8847.9 35391.6 44239.5 45419.2
Equipment (flue-pipes) 22500.0
BASE COSTS 91074.1 59065.1 65413.0 66259.4 23340.1 20840.1
10% PHYSICAL CONTINGEN. 9107.4 5906.5 6541.3 6625.9 2334.0 2084.0
TOTAL COSTS 100181.5 64971.6 71954.3 72885.3 25674.1 22924.1
PROJECT BENEFITS 1 2 3 4 5 6 7 8 9 10.. .. ... ............. ...
WITH YR 1 0.0 4168.0 16671.9 20839.9 21395.6 0.0 0.0 0.0 0.0 0.0
WITH YR 2 10977.7 43910.9 54885.6 56352.3 0.0 0.0 0.0 0.0
WITH YR 3 19813.2 79252.9 99066.2 101707.9 0.0 0.0 0.0
WITH YR 4 10693.4 53467.1 106934.2 151133.6 108360.0 54892.9
TOTAL BENEFITS 4168.0 27649.7 84564.1 166230.6 208885.6 208642.1 151133.6 108360.0 54892.9
PROJECT COSTS/BENEFITS STREAM
PROJECT YEARS 1 2 3 4 5 6 7 8 9 10
TOTAL BENEFITS 0.0 4168.0 27649.7 84564.1 166230.6 208885.6 208642.1 151133.6 108360.0 54892.9
TOTAL COSTS 100181.5 64971.6 71954.3 72885.3 25674.1 22924.1 0.0 0.0 0.0 0.0
NET BENEFITS -100181.5 -60803.6 -44304.6 11678.8 140556.5 185961.4 208642.1 151133.6 108360.0 54892.9
PROJECT ECONOMIC
RATE OF RETURN >>> 32.5% <
- 54 - Annex 2Page 7 of 7
TANZANIA TOBACCO CURING EFFICIENCY PROJECT
ANALYSIS OF SWITCHING VALUES
( in '000 TSh.)
Tanzania Interest Rate = 11.5X
29.6'%DECREASE IN BENEFITS 29.50% DECREASE IN BENEFITS 29.57%DECREASE.. . . . . . . . . . . . . ............................................ . ................ ................................. . . .........................
YEAR INCREMENT NET INCREMENT NET INCREMENT NET
BENEFITS BENEFITS BENEFITS BENEFITS BENEFITS BENEFITS********* ********* ~~~~~~~~~~~~~~~~~**** ** * **
1 2938.4 -62033.1 2938.4 -62033.1 2935.5 -62036.1
2 19465.4 -52488.9 19493.0 *52461.3 19473.7 -52480.6
3 59533.1 -13352.2 59617.7 -13267.6 59558.5 -13326.8
4 117026.4 91352.2 117192.6 91518.4 117076.2 91402.1
5 147055.5 124131.3 147264.3 124340.2 147118.1 124194.0
6 146884.0 146884.0 147092.7 147092.7 146946.6 146946.6
NPV -84.9 NPV 292.3 NPV 25.9
SWITCHING VALUE z 29.57%
- 55- Annex 3Page 1 of 12
BARN CENSUS AND INVENTORY
During the ESMAP pilot project, a census was conducted amongtobacco farmers in villages in the Tabora, Urambo, Iringa, and Chunyadistricts that had recorded tobacco production levels exceeding 50,000kgs per season in 1984/85 and 1985/86. In all, some 54 villages in 32wards were covered in the census to generate baseline data and an inven-tory of existing barns. The following information has been collectedfrom each of the 54 villages: (i) total number of barns per village;(ii) number of barns per farmer by size (i.e.. dimension); (iii) type anddesign of furnace; (iv) layout of flue-pipes and chimney systems;(v) number of tiers and bays used for hanging tobacco; (vi) number andlocation of top and bottom vents; (vii) previous year's output of curedleaf (in kgs); and (viii) previous year's area planted with tobacco (inha). A sample of the form used in gathering data for the census ispresented, together with a summary of the results, especially withrespect to barn dimensions.
The following steps have been used to establish a baselineinventory of barns that would constitute the principal target group forthe proposed project. First, the 54 villages were reclassified intoGroup A and Group B according to their respective tobacco productionlevels for 1984/85 and 1985/86: each Group A village produced over100,000 kgs of cured tobacco per season; and each Group B village,between 50,000-100,000 kgs of cured tobacco per season. Second, barns inboth Group A and Group B villages respectively were further reclassified,according to size, into three categories: (i) small-scale barns(12'x12'x13'); (ii) medium-scale barns (16'x16'x13'); and (iii) large-scale barns comprising either the low-profile barns (24'x16'x13'), or theother large barns (20'x20'x20') used by estate farmers near Iringa. Theresults are shown in Table 4.1.
- 56 -Annex 3
Page 2 of 12
Sample Form: Barn Census and Inventory Form
1. Name of the ward/village2. Name of the farmer3. Area planted under tobacco (in hectares)/production in kgs.
Area (ha) Production (kg)Previous season: 1986-87 .......... 00.........Current season : 1987-88 ........... $0*00......
4. Total number of barns5. Types of barns/capacity
I. Sizes
Total No. of BarnsUnder each category Roofing Nos.
( ) 12'x12'xH ................... ( ) Thatched ( ) 9'x9 x H ................... ( ) corrugated( ) any other size
II. Tiers
Bays CapacityNo. of sticks No. of sticks6' spacing 9" spacing
3 .......... 0# ..... ........ ....... ......
()6 .......... 00 ..... ........ ....... ......
- 57 -Annex 3
Page 3 of 12
Barn Inventory Form (cont'd)
III. Ventilators
( ) Yes: Present( ) Not present
If the answer is yes:Nos and Sizes
( ) Top vents( ) Bottom vents
IV. Chimney:
( 3 Yes present( ) Not present
if present indicate
X Wrong Right
V. Furnace:
C ) External( ) Internal( ) Half inside & half outside the barn
VI. Flue-pipe layout:
A. T-flue layoutB. U-flue layout
SUMMARY RECORDING SHEET FOR BARN CENSUS AND INVENTORY
Table 1:
Name of Ward/Division/Village:
Chimney Vents Corners FurnaceName of Area Planted Total No. Sizes/No. of Roofing Flue Layout Right (R) or (TV & BV) Elbow (E) or Design &Grower 86/87 87/88 of Barns Tiers & Bays Thatched C.I.S. T U Wrong (W) No. & Size Mud (M) Position
.9
Index: C.l.S. Corrugated Iron Sheet T.V. a Top Vents F.l. Furnace InsideT. - Flue Layout 3.V. a Bottoe Vents F.O. = Furnace OutsideU. = Flue Layout TH = Thatched Roof F.H. = Furnace Half lside, Half Outside.
OQ :3
x
0
I-'h
Table 2: SUMMARY OF BARN CENSUS FOR TARGET TOBACCO DISTRICTS
Number of Number of Number of
Wards Villages Farmers
Region District A B 12x12 16x16 16x20 24x16x13 a/ 20x20 24x16x20
Tabora Tabora 16 15 12 7,630 6,095 2,827 566 5
Urambo 5 5 7 2,556 4,385 2,765 954 -- -- --
Iringa Irlnga 2 2 4 1,885 520 253 332 -- 475 66
Mbeya Chunya 2 4 5 3,606 5,661 379 -- 2 -- --
Total 32 26 28 15,677 16,661 6,224 1,852 2 475 66
a/ Low Profile Barns.
Source: ESMAP Census, 1988.
I O
xU'
0
- 60 - Annex 3Page 6 of 12
Table 3: TABORA DISTRICT: BARN CENSUS GROUP('A Target Wards and Villages)
Sizes of BarnsNames of Number of (In feet)
Wards Villages Farmers 12x12 16xl6 16x20 24x16
1. Ufuluma Ugowola 186 346 64 20 --Ufuluma 217 530 178 8 1Chessa 200 62 302 6 --
2, Usagarl Migungumalo 286 182 198 20 --
Imalaudukl 258 325 16 -- --
3. ibiri Isimu/KlIungu 245 340 101 25 14 ltetemya Ntailkwa 202 300 130 -- --5. Ilalangulu Mbola 144 141 102 57 --
lslla 241 216 94 74 --
6. Mabama Kalola 285 202 1066 -- --
7. lsikizya lsikizya 147 380 104 65 --
8. Magirl Nslmbo n.a. 370 260 90 --
9. Tutuo Mole 585 224 229 56 310. Igalulu Kigwa 240 118 61 -- --
10 15 5,499+ 4,160 2,025 483 5Group A + B
19 27 7,630+ 6,097 2,827 571 5
Tabora District Total 7,924 13,939 5,185 1,292 5
Source: Regional Agriculture Development Office (KILIMO), Tabora.
- 61 - Annex 3Page 7 of 12
Table 4: TABORA DISTRICT: BARN CENSUS GROUP(B' Target Wards and Villages)
Sizes of BarnsNames of Number of (in feet)
Wards Villages Farmers 12x12 16x16 16x20
1. llolangulu Tumbi 194 186 55 82. Mabama Mbiti 157 178 23 --
Uturu/ldeka 179 153 88 473. lsikizya Ibelamilundi 250 380 28 --4. Ndono Nkulusi 118 348 48 --5. Kalunde Kalunde 156 90 20 76. Kakola Igombe 172 148 57 --7. Bukumbi Ishihimulwa 212 146 10 --
8. Kipanga Kipanga 177 61 61 --
Usunga 149 212 166 --
9. Kipill Zugimlole 130 n.a. n.a. --
9 12 2,131 1,937 802 83
Source: Regional Agriculture Development Office (KILIMO), Tabora,
- 62 - Annex 3
Page 8 of 12
Table 5: URAMHO DISTRICT: BARN CENSUS GROUP('A' and B' Target Ward and Villages)
Group A
Sizes of BarnsNames of Number of (in feet)
Wards Villages Farmers 12x12 16x16 16x20
lmalamakoye 1. Nsenda Kanoge 209 900 80 80Muungano 2. Muungano 274 501 273 213
3. Kalemela A. 229 740 359 89Itundu 4. Kasisi 219 395 216 --Songambele 5. Uyogo 225 124 510 110
4 5 1,156 2,660 1,436 430
Group B
Imalamakoye 1. imalamakoye 126 110 112 8Muungano 2. Kalemela 'BO 218 405 405 81ltundu 3. ltundu 'Al 207 194 160 177Songambele 4. Songambele 211 239 300 1
5. Jionee mwenyewe 205 230 247 110Vumilia 6. Motomoto 181 280 55 122
7. Nkokoto 252 267 48 28
5 7 1,400 1,725 1,327 5249 12 2,556 4,385 2,763 954
Urambo District 3,239 12,860 2,932 1,292
Source: Regional Agricultural Development Office (KILIMO), Tabora.
- 63 - Annex 3Page 9 of 12
Table 6: TOBACCO GROWING VILLAGES - IRINGA REGION(Southern Highland Zone)
District Division Ward Names of Villages
Iringa Kalenga Kalenga 1. Kiwere2. Mf yome4. Ngera
Nzlhi 5. Magubike6. Nzihl
Mufundi Sadani Sadani 7. Uyelia8. Lugoda9. Klbade
NJombe Wangingamb. Wangimgombe 10. Mayale11. lyaJi12. Mkomangombe13. Lullo14. Kingole15. Luano16. Lihagule
Source: TTPMB Branch Office, Iringa.
- 64 - Annex 3Page 10 of 12
Table 7: TOBACCO PRODUCTION - IRINGA RiEGIONSouthern High Land Zone, 1986-87
Number of Families Ha Production Number of Barns
Districts Growing Tobacco Planted (Kg) 12xl2 16xl6 20x16 20x20 24xl6
Iringa 1,844 625.9 417,678 520 250 293 -- --
Mufindi 276 67.0 16,895 -- 526 -- -- --
NJombe 174 43.6 16,767 16 43 49 -- --
Ludewa 189 38,4 14,281 12 49 6 -- --
SHTGA a/ 41 1,417.0 1,272,594 1 3 39 475 66Taro -- -- 389 -- -- -- -- --
Total 2,524 2,191.9 1,738,604 549 871 387 475 66
a/ Larger scale growers of Southern Highland Tobacco Growers Association.
Source: TTPMB Branch Office, Iringa.
- 65 - Annex 3Page 11 of 12
Table 8: TOBACCO PRODUCTION IN TARGET WARDS AND DISTRICTS IN IRINGA DISTRICT
Southern Highlands Zone - 1986-87 Season
Number and Names Number of Ha Production Number of Barns
District Division Ward of Villages Farmers Planted (Kg) 12x12 16x16 20x16 24x16
IringaTotalDistrict 1,885 625.7 417,678 520 250 297 ------------------------------------------------------------------------ __-----__-----------------------------
Iringa Kalenga Kalenga 1. Mfyome 320 136.4 111,248 208 21 -- 12. Mgera 280 65.0 66,301 44 21 5 1
3. Magubike 230 88.0 54,220 101 37 -- --
4. Kiwere 201 72.0 71,629 83 27 7 --
5. Kitapilimwa 100 39.2 20,596 18 25 20 --
Totals 1,131 400.6 323,994 454 129 32 --
Source: TTPMB Branch Office, Iringa.
- 66 - Annex 3Page 12 of 12
Table 9: TOBACCO PRODUCTION IN TARGET VILLAGES IN CHUNYA BRANCH-MBEYA REGIONSouthern Highland Zone - 1986-87 Season
Number of Ha Production Number of BarnsVillage Farmers Planted (Kg) 12x12 16x16 20x16 24x16x13 a/
LuwalaJe 427 422.4 152,052 652 -- -- 1Matwiga 515 332.5 113,615 1,246 -- -- --
Lupa 710 385.0 156,752 634 358 -- 1Ntanila 413 186.0 90,964 755 11 -- --
Namba 414 196.5 98,661 432 -- -- --
Nkungungu 348 194.0 104,473 951 -- -- --
Mafyeko 325 130.0 51,577 336 10 -- --
Gua 308 97.0 68,007 415 -- -- --
Kapalala 146 44.0 22,298 240 -- --
Totals 3,606 1,987.4 858,399 5,661 379 -- 2
a/ Low-Profile Barn.
Source: TTPMB Branch Office, Iringa.
- 67 -
Annex 4Page 1 of 6
THE TOBACCO CURING TRIALS
Objectives. The main objective of the pilot tobacco curingefficiency project which was implemented by ESMAP during the 1988 curingseason (December 1987 - May 1988) was to conduct curing trials toestablish the specific fuel consumption (SFC) levels of existingsmallholder barns (control barns). The curing trials were designed toinvestigate the relative and incremental savings in fuelwood required forcuring with the application of some or all of the proposed measures inthe technical package. In effect, the curing trials were used by ESMAPas the basis for assessing the relative and incremental costs andbenefits associated with measures in the technical package.
Design. The curing trials were held at the village of Ufulumain the Ilolangulu ward of the Tabora District. The site was well-suitedfor the purpose because: (i) about 20 traditional smallholder barns wereconcentrated in a 100-meter stretch in one part of the village, therebymaking it relatively easy to establish and monitor control barns;(ii) two of the barns were made ava.lable for full-time use of the ESMAPteam; and (iii) one farmer had previously upgraded to an improved 'LowProfile' barn under an earlier scheme sponsored by the TTPMB. The low-profile barn was also made available to ESMAP as a trial barn to evaluatethe impact of the technical package on larger dimension barns used by asegment of larger scale tobacco growers, notably members of the SouthernHighlands Tobacco Growers Association (SHTGA), which is based at Iringa.
The following four configurations of barns were used for thecuring trials at Ufuluma Village:
(a) Configuration One. This represented the technical package thatis recommended for the larger scale farmers, especially theSHTGA members. The barn was of the improved Low Profile'design type with dimensions of 24' x 16' x 13'. The barn wasretrofitted with a 'Malakisi slot-type' furnace, and the entireflue-pipe and chimney systems, originally consisting of 11"diameter ducts, was also retrofitted with 8" diameter ducts.Top and bottom vents were reinforced. The 'Low Profile' barnhad already been fitted with a roof made of corrugated ironsheets (CIS), as has been recommended for the larger barns. Aschematic of the upgraded barn used in the trials as Configur-ation One is shown as Figure 3 in the main report.
(b) Configuration Two. This represented the traditional small-holder growers' barn as upgraded with all elements of thetechnical package. The barn modifications included reinforce-ment of the thatched roof, repair and sealing (replasteringwith clay) of all cracks and leaks in the barn walls, door, andceiling. Top and bottom vents were retrofitted using theshutter and frame units designed by ESMAP. The Malakisifurnace was installed in place of the existing open-hearthfurnace, and a shed was built for the furnace. As with
- 68 -Annex 4Page 2 of 6
Configuration One, the original 11" diameter flue-pipes andchimney system was replaced with one using 8" diameter ducts.A schematic of the upgraded smallholder growers' barn used inthe trials as Configuration Two is shown as Figure 2 in themain report.
(d) Configuration Three. This represented the traditional small-holder growers' barn (with thatched roof) without any modifica-tions to the barn structure, the open-hearth furnace, and the11" diameter flue-pipe and chimney system. This barn wasoperated by the ESMAP field assistants (curers) to ascertainthe impact due exclusively to the application of improvedtechniques for managing and controlling the curing process,i.e., barn loading, use of wet and dry bulb hygrometer tomonitor changes in humidity levels, etc., as indicated in thevisual aid - A Guide to Successful Curing.' In effect, theaim with Configuration Three was to isolate, to the extentpossible, the fuelwood savings that could be achieved by awell-targeted and executed extension effort that would upgradefarmer know-how and skills for managing the curing processitself, regardless of other changes in furnace, flue-pipesystems, etc.
(e) Configuration Four. As the Control for the trials, these 15barns were operated by the farmers themselves without anymodifications or retrofits. The farmers were, however, closelymonitored and measurements were routinely taken of fuelwoodused and tobacco cured. The aim was to determine the SFCaverage for the 'business as usual' or base case scenario.
Results of the Curing Trials
In all, a total of six or seven curing cycles were completedfor each barn during the pilot project. The complete results arepresented below for reference purposes. A summary of the average SFCvalues for each configuration and for the control barns are presented inTable 1 below.
Annex 4Page 3 of 6
Table 1: SUMMARY OF RESULTS OF CURING TRIALS
CONFIG. 1 CONfIG. 2 CONFIG. 3 CONFIG. 4(Control) a/
Av. Output of Cured Tobacco
per Cycle (kg) 457 290 235 195Average SFC
(N3 stacked wood/
tonne tobacco) 7.6 9.7 15.3 20.1
a/ Control barns.
Source: ESMAP Curing Trials,
SUMMARY OF RESULTS OF CURING TRIAL
Table 2: BARN CONFIGURATION 1
^URiNGSItem First Second Third Fourth Fifth Sixth
1, Quality of woodfuel 1,500 1,530 2,100 2,115 2,300 2,207used, kg
2. Out-turn of cured leaf, 349 361 512 554 556 5073. Specific fuel consump- 4.30 4.24 4.10 3.82 4.14 4.35
tion (SFC)4. Consumption of solid 1.81 1.84 2.53 2.55 2.77 2.66
round wood (M43 )/cure
5. Consumption of solid 5.18 5.11 4.94 4.60 4.98 5.24round wood curedtobacco
6. Consumption of stacked 7.73 7.63 7.37 6.86 7.43 7.83wood (M3)/tonne ofcured tobacco.
Source: ESKAP Curing Trials.
Annex 4-70- Page 4 of 6
Table 3: BARN CONfIGURATION 2
CURINGS
Items First Second Third a/ Fourth Fiftha/ Sixth Seventh
1. Quantity of wood- 1000 1,050 1,240 1,805 2,327 1,989 1,921fuel used, kg
2. Out-turn of cured 180 196 301 361 328 360 355leaf, kg
3. Specific Fuel 5.55 5.34 4.12 5.00 7.09 5.53 5.41Consumption (SFC)expressed as KgA/gtobacco
4, Consumption of 1.20 1.26 1.49 2.17 2.80 2.40 2.31solid roundwood (M3) percure
5. Consumption of 6.69 6.43 4.96 6,02 8.54 6.66 6.52solid r undwood (M ) pertonne of curedtobacco
6. Consumption of 9.98 9.60 7.40 8.98 12.75 9.94 9.73stacked wood(143) per tonne
of cured tobacco.
a/ Not included in the average.
Source: ESMAP Curing Trials.
Annex 4
- 71 - Page 5 of 6
Table 4: BARN CONFIGURATION 3
CURINGS
Items First Second Third Fourth Fifth Sixth Seventh a/
1. Quantity of 1,470 1,580 2,050 2,590 2,358 2,140 2,099woodfuel used, kg
2. Out-turn of cured 161 184 239 311 243 270 307leaf, kg
3. Specific Fuel 9.13 8.59 8.58 8.33 9.70 7.93 6.84
Consumption (SFC)expressed asKg/Kg tobacco
4. Consumption of 1.77 1.90 2.47 3.12 2.84 2.58 2.53solid roundwood (M3)/cure
5. Consumption of 11.00 10.35 10.34 10.04 11.69 9.55 8.24solid roundwood (M3)/tonne
cured tobacco6. Consumption of 16.42 15.45 15.43 14.98 17.45 14.25 (2.29)
stacked wood(M3)/tonne ofcured leaf
a/ Not Included in the average.
Source: ESMAP Curing Trials.
- 72 - Annex 4
Page 6 of 6
Table 5: CONFIGURATION 4 (CONTROL BARNS) a/
Control Final Outturn of Woodfuel Specific Fuel Solid Wood St-._ked WoodBarns Cured Leaf Consumed Wood Consumption Used Per Tonne/ per Tonne/
(SFC) Cured Leaf Cured Leaf
(Kg) (Kg) (Kg/Kg) (M3/Tonne) (143/Tonne)
1 196 2,300 11.73 14.13 21.01
2 205 2,560 12.49 15.04 24.45
3 217 2,450 11.29 13.60 20.29
4 208 2,600 12,5 15.06 22.48
5 115 1,740 15.13 18.23 27.21
6 195 2,460 12.61 15.20 22.^97 163 1,460 8.95 10.79 16.10
8 153 1,515 9.90 11.93 17.81
9 261 2,531 9.70 11.68 17.4310 246 2,492 10.13 12.21 18.2211 222 2,081 9.37 11.29 16.85
12 154 1,687 10.95 13.20 19.7013 193 1,788 9.26 11.16 16.66
Averages 11.08 13.35 20.06
a/ Selected at random from Ufuluma.
b/ Density of Brachystigia Spiciformis Var Mpalensis (Mtundu) is 830 Kg/M (air-dry).
Source: ESMAP estimates based on Curing Trials.
TECHNICAL SUPPLEMENT
by
Mohammed A. Wahid(Tobacco Specialist)
Table of Contents
Page No.
I. The Tobacco Curing Process ............................... 1
II. Practical Guidelines for Management of CuringProcess by Smallholder Farmers ........................... 4
III. Guidelines for Loading Barns ............................. 7
IV. Sample Monitoring Sheet for Tobacco CuringEfficiency Schemes............... *0****** * * * ****............ 11
V. Specifications of 'Malakisi' Slot-Type Furnace(Ufuluma Type) ......... 12
VI. Specifications of Improved Medium Sized Growers Barn..... 16
VII. Specifications of "Low-Profile" Barn..................... 21
VIII. "Habari Za Tumbaku" Newsletter............................ 26
I. THE TOBACCO CURING PROCESS
1.1 Tobacco curing is a controlled process of removing moisturefrom the leaf which is made up of approximately 80% water, the balance of20% being made up of organic solids (75X) and inorganic solids (25%).Starch is the single largest component of the dry matter in mature greenleaf and accounts for 30% of the dry matter. It takes heat energy toevaporate the moisture, which is provided through respiration by thetobacco itself or supplemental sources. Green leaf varies in moisturecontent based on plant position, growing season, and other factors.
1.2 The process of curing is not mere drying of the leaf butinvolves complex chemical and physical changes, to achieve which, varyingphysical environments need to be maintained in the barn during the curingprocess, so that a commercially acceptable cured leaf of lemon or orangecolor is produced. The cured leaf, in addition, must also possesscertain desirable physical characteristics such as texture, elasticity,body, and aroma.
1.3 Curing of flue cured tobacco involves four phases to obtain thedesired cured leaf. These phases are:
(a) Yellowing Phase: The first and most important part of theprocess is a biological one, in which the leaf is kept aliveuntil an optimum chemical balance has been achieved. It is infact a period of accelerated ripening which can be obtainedwithin limits of temperature and relative humidity conditionsif quality is to. be maintained. The temperature should notexceed beyond 105 F and the relative humidity should be between100-80% until the desired color is obtained.
While the leaf is alive it continues to respire. The starch isconverted by the enzymes into simple sugars and these, in turn,are oxidized to carbon dioxide and water during the process ofrespiration, resulting in loss of dry matter and release ofenergy. The major parts of the starch conversion to sugaroccurs within the first 20 hours after the leaf is reaped andcuring started.
The various biochemical reactions taking place in the leafsynchronize with the destruction of cholorophyll and theunmasking of the yellow and orange colors. The completion ofyellowing, normally, is taken as an index of the necessaryconversion of starch to sugar, when an optimum chemical balanceis considered to have been achieved.
(b) Color Fixing: The second stage--color fixing--is a straight-forward dehydration process. By increasing the temperature anddecreasing relative humidity, the respiration process isretarded and the desired color is fixed, when biological
- 2 -
processes are halted and the chemical balance between starchand sugar preserved. Since dehydration of the lamina should becompleted within minimum time, the second phase has to overlapthe yellowing phase.
If the color fixing phase is prolonged, more sugar will beoxidized and both weight and quality would suffer. It is,therefore, necessary to dry out and kill the leaf as quickly aspossible, once the best balance of starch and sugar has beenattained.
The rate of removal of moisture needs to be controlled at thecolor fixing phase, if undesirable "browning reaction" due tooxidation of polyphenols is not to set in. If the browning igto be avoided, the temperature should not be raised to 130until the leaf moisture is reduced 40-50%.
(c) Lamina Drying: During the lamina drying process, emphasisshould be on drying rate rather than temperature. It ispossible to achieve better drying at a lower temperature if thehumidity can be reduced. If the temperatures are increased tooquickly for the ventilation available (in most casesnonexistent or insufficient), the humidity in the barn willrise, slowing down drying and "stewing" or "cooking" thetobaccot which will lose color and luster, turning a muddybrown, most common in Tanzanian tobacco.
The most critical point is at about 125 F when most of thedamage is done in discoloring the tobacco, attempting to raisethe temperature while the relative humidity is higher than30%. Discoloration can be reduced to a minimum, especially ifmaximum ventilation is given from early in the cure.
Use of Wet and Dry Bulb is essential to give precise guidanceon temperature increases and ventilation requirements in theconvectional barn.
(d) Mid-rib Drying: Once the lamina drying phase is completed,removing the remaining moisture from the mid-rib (stem) is astraightforward process.
Ventilation should be closed progressively at the top of thebarn, not the bottom. By closing the top vent of the barn, thehot air is forced to spread out within the barn, filling itfrom the top down. This helps to bring all parts to an eventemperature and speeds up drying of areas between channelsformed due to over and uneven packing of the barn.
- 3 -
Failure to close top vents as soon as the lamina is dry is alsoanother major fuel wasting factor, since more than 50% of thetotal fuel is used in this final stage of stem drying. Estatefarmers in Iringa Region have ridge ventilation which arepermanently open and this accounts for high fuel consumption bythe Greek farmers, according to the survey conducted.
- 4 -
II. PRACTICAL GUIDELINES PFOR ANAGENENT OF CURING PROCESS BY FARMERS
Points to be Observed in Curing
2.1 Prior to the curing season:
1. See that the barn is air-tight. Close all cracks by sealingwith cowdung and mud plaster, especially around foundation,doors, and vents. Insulated barns save 10-12X woodfuel.
2. Check furnace for damaged firebricks and exit flue-pipe.
3. Check all flue joints and seal them to prevent combustion gasesentering the barn.
4. Check the flue alignment to see that heat is distributed evenlythroughout the barn.
5. Check chimney for leaks and draw of exhaust gases.
6. It is always best to fire the barn once prior to commencementof the season and raise to maximum temperature to see that allsystems are working satisfactorily.
7. Provide a fire guard.
2.2 Leaf Preparation
1. The fitst essential step towards achieving good curing resultsis current and uniform reaping. With a firm demand for ripe,high flavor, high nicotine tobaccos on the internationalmarket, growers are urged to harvest mature leaf--on the riperside. Shorter curing time means less heat loss and moreefficient drying.
2. Harvest when leaf surface is dry.
3. Delay harvest a day or two after heavy rains.
4. See that the leaf is not bruised or broken during variousprocesses of handling during harvest, tying, and loading intothe barn.
5. Avoid scorching of leaf, excessive wilting, leaving green leafout in the sun or in windy location, or any step, that willresult in rapid drying of leaf which can affect coloring.
6. Avoid heating up of harvested leaf held in piles prior tostringing.
7. Carry out green leaf grading prior to stringing; load under-ripe leaf in top tiers, ripe leaf in middle tiers, and over-ripe leaf in bottom tiers.
8. Load racks uniformly: uniform loading with no "light spots" or"loose spots" assures even drying, better quality, and quicker"kill out" and less energy use.
9. String only 2/3 leaves to a hand, back to back.
10. Load sticks evenly in the barn; 6" or 9" spacing depending uponthe size of the leaf and type of tobacco.
11. Do not under-load barns. Partly filled barns usually means anuneven flow resulting in rapid drying, wastage of fuelwood andpoor cure.
12. Do not overload barn.
13. Load the entire barn in a day and within the shortest time.
2.3 The Curing Process
1. Commence firing as soon as barn is loaded.
2. Ensure that sufficient humidity is present in the barn duringcoloring period. If humidity is low, use wet sacks but neverpour water on the floor or excessively dampen floor.
3. Do not exceed temperature of 100° F while still coloring.
4. Do not open doors and observation windows frequently andunnecessarily.
5. Provide baffles or reduce bottom ventilation on the side ofprevailing wind, so that cold, unheated air is not blown intothe barn from outside.
6. During cool conditions or wet weather, give more top thanbottom ventilation.
7. Do not exceed temperature of 100° F until the tips begin tocurl, otherwise "Brown Sclad" will result.
8. Do not exceed 1650 to 170° F during stem drying, depending uponthe type of leaf, as otherwise scorching will result.
- 6 -
9. The curing should be slow with heavy bodied leaf, as comparedto thinner leaf.
10. Failure to close top vents as soon as the lamina is dry is alsoanother major fuel wasting factor, since more than 50% of thetotal fuel is used in this final stage of drying out the stem.
11. If "Browning Reaction" due to the oxidation of polyphenols isto be avoided at the color fixing stage, the temperature shouldnot be raised to 130° F or 135° F until the moisture is reducedto 40-50%.
12. Use wet and dry thermometer as an aid during curing.
- 7 -
III. GUIDELINES FOR LOADING BARNS
Size of Tobacco Farm
3.1 Crop area covered by a barn is calculated on a plantpopulation:
- At a sp4cing of 1 meter by 60 cm (row to row 1 m and plant toplant 60 cms) recommended in Tanzania, plant population perhectare would be 16,600, assuming there is 100Z stand, withoutany gaps in the field, which is rare. Farmers often have 15-20Z gaps due to poor crop husbandry and quality of seedlingsused for transplanting.
Allowing 5%, population would be about 16,000
No. of leaves reaped per primingunder optimum condition 2
No. of leaves tied per stick (approx) = 100
Harvesting 9-10 days interval (under normal growing conditions)
Acreage = No. of sticks x 10016,000 x 2
Based on the above calculation, the size of the barn required to cover agiven area can be calculated as follows:
For 1 Ha = 16,000 x 2 32,000 320 sticks100 100
So a barn of 16' x 16' x 13' would suffice to cover a 1 Ha plantationunder optimum conditions of quality (Range 1-1 1/2 ha). Low Profile barn(24 x 16 x 13) can cover 2-2 1/2 ha).
Number of Barns Required
3.2 The number of barns and the relative sizes to be built willdepend on factors such as total acreage put-down under tobacco,anticipated yield, and the rate of ripening of the crop.
3.3 In planning for total requirements of barn space, allowanceshould be made for maximum demand rather than an average demand. Whileduring reaping of sand lugs and top part of the plant, available barnspace calculated on average requirements will prove excessive (i.e.,configuration 1 & 2 - 1st and 2nd reapings), it is common for farmers tobe hard pressed for barn space when the most valuable leaf (middle of theplant) is being primed. The lack of barn space can further be aggravatedby wet spells and outbreak of leaf spot diseases on the crop--most commonin Tanzania when the rainfall pattern is most erratic and unpredictable.
- 8 -
3.4 Efforts should be made to increase the utilization of the barnsby staggering plantation. However, very careful planning and exposure isneeded for this. When large acreages of tobacco are planted by oneindividual (Medium and Estate farmers) he should be capab'e of handlinghis crop as long as he provides one low-profile barn (24' x 16' x 13) forevery 2-2 1/2 ha (5-6 acres), and if there are fears that the crop mightmature fast, which calls for reaping at intervals closer than 7-9 days,it would be preferable to have one medium sized barn (16' x 14' x 13') asa stand-by. This barn could also be used during reapings of sand lugsand top leaves instead of using a big barn.
3.5 The decision regarding number of barns and the size of thebarns can only be reviewed in relation to farm size, yield capitalavailable, and the value of the tobacco produced.
3.6 A farmer growing one hectare of tobacco and producing anaverage of about 700 kgs per hectare of cured land can do an average 4-5curings only in a single conventional barn of 16' x 14' x 13' (HL).
3.7 The average cured leaf per cycle for control barns (15) was 168kgs only, while the experimental barns were loaded to full capacity at 6"spacing instead of 9" spacing since the team had considerable experienceand could control the humidity and temperature with the help of Wet andDry Bulb Hydrometer without any adverse effect. This resulted inconsiderable saving in fuelwood use, and good quality of cured leaf aswell.
Capacities of Barn Used in
3.8 Low Profile Barns
Size: 24 x 16 x 13 (HL)Bays: 6 bays (sections)Tiers: 4 tiers (2 1/2' spacing between tiers - vertical)
Capacity: (a) At 6" spacing between sticks on the tiers =width of the barn in inches x Bay x Tier No. of sticks
Spacing
16 x 12 x 6 x 4 = 765 sticks6
(b) At 9" spacing between sticks on the tiers
16 x 12 x 6 x 4 =512 sticks9
-9-
3.9 Medium Sized Barns
Sizes: 16' x 14' x 13' (HL)Bays: 4Tiers: 4
Capacity: (a) At 6" Spacing
14 x 2 x 4 x 4 = 448 sticks6
(b) At 9" spacing
14 x 12 x 4 x 4 = 340 sticks9
Curing Time
3.10 The average curing time taken was 5-7 days in variousconfigurations (1-3 tried, showing a reduction in curing time by 1-1 1/2days (24-36 hours), including configuration 3 (nonmodified barn operatedby ESMAP field assistants), compared to the 15 control barns monitoredwhose average ranged between 7-9 days. Only in one case it took about 10days to cure because of the immature leaf reaped and loaded into thebarn.
3.11 The farmers take a longer time to cure due to lack of propercuring techniques adopted, which is evident from the results of configur-ation 3.
3.12 One day to 1 1/2 days (24-36 hours) savings in curing timemeans a lot, not only in conservation of fuelwood but to cope with fastmaturing varieties or quick ripening sometimes experienced in the fieldunder adverse climatic conditions.
Labor
3.13 One curer and two foremen can manage a group of about fivebarns, if closely located.
Curing Schedules
3.14 It is impossible to lay down a fixed schedule for curing inview of the variability of the raw material, environmental conditionsthat prevail during the process of curing and the varying patterns ofbarn construction. The following factors need to be taken intoconsideration on determining curing procedure:
(a) Maturity: Mature leaf colors faster than immature leaf andalso gives off moisture more easily during curing that immature
- 10 -
leaf. Unripe leaf may require 15-25 extra hours for coloring.By and large, the heavier the tobacco, the longer will be theperiod of yellowing and the slower will be the rate of drying.
(b) Weather: Wet weather tobacco is much easier to cure andyellows quicker than dry weather (drought) tobacco.
(c) Plant Position: Bottom leaf may yellow in a period of 24-30hours, while the top leaf may take as long as 60 hours toyellow. Since the thickness of the leaf increases with higherplant positions, the rate of drying has to be adjusted and willbe much slower than that for bottom leaf.
(d) Crop Husbandry: Production practices such as the topping andspacing of leaves, and fertilization. All factors that resultin thinner, lighter, tobacco will mean a different curingprocedure as compared to heavier, thicker, and darker tobaccos.
- 11 -
IV. SAMPLE MONITORING SHEET FOR PROPOSED PROJECT
1. CHARACTERISTICS
Farmer Code No....................................................Location; ward/village........................................
Flue layout (design)..............................................Bottom/top vents (size and amount)o...............................
2. Quantity of green leaf per cure (kg)..............................
3. Total number of sticks loaded into the barn.......................
4. Time taken for each curing (hrs)..................................
5. Quantity of woodfuel used for each cure
6. Final out-put of cured leaf (kg)..................................
7. Percentage of top grades..................................
8. Weight of cured leaf in each stick (kg)...........................
9. Ratio of weights of green leaf to cured leaf.....................
0. Avera(,e price per kg of cured leaf................................
1. Actual amount of fuelwood consumed (in kg) perkilogram of cured ............. ...................
2. Leaf count for top/middle/bottom leaf(no. of leaves per kilogram)...............................
3. General information (crop history)..........................
Previous Crop: Area Planted Production(1987/88)
Current Crop:(1987/88)
(a) plant population and spacing;
(b) topping height/time of topping; and
(c) maturity: fast/slow, etc.
- 12 -
V. SPECIFICATIONS OF MALAKISI SLOT-TYPE FURNACE(Ufuluma Type)
Special Features
5.1 Furnace Floor: From the door, the floor slopes at an angle of45 to the air inlet slit. From thg air inlet slit, the floor slopes upand back at a gentler angle of 30 from the hor.zontal plane for 500MM. It then rises steeply, at an angle of 60 from the horizontalplane. This second step rise acts as a fuelwood stop (Baffle), therebyensuring that the furnace pipe exit is not blocked with fuelwood duringuse.
5.2 Floor Length: The length of the furnace floor from the airinlet slit to the back is 500MM to accommodate pieces of wood of thatlength or smaller. Fuelwood for use in this furnace should, therefore,be cut to this length of 500MM (20"), and then split to pieces not largerthan 100MM (4") in diameter. Therefore, the best source of fuelwood foruse in this furnace would be the woodlots planned for that purpose. Ifthe trees are felled when they are 3-5 years old, they should be easyenough to split with an ordinary axe, when they are only 500MM long. Inthe absence of woodlots, suitable pieces of miombo wood can be selected,cut into 20" lengths and used carefully, as was done in the trials.
5.3 The Ash Pit: In the original Malakisi furnace, the ash pit/airinlet was only one brick course high. This tended to fill with ashfairly quickly, thereby reducing the amount of air going into the furnaceand hence its efficiency. To achieve good, continuous air supply it wasnecessary to remove the ash several times during each cure. In the MarkIV type, the ash pit has been made three courses high to solve theproblem. Ash can be cleaned out at the end of each cure.
5.4 The Size of the Flue - Pipe Exit: The size of the flue pipeexit from the furnace is such that it will accommodate a flue-pipe whosediameter is obtained by cutting a flat sheet of galvanized iron measuring1000MM (40") by 2000 (80") into three equal pieces, each 1000MM (40")long and 2000MM (80") wide.
5.5 Brick Size: Bricks used for Malakisi furnaces have thefollowing dimensions:
Length 190 MM (7.6")Width 90 MM (3.6")Height 75 MM (3")
- 13 -
The mortar joining the brick is assumed to be 10MM thick (0.4") if themortar thickness is added to the brick dimensions, norminal brickdimensions are as follows:
Length 200 MM ( 8")Width 100 MM ( 4")Height 85 MM (3.4")
5.6 Modified Malakisi Furnace (Ufuluma Type): In the Malakisifurnace (Mark IV type), a chambered brick slot which functions as aventuri to provide air at high velocity replaces the grate. The slot is4 inches wide and eight inches long to allow air to penetrate the fuelfrom below. However, farmers in Uganda using Mark IV type furnacesexperienced that the slot is often obstructed-by charcoal and fuelwoodand the brick slot breaks when the fuelwood pieces are pushed into theslot while stoking.
5.7 To overcome this problem and to improve combustion, fire bars(grate) using 5 old railway pieces (20" long) have been provided toreplace the chambered brick slot in the modified Malakisi furnace(Ufuluma type). This allows air to penetrate the woodfuel more evenlyfrom below through the ashpit/air inlet and also reinforces thechamber. The cost of the railway line pieces (5 Nos of 18" length) is T.Shillings 400/- which would make use of locally available rejectedrailway lines for the most part and is long lasting.
5.8 From one railway line of 30 foot length, 20 pieces of 18"length can be obtained. The Chief Civil Engineer, TRC, has assuredsupplies of rejected railway lines at a nominal cost.
THE MALAKISI FURNACE (UFUWMA lYPE)Scale Imm tor I0 mm
LONGITUDINAL SECTION OF MAtAIS RXRNACE(Uhtun Type)
4-
Side barn wail
. A ........
7 GroundlevelFkepo~ Raifa" 6
Above G.L. le. 5 REAR tlEVAltON FRONT ELEVATIONSIDE ELEVATION: 4
1 l 1 1 1 T . l . | |3 r -rl-T- t3 r Bom wall - 1,200 mm fl I I/2Wt
1 12 1~~~~~~~~~~~~~~~~ brLck course -205mm T S I I I T I I I I / i flO 467.5mmiRaikway line (20 length pieces-5 Nos) ;-
" 6.5m 7 Gound level
205 mm I 1 6 0 C e Of r l 2
35~ ~ ~ i I I I '1 I I I I I I I 11 _ 40~ mm I a Gion Ask !|I] :l| d
6 3
Ash pReioIe nin 1O wide
PLAN VIEW OF MAIAICSI FURNACEAsitopglpe)
- 15 -
,.;:1 - ' -
'M~~~~~~~~~-','-'c' d.''.
a LUa- Version
m !i[''"-'' "'~ #'' ~~_ 4
.'=- X,\ . ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~'i~~~~~~K 7tjG.
4~~~h Maaks Slot-Type Furnac
' , , .,..(Ufl maVerion)
- 16 -
V'I. SPRCIFICATIONS OF IMPROVED MEDIUM SIZED GROWERS# BAR
- 17 -
ATYPICAL BARN
CROSS SECTIONOF OPEN HEARTH ARCH FURNACE
World Ba*k-448:6
PLAN
furae 5" tlong. 1' 6 wide (lnstde)
G Z 5 0" unbumnt b?ick In mud mortar
17ffi~~ ~~ ~ ~~~~~ ill Dba hole
r a, ----------6 DJobay -n_ Dla hole 1 uprIghtS Note:
4'6" Walls: Made up of foret wood tied and mud ptatered
Root Reed gras and wood
Roor Beaten eat'h
0 [ l Door. Batten door
t~ _L_ e Typing Shelter
| Door Z 6" x 8 v | | _ Tter Pote
PLAN V1EW OF CONVENTIONAL SIZE CURING BARN(Small SCale Growe)
Z~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~'0-$
.~~~~~~~~~~~~~~~~~~~~~~f . ,_c
~ 3-Dia
3" Dia
AUnbmt BrLkJO in IMudWatrW 6' Dio 0
REAR ELEVATION OF CONVENTONAL MEDIUM SIZE CURING BARN FRONT ELEVATION OF CONVENTIONAL MEDIUM SIZE CURING BARN
- 19 -
30ez 98"
x.1
rr- 1/2"
| |156" (13') 142" TI T2(12') T
To 4-9m 13 6ChimneV
168" (14') 1 Section X-X x 134 0T - Rue Layout T - Thermocouple
T4 At the top of chimney
U = FWE LAYOUT WITH IMPROVEDFURNACE AND HEAT EXCHANGE LAYOUT
End Viewof Barn I4Stack
Flue Layout o fl (14" Dba Rue Pipe)
U - Flue Layou,t
FLUE PIPE LAYOUT OPTIONS FOR OPTIMAL PLACEMENT OF CHIMNEY OUTLETSMALL AND MEDIUM SIZE CURING BARNS TO PREVENT DOWN DRAFT IN STACK
Word Bank-44808:3
- 20 -
ilr~~~~~~~~J I
Improved Medium Sized Grower's Barn
- 21 -
VII. SPECIFICATIONS OF 'LOW PROFILE' BA
- 22 -
,1 3'-S' ,' I 30-5" ,1 2 3..5" 1z
Mangalore Tiled Root
0a ~ ~ ~ ~ ~ ~ Tier Poles
0 ,5 .o oS) 4 '
I IbIl
LOW PROFILE CURING BARN(AB side elevation)
-0r
LOW PROFILE BARN SIDE ELEVATION
(Show1ng (T) thermomneterwindowv and venlilatore (Show rg top (ridge) and bottom (venttiators)(top and bottom)
T -Wlndow for observing hygrometer/curometer W1 - Observation window
V-BSottom shuters/vents V-Bottom shutters/vents
Worfd Bank.44808:1
- 23 -
6' '1 -- }
-4'26-- . 1t t $~~~~~A- WI Z 6" Sliding Ud (Plank 3/4" with Gi sheet caulng on top and sides)
13' " .s l ,,- -::::---,:::::::::-:::::::::l:_RoofI , 6- ~~~Top _____ _____
V V 1 g 10",.0L IBI n 1'.0 = I 1!; Opening 3" _ , 2- Rod
C C Baind Pllnth Sab 2,.liJI
{;|M Ske Slone Masonrv for $ ts,,,lFoundaHon and Boserynt I
n ~~~C.C 1:4:8 For e
COSECIION ON XY
Slding Ud Plank 3/4' with GlI sheet ccMedng on top and sidesCROSS SECTION OF LOW PROFILE BARN M.S. Rod Hooks -
i 3 Iit A Roof
Box(PlOnk1") TOP
TOP VENTILATORShowlng (closed/opened) posffons.
< \ ~~~~~~~~~~~~~~~2- x 4' VenfilatarRabe
\ 4%a >^ \ 3 T Hlngws
Rafter and 1" x6"
\ \ horn ~~~~~~~~~~~~~~this end asf
34---atln \ V t 1x6'$5~~~~~~/2" PoutyNeffHrig <Do
H j '2x4"x8"RcafterZO.G
1 x8" BoOrdx 16" Hinged Door
16Ov l v x 61xi2Bocs6 o8O.C. Ventilator Foming Detoll
V ( Rops...|\ ~~~~Barn Rafetes
CROSS SECTION
TYPICAL FARM CONSTRUCTED TOP VENTILATOR FOR LOW PROFILE TOBACCO DARNS
wt'wfr4 P-mit.A&A M
- 24 -
18'44' '
16' 0 -
C
x. X- - 1
,Furnace hme p
(7-1/4' Dia)
PAN
LAYOUT OF FLUE PIPES (PLAN VIEW)
Rue PlpesC.Pp
ELEVATION OF FLUES
Wk nd Bank-44808
- 25 -
-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ . ............. -
;-, ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~-
I -
"Low-Profile" Barn
- 26 -
VIII. HARAR ZA TUNA' UHWSLETE
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ENERGY SECTOR MANAGECMET ASSISTANCE PROGRAN
Activities Completed
Country Project Date Number
Energy Efficiency and Strategy
Africa Regional Participants' Reports - Regional Power Seminaron Reducing Electric System Losses in Africa 8/88 087/88
Bangladesh Power System Efficiency Study 2/85 031/85Botswana Pump Electrification Prefeasibility Study 1/86 047/86
Review of Electricity Service Connection Policy 7/87 071/87Tuli Block Farms ElectrificationPrefeasibility Study 7/87 072/87
Burkina Technical Assistance Program 3/86 052/86Burundi Presentation of Energy Projects for the
Fourth Five-Year Plan (1983-1987) 5/85 036/85Review of Petroleum Import and Distribution
Arrangements 1/84 012/84Burundi/Rwanda/Zaire
Evaluation de l'Energie des Paysdes Grands Lacs (EGL) 2/89 098/89
Costa Rica Recommended Technical Assistance Projects 11/84 027/84Ethiopia Power System Efficiency Study 10/85 045/85The Gambia Petroleum Supply Management Assistance 4/85 035/85Ghana Energy Rationalization in the Industrial
Sector of Ghana 6/88 084/88Guinea- Recommended Technical AssistanceBissau Projects in the Electric Power Sector 4/85 033/85
Management Options for the Electric Powerand Water Supply Subsectors 6/89 100/89
Indonesia Energy Efficiency Improvement in the Brick,Tile and Lime Industries on Java 4/87 067/87
Power Generation Efficiency Study 2/86 050/86Diesel Generation Efficiency Improvement Study 12/88 095/88
Jamaica Petroleum Procurement, Refining, andDistribution 11/86 061/86
Kenya Power System Efficiency Report 3/84 014/84Liberia Power System Efficiency Study 12/87 081/87
Recommended Technical Assistance Projects 6/85 038/85Madagascar Power System Efficiency Study 12/87 075/87Malaysia Sabah Power System Efficiency Study 3/87 068/87Mauritius Power System Efficiency Study 5/87 070/87Panama Power System Loss Reduction Study 6/83 004/83Papua New Energy Sector Institutional Review: ProposalsGuinea for Strengthening the Department of
Minerals and Energy 10/84 023/84Power Tariff Study 10/84 024/84
Senegal Assistance Given for Preparation of Documentsfor Energy Sector Donors' Meeting 4/86 056/86
Seychelles Electric Power System Efficiency Study 8/84 021/84Sri Lanka Power System Loss Reduction Study 7/83 007/83Syria Electric Power Efficiency Study 9/88 089/88
Energy Efficiency in the Cement Industry 4/89 099/89Sudan Power System Efficiency Study 6/84 018/84
Management Assistance to the Ministry ofEnergy and Mining 5/83 003/83
ENERGY SECTOR MANAGEMENT ASSISTANCE PROCRAM
Activities Completed
Country Project Date Number
Energy Efficiency and Strategy (Continued)Togo Power System Efficiency Study 12/87 078/87Uganda Energy Efficiency in Tobacco Curing Industry 2/86 049/86
Institutional Strengthening in the Energy Sector 1/85 029/85Power System Efficiency Study 12/88 092/88
Zambia Energy Sector Institutional Review 11/86 060/86Energy Sector Strategy 12/88 094/88Power System Efficiency Study 12/88 093/88
Zimbabwe Power Sector Management Assistance Project:Background, Objectives, and Work Plan 4/85 034/85
Power System Loss Reduction Study 6/83 005/83
Household, Rural, and Renewable EnergyBurundi Peat Utilization Project 11/85 046/85
Improved Charcoal Cookstove Strategy 9/85 042/85China Country-Level Rural Energy Assessments:
A Joint Study of ESMAP and Chinese Experts 5/89 101/89C6te Improved Biomass Utilization--Pilot Projectsd'Ivoire Using Agro-Industrial Residues 4/87 069/87Eth'iopia Agricultural Residue Briquetting: Pilot Project 12/86 062/86
Bagasse Study 12/86 063/86The Gambia Solar Water Heating Retrofit Project 2/85 030/85
Solar Photovoltaic Applications 3/85 032/85Global Proceedings of the ESMAP Eastern & Southern Africa
JHousehold Energy Planning Seminar 6/88 085/88India Opportunities for Commercialization of
Non-Conventional Energy Systems 11/88 091/88Jamaica FIDCO Sawmill Residues Utilization Study 9/88 088/88
Charcoal Production Project 9/88 090/88Kenya Solar Water Heating Study 2/87 066/87
Urban Woodfuel Development 10/87 076/87Malawi Technical Assistance to Improve the Efficiency
of Fuelwood Use in the Tobacco Industry 11/83 009/83Mauritius Bagasse Power Potential 10/87 077/87Niger Household Energy Conservation and Substitution 12/87 082/87
Improved Stoves Project :'/81 080/87Peru Proposal for a Stove Dissemination Program
in the Sierra 2/87 064/87Rwanda Improved Charcoal Cookstove Strategy 8/86 059/86
Improved Charcoal Production Techniques 2/87 065/87Senegal Industrial Energy Conservation Project 6/85 037/85
Urban Household Energy Strategy 2/89 096/89Sri Lanka Industrial Energy Conservation: Feasibility
Studies for Selected Industries 3/86 054/86Sudan Wood Energy/Forestry Project 4/88 073/88Tanzania Woodfuel/Forestry Project 8/88 086/88Thailand Accelerated Dissemination of Improved Stoves
and Charcoal Kilns 9/87 079/87Rural Energy Issues and Options 9/85 044/85Northeast Region Village Forestry and WoodfuelPre-Investment Study 2/88 083/88
Togo Wood Recovery in the Nangbeto Lake 4/86 055/86Uganda Fuelwood/Forestry Feasibility Study 3/86 053/86
Energy Efficiency Improvement in theBrick and Tile Industry 2/89 097/89
IBRD 20794
UGANDA 36TANZANIA
VGN/c C /A /RR KENYA TOBACCO PRODUCING REGIONSa / IRI TEiuWohme' Project Disrkictt
R WAND A UkI'~0S U l.e C.red Tbbeo Mo,RnBod,Bukinro K R W A N D A AD42=:E Fine Cured Tobacco Redwaysin ~~~~~~~.f,1 a,; ~~~~~~~~~~~~~~~ ~d9Z%r DotleyTobeco .i--n-i-.-. TAN-ZAMS Roid"y
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wb~~~~~~~~~~~ 00 C _Tudm nya L iiSOOI DI iA n
ZAIR\E dLE N D MO r7vta ' l. ) m i~~~/ e Q f ami.we
- , 200 2 00 p- t 8 0 -O °Sto otA rA .
KILOMETERS 300 By efingao if i u e U 0 0 CaAko
ZAMBIAALAWI r 360 , O MOZAMBiQUE 40n
_ | o ' _ } i~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ULY ;9EB
tBRD 2094A
this r>.7p ha.s be,n prep.aired byrhe I 'ard &B.A s s.ta er.sv clusy iveT ItPosF te CO iec f thye T N Areaders aud ,s e.IV eA' for the TANZANIA.,,tern~ai ;s4r of fb /d ENERGY EFFICIENCY INon this ma o o n,A o hparon thef rWod E an F *nd the TOBACCO CURINGan,oludg°etent n~ the legalstartus
an.yors territoy or amee) Dissemination Projectsuch LoU^daros. R z 1 NzegaO O g Tabora Region
[GUNGA tO~~~~~W* ~Pilot project siteN E GA IGU, NG jA To^, N a (D (Ufuluma village)L RAM B O /A Group A villages
A~ Group B villages0 Main towns
A~~~~~~~~~~~~~ ~~~~~~RoadsA 21 ~~~~~~~~~~~~----Railroads
r a ^ IA20~~~a 45 15A, 22 I Ralodraimbo ~~~~~~~~~~~~~~~~~District boundaries
Region boundariesA UramABORA 75 ts- International boundaries
t ( 1Q~~~~l 9 * 12 \\ ^ '
Villages
A Xr 29a--|1Tabora District7'Ai~'- (i L A mti Group A Group B
'I Uggowola 1 6 Tumbi2 Ufuluma 1t7 LMlaZngulu
TABORA ~~~~~~~3 Chessa 1 8 Mbiti4 Migungumalo 1 9 UturaAldeka3 Imalauduki 20 Nkulusi6 lsimuIl(lungu 21 Kalunde
A t ^ . 7 Ntalikwa 22 ibelmilundi8 Mbola 23 Igombe
_ *s f '- ^ 9 Isila 24 tshihinulwaR~~~~~~~~~~~~ANDA 1~~~~~~~~~~~~~~~~~~~~~~~~~~~~~I0 K(alola 23 Kepanga
KENYA I Iisikizya 26 Usunga
l',d ,,, ~~~~~~~~~~~~~~~~~~~~~~~~1 2 goko
WoWSlu~7, 1 ;'4t"t > /\ 2s 13 Nsimbo14 Mole
1Af-1)KA ro AoAfida ~~~~~~~~~~~~~~~~~~~13 Klgwa,('A')N\ I, nzStt,d,ian,
t oMp. Urambo DistrictxA \ D.,lsn E, .. -. Group A Group B
ZA TANZANIA Kanoge 6 SongambeleTANZANIA 2 Uyogo 7 lonee (Bs r X ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~3 Muungano 9 Motomoto(B
4 Kalemela (A) 9 Motomoto
ZAMBIA 41 Ud,, 0 2.s MILES ruws 5 ; Kasisi 10 Nkokoto
________________ 11 It malamakoye
MAIAS It_ I o is so ItOMETERSm 12 llundu
September 1988
IBRD 20999
T A N Z A N I A
ENERGY EFFICIENCY IN TOBACCO CURINGDissemination Project
Iringa and ChunyaVi llages
A Group A villages Iringa District Chunya DistrictA Group 8 villages GROUP A GROUP A® Region headquarters 1 Mfyome 1 Luwalaje
-Roads 2 Matwiga
Minor road GROUP B 3 Lupa1 Railroad ~~~~2 Kiwere-'---I-- Railroad 3 Mgera 4 Nkugungu
District boundaries 4 Magubike- Region boundaries S Nzihi GROUP 8
International boundaries 6 Kitapilimwa S Mtanila6 Mamba
0 25 50 75 100 MILES MambaI I I I i 7 Mafyeko
I 50 100 50 ILOMETRS 8 Gua
320 360
To Tabora 7 Dod m
} /A2 ~~~~~~~~~~IRINGA A t\O TiorCHUNYA A 2 A2/
'L 8 3 5RN
7 \ ^4 j tt, MB~~~~~BEYA 4 O
RukwvvaiA /\ 6 I / K Y
This ma hass ben raedb
aBEE J AhBOZI Tn o _ Iff akara
Toi Ju h N11sBEj Y
rhe Uo'd fJn. tf x/.ie \I\)T AN Z AN IA nfor the convenience of the eatreaders and Ls exW sivei for theJrn7thre yseofrb ijd Bnk Mawi\. Corporatfion. The denomnination.s \\|es\} ,<a> D used and the boundaries shown /on this map do not im o/, on the_part of rhe Wor/ d a1nk and theinternational Fina/nce Corportion, f Iant'ludgement on the iegai status ^ZAMBIA
such boundares. MALAW |
SEPTEMBER T1988