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View pictures from the Honduran Sugar Cane Demonstration Project
Read the article "Building A Better Boiler" as printed in the Vermont Quarterly magazine in Fall 2004.
Purpose and Activities
This project built on earlier F2F projects transferring and adapting maple syrup technology to address the human health, environmental and economic challenges faced by small Honduran sugarcane processors. In past projects a series of evaporator designs have been tested and the ovens modified. A commercial-sized evaporator was constructed in 2001. A summary of past F2F projects is attached to this trip report.
Objectives of the Current Project
The currently proposed project has the following objectives:
1) Investigate and modify labor and management of the new evaporator to improve sugar quality and reduce
costs.
2) Investigate and modify the new evaporator itself as necessary.
3) Measure and record costs of production using the new evaporator.
4) Demonstrate the results of this project to sugarcane processors in Taulabe and the Comayagua region.
During the F2F trips leading up to the trip this November every time we experimented with a new design the main operation was shut down for that period, adding to the expense borne by local partners. During the November 2001 trip an entire new oven was constructed that was dedicated to the new evaporator. Designing and constructing this new oven took most of the 10 day trip. Cost of production data was gathered and analyzed. We found that the new evaporator was able to produce sugar that covered its cost of production. At the time of the analysis 200 pounds of medium quality sugar (“1 carga”) was selling for 650 L. At this price, income from 2 ½ cargas was 1,625 L and our costs were 1,375 L. These costs were higher than would normally be expected because of cold, wet weather. A detailed cost analysis was prepared and can be sent under separate cover.
We conducted a series of experiments
using alternative configurations of labor and firing methodologies, seeking to isolate the
problem that limited our ability to produce high-quality sugar. By the end of the trip we were convinced that the
problem lay with the mixing of the “cochasa” (scum) due to the fast and hard
boil of the new evaporator.
At the end of the November trip 2 items
remained unfinished. First, although the new
evaporator could cover the costs of production, because we were producing a medium-quality
sugar, it was still slightly more profitable to continue to burn tires. When I left my Honduran partners in November it
was our shared feeling that we were very, very close to success and that we needed to make
a few slight modifications to improve the design and produce a top-quality sugar. Second, because we had already done numerous
demonstrations of the new evaporator in the past, and because we felt we were so close to
making the final necessary modifications, we chose to postpone the demonstration until I
could return this January.
In January 2002, while on a trip
sponsored by the University of Vermont, I spent a few days working on the F2F sugarcane
project. Within 24 hours of arriving we made
one final change to the design and entered a whole new world. With this one modification we immediately began to
make top-quality sugar using only bagasso, no firewood or tires. We demonstrated the design informally for a week,
mainly to convince ourselves of the breakthrough. During
this time producers and sugar buyers came by and we showed them the process. On January 13th we held a major
demonstration with producers, buyers and 2 alcaldes in attendance. It was a major success! The demonstration included not only the n new
evaporator, but also a “museum” that included photographs showing the progress
of the experiment as well as models of earlier evaporators we had constructed and tested. In addition, the demonstration included
examples of our early experiments with value-added sugar products, including hard candy,
cane syrup and granulated brown sugar.
Project Results/Impact
During the week preceding the
demonstration, as well as the demonstration itself, an estimated 30 producers and buyers
visited the project site at Goldon Aguilar’s molienda (sugarhouse). Most important, among these visitors were two
local alcalde’s (mayor’s) who wield considerable influence over municipal
policy, such as the policy that allows or disallows burning tires. The interest of the alcalde’s was clearly
evident not just by their long stay at the demonstration, but by their contributing ideas
and suggestions for further refining the evaporator and disseminating the information.
A similarly positive sign was seen
amongst the workers at the molienda. While
during past experiments comments had tended toward friendly ribbing (e.g. “the
problems would be solved if we could just throw in a little bit of tire”) during the January trip the comments were entirely
geared toward improving the operation of the evaporator.
Two workers in particular, including the young “puntera”, suggested
modifications that were implemented and proved quite successful. Developing such “ownership” of
the process was one of the great, initial signs of success.
Before my arrival Goldon had purchased a
new shipment of tires to burn during the wet weather.
Before I left, with the rains still present, Goldon had sold the pile of tires
because they were no longer needed. Even with
a moist baggaso the new evaporator produces a sugar that is competitive with that produced
by the traditional, tire and wood consumer systems.
On the night before I left I heard that one of the top
producers in the region had visited the new evaporator and taken measurements. Since returning to the United States I have
received letters from Honduran partners reporting that two of the top producers in the
region have already had the new evaporator constructed and are using it successfully. It seems likely that more producers will follow
these innovators after they witness their results.
Lessons Learned
The only difficulties I encountered is
that these projects take commitment, and that results may not be immediate. It took two years and multiple trips to Honduras
to modify the design so that it works with sugar cane under Honduran conditions. The willingness of the Farmer to Farmer program to
maintain continued support for the project, and to fund multiple trips was a key to
success.
The essential ingredient in this project
was not the technology, it was partnership and trust between Honduran and U.S. volunteers. In 2001, a year before the final design was
achieved, Goldon Aguilar and I discussed the components of a successful project. Those components are attached to this document.
Anticipated Long-Term Benefits
The project is expected to have long-term
benefits to the region. Pulminary illness is
rampant in the region and smoke from burning tires is believed to be a major contributor. Throughout Taulabe and adjoining municipalities
piles of tire ash can be seen, leading to water and soil pollution. With the introduction of an economically
attractive technology that has affordable up-front costs we can expect that this
technology will improve human and environmental health.
It is expected that there will be a
number of projects that will follow. There
are a number of opportunities to make significant improvements in the design of the
evaporator that will improve efficiency and economic attractiveness. A serious effort should be made to disseminate the
technology, followed by an assessment of this process of dissemination. A more detailed and extensive study of the
economics of the new evaporator should be undertaken now that it is being used by
different producers in a commercial, rather than experimental, context. A videotape of the new design and its operation
should be made to facilitate dissemination (see below).
Project Outreach
In the U.S. we are currently preparing a press release that will be disseminated to area newspapers. A television station has expressed interest in airing a video that will hopefully be prepared during the next F2F trip. A series of public presentations have been started and will continue. Honduran partners are continuing to conduct demonstrations at the project site. Goldon Aguilar, at whose molienda the primary experimentation has been done, will visit Vermont, hosted by the VT Farmer to Farmer committee, in March 2002. An extensive educational experience in a matrix of visits to a variety of maple sugar operations is planned, including small scale candy manufacture, car washes, living machine wastewater systems, dairy farms and organic vegetable farms. Goldon will assist in presentations on the sugar project while in Vermont. Dan Baker will be the primary house and coordinator of Goldon’s visit, with a number of other POA and F2F volunteers assisting with various portions of Goldon’s trip.
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