Manufacturing in Ghana

We’ve been considering a few other products that fit with our brand promise – affordable goods and services that enable our clients to do more with their resources. One area of interest is cooking. Most people in Ghana cook with either charcoal (mostly in the cities) or wood. Those who use charcoal use a welded steel stove that has no insulation or capability for adjusting heat.

A new concept has been introduced that is a frame made of sheet metal with a clay insert. The clay absorbs and holds the heat from the charcoal and allows the cook to use less fuel. Even after the charcoal is past its peak, the clay continues to reflect the heat it is holding, maintaining a cookable temperature longer. Testing has shown that the clay coalpot uses about 40% less charcoal and since charcoal is made from wood and since Ghana is running dangerously low on the stuff, it’s a product whose time has come.

So, how are these coalpots manufactured? By hand – every one. The frame is made from scrap sheet metal – mostly roofing scraps and large tomato sauce cans – that are hammered flat and cut into the shapes needed for the stove. These are then hammered into shape, welded, and riveted as needed. I visited the factory and could barely stand the noise. There were only about 5 guys working there but the sound of hammer on steel is piercing. I had no ear protection and neither did the workers, although the factory manager said ear plugs were available to employees who wanted them.

The clay inserts are made elsewhere and I didn’t get to see it. Basically, the clay, which is plentiful in Ghana (as you can see by looking back at some of my blogs from the rainy season and having a look at the roads, which are reminiscent of a scene from Ghost) is formed using a mold and then fired.

I hope the stoves catch on because they will save a lot of trees. We’re also looking at charcoal that is made from compressed sawdust. It is very dense and after it has been carbonized provides about twice the amount of heat as regular charcoal. That should mean you can cook with ½ as much. Put that together with the 40% less charcoal by using the clay coalpot and you’re talking about real savings in both family spending and trees.
XO