Chitedze Research Station

At the same time, 25 advanced lines that show potential to become released varieties are being tested by DARS at Chitedze and other research stations across the country. And, 12 released varieties, including the most commonly grown standards (CG7 and Chalimbana), are grown at Chitedze and other sites to evaluate their performance under different growing conditions over several years. While these trials will continue indefinitely, the entries may change as new lines are released and old lines retired.

Site 2: Seed Multiplication 

Certified seed is seed that has followed a documented, multigeneration process to guarantee that it meets standards such as purity and germination, so that farmers know what they are planting. The first step in the process of producing certified seed is growing breeder’s seed, seed that is normally produced by the person or entity that released the variety. Since this seed is the basis for all other seed, it is maintained in a rigorous way to protect the purity and quality of the variety. Harvested breeder’s seed will be sent to seed producers to multiply by growing the next generation of seed – pre-basic to basic to certified seed.

Site 3: Small-scale machines 

Groundnut can be harvested, threshed and shelled by hand, but those steps are labor intensive. DARS and similar research locations across Africa use machines created by Frank’s Designs for Peanuts with the Peanut Innovation Lab. After harvested vines dry in the field for a few days, a small-scale thresher can separate the nuts from the vines much faster than a person could do by hand. A small shelling machine can process 225 kg/hour with minimal breakage, allowing research to proceed much quicker and at a lower cost. 

Horizon Farm

While all farmers want to use good production practices and the best inputs they can afford, seed producers must ensure that the seed is pure and has the highest germination and vigor possible.This means they will invest more heavily in soil fertility (optimal soil pH, land preparation, fertilizers), use of seed inoculants, better weed/disease/pest management and assure optimal harvest timing and post-harvest management.

Site 5: Farmer Training

Horizon Farms has been working on groundnut production for over 10 years and honed a system that allows nearby farmers to participate in the mega-farm. Growers from the community can sign up for a plot on Horizon Farms land, where they grow groundnut and benefit from the farm’s equipment, inputs and experience. These farmers are often called, “in-growers” as opposed to contracted out-growers. Later, those farmers become lead farmers on their own land and grow groundnuts that Pyxus may buy.

Site 2: Mechanized Groundnut Harvesting

For Malawi’s groundnut sector to thrive, the scale of production must grow beyond what is possible with manual harvesting. Mechanization is necessary but mechanized groundnut production presents several challenges, from the fragility of the seed, to the fact that pods must be harvested from underground, and requires specialized equipment.

At Pyxus’ Lisandwa Farm, planters, diggers (which lift the pods from underground) and combines (which remove the pods from the plants), increase the capacity of the facility, allowing the farm to produce a large quantity of groundnut seed. The lifting and combining of a groundnut crop is an exciting event during the season since it is the first time the farmer can truly know the yield of the crop for the year.

Mpale Research & Development Farm

Site 4: Crop Rotation and Tillage 

While researchers have a lot of data about the advantages of certain inputs in Malawi, they still are learning practical options for crop rotation and alternative tillage practices here. Trials at Mpale help to evaluate the impact crop rotation has on reducing disease and increasing soil fertility. Likewise, trials are evaluating the impacts of deep tillage, which can break up a very hard layer of compacted soil known as the “hard pan”, followed by reduced tillage on the surface in later years. This practice may improve soil fertility and water infiltration but presents some challenges to traditional weed and disease management.

In addition to this tillage and rotation trial, Pyxus is undertaking several soil health research trials focused on addressing low pH and organic matter in the soil. By blending micronized lime into NPK fertilizer blends Pyxus has shown an increased yield in multiple crops, including groundnuts, without adding any additional labor for farmers. 

Site 5: Contracted Farmer Production

Pyxus Agriculture Malawi contracts with more than 10,000 farmers each season. A Pyxus contracted farmer receives inputs on credit, extension services, and a guaranteed market and price for their whole harvest. Since 2019, Pyxus has purchased over 10,000mt of groundnuts from their contracted growers and expects to purchase an additional 5,000mt this season. On average, a Pyxus groundnut farmer contracts for 1ha of groundnuts and 80% of farmers implement good management practices like double-row planting and inoculant use.

To help increase the adoption of new technologies Pyxus sets up groundnut demo fields in partnership with lead farmers in their network, known as Groundnut Research Extension and Adoption of Technology (GREAT) trials.  Designed and implemented in partnership with the Peanut Innovation Lab based on past research, these GREAT trials are used by Pyxus extension staff for farmer trainings and field days. This year, there are 147 GREAT trials in farmer fields, at least one for every Pyxus farmer network across the main groundnut regions in Malawi. The straightforward trial design builds from a control plot, similar to traditional practices, and incrementally increases inputs (double-row planting, inoculant and legume fertilizer) into an optimized bundle. The GREAT trials at Mpale are focused on improving farmer yields and return on investment. By evaluating individual inputs, as well as inputs put together into packages, these trials help inform farmers of the best production packages in their own fields.

Site 7: Quality Control & Aflatoxin Testing

To help monitor the quality of nuts entering and exiting the factory, Pyxus operates its own quality lab. Quality parameters include shelling percentage, grade, moisture, and aflatoxin. Everything done within the factory maintains the traceability started in the field, where QR codes on each bag are scanned as they enter the factory. Even after groundnuts are shelled and sorted (based on size and quality) into lots, these lots remain traceable back to the farms where they were grown. Every lot is tested for aflatoxin before being shipped out of the factory to a warehouse or customer. The lab also serves as an important research point for aflatoxin management in Malawi and works closely with LUANAR to develop standards and validate testing procedures. 

Site 8: Pellets from shells

While discarded groundnut shells have been used for many purposes, -- such as fuel, mulch and animal bedding – the Kanengo Factory has turned what might be a waste product into something different: pellets. These pellets are being used as an important fuel source for Malawi. To date the primary use of the pellets have been to replace 4,500mt/year of coal in Alliance One Tobacco Malawi’s factory’s boilers. In addition to this, Pyxus has increasingly been selling pellets into the fuel-efficient cook stove market which replaces the use of unsustainable and illegal charcoal and firewood usage.

Bingu International Conference Center