Buffalo Millers’ Journey to Enhanced Production and Quality

Buffalo Millers, a maize flour milling company in Kenya, has experienced remarkable growth, increasing its milling capacity from 20 metric tons of maize per day to 100 metric tons, and is now operating at a capacity of 220 metric tons. Over the years, the company has undergone significant transformation. With the support of Millers for Nutrition, Buffalo Millers has effectively managed its growth, improving product quality, expanding its reach, and ensuring a positive customer experience. The company has made notable strides in operations, including advancements in quality control, fortification practices, and food safety management.

This success can be attributed to several key factors, including a strong commitment from top management to quality and continuous improvement, streamlined processes, and a focus on delivering an exceptional customer experience. For instance, the facility has significantly improved operational efficiency, reducing grain truck unloading times from over two hours to just 30 minutes, enhancing traceability of the final product, and optimizing production capacity.

“Our ability to produce more while maintaining high quality has unlocked new market opportunities and strengthened our customer relationships,” said Ruth Butende, Quality Control Personnel at Buffalo Millers. “Since receiving technical assistance, we’ve made substantial improvements to our processes, ensuring that tasks are executed accurately and that every staff member understands their role. We now use detailed checklists for each procedure, streamlining workflows and ensuring the quality of our final products.”

As part of their improvements, Buffalo Millers has revamped its Standard Operating Procedures to prioritize safety, achieving the prestigious Diamond Mark. This achievement has positioned the company to pursue ISO 22000 certification, an international standard for Food Safety Management Systems awarded to mills that consistently provide safe products and services.

The enhanced focus on quality has also boosted employee morale, fostering a positive work environment and increasing productivity, which in turn leads to a better customer experience. “The technical assistance provided by Millers for Nutrition has not only enhanced our operational efficiency but also significantly improved our employees’ work experience,” said Kelvin Chepkener. “The combination of improved safety, clearer processes, and a shared vision has created a more positive, engaged, and productive workforce.”