Our manufacturing partner in Sierra Leone, Westwind Energy SL Ltd. (WWE) has been recognized with the prestigious "Clean Cooking Project of the Year" award by ECOWAS at the 2024 Sustainable Energy Forum for their groundbreaking institutional cookstove. The stoves, which have gained widespread adoption in school kitchens across Sierra Leone, are based on innovations by Burn Design Lab (BDL). Their success has reached new heights as The World Food Programme (WFP), a United Nations organization providing daily meals to 750,000 children in Sierra Leone, has approved and contracted these stoves for large-scale deployment. The project is modernizing and scaling the manufacturing processes and product design to meet this significant demand.

In the fourth quarter of 2024, BDL’s engineering team traveled to Sierra Leone to implement the new stove design and an interim manufacturing system. This effort will enable WWE to fulfill an initial order of 246 stoves for WFP in the first quarter of 2025. Throughout 2025, BDL plans to collaborate further with WWE to scale up the manufacturing system and transition to a new and improved cookstove factory, in order to meet increased demand of institutional and household cookstoves for years to come.

Update on Pot Casting Progress and Challenges

The team has successfully poured the smaller 4L household pot in-house at WWE, marking a key milestone in advancing our casting capabilities. However, the current focus is on achieving a successful pour for the larger Institutional Stove 100L pot and creating a permanent aluminum pattern. The main challenge lies in optimizing the sand composition used in the casting molds. Issues such as inadequate strength during packing, insufficient binder, and unsuitable sand grain size have hindered progress. While river and beach sands have proven too contaminated, efforts now center on identifying a clean and consistent sand source. Testing procedures have been outlined to refine the composition, including tests for detail, strength, and bonding. These tests will help ensure the sand is properly conditioned and suited for the casting process. Comparative analysis of bonding agents, moisture levels, and sand types will guide the optimization. Interim procedures for mulling and working the sand between pours are being developed, along with identifying a local source of suitable sand. Leveraging expertise in Sierra Leone is also advised to streamline the process. The ultimate goals are to pour the aluminum pattern successfully, cast the first 100L pot, and establish clear targets for ongoing improvements in the casting process.

Cover photo: WWE team members and Director of Engineering, Jeremy Su working with casting sand. Above: WWE’s Hannah Max-Macarthy Receives Award, Right: Initial pot casting

The Shea Butter Project team continues to make strides in Northern Ghana through its collaboration with Fair Trade Africa (FTA). The team has engaged eight Fair Trade-certified shea butter processing cooperatives, including Sorugu Asheba, Agape, Akoma, Hope Givers, and Sumwaana. These efforts have already led to the sale of two roasters, with further engagements anticipated to secure additional orders. The team also participated in two key events: the launch of the “Strengthening the Shea Value Chain in Northern Ghana” project, funded by Kosmos Innovation Center (KIC), and the “Pre-Harvest Agribusiness Exhibition and Conference.” A significant outcome of the FTA project launch was the potential collaboration with Shared Interest to provide concessionary loans, enabling cooperatives to acquire roasters. To further support the cooperatives, the team has submitted funding proposals to the Ghana Enterprise Agency (GEA) and Kosmos Innovation Center (KIC), aiming to secure resources for additional roasters. This work highlights the project's commitment to empowering cooperatives and strengthening the shea value chain.

Thanks to the generous technology grant from F5, Burn Design Lab was able to purchase a new and improved SawStop table saw. This advanced piece of equipment significantly enhances our workshop's safety and precision capabilities. The SawStop’s innovative blade-stopping technology is a critical upgrade, prioritizing the well-being of our team while allowing us to focus on creating high-quality, efficient stove designs. The saw’s main use is to prepare fuel for testing, a vital step in ensuring the performance and reliability of our stoves. This addition to our shop not only reinforces our commitment to safety but also increases our ability to innovate and produce impactful solutions for communities worldwide. We are deeply grateful to F5 for supporting our mission.