From Coconut Shells to Industrial Carbon — A Manufacturing Venture Built on Real Analysis

When Daouda Zombo came to us, he had a clear idea of what he wanted — a manufacturing business that made sense for Côte d'Ivoire, used locally available materials, and had genuine export potential. What he needed was the analysis to back it up.

After reviewing his objectives, our team identified activated carbon manufacturing from coconut shells as the right fit. Côte d'Ivoire produces coconuts. The shells are typically treated as waste. And the global market for high-quality activated carbon — particularly coconut-shell grade — has been growing steadily across water treatment, pharmaceuticals, and gold recovery sectors. The economics were there. The raw material was there. The opportunity was real.

We got to work.

Over nine weeks, our consultants completed a full techno-economic feasibility study and Detailed Project Report covering everything from raw material sourcing logistics to financial modelling, process selection, equipment specification, and regulatory compliance pathways. On the technical side, we recommended steam activation over chemical methods — cleaner output, lower regulatory burden, and a product that meets international purity standards without the complications of corrosive chemical inputs.

The financial picture came out strong. Manufacturing cost sits at approximately USD 1.82 per kg, with a total product cost around USD 2.15 per kg — comfortably within reach of U.S. import benchmark pricing. Gross margins in the 35–45% range, an IRR above 21%, and payback within five years made this a project worth moving forward on.

Beyond the numbers, we mapped out his export strategy — identifying the U.S., EU, and regional West African markets as primary targets — and put together an implementation roadmap covering site selection, equipment procurement, ISO certification, and go-live planning.

Mr. Zombo approved the project. He's now in the process of securing land near Abidjan, negotiating with equipment suppliers, and establishing raw material agreements with local coconut processors. NPCS continues to support him through implementation.

This is exactly the kind of project we exist for — turning a well-reasoned idea into something fundable, executable, and built to last.