What if Lesotho’s mountains of maize cobs—those usually discarded or burned after harvest—could be turned into something valuable, like paper bags? That’s exactly what Moeketsi Shale, a Chemical Technology student at the National University of Lesotho (NUL) is doing.

Lesotho’s paper bag manufacturing company, Molhen Paper Solutions—was the perfect partner in this exciting experiment.

The company is already making waves as the first to produce locally made paper bags in the country, helping Lesotho reduce dependence on imported plastic packaging. Moeketsi’s research could boost this effort by adding a low-cost, sustainable local material—corn cobs—as a key ingredient in their paper products.

“maize cobs are everywhere after harvest and they usually end up as waste,” said Moeketsi who was supervised by Mr Seliee Thabane. “But they contain cellulose, which is exactly what paper is made from. So I thought—what if we turned this waste into something useful, sort of like, paper bags?”

The process is as clever as it is simple.

First, the maize cobs are gathered, cleaned thoroughly to remove any dirt or unwanted material, and chopped into small pieces. These are dried in an oven to remove moisture, then milled into fine powder. This powder is treated with the right chemicals and hot water in a process called pulping—designed to separate the useful cellulose fibres from the unwanted parts.

But here’s where it gets interesting.

After pulping, Moeketsi bleached the fibres to improve their colour and brightness, making the final paper sheets more attractive and market-ready. Then the pulp was spread on mesh frames and carefully pressed into paper sheets. The final result? Smooth, flexible, and durable paper sheets reinforced with maize cob fibers—perfect for packaging and other applications.

And the potential is enormous.

By using maize cobs, Lesotho can reduce its reliance on wood-based paper imports—saving money, preserving forests, and cutting pollution all at once. “This is about creating a circular economy,” Moeketsi explained. “Instead of burning cobs or letting them rot, we give them a second life as paper products. It’s good for business, good for the environment, and good for Lesotho.”

But he went futher.

He also explored the use of hemp fibres as a possible addition to the paper pulp. Hemp is famous for its strong, durable fibres and fast growth rate—making it another perfect fit for eco-friendly papermaking. “Mixing maize cob and hemp could make the paper even stronger and more versatile,” he noted. This could open the door to new paper products such as gift bags, office stationery, and even biodegradable food packaging.

To make sure the process could be easily repeated and scaled up for small factories, Moeketsi carefully documented every step. From washing the cobs to bleaching the pulp and drying the final sheets, everything was optimized for cost, safety, and simplicity.

The results were impressive.

The cob-based paper sheets showed excellent strength, texture, and appearance—proof that agricultural waste could rival traditional wood pulp in quality. And because the process used only basic equipment and affordable chemicals, it can be done in small workshops without huge investments.

But he also discovered some challenges.

The bleaching process, for example, required fine-tuning to balance whiteness with fibre strength. Using too much bleach made the paper weak, while too little left it too dark. After several trials, he optimized the process—reducing chemical use while keeping the paper bright and strong.

Unlike plastic bags that take hundreds of years to degrade, the maize cob paper is fully biodegradable—breaking down naturally without harming the environment. This makes it perfect for eco-conscious customers and businesses who want to cut down on plastic waste.

The impact of this project could be huge for Lesotho.

Lesotho currently imports most of its packaging materials—a costly and unsustainable practice. By producing paper bags from local farm waste, the country could save money, create jobs, and reduce waste all at once. Moeketsi’s research could even inspire new industries in rural areas—bringing innovation and income to farming communities.
_________________
Brought to you by NUL Innovation Hub, Where Academia Meets Industry