MECHANIZATION OF SUGARCANE AGRICULTURE A solution for - low sugarcane availability

Dr. R P Singh, Director, STM Projects Ltd., New Delhi & Sh. S S Panghal* 1.0 ABSTRACT

On one hand the importance of sugarcane crop is taking new dimensions due to its diversified use towards production of Energy whereas on the other hand, its production has drastically declined which is causing a serious concern to the Govt, Sugar industry as well as the consumers. Analysis of the problem has revealed that, return to the farmers from sugarcane crop as compared to alternative crops like Paddy, Wheat etc needs to be enhanced by improving productivity of sugarcane per unit of land area. In this study the authors have observed that the productivity of sugarcane is stagnating around 65-70 Tonne/ha. for the last about 2 decades mainly on account of non implementation of recommended package of practices on the ground, due to non availability of manual labour to undertake various practices in time. The cultivation of sugarcane crop is highly labour intensive as higher numbers of Mandays (332 days) are required for cultivation of sugarcane crop as compared to other crops like Paddy (158 days), Wheat (106 days). Infact, the various cultivation of Paddy and Wheat crops have been successfully mechanized and the farmers have accepted it. The farmers are facing acute shortage of manpower to cultivate sugarcane crop. The authors therefore, has suggested to mechanize various activities of sugarcane agriculture including planting, weeding, harvesting and loading for transportation of sugarcane. The author has also suggested alternative machines and implements in this paper. 2.0 INTRODUCTION

Sugarcane is an important cash crop. It provides Food, Fodder, Fuel power, Energy and cash. Its utility in the recent years has taken new dimensions with the advent of its use for producing Energy. Sugarcane is utilized to meet various demands, but it will continue to be the main raw material for sugar complexes including sugar producing units, Distilleries cogen projects, Bio-compost etc. Sugarcane is, perhaps, the cheapest source of energy. However, for production of sugarcane crop, availability of extra land is an essential asset as there are other competing completing crops like paddy, wheat, millets, pulses, oil seeds etc. The production of additional Sugarcane can be achieved through efficient utilization of land resources which is becoming scarce due to uncontrolled urban expansion and formation of SEZ. Therefore, necessary efforts are required to maximize output (Yield) of sugarcane with good sugar and fiber content per unit of land area, per unit time.
* Divisional Head Shrijee Engineering Works, Mumbai

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3.0

STAGNATION OF SUGARCANE PRODUCTIVITY IN INDIA

Considerable Research and Development activities have been undertaken by various Research Institutes / Centers of ICAR, State Govt. as well as the Sugar Industry themselves. Improved varieties and Modern Agro-techniques developed by the Research Centers have shown encouraging results in demonstration plots. However, the over all productivity has stagnated between 65 to 70 tonnes / ha. for the last two decades. Year wise productivity in India for the last two decades is shown in the following figure:
72 70 Yeild T/hac. 68 66 64 62 60 1989- 1990- 1991- 1992- 1993- 1994- 1995- 1996- 1997- 199890 91 92 93 94 95 96 97 98 99 S e a sons
72 70 68 66 64 62 60 58 56 54 52 70.9 68.6 67.4 63.6 59.4 64.8 66.9

71.3

71.1

71.2

67.1 65.6 65.4 66.1 63.8

67.8 66.5

69.0

67.8

66.8

Yeild T/hac.

1999- 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2000 Se asons

It may be noted that the productivity of sugarcane in Haryana has shown significant improvement whereas over all productivity in India stagnated.

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The cane yield obtained in the demonstration plots as well as in some normal plots of farmers is much more than the average yield of zone. This variation is due to non-implementation of appropriate techniques at appropriate time mainly for availability of manual labour in time. 4.0 MANPOWER REQUIREMENT

Comparative man days required for cultivation of sugar cane crop and other alternative cropping system i.e. Paddy-Wheat is summarized below: Major Package of Practices i) ii) iii) iv) v) vi) vii) viii ) Planting / sowing Intercultural / weeding Irrigation Fertilizer Harvesting including detrashing / thrashing Plant protection Transport & loading Average No. of Man days per hectare Sugarcane 35-40 65-70 10-12 5-6 150-200 12-15 20-25 332 Paddy 35-40 25-30 10-12 5-7 60-70 4-5 6-7 158 Wheat 10-12 22-25 8-10 4-5 35-40 4-5 15-20 106

It may be observed from the above that the manual labour requirement for sugarcane production is tremendously high. In fact, with the advent of intensive agriculture and increasing level of education, adequate manpower is not available to complete important agricultural practices in sugarcane crop. Due to non-availability of adequate labour in time, various agricultural operations are not taken up in accordance to the recommendations which adversely affect the production of sugarcane, besides it enhances the cost of production of sugarcane crop. It has been observed that even the partially educated rural folk do not want to work in the fields as manual labour. However, if they are provided suitable automatic or semi-automatic machines / implements they can happily operate the same to carry out various agricultural operations on the ground. This can help minimize the cost of sugar production, with simultaneous improvement in the productivity at sugarcane, due to timely completion of various packages of practices. 5.0 CONSTRAINTS IN MECHANIZATION

Lack of emphasis towards mechanization of sugarcane cultivation primarily due to the fact that in the past surplus manpower at cheap rates was available in India. Following are the major constraints in popularizing mechanized farming in India:

 6.0

Small land holdings and socio economic factors. Non-availability of suitable machines / implements Problem of unemployment
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Unawareness Local problems and practices like spacing etc. Different sugarcane regulatory acts and rules in different state.

EFFORTS & PROGRESS OF DEVELOPMENT OF MACHINES FOR SUGARCANE PRODUCTION

The Indian Institute of Sugarcane Research, Lucknow has been making continuous efforts to develop various machines / implements & tools for cultivation of sugarcane crop. The Institute has so far developed various machines, out of which following machines are much popular and in use among the farmers for sugarcane production: 6.1 Planting Equipment Power operated sett cutting machine Tractor operated semi- automatic planter Tractor operated sugarcane cutter planter (modified version) Tractor operated paired row sugarcane cutter planter Tractor operated two row pit digger Companion Cropping Equipment Tractor drawn seeder-cum-sugarcane cutter planter Tractor operated raised bed seeder Tractor operated raised bed seeder-cum-sugarcane cutter planter Seed Treatment Equipment Moist hot air unit for heat therapy of seed cane Intercultural/Earthing Equipment Engine operated walking type weeder Tractor operated earthing up equipment Plant Protection Equipment Wide swath spray boom for tall cane crops Boom spray Harvesting and Detrashing Equipment Tractor operated sugarcane harvester Power operated sugarcane detrasher Ratoon Management Equipment Tractor operated two row multi purpose stubble shaver

6.2

6.3 6.4

6.5

6.6

6.7

Tractor operated ratoon management device

Out of above mentioned machines following few machine may be useful to reduce man power consumption for sugarcane cultivation.
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Brief description implements

of

various

mechanized

TRACTOR OPERATED RIDGER TYPE SUGARCANE CUTTER PLANTER

Utility : To perform operations involved in cane planting such as sett cutting; furrow opening placement of seed setts, fertilizer and chemicals; soil covering over setts and tamping of soil, in a single pass. The power requirement is 35 HP tractor. The Planting capacity is about 2 Hact. per day with the help of 4 labour. Approximate Cost : Cost of equipment Cost of operation Saving in cost of operation Saving in labour requirement : : : : Rs. 75000 Rs. 1750/hact. Rs. 2550/hact. (60%) 37 man-d

Description of equipment : It is tractor operated equipment mounted with three point linkage. The equipment is hydraulically controlled for its lifting and lowering. Power is derived through tractor PTO for operations of sett cutting and fertilizer metering while tractive power is used for other operations. Status of development Source of availability Number of prototypes manufactured / supplied : Released for commercial use : IISR Lucknow, Shrijee Heavy Projects Works Ltd. : 41

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7.2

TRACTOR OPERATED RAISED BED SEEDER

Utility and Specification : To make three raised beds (2full beds + 2 half beds) and drill three rows of wheat at each bed, at a spacing of 17 cm. The source of power is 35HP. The type of furrow is multipurpose furrow with raised bed. Per day capacity is about 3 Hact. with one labour. Approximate Cost : Cost of equipment Cost of operation Saving in cost of operation Description of equipment : A tractor drawn three row raised bed seeder has been developed. The equipment can be operated by any tractor of 35 hp. This makes three raised beds (2 full beds + 2 half beds) and drills three rows of what at each bed, at a spacing of 17cm. Depth of furrows is about 22cm and bed width is 48-50 cm. Status of development Source of availability Number of prototypes manufactured / supplied : R&D : IISR Lucknow : 11 : Rs. 65000/: Rs. 1350/hact. : Conventional practice is not available for comparison

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7.3

TRACTOR OPERATED RATOON MANAGEMENT DEVICE

Utility and Specification : For stubble shaving, deep tilling, off-barring, placing manure, fertilizer/bioagents, chemicals in liquid form and earthing up operations in one or subsequent passes of the equipment for rationing of sugarcane. Source of Power is 30HP tractor. The working capacity is about 3 Hact. Per day with one labour. Approximate Cost : Cost of equipment Cost of operation Saving in cost of operation Saving in labour requirement : Rs. 65000/: Rs. 800/hact. : Rs. 800/hact. (60%) : 19 man-days/hact.

7.4

Imported Machines

Generally, a large no. of manpower is required for harvesting, detrashing, loading of sugarcane for its transportation. In order to mechanize these activities following efficient, sturdy machines are marketed by M/s Shrijee Heavy Projects Works Ltd.

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7.4.1

SUGAR CANE HARVESTER SM-135

Utility and Specification: It is compact small and less weight(about 7 MT) Cane Harvester which is suitable for small cane fields for small farmers for cane harvesting, cleaning/stripping and loading in truck/tractor-trolleys in the field /on the road. It is a better substitute of cane harvesting labour. It is suitable in such small fields which are not accessible by regular harvesters. Rubber belt track to reduce soil compaction, gives better ratoon growth, improves yield and helpful to work in rainy season. Cane Harvester is suitable to harvest 10 bunch or dense cane. The overall length is 6930 mm, height 3974mm. The chopper width is 224 mm. The fuel tank capacity is 180L. Cutting blades 8 pieces (2 sets). ADVANTAGES User friendly for farmers. Negligible maintenance. Fuel consumption is 1.3 to 1.4 liters per ton. Rate of harvesting is upto 15-25 tons per hour depending on field conditions, size and variety of cane. With a center to center gap between rows at 1.50 meters, the machine can harvest either double rows or parallel rows. The machine is specifically suitable for smaller sizes of field viz. 30 m wide x 60 m lengths. Substantial Labour and cost savings. Suitable for harvesting of different conditions of lodged, semi lodged or fully lodged cane. Safe in cane field with underground irrigation system. Other Relevant Information: Loss on field 2-5% (This depends upon sugar cane field size, varieties of cane and soil condition.) Operational Cost: For Harvesting, stripping/cleaning and loading of One Hectare (700 qtls. cane) about 140 man days @ Rs.100 = Rs.14000/- is spent while

with the Cane Harvester about Rs.11000/- will be the expenditure. The net saving is Rs. 3000/- per Hectare i.e. 27%. Estimated cost of Cane Harvester is Rs. 90 Lacs. Source of Availability: Shrijee Heavy Projects Works Ltd., Mumbai Page 8 of 11 7.4.2 SUGAR CANE HARVESTER SM-205

Utility and Specification: It is medium size compact cane harvester having about 13 MT Weight. It can harvest 150 m X 200 m sugarcane fields, having about 62 ton/hectare density of cane, in estimated time of 45 minutes. The fuel consumption is 1.5 L/ton of cane. Joystick controller is there for easy driving and fuel saving with quick 10 sec. turning at each lane end. It has better weight distribution to prevent soil compaction and increase better ratooning and production. It is suitable for medium to large size fields. The overall length is 7631mm. Cutting blades 8 pieces(2 sets ), ground contact is 150 X 1660 mm. The main hydrostatic fan speed is 01200 rpm. Advantages: High efficiency especially in cane fields with fallen or extensive bunch. Suitable for cane field of any condition and size. Better weight distributions to prevent soil compaction with stumps thus, increase production. 8 Km/hr. forward speed. Easy and low maintenance cost. Operational Cost: For Harvesting, stripping/cleaning and cane loading of one Hectare (about 700 qtls. cane) about 140 mandays @ Rs.100/- each = Rs.14000/- will be labour expenditure while with the help of Cane Harvester about Rs.10500/- will be total expenditure. The net saving is Rs. 3500/- per Hectare i.e. 33%. Estimated cost of Cane Harvester is Rs. 110 Lacs.

Source of Availability: Shrijee Heavy Projects Works Ltd., Mumbai

7.4.3

SUGAR CANE LOADERS SM-95T and SM-97

Utility and Specification: The height of Boom is 5.5 Mts. and dumping height is 5 Mts. The estimated weight is about 2 MT (without tractor). Two types of cane loaders are available, one is SM-97 front cane loader and second is SM-95 T rear Cane Loader, which has maximum working load on rear wheel of the tractor, as both the cane loaders are tractor mounted. They are working with the hydro static system. The hydraulic system is almost trouble free. The repair maintenance is negligible. The loaders are suitable to work 24 X 7 without any problem as the wear and tear is very less. The operational cost is less than Rs.1.5/qtl. It is best substitute for cane loading labour. These cane loaders can be used for other purposes like loading of wood logs, Soil/ash digging loading, stone, rowdy crasher loading etc work after making minor changes in their grabber or putting basket in place of grabber. Hence they are multipurpose. Advantages Removable cane loader frame enables the use of tractor for other purposes. Substantial labour and cost saving. One person operator requirement. The front cane loader is easily attachable/detachable from the tractor, so that tractor can be used for other works in off season Lubrication/oil system ensures trouble Free clean condition for a long time The Road speed is about 30km/hr suitable to work more than one centre or one place to another place shift in shortest time. Able to load upto 350 qntls. Cane / Hour. Cost of operation: The cane loading charges with the help of labour will be about Rs. 2.30 per qntls. While with the help of cane loader cane loading expenditure is about Rs. 1.50 per qtls. The average saving is (Rs. 2.30 -1.50) = Rs. 0.80 per qtls. i.e. 35%. The estimated price of front cane loader is Rs. 5 Lacs without tractor and

Rs.11.25 lacs with Tractor having power steering global excel, heavy duty clutch plate of 55 HP. The estimated price of rear cane loader is about Rs. 6 lacs without tractor and Rs. 13 lacs with tractor. Source of Availability: Shrijee Heavy Projects Works Ltd., Mumbai
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7.4.5

BOOM SPRAYER

Utility and Specification: Boom sprayer is a mechanized hydraulically operated device for effective and optimum spraying of fertilizers & pesticides. It is suitable to spray small crop to 160 cm height crops. It can spray upto 12 acre fields in one day with one operator. ADVANTAGES : No wastage in utilization of fertilizer. Substantial cost savings Facilities increase in yield. Boom spray height and design can be customized as per requirement. Cost of operation: The cost of operation is about Rs.195 per Hact. Estimated cost of Boom Sprayer is Rs. 3.6 Lacs. Source of Availability: Shrijee Heavy Projects Works Ltd., Mumbai

8.0

ACKNOWLEDGEMENT

Authors are grateful to Sh. J J Bhagat, MD, STM Projects Ltd., New Delhi for this guidance and encouragement for undertaking this study. The authors also thankfully acknowledge the technical support provided by Er. M.P Sharma, Principal scientist IISR Lucknow. Authors also wish to

express thanks to Sh. G D Agarwal, Chairman Shrijee Group, Mumbai for his active support. ..
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