EMERGING CHALLENGES IN

AGRICULTURAL ENGINEERING
Dr. Nawab Ali
Deputy Director General (Engg.)
Indian Council of Agricultural Research
New Delhi – 110 012

•Introduction
•Farm Mechanization
•Post-Harvest Management
•Energy and Power
•Emerging Trends
•Holistic Human Health
•Recommendations
 INTRODUCTION - 1
 Food 1025 Million Indian people
 Water (17% of world population
with 2.4% land & 4.3% water)
 Air

Agriculture Raw Food Materials

Plant based : 650 Mt
Food Animal based : 100 Mt

 GOI is committed for HHF&NS through enhanced

agricultural productivity, diversity and value addition, on
sustainable basis.
 ICAR/NARS is MANDATED FOR THIS.
 INDIAN COUNCIL OF AGRICULTURAL
RESEARCH (ICAR)
• ICAR is an autonomous organisation under DARE, MOA, GOI
• ICAR is an apex body for coordinating, guiding and managing
research in agriculture.
VARIOUS DIVISIONS:
• Crop Science
• Horticulture
• Animal Science • Secretary, DARE & DG, ICAR.
• Fishery Science • AS/DARE & Secretary, ICAR
• NRM • AS & FA, ICAR
• Agricultural Engineering
• Director, Personnel
• Agricutural Education
• Director, Finance
• Agricultural Extension
• NAIP & PIM • Director, DARE
• IPR & CDN
• DIPA & Library
AGRICULTURAL ENGINEERING DIVISION

• Farm Mechanisation
Purpose • PHM & Value Addition
• Agricultural Energy and Power
• CIAE, Bhopal
• CIPHET, Ludhiana
• IINRG, Ranchi
Institutes
• CIRCOT, Mumbai
• NIRJAFT, Kolkata
• IASRI, New Delhi
• FIM, UAE, RES, ESA
AICRPs • PHT, APA
• Livestock feed from CR & BP
Networks • PP of MAP
• Mechanisation of Hort. (Proposed)
 SUN
(Solar
Energy)

•Natural & other Resources on the planet Earth

(Soil, water, climate, Biomaterial, Farmer, Finance)

•Technology •Agricultural Production •Seed & Saplings

•Machinery Yield, Crop Residue, Wastes •Feed & Fodder
•Management (t/ha.l(Kg)/Animal) •Fertilizers
•Market Commodity Specific •Chemicals
•Water

•Processing & •Post Harvest Management •Cleaning

Value Addition (Commodity Specific) •Grading
•Market •Conditioning
•Packaging
• Storage
•Product
•Byproducts
(Commodity Specific)

• Consumption & Utilization

• (Food, Feed, Fibre, Fuel, Fertilizer)

Fig-1: Flow Diagram of Agricultural Production to Consumption System

AUGMENTATION OF FOOD PRODUCTION
IN INDIA THROUGH ENGINEERING
INTERVENTIONS
Augmentation
Activity/Intervention of total food
production, %

•Farm Mechanization 10-15%

•Post-Harvest 5-10%
Management
•Value Addition 25-400%
 Present population and annual production of
some of the farm power sources,
implements and machines in India
Implements/ Annual Population Projected
machines sales in 2004-05, numbers in
million 2025,
million

Tractor 2.75 lakhs 3.00 8.00

Power tiller 10000 0.130 0.25
Combines 600 0.006 0.10
Irrigation pumps 7.00 lakhs 12.00 20.00
Power sprayer/duster 4.5 lakhs 0.150 1.50
Seed drills 2.5 lakhs 1.700 2.50
Threshers 4.0 lakhs 2.500 15.00
 Farm Mechanisation Facilitates

• Timeliness of operations
• Saving in labour requirements
• Increase in land productivity/cropping intensity
• Reduction in human drudgery

Saved labour due to mechanisation can be used for

• Processing of agricultural produces

• Marketing of fresh & processed products
• Manufacturing & sale of farm tools and equipments
• Other allied activities

All these lead to employment and income generation

resulting into higher agricultural profitability
Level of Mechanisation in some of
the agricultural operations in India
Agricultural Level of
Operation Mechanisation (%)

• Tillage 40
• Sowing 30
• Irrigation 40
• Plant Protection 35
• Threshing 50
• Harvesting 5
 Status of some of the Farm Power
and Machinery Industry in India

Equipment manufacturers No. of

units
• Agricultural tractors 19
• Power tillers 2
• Irrigation pumps 190
• Agricultural tools and implements 7000
• Combines 15
• Reapers 45
• Tractors parts and accessories of agricultural machinery 550
• Earth moving machinery and parts 180
• Diesel oil engines 200
• Rice processing machinery
300
• Diary and food industries
500
• Village craftsmen
1 million
Projected Scenario of Ergonomics &
Safety in Agriculture for 2020
 By 2020, the population of agricultural workers
will be about 258 million (about 40% of total
workers in the country).
 Of these about 50% will be the male workers
and 50% will be female workers. This will be
due to migration of male workers to urban areas
in non-agricultural sector.
 The number of tractors are expected to be more
than 6 millions.
 The number of farm machines would be about
400 million.
 The number of hand tools and manually
operated equipment would be about 800 million.
 Percentage of share of different
power sources

Year Agricultural Draugh Tractor Power Diesel Electric Total

Worker t Tiller Engine Motor Power,
Animal kW/ha
1971-72 15.11 45.26 7.49 0.26 18.11 13.77 0.295
1981-82 10.92 27.23 19.95 0.33 23.79 17.78 0.471
1991-92 8.62 16.55 30.21 0.40 23.32 20.90 0.759
2001-02 6.49 9.89 41.96 0.54 19.86 21.26 1.231
2005-06 5.77 8.02 46.70 0.60 18.17 20.73 1.502
 Resource Conservation Equipment & Technology
•Laser land leveler •30-50% saving in water
•Rotavator •50% fuel saving & better quality seed bed
•Zero till drill/minimum till drill/ •5-10% increase in yield and saving of Rs. 2000-
multipurpose tool bar/ raised 3000/ha.
bed planter
•Pressurized irrigation •20-30% saving in water

•Rotary power weeder •20-30% saving in time and labour

•Vertical conveyor reaper/ •Timely harvesting, more yield
combine
•Multi-crop thresher •50% saving in labour and time and 54% saving
in cost of threshing
Straw combine •Recovers 50% straw and also 70-100 kg
grain/ha resulting into an average saving of Rs.
1250/ha.
•Straw baler •Makes bales and checks environmental
pollution
•Straw cutter-cum-spreader •Cuts and spreads the straw evenly and helps in
sowing by zero till drill.
•Improved manual harvester for •No damage to fruit and higher capacity
mango & kinnow
 Laser Land Leveler

•30-50% saving in water and 5-10% higher yield

•Cost is between 4-5 Lakhs. Becoming popular among small
and medium Farmers on custom-hire basis
 Zero Till Drill

Saves Rs. 2000-3000/ha on account of time and fuel

 Impact of Zero till drill Adaption
Potential
•Total wheat area =26 Mha
•If only 11Mha is sown by zero till, total saving
expected is Rs.2200-3300 crore.
•Average Field capacity is 3ha/day (sowing
time=20 days)
•Number of drills needed=1.8 lakhs
•Funds needed = Rs. 360 crores
Benefits
•Saving in cost of production =Rs.2200 crores
• 50 to 65% saving in time in land
preparation and sowing. •Increase in wheat production= 2Mt.
• 40-65% reduction in cost of
operation
• Saves Rs. 2000-3000/ha.
• Yield increase by 5%
• Saving in fuel by 30 %
Self propelled 8-row rice transplanter
Sprinkler irrigation to save water (20-30%)
Drip Irrigation to save water (30-35%)
Power Weeder to save time & labour (20-30%)
Combine harvesting is now most popular on custom-higher basis
 FARMER

Agricultural Produce

Self Consumption & Marketing Storage, Processing & Trade

Processing

Primary (No change Secondary (Transformed into Tertiary (Ready to

in shape, size, form) more convenient form to use) Utilize/consume)

●Cleaning ●Paddy Rice ●Cooked Rice

●Conditioning ●Oilseeds Oil ●Bread & Biscuits
● Grading ● Wheat Flour ●Cooked Meat
● Packaging ● Goat Meat ● Ketch UP
● Storage ● Fibre Fabric ● Garments

•Processed Products are Packaged, Transported, Stored and Retailed to the Consumers
•At Every Stage of Processing Value is Added
A generic flow diagram indicating the movement of agriculture from farmers to consumers
 Share of Farmers in Consumer Price
Basic Food Item Value added Value added % of producer’s
products products price, share in
Rs. per kg/ liter consumer’s price
Bengal Gram Splits (dal) 40 56

Milk Packaged milk 15 66

Milk Tetra Packed 30 33

having long
shelf life
Tomatoes Tomato 70 10
ketchup
Tomatoes Tetra packed 65 5-1-
Juice
Grapes Tetra packed 65 5-10
Juice
Papayas/Guavas Mixed fruit jelly 100 5-10
 Advantages of Processing of Agricultural
Produce in the Production Catchment
(About 70% Human population and most of the livestock are in Production Catchment)

Fresh, Nutritive Crop Residue & Agricultural and

and low cost Byproducts for low-cost livestock wastes
edible Products Livestock feed for manure and/
for Human resulting into Higher or soil
Consumption Productivity of milk, amendment &
egg, meat & fish fuel

Better Better Better

Human Animal Soil
HEALTH HEALTH HEALTH

Positive Attributed of Processing Agricultural Produce in the Production Catchment

Paddy- rice System
 PHT FOR EMPLOYMENT AND INCOME
GENERATION-1
Fullfat soyflour
 One of the simplest soybased food products
to be used in combination with cereals and
pulses.
 10% addition of soyflour is recommended to
start with and can be increased upto 20%.

 Preparation and use of recipes from soycereal/pulse blended flour

does not demand any change in the traditional food habits.
 Contains 40% protein and 20% oil besides carbohydrates, minerals
and vitamins.
 Production of medium fat soyflour involves expelling of about 70%
oil from the beans. It, therefore, contains less fat (4-6%) and more
protein (45-50%). It can be used in food products in the same
manner as that of the fullfat soyflour.
PHT FOR EMPLOYMENT AND INCOME GENERATION-2

Soyfortified biscuits
 Made by adding 12-15% soyflour to refined
wheat flour and other ingredients.
 About 1.8 kg biscuits can be prepared form
one kg refined flour and other ingredients
in suitable proportions.
 Protein content of soyfortified biscuits is 11-12% against 7-8% in
commercially available equivalent product.
 Soyfortified muffins, bread and buns can also be prepared.
These bakery products have a great potential for combating
protein calorie malnutrition at low cost.
 Process for making soyfortified biscuits has been standardized
for adoption at home and industry levels. It consists of creaming,
mixing, sheeting, cutting and baking.
PHT FOR EMPLOYMENT AND INCOME GENERATION-3

Soypaneer (TOFU)
Soymilk is a water extract of soybean and
it is the base material for making
soypaneer, soy-yogurt and other dairy
analogs. One kilogram of dry soybean
yields 6-8 litres of milk. Special features
of soymilk are low cost, good nutrition and suitability of lactose
intolerant people. Soymilk contains about 90% water, 2.5% fat and
3.5 protein, and other nutrients. Soypaneer, popularly known as
TOFU in the orient is a coagulated and pressed soy-protein. At
72% moisture, it contains about 14% protein and 9% fat. The
production cost of soypaneer is Rs. 20-25/kg. Soypaneer is used
in vegetable curry, paneer pakoda and paneer -paratha. Soy-
yogurt is a cultured dairy analog produced by fermenting soymilk.
It is nutritious and easily digestible food.
Cottage Scale
Soy Milk and
Paneer Plant at
CIAE, Bhopal
Training of potential entrepreneurs in soymilk,
soypaneer and soybased other dairy analogs
 SUGARCANE (280 Mt)

 Conventional Products
Sugar
Jaggery and
Khandsari

 Product Diversification
Solid jaggery (cube or bricks)
Liquid jaggery
Granular jaggery
Jaggery chocolate
Sugarcane based
diversified products
for small and micro
enterprises in rural
sector.
 Some Women friendly Post
Harvest Tools and Machines - 1

Groundnut decorticator
 Some Women friendly Post
Harvest Tools and Machines-2

Hanging type grain cleaner

Dal mill Flour sifter

AGRO PROCESSING CENTRE (CONCEPT)

The concept of processing and value addition to agricultural

produce in the production catchment experimented by AICRP
on PHT in the form of APC, has been a success and it has
shown that with an investment of Rs. 90,000’ employment for
2-3 persons and a profit of Rs. 3000/month can be generated.
At high investment level of Rs. 4-5 lakhs, 5-7 persons could be
employed and a profit of Rs. 90,000/year can be obtained.
Such APCs have generated significant work in rural sector.
Ariganahalli APC, Kolar District,
Karnataka
• A cluster of 8 villages
• Indira Gandhi SHG
• NARS, IG-SHG & IFFCO as promoters
• A shed of 7mx5m
• Open space 7mx4m
• Ragi, Pulses and Paddy (20,000t)
• Employment for 05 persons
• Self consumption and markets
• Investment about 5 lakhs
 COTTON- Production to Utilization System
Present Scenario Potential to be realised
through PCS Research
(A) Total Biomass production (A) Processing and Value
4t/ha Addition
• 0.5t lint
• Lint –0.5t
@Rs. 40/kg = Rs. 20,000
• Seed-1.5t
• 525 kg hull
• Stalk-2.0t
@Rs. 5/kg = Rs. 2625
(B) Economic Value
• 320kg Oil
• 2t seed cotton@ Rs. 20/kg= 40,000 @ Rs. 45/kg = Rs. 14,400
• 2t stalk @ Rs. 500/t = Rs. 1000 • 655 kg cotton-meal
@Rs. 10/kg = Rs. 6550
• 2t cotton stalk yielding 1600 kg
particle board
@ Rs. 20/kg = Rs, 32,000
• 75 kg linters
@ Rs. 16/kg = Rs. 1200
Total = Rs. 41000/ha Total = Rs. 76,755/ha
AGRICULTURAL ENERGY AND POWER

• Life is energy
• Energy comes from food
• Food comes from agriculture
• Agriculture depends on solar energy
• Solar Energy is natural & renewable
Energy is capacity for activity
(Physiological and Mechanical)
Survival, convenience and comfort of human beings
depend on how best the Solar Energy is captured,
transformed and utilized.
 SOLAR ENERGY & AGRICULTURE

•Solar radiation
•Photosynthesis
•Primary agricultural produces
•Processed agricultural products
•Food & Feed for humans & animals
Human & animal are used as Animate Sources of
power for agriculture
Percent contribution of different power sources in
Indian Agriculture (2005-06)

•Agricultural worker 6
•Draught animals 8
•Tractor 47 Total power
•Power tiller 01 = 1.5 kw./ha
•Diesel engine 18
•Electric motors 20
 Tractor density in some of the states of India

States Number of Remarks

tractors
per 1000 ha

• Punjab 71.4
• Haryana 60.1
• Uttar Pradesh 28.0 Tractor density in India
• Tamil Nadu 12.3 Highest in Punjab: 72
• Gujarat 12.3 Lowest in Orissa : 01
• Rajasthan 9.8 All India : 13
• West Bengal 1.5
• Orissa 1.3
• All India 13
 Farm power availability and average
productivity of Foodgrains in some of the
states of India in 2000-01

Name of the Farm Power Food grain

State Availability, productivity,
kW/ha kg/ha
Punjab 3.50 4032
Haryana 2.25 3088
Uttar Pradesh 1.75 2105
Andhra Pradesh 1.60 1995
Bihar 0.80 1622
Madhya Pradesh 0.80 907
Orissa 0.60 799
Chhattisgarh 0.60 799
All India 1.35 1723
 Energy Issues Involved in Agriculture-1

Source of Issues Involved

Energy
Draught • Enhancement of DAP utilization efficiency through
Animal Power appropriate harnesses and matching equipment for different
breeds
(Draughtability, matching equipment and work rest cycle)
• Expanding the annual use of DAP through haulage (carting)
and rotary mode of operation for agro-processing and
electricity generation
(Rotary mode of operation)
• One pair DAP based optimum farm size and other annual
usage for economic viability
(DAP based optimum farm size)
 Energy Issues Involved in Agriculture-2

Source of Issues involved

Energy
Renewable •Crop residue based decentralized power generation through
Energy Sources gasification (flue gases) or anaerobic decomposition (biogas) or
fermentation (fuel alcohol). System and gadgets need to be
developed tested and upgraded to a pilot plant of an
appropriate size. Performance evaluated and management
package developed.
(Biomass based DPG using thermal or bio-conversion route)
•Promotion of biomass based improved cook stove, solar
cooker and biogas & SPV appliances in rural sector.
(RES based gadgets and appliances)
•Bio-fuel from Jatropha and Karanj for tractor and diesel
pump sets.
(Bio-fuel/diesel)
 Energy Issues Involved in Agriculture-3

Source of Issues involved

Energy
Conventional •Development and promotion of
Energy Sources energy conservation technology
(Petroleum) and maximization of energy use
efficiency
(Energy saving technology)
 Role of RES and GOI Programme

•RES is inexhaustible and Environment friendly. District

Advisory Committee on renewable energy has been constituted
(532/605).
•Energy consumption as an Indicator for Growth & Progress
•Electricity consumption per capita in India is 36 kW/h
______________________________________________________
•RES like sun, wind, water and biomass are being used from
very beginning of human life on the planet earth. It is needed
to be modernized and strengthened.
Wind Mill for Water
Lifting and Solar
Energy for Crop
Drying
Biogas run
Water Pump
Solar/Sun Drying and
Marketing of
Agricultural Produce
 Renewable Energy Technology and
Gadgets for Rural Sector
For Domestic Application For Agro-industrial Application
•Biogas Plant •Solar Photovoltaic Pump
•Biomass Cook Stove •Solar Tunnel Dryer
•Solar Cooker •Biomass gasifier
•Solar Water Heater •Biogas slurry as manure
•Solar Dryer

Biogas Plant Solar Cooker Photovoltaic Pump

 Priorities in Agricultural
Engineering
• Land leveling using laser guided technology for precision
control
• Minimum tillage and raised bed farming
• Precision sowing, planting, fertilizer and pesticide
application
• Mechanical weed control and mulching
• Mechanization of hill agriculture, horticulture, and
commercial crops
• Efficient use of various sources of energy and minimizing
drudgery involved in farming
• On-farm primary processing and model agro-processing
centers in production catchment
• Standardization and establishment of testing and
evaluation facilities and referral laboratories
• Training and entrepreneurship development using IT
• R&D and TOT in public-private partnership mode
• Industrial liasoning and commercialization of technology
 INTEGRATED AND MULTI DISCIPLINARY
APPROACH TO PCS RESEARCH
(For an Identified Production Catchment)
Scientific Group Activity

• Natural Resources •Farm development, SS&LUP

•Crops, Horticulture, •Development and identification of suitable

Animals, Poultry and variety/species/breed and appropriate package of practices
Fishery

•Engineering •Land Leveling, tillage, sowing & planting, animal

structure, fish pond and hatchery, irrigation/drainage,
plant ad livestock protection and harvesting

•Post-Harvest Management •P.H. Conservation, Value Addition, Crop residue &

byproduct utilization, packaging and storage

•Home Science, Economics & •Food & Fibre utilization, Consumer feed back, cost-
Extension benefits studies, marketing,coordination among all
stakeholders (scientist, industry, farmers, bank,
developmental agencies, impact assessment and TD
 PADDY-RICE SYSTEM-1
(For an Identified Production Catchment)

Situation/Activity Scientific inputs from CRRI, PD-Rice,

IARI, CIPHET, SAUs, CIs, etc.
•Upland/low land, •Suitable variety and production
coarse/fine, scented/ practices
non-scented

•Production and •Standard agronomic and PP

Protection Practices
•Harvesting •Harvesting at physiological maturity (5-10%
additional yield & better quality rice)

•Milling •Modern rice milling practices and

byproducts utilization (Rs. 50,000 crores
additional revenue)

•Marketing •Domestic and export

 SUGGESTIONS
•ICAR Commodity Institutes/NRCs having multi-disciplinary
team may go for PCS Research for higher productivity and
profitability.

•In case of paucity of scientist/engineer of particular discipline,

collaboration with ICAR Institutes, SAUs/CIs where such
scientists/expertise are available may be done.

•Network Projects on PCS Research for socially and

economically important commodities such as coarse cereals
and millets, M&A Plants, Livestock feed from organic wastes
and byproducts, biofuel, etc. may be taken up.
 HOLISTIC HUMAN HEALTH
•HHH Comprises of physical, • Balanced diet, good hygiene, daily
mental, emotional, social and exercise, required sleep and
spiritual healths. discipline for HHH.
 FOOD & MEDICINE
Food is no longer merely an energy and nutrient supplier;
but a disease –preventing and even a disease-curing agent.
The border between food and medicine is obscure.

•Designer Foods
•Functional Foods
•Dietary Supplements
(Nutraceuticals)

Food Medicine

No Claim Health Claim Drug Claim

Definition and Regulatory Status of Health Foods

CEREALS
 Full fat soy flour Soy biscuits

Soy-paneer Full-fat soyflour Soy-biscuits

Okara based soy gulabjamun Soy yogurt Soy-muffins

Soy-rasogulla Soy-yogurt Soy-muffins

Soy shrikhand Soy amrakhand

Soy-nuts Soy-shrikhand Soy-amrakhand

FRUITS, VEGETABLES & FISH
 RECOMMENDATIONS-1
 Appropriate mechanization of
agriculture using energy and cost
efficient farm machines,
preferably on custom-hire basis.

 Use of renewable energy based

gadgets and appliances in rural
sector
 RECOMMENDATIONS-2
 Establish and operate agro-processing centers in
the production catchment to minimize losses
and transform the raw food materials into
palatable and nutritive edible products at an
affordable price by one and all.
 Make better use of crop residues and process
by-products and wastes in eco-friendly and
economically rewarding mode.
 Meet hygiene and quality standard specified for
domestic and export markets for fresh and
processed products.
 Knowledge and resource conservation based
agriculture using appropriate tools and machines
would lead to happiness and prosperity
Thank You