HABITAT Genome Improvement Primary Producer Company ...

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HABITAT Genome Improvement Primary Producer

Company, Ramayan, Hisar

Agenda No.5.47. “Bio-Fertilizer and Bio-Pesticide production unit to support

innovations in establishment of Green Economy village movement

in Haryana”

Executive Summary:

The bio-fertilisers are being produced both under public and private laboratories/ production units and

are being distributed to the farmers. Depending upon the method of application 200gm to 4 kg of bio-

fertilizer is needed for 1 acre, costing about Rs. 10 to 200 per acre. The benefits obtained by the use of

bio-fertilizers are not as visible as that of chemical fertilizers. Many farmers are not aware of the

significance, excepting in States like Maharashtra, Gujarat, part of Karnataka and Tamil Nadu, where

these are more commonly used with Government's support. But looking to the increased awareness

about the sustainability of the system and increasing awareness about organic farming their demand is

on the rise.

It is estimated that the production of bio-fertilisers and bio-pesticides in the country by the existing

units is about 40,000 and 90,000 TPA respectively against the installed production capacity of about

1,80,000 TPA as on 2014-15 (Most of the production units produce both bio-fertilizers and bio-

pesticides). This is far below the potential requirement of 7.6 lakh TPA of bio-fertilizers and 15 lakh

tones of bio-pesticides in the country.

The proposal is submitted to promote the twin technologies in alliance with institutions of Gaushalas

with whom our Company has signed MoU at village Dobhi in Hisar. It is our aim also to reach out a

Memorandum of Understanding with Department of Microbiology of CCSHAU, Hisar as we have

filed a bid to take control and run its ‘Biofertiliser Unit’ as we hope to join forces with recently

established Deendyal Upadhyay Centre of Excellence on Organic Farming of the University to align

Gaushalas to create at least ‘three Green Economy Villages’ in Haryana as part of this project

proposal so that these villages could be branded for ‘safer and sustainable production of supply of

grains, vegetables and may be milk’. These villages may be named Green Economy villages and may

also undergo to establish Green Economy Technology Park, an institutional innovation, which this

Company has submitted in its First Project proposal approved by RKVY, Haryana in year 2016-17.

Current proposal is continuation of our continued thrust.

1.0. CONTEXT/BACKGROUND:

Sustainable crop production requires self-generating, environment friendly-non degrading

technologies for nutrient management and plant protection. Growth of crop plants depend much on

good soil health. Soil health maintenance warrants optimum combination of organic and inorganic

components of the soil. Repeated and excessive use of chemical fertilizers adversely affects soil biota.

In nature, there are number of useful soil micro-organisms which can help plants to get nutrients.

Their utility can be enhanced with human intervention by selecting efficient organisms, culturing

them and formulating them into ready to use products for use on seed, plant roots or in soil. The

cultured micro-organisms beneficial for crop growth and soil fertility, formulated into carrier based

powdered form or in liquid form are called bio-fertilisers.

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Similarly for sustainable crop protection there are large numbers of micro-organisms and other bio-

agents which act as enemies of crop pests and control their spread through antagonism or by causing

pathogenicity. With research many such micro-organisms (bacteria and fungi) have been identified

which on application to soil and plant attack the pests and inhibit or control their spread. Such

laboratory cultured antagonistic or pathogenic microorganisms formulated into ready to use products

are called bio-pesticides.

Bio-fertilisers enhance the nutrient availability to crop plants (by process like fixing atmospheric

nitrogen or dissolving insoluble phosphorous present in the soil); and also impart better health to

plants and soil thereby enhancing crop yields in a moderate way. Bio-pesticides on the other hand on

application through seed, foliar spray or as soil treatment increase their activity and prevent the

growth of pathogenic fungi through their antagonistic activity or develop pathogenicity in target

inspect pests. These are natural, pollution-free and eco-friendly methods.

In the vast areas of low input agriculture, these products will be of much use to give sustainability to

production.

In view of the priority for the promotion of organic farming (low input or Zero Budget Natural

Farming or ZBNF) and reduction of chemical residues in the environment, special focus has to be

given for the production of bio-fertilisers and bio-pesticides.

Our Company has also applied to run the Biofertiliser Unit of Department of Microbiology,

CCSHAU, Hisar but has yet not got invitation to participate in discussion for the bid. We propose

here also to strengthen this Unit to make it commercially viable as to increase the capacity may be

required. Further, our proposal also makes the university to add further value as it will also house

“Biopesticide Unit”.

Our Company is also filing an application to get space and become an Incubatee at its NABARD

Business Incubator Centre of CCSHAU, Hisar, which was inaugurated very recently.

2. Problems to be addressed:

Main problems identified and to be addressed are:

(i), destruction of soil, water and air due to heavy use of chemicals resulting in lowering the

sustainability of soils of Haryana;

(ii), produce and products of such villages have exposed human, animal and plant with all

kind of health risks;

(iii), increase in cost of production per acre due to ever-increasing costs of inputs.

3. Aims and Objectives:

Aim:

Enhancing coverage of production of crops through sustainable and Green Economy

technologies, supporting biological provisions of fertilsation and crop protection

Aligning Government Institutions, university with Gaushala of villages and build their

capacity in adoption of sustainable and Green Economy technology along with Zero Budget

Natural Farming (ZBNF)

Objectives:

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i. The primary objective of the project is production of various strains of good quality bio-fertilisers and bio-pesticides using most modern technology.

ii. To enter into Memorandum of Understanding with CCSHAU, Hisar as the infrastructure and laboratory facilities required for the production of these two

commodities are similar and both can be produced with common facilities as this

could strengthen the current Unit of CCSHAU, Hisar as multi product range of our

proposal will ensure economic viability of the project.

iii. To produce the bio-fertilizers, namely, Rhizobium, Azotobacter, Azospirillum, PSB,

Mycorrhiza and Trichoderma. Important biopesticides include Trichoderma, Pseudomonas fluorscens, Metarhyzium anisopliae, Bauveria bassiana and

Verticillium lacini.

4. Strategy:

i. To align with Gaushala and CCSHAU, Hisar to promote technical competence of Green

Economy Hub Villages. We will create a Model at Dobhi Gaushala so that 53 Big Gaushalas

of Haryana and at each Block of the State could emulate the Model.

ii. To align with seed companies and Haryana Seed Development Corporation to promote the

practice of seed treatment with Biofertilisers.

iii. To align with Export Units of Basmati Rice, Vegetable, Cotton and suppliers of quality fresh

fruits, vegetables and grains in Residents’ Welfare Associations (RWAs) promoted by our

Company

iv. To align with CCSHAU, Hisar to promote GOBARDHAN CLUSTERS in Haryana villages.

5. Target beneficiaries:

(i) Farmer-members and others of Basmasti Zone

(ii) Farmer-members and others of Cotton Zone

(iii) Farmer-members and others of Vegetable Zone

(iv) Farmer-members and others of all other areas of Haryana

6. Management:

6.1 Manpower

For a unit manufacturing 300 TPA bio-fertilisers the requirements of manpower is as under:

1 Chief Microbiologist

2 Assistant Microbiologists

2 Sales Officers

1 Accountant and clerical Assistant

2 Drivers

1 Floor Supervisor / Production Supervisor

1-2 Technical Staff (boiler operation where boiling operation is required, mechanical maintenance,

packing machine operations, electrical maintenance).

4-5 Skilled labourers

5-8 Semi-skilled labourers, depending upon the volume of production

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6.2. Size of Unit

The size of a bio-fertiliser/bio-pesticide unit could be expressed in terms of the capacity of production

for various types/strains of bio-fertilisers/ bio-pesticide per annum. The projects so far set up in our

country vary from 10 TPA to 2000 TPA.

The size envisaged in the present model is 300 TPA in one shift. The capacity can be easily expanded

by adding a few additional equipments like fermenters and automation in packaging.

In line with the technology and objective of bio-fertiliser/bio-pesticide production, various facilities

will be created as indicated below.

6.3 Land - It is required to set up laboratory and other facilities and office. Space may also be

required for installing tube well / dug well and parking of vehicles. A minimum of 1500 - 3000 sq.mt

of land is required for setting up of a 300 TPA unit. Preferably, the entire site should be fenced with

barbed wire or compound wall with gates at suitable places. The boundary may be planted with thick

and all season growing tree species like Asoka, Eucalyptus etc to filter air and reduce dust.

If provided by CCSHAU, Hisar, there will be no need of it.

6.4 Layout and buildings - The civil works comprises of factory building for laboratory, Carrier

preparation and enrichment, sterilization, Inoculation and quality control, maturation of culture,

mixing and packing, storage/staff etc,. The total covered area of about 6000-9000 sq ft is required for

the product manufacturing and other utilities. Rest of the area of land will be required for future

expansion up to 400 to 600 Tons per Annum.

If provided by CCSHAU, Hisar, there will be no need of it.

6.5 Plant and Machinery - Manufacture of bio-fertilisers/bio-pesticides needs a good number of

laboratory equipments as well as other production facilities such as fermenters, culture medium tank,

fermenter assembly, autoclaves, boiler, broth dispensers, demineralising plant, air compressor etc,.

The section wise equipment required, their specifications, quality required and average costs etc are

indicated in Annexure I. All the machines are manufactured in the country. Some of the suppliers may

undertake the installing of units on a turnkey basis.

If provided by CCSHAU, Hisar, there will be need for some additional equipments for mass

production of biofertiliser as the capacity is higher as well as Biopesticide Unit has to be created

afresh.

6.6 Manufacturing process and Source of technology - The mother culture of various strains of

bio-fertiliser are supplied from CCS Haryana Agricultural Universities, Research Institutes and

National / Regional Centres of Organic Farming (MOA).

Bio-pesticide strains are available with technology dissimination centres and as per the requirements

of license. The operations involved in the manufacturing process are given in the form of a flow

diagram (Fig 1 A & 1B). The unit generally comprises of media preparation room, media store room,

inoculation room, growth room, culture transfer room, sterilization, mixing and packing etc. The floor

plan should be designed to promote maximum efficiency and minimum contamination. The design

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should facilitate maintenance of optimum temperature, humidity and ventilation. Inside air of the unit

should be free from dust particles.

6.7 Infrastructural Facilities for raw material, carrier material and utilities - The raw material

required for biofertiliser/biopesticide production include ingredients for growth medium for the

production of broth, carrier, packing materials like polythene packets, bottles, corrugated boxes,

etc,.

Utilities :-

i) Power

Normally a three phase electric supply is required for these plants. The normal requirements of a 300

TPA unit is about 40-75 KVA (depending upon the type of machineries and fuel used). Depending

upon the position of power supply, stand by generator may be needed.

ii) Water

A Bio-fertiliser/bio-pesticide production unit requires water mainly for steam generation for

sterilization of carrier, broth preparation and cleaning of equipments. Accordingly well / bore well of

appropriate capacity and according to the quality of water demineralisation equipments are to be

installed. The average per day requirement of water for 300 TPA capacity shall be about 2500 to 3000

litres.

iii) Compressed air

It will be required for various pneumatic operations as well as for controlled air supply to fermenters,

sterilization / cleaning operations etc.

Fig. 1 a. schematic diagram showing multiplication stages of bio-fertiliser/ bio-pesticide mother

culture

Maintenance Petri plate streak for

culture isolated colonies

Q.C.

Media preparation

& sterilization

Test tube culture

Q.C.

Mother culture - I

Q.C.

Mother Culture - II

FIG. 1 B Chart showing steps in production

Mother Culture

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Q.C.

Broth preparation and Seed fermenter

Sterilization Bulk fermenter

Sterilization Carrier Liquid formulation

Blending Bottling

Packaging

Batch-wise Q.C., storage under controlled temperature, release for sale

Fig. 2 Production Flow Chart for Mycorrhizal Biofertilizers

Maintenance of Infection of host plant

Culture Collection of infected roots and spores

Media preparation

& sterilization Tissue culture

Q.C.

Infection of cultured tissue

With mycorrhizal inoculum

Q.C.

Mass Culture of tissue biomass

Infected with Mycorrhiza

Harvesting of infected biomass

Drying of biomass

Grinding

Mixing with carrier material

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Quality checking and release for sale

6.8. Environmental aspects and Pollution Control:

No hazardous effluents are generated from bio-fertiliser/ bio-pesticide unit.

6.9. Requirement of Registration/license

Bio-fertilizers are covered under Fertilizer Control Order of Essential Commodities Act.

Specifications for Rhzobium, Azotobacter, Azospirillum, PSB and Mycorrhiza have been specified.

All production facilities and trading units are required to register and obtain necessary license for

production/ sale of bio-fertilizers from state controlling authorities (Department of Agriculture). Bio-

pesticides are covered under Central Insecticides Act and all manufacturers are required to obtain

mandatory license from Central Insecticides Board, Govt. of India,Faridabad.

7. Finance:

The cash flow statement covering the Benefit Cost Ratio (BCR), Net Present Worth (NPW) and

Internal / financial rate of return (IRR/FRR) have been worked out for the project and can be

presented.

List of Equipments is given at the end of document in Annexure-1.

As all the financial indicators meet the requirements, the bio-fertiliser and biopesticide production

unit will be viable.

Budget requirements Year 2019-20

a)

i.

Non-recurring

infrastructure

100 lakhs

ii. M& E 245.05 lakhs

iii. Repair & Maintenance 10 lakhs

b) PSS/Contractual services 30 lakhs

c) Office expenses 3 lakhs

d) Other charges 4 lakhs

e) M&S 63 lakhs

Grand total 455.05 lakhs

8. Time-frame:

Project is likely to be completed in a period spanning three years.

ACTIVITY : Year 2019-20

a)

Building work

:

Completed

b) Tender Process for purchasing equipment and

completion of Purchase of equipments

: To be completed within the year

c) Installation of equipments : To be completed in first 6 months

d) Production work started : First quarter of the first year.

e) Organisation of Consortia Meetings for

Review

: First Month of Implementation and

then, after six month to review the

implementation details.

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f) Research, analysis and reporting work with

CCSHAU, Hisar

: To be started from the first month itself

and continue throughout year

9. Cost benefit analysis:

Based on the various techno-economic parameters, the economics of the project have been worked out

for the project period or till the repayment of bank loan. The items of income includes sale of bio-

fertilisers and bio-pesticides. While the expenditure includes the cost of raw material, transportation

and commission, power, fuel, packing, distribution, wages and salary, repairs and maintenance,

insurance, advertisement and other overheads. The income as well as expenditure for each year are

worked out and subjected to cash flow analysis.

10. Risk Analysis:

The critical factors which are responsible for the effectiveness of these bio-inputs are as follows:

a. Suitability of the species to the target crop/pest

b. Suitability of the stain

c. Identification of strains as suited to the agro-eco system, particularly the soil pH and

moisture conditions. Through research, specific strains as suited to a particular soil and environmental conditions have been identified and pure mother cultures are

maintained in research labs for supply to the commercial manufacturers.

d. The aseptic conditions of manufacturing, the cell count of living organism present in the carrier material, purity and level of contamination.

e. The conditions of carrier material in which the culture is packed and the quality of the

packing material, which determine the shelf life. f. The conditions in which the packed materials are stored, distributed and kept with the

farmers before it is applied.

g. Soil conditions particularly pH, organic matter content and moisture level; and

agronomic practices.

11. Outcome:

Conversion of at least three villages to complete Green Economy Technology along with usages of ZBNF, one for Basmati, one for Cotton and last one for vegetable.

Creation of working relationship with research organizations such as CCSHAU, Hisar, along with some reputed Gaushalas of three villages, may result in enhancing the chances that these villages may

establish Green Industry Incubation Technology (GIIT) Parks, which will promote a new kind of thinking in diversification of primary production to a ‘green and sustainable production system’.

Consumers may get confidence and villages could be branded as ‘sourcing hubs’ for grains, clothes and vegetables.

12. Evaluation:

The outcomes are usually not as visible as that of chemical inputs except in some critical conditions.

Bio-fertilisers can add nitrogen from 20 kg/ha to 200 kg/ha depending upon the optimum conditions. Pastures and forage legumes respond more than grain crops.

The yield increase usually range between 10-35%.

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However, in the vast areas of low input agriculture and in the context of imparting sustainability to crop production at reduced chemical pollution, this product will be of much use.

Rhizobium culture treatment becomes essential when new types of legumes like soybeans are introduced in new areas. On the other hand, the application of PSB helps plant to get phosphorous as its nutrient.

Antagonistic bio-pesticides help in reducing the incidence of soil borne disease and are being widely adopted by farmers as alternative to chemical seed dressers.

Other microbial bio-pesticides help in control of targets pests below economical threshold limit. Under organic management system where chemical pesticides are prohibited, bio-pesticides are ideal substitutes.

Annexure - I

List of Equipments and Plant and Machinery

(Production capacity 200 MT carrier based and liquid)

A. Essential equipments, for strain maintenance and quality control glassware,

plastic ware etc. (Rs. Lakh) S.No. Item Quantity

required(No)

Rate Amount

1 Vertical Autoclave 600x350 mm 2 1.00 2.000

2 Hot air Oven 24x24x24₺ 1 0.50 0.500

3 Refrigerator 300 litre 2 0.45 0.900

4 BOD Incubator 290 litre 2 1.4 2.800

5 Laminar air flow work station, working table

size 3’x2’

2 1.7 3.400

6 Rotary shaker (capable of holding 25 no. flasks

of 100-500ml capacity)

2 1.50 3.000

Incubator shakers - (capable of holding 25 no.

flasks of - small, medium and Large 1 L-2 L capacity)

3 4.0 12.0

7 Binocular research microscope with phase

contrast attachment (MOST IMPORTANT)

having turret condenser and matching phase objectives of 10x, 40x and 100x magnification,

10x wide field eye pieces and telescopic

centring eyepiece.

1 2.80 2.800

8 pH Meter (Micro Processor based) 1 0.45 0.450

9 Small oil free air compressor 2 0.70 1.400

10 Airconditioners 1.5 ton split type 4 0.40 1.600

11 Miscellaneous equipments and tools such as colony counter, balances, microliter pipettes

etc.

- LS 3.500

12 Glassware and plastic ware aids 60 LS 4.800

13 Centrifuge 1 0.55 0.550

14 Deep Freeze – 300 litre capacity (For culture storage or culture Bank)

1 0.65 0.650

Total for A 40.35

B. Fermentation and biomass up-scaling equipments and machines

1 Mother culture glass vessels/fermenters 1-2 lit capacity 40 0.08 3.200

2 Stainless steel seed fermenters 50 lit capacity, aerated,

stirred type with auto pH, aeration and temperature

4 5.00 20.00

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control

3 Stainless steel fermenters, aerated, stirred type, with auto

pH, aeration and temperature control, Total vessel

capacity 750 litre and working capacity 500 litre.

3 12.00 36.00

4 Stainless steel fermenters, aerated, stirred type, with auto

pH, aeration and temperature control, Total vessel

capacity 2500 litre and working capacity 2000 litre.

5 16.00 80.00

5 Chiller 1 ton capacity 2 2.50 5.00

6 Automatic steam generator 200 kg capacity 1 10.50 10.50

7 Fittings, pipe lines, filters and miscellaneous items - LS 7.00

Total for B 161.70

C. Product handling, packaging equipments and machines and storage equipments

1 Autoclave Horizontal 2x2x4 ft chamber size 1 6.20 6.20

2 Automatic bottle filling machine with necessary conveyor system and laminar air-flow provision at

filling chamber

1 15.50 15.50

3 Capping and labelling machines and miscellaneous items

1 7.50 7.50

4 Miscellaneous fittings, electrical installation, other

tools and equipments

- LS 4.50

5 Air conditioners for storage 4 0.60 2.40

6 Pedal Mixer or Ribbon Blender 1 0.70 1.40

7 Generator (DG Set of 65 KVA) 1 5.50 5.50

Total for C 43.00

Grand Total for A+B+C 245.05

Hence, the SLSC is requested to consider to approve the above project with an outlay of

Rs.425.05 lakh for implementation during 2019-20.