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NAIP INTERVENTION

Navsari Agricultural University

Eru Char Rasta, Navsari

(Gujarat)

2014

FINAL REPORT

National Agricultural Innovation Project

(Indian Council of Agricultural Research)

A Value Chain on Utilization of Banana Pseudostem for Fibre and Other

Value Added Products

FINAL REPORT

National Agricultural Innovation Project

Component - 2

(Indian Council of Agricultural Research)

A Value Chain on Utilization of Banana Pseudostem for

Fibre and Other Value Added Products

Navsari Agricultural University

Eru Char Rasta, Navsari 396 450

(Gujarat)

2014

Printed on : June, 2014

Component : II

Citation : Final Report of NAIP Component – 2 Sub-project “A Value Chain on

Utilization of Banana Pseudostem for Fibre and Other Value Added

Products”. Navsari Agricultural University, Navsari, Gujarat, India.

Copyright : © Indian Council of Agricultural Research (ICAR), New Delhi. All

rights reserved. Reproduction of material in this report for

educational or non commercial purposes is permitted but must be

duly acknowledged.

Disclaimer : The information presented herein is contribution of the consortium

and ICAR shall not be responsible or liable for any discrepancy

whatsoever.

Published by : Dr. A. R. Pathak, Vice Chancellor, Navsari Agricultural University,

Navsari – 396 450 (Gujarat), India

Phone: 02637-283869, 282771 to 75; Fax: 02637-282554

E-mail: vc@nau.in; Website: www.nau.in

Edited by : Dr. R. G. Patil

Consortium Principal Investigator

Dr. R. P. Nachane

Co-Consortium Principal Investigator

Compiled by : Dr. J. M. Patel, Shri. S. L. Pawar and Dr. C. S. Desai

Hindi translation : Smt. Manisha Gorakshnath Kurhade

Other Credits : Dr. B. N. Kolambe, Dr. N. Shanmugam, Shri. M. G. Parikh,

Shri. D. K. Singh and Dr. S. K. Desai

Cover page

photographs

: Banana plantation, pseudostem disposal before NAIP intervention,

utilizing pseudostem for fibre extraction and production of non-

woven fabric, organic liquid fertilizer from sap and candy from

central core on large scale through NAIP interventions

___________________________________________________________________________

Printed at Shah Prints Pvt. Ltd., Khanduji tekra, Valsad

Acknowledgement

I sincerely acknowledge the World Bank and all the concerned in ICAR including NAIP for the

support and financial assistance I received during execution of the project. Particular gratefulness is

acknowledged to-

Dr. S. Ayyappan, Secretary (DARE) and Director General, ICAR, New Delhi

Dr. Mangala Rai, Ex Secretary (DARE) and Ex Director General, ICAR, New Delhi

Dr. Mruthyunjaya, Ex National Director (NAIP), New Delhi

Dr. Bangali Baboo, Ex National Director (NAIP), New Delhi

Dr. D. Rama Rao, National Director (NAIP), New Delhi

Dr. J. P. Mittal, Ex National Coordinator, Component-2 (NAIP), New Delhi

Late Dr. R. K. Goyal, Ex National Coordinator, Component-2 (NAIP), New Delhi

Dr. R. Ezekiel, National Coordinator, Component-2 (NAIP), New Delhi

Late Dr. R. P. S. Ahlawat, Ex Vice Chancellor, NAU, Navsari

Dr. A. R. Pathak, Vice Chancellor, NAU, Navsari

Dr. M. M. Mustafa, Director, National Research Centre for Banana, Trichy

Dr. H. C. Pathak, Ex Director of Research, NAU, Navsari

Dr. A. N. Sabalpara, Director of Research, NAU, Navsari

Dr. S. Sreenivasan, Ex Director, CIRCOT, Mumbai

Dr. A. J. Shaikh, Ex Director, CIRCOT, Mumbai

Dr. R. P. Nachane, Ex Principal Scientist and Head, QEID, CIRCOT, Mumbai

Shri. N. K. Agarwal, Executive Vice President, JK Paper Ltd., Songadh

Dr. S. K. Basu, Director, MANTRA, Surat

Special thanks are due to Dr. P. Rethinam, Chairman, Consortium Advisory Committee for his

interest in the work done and constant advice and help extended during execution of the project. I

thank all the CAC members for their constructive inputs and constant encouragement.

Thanks are due to all my CoPI and CCPIs, namely, Dr. B. N. Kolambe, NAU, Navsari, Dr. N.

Shanmugam, CIRCOT, Mumbai, Shri M. G. Parikh, MANTRA, Surat and Shri D. K. Singh, JK Paper

Ltd., Songadh. Special thanks are due to Ex. CCPIs, Shri. Radhamohan, Shri. Sanjay Chechi from JK

Paper Ltd., Songadh, Dr. S. R. Naik from MANTRA, Surat, Dr. P. K. Mandhyan, Dr. S.

Venkatakrishnan, from CIRCOT, Mumbai and Er. S. P Shukla, Dr. V. Kumar, Dr. A. M. Bafna, Smt.

Ruchira Shukla, Er. N. G. Savani, Dr. D. R. Prajapati, Dr. V. R. Naik, Dr. A. M. Patel, Shri. K. K.

Patel, Shri. B. M. Solia, who were directly or indirectly involved in the project work. I also thank Dr.

R. V. Vyas and Shri. Baljeet Singh from BPD unit AAU, Anand and Dr. A. K. Bharimalla, Scientist &

CPI, ZTM & BPD Unit from CIRCOT, Mumbai for their concerted efforts in commercializing the

technologies. I wish to thank all the contractual staff who worked under the project and helped me and

my team to achieve the objectives of the project successfully.

I am thankful to all the participating farmers, public and private sector associates without

whose help, we could not have succeeded in execution of the project.

This report is based on the work carried out by team of large number of scientists, technical

officers, administrative and supporting staff on a variety of objectives.

(R. G. Patil)

Research Scientist,

and Consortium Principal Investigator

Soil and Water management Research Unit,

NAU, Navsari (Gujarat)

CONTENTS

Pg. No.

Forewords I-III

Preface IV

V-X

Executive Summary/ Key words XI-XIV

Part-I: General Information of Sub-project 1

Part-II: Technical Details 3

1. Introduction 3

2. Overall Sub-project Objectives 3

3. Sub-project Technical Profile 4

4. Baseline Analysis 7

5. Research Achievements 9

6. Innovations 43

7. Process/Product/Technology Developed 45

8. Patents (Filed/Granted) 46

9. Linkages and Collaborations 47

10. Status on Environmental and Social Safeguard Aspects 48

11. Constraints, if any and Remedial Measures Taken 49

12. Publications 50

13. Media Products Developed/Disseminated 51

14. Meetings/Seminars/Trainings/Kisan Mela, etc. organized 52

15. Participation in Conference/ Meetings/Trainings/ Radio talks etc. 53

16. Foreign Trainings/Visits 55

17. Performance Indicators 56

18. Employment Generation 57

19. Assets Generated 57

20. Awards and Recognitions 59

21. Steps Undertaken for Post NAIP Sustainability 60

22. Possible Future Line of Work 60

23. Personnel 62

24. Governance, Management, Implementation and Coordination 64

Part-III: Budget and its Utilization 67

Part-IV: Declaration 68

Appendix/Annexure i-xxviii

I

Foreword by CAC Chairman

It is a great privilege for me to be the Chairman of the project entitled, “A Value

Chain on Utilization of Banana Pseudostem for Fibre and Other Value Added

Products”. The project is unique as compared to any other value chain projects in the sense

that the value added products are developed from completely waste pseudostem of banana.

The project has made a humble beginning and achieved its goal beyond the envisaged project

work. It has succeeded in developing an array of value added products from each and every

component of the pseudostem. The technologies developed are stakeholders friendly and

adoptable at the farmers as well as industrial levels, thus has immense potential in generating

employment both in rural and urban areas. It has potential to safeguard social as well as

environmental security. The project can be taken up not only in India but also in

underdeveloped and developing countries. I take this opportunity to thank Director General,

ICAR, New Delhi and PIU, NAIP for appointing me as a Chairman of the project. I thank, Dr.

A.R.Pathak, Vice Chancellor, Navsari Agricultural University, Navsari and Consortium

Leader for his proactive support during the entire project period. I congratulate the team

leader Dr R.G.Patil, very sincere Research worker, CoPIs, CCPIs and other scientists

associated with this project for fulfilling the objectives with great success and bringing out the

final report. Now, it is time to fine tune the technologies and work towards reducing the cost

of the fibre. Awareness has lot of credential, hence efforts should be made in this direction. I

definitely see that the project proliferate in other areas of the country. This in fact is a

landmark project which can not only provide additional income to the banana growers but

also alternative/supplement eco-friendly natural raw material to some of the industries. The

sap liquid and vermicompost will go a long way in improving soil health. This can be utilised

for organic farming successfully. This is an award winning project and I wish everyone

involved in this project should be recognized for their sincere, devoted and hard work. Once

again I congratulate and thank all the research personnel associated with the consortium and

wish all of them a great success in their future endeavor.

Date: 16/06/2014 (P. Rethinam)

Dr. P. Rethinam (CAC Chairman)

Former Executive Director,

Asian and Pacific Coconut Community, Jakarta

Bhagireth, 18, Laxhmi Nagar, S. N. Palayam,

Coimbatore, Tamil Nadu

II

Foreword by Consortium Leader

Banana is a common mans’ fruit grown in about 7.0 lakh ha area of India. Apart from

fruit, banana crop generate huge quantity of waste biomass in the form of pseudostem, leaves,

suckers etc,. At present, this biomass is absolute waste in most of the states of India. Not only

this, but farmers are spending about Rs. 15000 to 20000/ha for disposing off this waste from

their fields. The present mode of disposing off pseudostem waste in nallas, borrow pits, road

sides, burning etc; is causing environmental problems. In order to utilize this waste

particularly pseudostem for developing different products, a project viz; “A Value Chain on

Utilization of Banana Pseudostem for Fiber and Other Value Added Products” was

sanctioned under NAIP (comp. II) in consortium mode by ICAR, New Delhi during 2008.

Through concerted efforts of all the partners of this consortium, different products viz; fiber

and non woven fabrics, handmade papers and boards, vermicompost, enriched sap (organic

liquid fertilizer) and candy have been developed which are techno economically viable. The

viability is substantiated by the fact that three parties have already signed MoU with NAU,

Navsari for commercial production and marketing of organic liquid fertilizer prepared using

banana pseudostem sap. Simultaneously, processes for the products like microcrystalline

cellulose from fiber, sap as a mordant in textile dying, pseudostem scutcher based

vermicompost as fish feed etc; have also been standardized during the current project period.

Looking to the array of products developed using the waste pseudostem, not only

farmers will get additional income, but industries like textile, paper, pharmaceutical,

confectionary etc; will also have eco friendly alternative/supplementary raw material. In my

opinion, the products developed and processes standardized for some of products under this

project have vast potential i.e.; Wealth from the Waste. I would consider it as the path

breaking research in the area of banana cultivation.

I put on record that commendable work has been done by the team of scientists of

consortium which has been appreciated at state and national levels. I am happy that the work

done under this project being brought out as a Final Report which will be of immense help

to the entrepreneurs, researchers, policy makers, farmers and banana co-operatives. I

congratulate the team of scientists involved in this project for doing such a wonderful work.

Place: Navsari

Date: 16/06/ 2014 (A. R. Pathak)

Dr. A. R. Pathak

Vice Chancellor & Consortium Leader

Navsari Agricultural University

Navsari 396450 (Gujarat)

III

Foreword by CAC Member

Banana being poor man’s fruit, it is grown in almost all the states of India. It covers

about 7.0 lakh ha area. Apart from fruit yield, huge amount of waste biomass in the form of

pseudostem, leaves, suckers etc., is generated. Disposal of such a huge biomass in unscientific

way creates environmental problems. Not only this, but farmers have to spend about Rs.

15000 to 20000/ha for removing the waste biomass from their fields. In order to utilize this

waste biomass in profitable way and resolve disposal problems, a project viz., “A Value

Chain on Utilization of Banana Pseudostem for Fiber and Other Value Added Products”

was sanctioned under NAIP (comp. II). During last five years, commendable work has been

done in this project which has attracted banana growers, entrepreneurs, policy makers and

some industry peoples as well. Using pseudostem, products like fibre, fabrics, paper, organic

liquid fertilizer, candy, vermicompost, etc., have been developed. These products are capable

of not only generating additional income for the farmers but can also provide alternative /

supplemental eco-friendly natural raw material for some of the industries. The work done by

all the consortium partners during past five years are summarized in this report along with

some suggestions for future line of work in this area. I opined that this report will act as a

guide line for all the stakeholders. I congratulate the team of scientists who have contributed

in developing technologies and also bringing out this publication.

Place: Navsari

Date: 16 /06/ 2014 (A. N. Sabalpara)

Dr. A. N. Sabalpara

Director of Research and

Dean Faculty of PG Studies

Navsari Agricultural University

Navsari - 396450 (Gujarat)

IV

Preface

Management of crop residues in eco-friendly and profitable way is one of the major issues in

agriculture. Though, in some of the crops like sugarcane, wheat, rice etc, it has been achieved to some

extent, yet lot is to be done on massive scale in India. Among various crops, banana is one such crop

which generates huge quantity of fresh biomass and so far not much attention has been given towards

its effective utilization. However, the residue of banana mainly consisting of pseudostem has

tremendous potential to provide alternative/ supplementary raw material to industries like textile,

paper, pharmaceutical, confectionary etc,. In view of this, a project entitled “A Value Chain on

Utilization of Banana Pseudostem for Fiber and Other Value Added Products” was

conceptualized under the able guidance of First Vice Chancellor of N. A. U., Navsari, Late Dr. R.

P. S. Ahlawat and submitted to the World Bank for funding. It was sanctioned under NAIP by ICAR,

New Delhi during 2008 in consortium mode. The consortium comprises of Navsari Agricultural

University, Navsari as lead center and Central Institute for Research on Cotton Technology, ICAR,

Mumbai, Manmade Textile Research Association, Surat and J. K. Mills Ltd., Songadh as the partners.

The basic aim of this project was to develop different value added products using presently waste

banana pseudostem as raw material.

As envisaged in project proposal, the value added products viz; fiber and non woven fabrics,

handmade papers and boards, vermicompost, enriched sap (organic liquid fertilizer) and candy have

been developed which are techno economically viable. The viability is substantiated by the fact that

three parties have already signed MoU with NAU, Navsari for commercial production and marketing

of organic liquid fertilizer prepared using banana pseudostem sap. Simultaneously, processes for the

products like microcrystalline cellulose from fiber, sap as a mordant in textile dying, pseudostem

scutcher based vermicompost as fish feed etc; have also been standardized during the current project

period. This has become possible due to highly dedicated efforts put in by the team of scientists from

all the four partners and full moral boosting supports by their authorities in implementing the project

smoothly.

Though, this document is called as Final Report in terms of time schedule, friends this is the

beginning of the new phase of the value added products development using banana pseudostem as raw

material on commercial scale. This report will be a bench mark document for taking up any new

research and developmental projects on this aspect by anybody in future. I take this opportunity to

express my deep sense of gratitude to all the scientists involved in consortium work and authority of

their respective organization for providing constant encouragement and support. I am also thankful to

the world bank for funding and the authority of PIU, NAIP, ICAR, New Delhi for providing excellent

support in terms of fund release, administrative sanctions and monitoring throughout the project

period.

Place: Navsari

Date: 16/06/ 2014 (R. G. Patil)

Dr. R. G. Patil,

Research Scientist and CPI

Soil and Water Management Research Unit

Navsari Agricultural University,

Navsari – 386 450 (Gujarat)

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XI

Executive Summary

Banana is grown in around 0.8 million ha and generates 64 million tonnes waste (@

0.07 million kg/ ha) in the form of pseudostem. Baseline survey of the project indicates that

33 percent farmers are either composting the pseudostem or chopping and incorporating it

into the fields while rests two-third farmers are disposing it either on field bunds or in nallas.

Not a single farmer was found to develop any value added products from it. With this

perspective, the project entitled, “A Value Chain on Utilization of Banana Pseudostem for

Fibre and Other Value Added Products” was sanctioned by NAIP on 29 May 2008 to

examine prospects of using banana pseudostem fibre as supplemental raw material for textile

and paper industries with the overall objectives of 1) Standardize processes for extracting

textile grade fibres from pseudostem and prepare home furnishings, 2) Standardize processes

of pulp and paper making from pseudostem, fibres and scutching waste both at hand made

and industrial levels, 3) Develop value added edible products from central core, 4)

Preparation and evaluation of enriched sap and scutching waste based vermicompost and 5)

Develop linkage for marketing of pseudostem based products. The consortium consists of

NAU, Navsari as lead centre and CIRCOT (ICAR), Mumbai, MANTRA, Surat and JK Paper

Ltd., Songadh as partners.

In India, area under banana cultivation is showing increasing trend which means

ample raw material is available. Generally, in India fibre from banana pseudostem is extracted

manually or by some low efficient machinery. Filament yarn is generally prepared by noting

long length individual fibres at end to end, which is highly laborious and time consuming

process. In this project, the main objective was to improve the process of fibre extraction and

fabric preparation. The process of fibre extraction is done by modified raspador machine

developed by CIRCOT, Mumbai and our experience shows that the machine is highly

efficient with low operation and maintenance cost. Some modifications have been done to

suite farmers’ fields conditions. Before fibre extraction, where splitting of pseudostem is

essential which was earlier done manually using knife blade or koyata. For speedy splitting of

pseudostem a cutter machine has been developed by NAU, Navsari which facilitates easy

separation of sheaths. Fabrication and development of machineries for yarn preparation have

been done. However, there is still scope for further refinement towards improvement in

quality of yarn. Considering the present quality of yarn and fabric, it can be used in technical

textile where huge market potential is available. Under this project, so far about 41.6 tonnes

dry fibre has been extracted from pseudostem (farmers + university) and used for preparing

yarn (2.6 t) on jute spinning system. A part of it has been woven into fabric (250 m). The yarn

prepared at Kolkata was tested and different quality fabrics were developed by MANTRA and

CIRCOT. At MANTRA, processes for scouring, bleaching, dyeing and printing were carried

out. The finished fabric product was found to have good water repellency and fire resistance

property. Finished products like coat, apron, caps, gloves, shoes (mojari) were also prepared.

Further, at Gloster mills, Kolkata around 500 m of fabric was prepared and used for making

hand bags. The hand bags were printed with floral designs apart from printing of NAIP,

ICAR, NAU and CIRCOT logos. Apart from this, mats were prepared on handlooms at

Grameen Shramik Pratishthan, Latur (Maharashtra).

XII

At present no grades for banana fibre are available. Under this project, based on

quality parameters of 25 widely grown varieties of banana, a catalogue is prepared which will

help in selecting type of fibre required for particular use.

In case of non-woven, 3.1 t of different GSMs fabrics were prepared using needle

punching technique at Gloster mills, Kolkata. The non-woven fabrics samples sent to

MANTRA were treated with different chemicals and dyes which can be used as floor

covering materials. Further, resin reinforced composites of non-woven fabric were also

prepared by treating it with polyester and acrylic resin at MANTRA and CIRCOT. These

natural fibre composite boards could offer an excellent eco-friendly solution as wood

substitutes. Banana fibre composites being light in weight can have wider applications in

automobiles and railway coaches.

Apart from fabrics, banana fibres were utilized for preparing paper both at handmade

and industrial scale. Partial blending of these fibres with other raw materials can compensate

the high cost of these fibres in paper making. Handmade paper unit established at NAU,

Navsari of 100 kg/ day capacity has been used for making papers and boards of different

qualities. From these boards and papers (about 6 t) various stationary articles have been

prepared and sold within the University. Simultaneously, JK Paper Ltd., Songadh have

optimized processes for pulping, time and temperature for cooking and bleaching studies for

banana fibre. The physical properties of the pulp and paper prepared by using fibre and

scutcher with and without bleaching were tested. Apart from quality testing done at JK Paper,

the paper samples were also tested at CIRCOT, Mumbai and PAPRI, Rayagada (Orissa). The

paper prepared using banana fibre pulp is having high brightness. The strength properties of

hand sheets in terms of double fold and burst factor are good and showing good paper making

potential. Processes for preparing different quality papers viz., cheque and grease proof papers

from banana fibre was also successfully standardized. The major hindrance for using banana

fibre as raw material in paper industry is the cost of fibrous raw material produced from

banana pseudostem and needs to be addressed. To make it commercially viable for industries,

its cost should be comparable to the cost of normal raw materials like eucalyptus, subabul,

casurina etc. Characterization of effluent generated during pulping and bleaching was also

studied. It was found to be not hazardous in nature as it required lower chemical doses as

compared to routinely used process for other raw materials. Trials were also conducted for

mechanical depithing of whole pseudostem followed by pulping and the results indicate that

whole pseudostem (fresh) has good pulp properties, comparable to that of pulp from fibres

extracted by raspador machine. All these trials require further research and development for

utilizing banana fibre in paper industry.

Other products from fibres include microcrystalline cellulose (MCC) for which the

process has been standardized at CIRCOT, Mumbai at laboratory scale and its quality was

found to match with the commercially available pharmaceutical grade MCC. Though, fibre as

raw material for MCC is available indigenously, yet pharmaceutical industry is not coming

forward to use this raw material due to cost factor.

In India, banana fibre is well known for its use in handicrafts, where NAU has also

prepared various articles with the help of MANAV Kalyan Trust, Navsari (NGO). Training to

the SHGs has also been given for preparing handicrafts using banana fibres.

XIII

During fibre extraction, scutching waste (30 to 35 t/ha), sap (15000 to 20000 l/ha) and

central core (10 to 12 t/ha) are also obtained simultaneously. Scutching waste has been used

for preparing vermicompost. This process has been standardized at NAU, Navsari and the

ratio of 70: 30 (scutching waste: cow dung) was found to be an ideal from nutrient point of

view. So far about 250 t vermicompost has been harvested from one acre unit established at

NAU, Navsari. The results of experiments conducted with banana and sugarcane and

demonstrations (12 nos.) on farmers’ fields have shown that this vermicompost can be an

economically viable alternative to FYM and biocompost. Experiments have also been

conducted to test its use as fish feed in which up to 30 per cent of routinely used cattle feed

could be substituted by scutching waste based vermicompost (pelleted) without affecting the

biomass production of fish but reducing the fish feed cost by 10 per cent.

Further, at CIRCOT, Mumbai scutching waste was used for preparing particle board.

The dry scutcher waste was also used for preparing handmade paper and board, but the

recovery was very low.

NAU and CIRCOT have been developing technologies for using sap in a profitable

way. Sap can be used directly or through organic enrichment as liquid fertilizer or nutrient

spray. Sap as liquid fertilizer through drip was tested in sugarcane, banana and papaya as well

as demonstrated on farmers’ fields (12 demonstrations) where 10 to 15 per cent increase in

yield of different crops was recorded. As a nutrient spray of sap alone or along with vermi-

wash in vegetables seedlings (brinjal and chillies), it was observed that the seedlings attained

transplantable stage 8 to 10 days earlier as compared to no spray. Spraying of enriched sap on

mango induced flowering and also resulted in higher fruit retention. Being convinced of the

beneficial effect of sap its enrichment process using only organic ingredients and incubating

under anaerobic conditions was developed and standardized. The product so obtained was

tested in different crops and the magnitude of increase in yield was around 10-15 per cent.

The feedback from the users is highly encouraging. As a result of this, three MoUs have

been signed for production and marketing of Organic Liquid Fertilizer on commercial

scale. In view of its novelty, the patent was filed not only in India but also in four other

countries. The commercial production and marketing is expected to take-off during ensuing

monsoon season.

Similarly, at CIRCOT, Mumbai, laboratory scale trial was taken up to test sap as

mordant with natural dyes like manjistha and annatto. The test results have indicated good

fastening properties of these dyes when used in combination with sap. The sap seems to be a

natural mordant in textile dyeing industry wherein tanin is used presently.

Central core being the edible component of pseudostem, NAU, Navsari has

standardized the processes for preparing various edible products like candy, ready to serve

drinks from left out syrup during candy preparation and pickles. The candy so prepared has

been tested at CFTRI, Mysore and SICART, Anand. The results revealed that it is rich in Fe

and also content B3 and B5 vitamins in appreciable quantity. The process has also been

applied for patenting at national level. The central core is an excellent raw material for

confectionary industry with high nutritive value.

The production and processing technologies developed under this project were

screened by a National Committee. It has shortlisted the following three technologies in the

category of ready for commercialization.

XIV

1. Extraction of fibre from banana pseudostem and preparing nonwoven fabrics.

2. Preparation of organic liquid fertilizer using banana pseudostem sap.

3. Candy preparation using central core of banana pseudostem.

With respect to transfer of technologies, in all eight (six for farmers and two for

women) training programs were organized covering 427 persons. Similarly, for creating

awareness about the importance of pseudostem among the stakeholders, investors meet (2),

media meet (1), national workshop (1), industry-interface (2), radio and TV program (2),

news paper reports (27), e-media (11), website, national KVK meet (2), Krishi rath organized

by GoG (4), farmers’ day, visitors, personal communication and demonstration were

organized / participated.

The monitoring mechanism as suggested by World Bank was followed and

implemented stringently by organizing CIC (10), CMU (9) and CAC (10) meetings regularly.

During the entire project period, the cooperation from the partners in implementing the

approved activities of the project was excellent in terms of financial and technical

achievements.

From environmental and social safeguard point of view, all the activities of this

project have scored positive points. Not only this, but this project has capacity to generate

rural employment (183 man-days/ha annually), provide alternative / supplemental eco-

friendly raw material to textile, paper, pharmaceutical, fertilizer and confectionary industries.

A farmers growing banana can realize an additional income of Rs. 60,000 to 70,000 per ha

from fibre, sap and vermicompost preparation on annual basis. In a nut shell, this project has

shown a new path for generating wealth from waste in a most eco-friendly way and the

income sharing among the farmers, entrepreneurs, industries and end users as well.

The scaling up activity needs to be taken up in comprehensive way on cluster basis.

Further, government/entrepreneurs/ farmers cooperative should act as a facilitator between

banana growers and industry for confidence building between them. In this direction, National

Horticulture Mission, MoA, GoI, New Delhi has already uploaded the information of this

project on its website. In order to give insight in the monetary benefits in pseudostem based

products, business models for fibre extraction and preparing non woven, preparing organic

liquid fertilizer from pseudostem sap and preparing candy from central core of banana have

also been included in the report. Apart from this, the status of banana pseudostem processing

before and after NAIP interventions is also reported diagrammatically.

Key words: Banana pseudostem, pseudostem fibre/natural fibre, microcrystalline

cellulose, banana woven & non woven fabrics, handy crafts, high quality papers,

enriched sap (organic liquid fertilizer), pseudostem scutcher, central core of banana

pseudostem & candy, CIRCOT – Phoenix charkha, raspador machine, yarn making

machines for banana fibre, bio digester

V

केले के तन ेकी उपयोगिता हेत ुरेशें और अन ् य मलू ् यवर्धक उत ् पादन की मलु ् य श्ुुंखला रा.कृ.न.प. - नवसारी

केले की खेती लिभि ०.८ मममलयन हेक ्टर में होती है और ६४ ममलीयन टन अवशषे (०.०७

मममलयन ककलो/ हेक ्टर दर) तनेके रुप में शषे रहते है । आर्ार रेखा सवेक्षण यह दशधता है की ३३

प्रततशत ककसान या तो तने से खाद तनमीती करते है अन ् यथा तने को काटके खेत में ममला देते है ।

अन ् य दो ततहाई ककसान खेत के ब ुंर् पर या नाले में फैं ककर तने का तनपटारा करते है । एक भी ककसान

केले के तने से मुल ् य-वर्धक उत ् पादन करते हुए नही पाया िया । इसी दृष ् टीकोन को लेकर केले के तन े

की उपयोगिता हेतु रेशें और अन ् य मुल ् यवर्धक उत ् पादन की मुल ् य-श्ृुंखला नामक प्रकल ् प रा.कृ.न.प.

द्वारा २९ म,े २००८ को स ् वीकृत ककया िया । जिसमें केले के तने की रेशों का कच ् च ेमाल के रुप में टेक ्सटाइल और पेपर उद्योि में उपयोि की सुंभावना ि ुंचन ेहेतु आिे दशाधये िये उदे्दश ् य को र् ् यान में रखा िया ।

1 टेक्सटाईल शे्णी के रेशों को तने से तनकालने की प्रकिया का मानकीकरण और िहृउपयोिी वस ् त्र प्रावरण का तनमाधण

2 तना, रेशें और अवशषे से लिुदी और पेपर बनाने की हस ् त तनममधत और औद्योगिक प्रकिया का मानकीकरण

3 तने के मर् ् य कोश से मुल ् य खादय पदाथध की तनमीती 4 तने का समरृ् ् द रस और स ् कचर अवशषे के आर्ाररत कृममखाद की तनममधती एवुं मुलयाुंकन

5 तने पर आर्ाररत ववपणन श्ृुंखला का तनमाधण

इस पररयोिना के सारे सदस ् य इस प्रकार से है, न.कृ.वव, नवसारी मुख ् य कें द्र और मसरक ट

(भा.कृ.अ.प.), मुुंबई, मुंत्रा, सुरत, िे.के. पेपर ली., सोनिढ इन ् होंने सहयोिी के रुप में कायध ककया ।

भारत में केले की खेती बढते हुये स ् तर पर ददखाई दे रही है । इसका यह मतलब है कक कच ् चा माल पयाधप ् त उपलब ् र् है । सार्ारणत: भारत में केले के तनों से रेश ेमानव द्वारा अथवा कम कायधक्षम

के युंत्रों द्वारा तनष ् कवषधत िाते है । इससे िो सतू बनाया िाता है वो एक-एक रेशों को ि ुंठ ब ुंर्कर

बनाया िाता है । यह अत ् युंत श्मदायी और समय लेन ेवाली प्रकिया है । इस प्रकल ् प का मुख ् य उदे्दश ् य

यह था कक रेश े तनकालने की प्रकिया का याुंत्रत्रकीकरण करना और वस ् त्र तनमाधण करना । मसरक ट,

मुुंबई द्वारा रासपाडोर युंत्र की तनममधती की ियी जिससे रेश े तनष ् कवषधत की प्रकिया सरल हो ियी ।

VI

हमारा अनुभव यह बताता है कक मशीन अत ् युंत कायधक्षम सा त्रबत हुई और जिस ेचलाने का खचध भी कम

है । इस युंत्र में कुछ बदलाव करके ककसानों को खेत में उपयोि करने योि ् य भी बनाया िया । रेशें तनकालने से पहले तने को फाडना िरुरी होता है । पहले यह कोयता अथवा अन ् य अविार द्वारा हाथों से ककया िाता था । तने के िल ् द फाडने की प्रकिया हेतु कटर मशीन का तनमाधण न.कृ.वव, नवसारी द्वारा ककया िया जिससे आवरण का अलि करना आसान हुआ । सूत तनममधती की याुंत्रत्रकी प्रकिया के

मलये मशीन की रचना तथा तनमाधण हो चकुा है । इस मशीन स े तनममधत सतू का दिाध बढ ाने की ओर

प्रयास चल रहा है । सतू और वस ् त्र की सद्य जथथतत को र् ् यान में रखते हुए यह तकनीकी टेक ्सटाईल

में काम आ सकती है जिसे काफी अच ् छा माकेट उपलब ् र् है । इस प्रकल ् प के अुंतिधत अबतक ४१.६ टन

(ककसान/ववश ् वववद्यालय) शुष ् क रेशें तने से तनष ् कवषधत िये है जिसस ेपटसन कताई याुंत्रत्रक प्रकिया का उपयोि करके सूत (२.६ टन), बुना वस ् त्र (२५० मी) बनाया िया । कोलकत ् ता में बनाया िया सतू

तथा मसरक ट और मुंत्रा में बनाये वस ् त्र ववववर् िुणता के मलये मूल ् याुंकीत ककये िये । मुंत्रा में अमभमािधन, ववरुंिन, रुंिाई और छपाई की ियी । इस वस ् त्रोत ् पादन में उत ् तम िलावरोर्ी और

प्रततरोर्ी िुण पाया िया । कोट, एप्रन, टोपी, ि ् लोवन, मोिडी िैसी चीझ ेभी बनाई ियी । ि ् लोस ् टर

ममल, कोलकत ् ता में लिभि ५०० मीटर कपडा बनाया िया और उससे थमैलय ुं बनाई ियी । इन

थमैलयों पर फुलों की रचना और रा.कृ.न.प, भा.कृ.अ.प, न.कृ.वव., मसरक ट के 'लोिो' भी छपाये िये ।

अभी केले के तनों के रेशों के मलए शे्णीया उपलब ् र् नहीुं है । इस प्रकल ् प के अुंतिधत रेशों के

िुणता के आर्ार पर २५ बडी मात्रा में उिाई िाने वाली केले की ककस ् मों के मानक बनाये िये, सूची पत्र

(कॅटलोि) बनाया िया िो उपयोि अनुसार रेशों के चयन के मलए मािधदशधन करेिा ।

तनडल पुंचीि तकनीकी का उपयोि करके ववववर् िी.एस.एम. के न न-वोवन फेत्रिक ि ् लोस ् टर

ममल कोलकत ् ता में बनाये िये । इस न न-वुवन फेत्रिक के नमुन े 'मुंत्रा' में भेि े िये वह ुं ववववर्

रसायनों का तथा रुंिको का प्रयोि करके िममन पर त्रबछाये िाने वाला फेत्रिक तैयार ककया िया ।

न न-वोवन फेत्रिक से राल परबमलत कुं पोझझट का तनमाधण पामलएस ् टर और एिेमलक राल के इस ् तेमाल

से मसरक ट एवुं मुंत्रा में ककया िया । यह नैसगिधक रेशों स े बनाये िाने वाला कुं पोझझट पयाधवरण

अनूकुल उपाय के रुप में लकडी में बनाये िये कुं पोझझट को पयाधयी समार्ान दे सकता है । केले के रेशों से बनाये िाने वाला कुं पोझझट विन में हल ् का होने के कारण भारी मात्रा में वाहन एवुं रेल ् वे के डडब ् बों में अनुप्रयोि कर सकते है।

फेत्रिक के अलावा केले के रेशों का उपयोि हस ् त तनममधत और औद्योगिक दिे के पैमाने पर

कािि बनाने के मलए हो सकता है । इन रेशों को अन ् य कच ् च े माल के साथ अशुंत: ममश्ण करके

कािि बनाने से इन रेशों की उच ् च ककमत की क्षततपूतत ध की िा सकती है । हस ् त तनममधत कािि की इकाई िो न.कृ.वव., नवसारी में स ् थावपत की ियी है, जिसकी क्षमता १०० ककलो प्रतत ददन है, इसका

VII

प्रयोि मभन ् न िुणता के कािि और बोडध तनमाधण के मलए ककया िया । इससे बनाये िये बोडध और

कािि (लिभि ६ टन) से तनममधत लेखन-सामग्री की चीिे ववश ् वववद्यालय के अुंदर बेची ियी । साथ

ही िे.के. पेपर मल., सोनिढ ने रेशों से लुिदी बनाना तथा तापमान और समय, िो कुककुं ि और रुंिन के

मलए कािि बनाते समय आवश ् यक है, उसका अर् ् ययन करके बेहतर प्रकिया का अववष ् कार ककया ।

रेशों और स ् कचर से तनममधत लुिदी और कािि की भौततक िुणर्मध का पररक्षण । िे.के.पेपर ली. के

साथ साथ मसरक ट, मुुंबई और पी.ए.पी.आर.ई., (ओडडसा) में ककया िया । केले के रेशों की लुिदी स े बनाये िये कािि अगर्क चमकीले होते है । हस ् त कािि की दो-बार मोडने के पश ् चात

ताकत और स ् फोटन ताकत उत ् तम पायी ियी और इस कािि की क्षमता काफी अच ् छी है । ववमभन ् न

िुणता के कािि, िैस े की र्नादेश एवुं गग्रस प्रुफ कािि बनाने की प्रकिया बनाने की कृती का सफलतापूवधक मानकीकरण ककया िया । केले के रेशों को कच ् च ेमाल के तौर पर उपयोगिता में लाने में बार्ा पहुुँचान ेवाली मुख ् य समस ् या ऐसी है कक केले के रेशों की ककमत कािि उद्योि में इस ् तेमाल

ककये िाने वाले अन ् य तुंतओुुं के मुकाबल अगर्क है । इस जथथतत पर र् ् यान देते हुए इस तुंतू को व ् यापर

योि ् य बनाने हेतु प्रयास की आवश ् यकता है । लुिदीकरण के दौरान बननेवाली बही:प्रवाहीर्ारा के

िुणर्मध का अर् ् ययन ककया िया और यह पाया िया की यह र्ोखादायक नहीुं है क ्यों कक इसमें अन ् य

कच ् च े सामग्री से तूलना करे तो कम मात्रा में रसायनों का प्रयोि होता है । पुणध तन े का याुंत्रत्रकी डडवपथीुंि करने पर पुवध पररक्षण में यह पाया िया कक पुणध तािा तने की लुिदी के िुणर्मध रासपेडार

युंत्र से तनष ् कवषधत रेशों से बनुाई लुिदी के समान ही है । यह सारे पुवध पररक्षण के आर्ार पर भववष ् य में केले के तनों को कािि उद्योि में उपयोि में लाने के मलए अगर्क अनुसुंर्ान एवुं ववकास की आवश ् यकता है ।

रेशों द्वारा तनममधत अन ् य उत ् पादन है माइिो ककस ् टलाइन सेल ् युलोि (एम सी सी) जिसके

मलए मसरक ट में प्रकिया का मानकीकरण ककया िया । इस एम.सी.सी. का दिाध व ् यावसातयक तौर पर

उपलब ् र् फामाधस ् युटीकल शे्णी योि ् य पाया िया । एम.सी.सी. तनमाधण के मलए भारत में रेशों की उपलब ् र्ता है, ले ककन फामाधस ् युटीकल उद्योि केले के रेशों की ककमत की विह से इसके उपयोि हेतु आिे नहीुं आ रहा है।

भारत में केले के रेशों का हस ् तकला में उपयोि काफी प्रमसर् ् द है । इसी आर्ार पर न.कृ.वव. के

मानव कल ् याण ट्रस ् ट, नवसारी (एन िी ओ) की सहायता से बहुत सारी वस ् तूयें बनाई है । एस.एच.िी. को केले के रेशों से हस ् तकला की वस ् तूयें बनाने का प्रमशक्षण भी ददया िया है ।

रेशों के तनष ् कषधण प्रकिया के दौरान, स ् कगचुंि अवशषे (३०-३५ टन प्रतत हेक ्टर), सैप (१५,०००-

२०,००० ली/हेक ्टर) और मर् ् य भाि (१० स े१२ टन प्रतत हेक ्टर) एक साथ प्राप ् त होत े है । स ् कगचुंि

अवशषे का उपयोि कृमीखाद बनाने हेतु ककया िा रहा है । न.कृ.वव., नवसारी ने इस प्रकिया का

VIII

मानकीकरण ककया है । पोषक तत ् वों को निर रखते हुए स ् कचर अवशषे का िोबर से ७०: ३० का अनुपात प्रमाझणत पाया िया है । न.कृ.वव., नवसारी में स ् थावपत एक एकर यूतनट में आि तक २५० टन

कृमीखाद का उत ् पादन ककया िया है । केला तथा िन ् ने का प्रयोि कृमीखाद उत ् पाद करने के मलए

ककया िया, तथा इस प्रयोि में यह पाया िया कक ये कृमीखाद एफ.वाय.एम. और िैव खाद के मलए

आगथधक रुप से सूकर पयाधय है । प्रयोि करके यह भी ि ुंचा िया है कक इस खाद का उपयोि मस ् य खाद

के रुप में ककया िा सकता है । इस स ् कगचुंि अवशषे आर्ररत कृमीखाद को सदय-जथथतत में इस ् तेमाल

में आने वाले पशू खाद के बदले में ३० प्रततशत तक उपयोि में लाया िा सकता है । जिसस ेमछली के

िैव मात्रा उत ् पादन को नुकसान पहुुँचाये त्रबना मत ् सखाद खच ेमें १० प्रततशत कटौती हो सकती है ।

मसरक ट, मुुंबई में स ् कगचुंि अवशषे का उपयोि कणपट्ट (पाटीकल बोडध) बनाने हेतु ककया िया है तथा सूखा स ् कचर अवशषे हस ् ततनममधत कािि एवुं बोडध बनाने के मलए ककया िया । लेककन इस

प्रयोि में यह पाया िया कक इनका पुन:प्राजतत िुणर्मध बहुत कम है ।

न.कृ.वव और मसरक ट में सैंप का प्रयोि फायदेमुंद तरीके से करने हेत ुप्रौद्योगिकी का तनमाधण

ककया । सैप प्रत ् यक्ष तथा परूी तरह िैववक समदृर् करके द्रव उवधरक तथा पोषक फूहार की तरह प्रयोि

में ला सकते है । द्रव उवधरक सैप का टपक पर् ् दतत से िन ् ना, केला तथा पवपते के खेत में प्रयोि करके

ि ुंचा िया, साथ ही में ककसानों को इस पद्ध ्तत से अवित कराया िया । इस प्रयोि में यह पाया िया कक

फसल की उपि में १० से १५ प्रततशत बढौती होती है । वनस ् पततक अुंकूर (बैंिन एवुं ममचध) पर सैप का पोषक फुहार केवल अथवा वमी-व श के साथ करने पर अुंकूर ८ स े १० ददन पहले ही प्रततरोपण की जथथतत में पाये िये है । समदृर् सैप का आम के वकृ्ष पर फुहारा करने स ेयह देखा िया कक ये पुष ् पण को प्रेवषत करता है त था फलों की र्ारणा काफी अच ् छी होती है । सैप के लाभदायक पररणामों से अवित

होने के पश ् चात, िैववक घटकों का उपयोि सैप के समदृर्ीकरण में ककया िाना और अवायू जथथतत में उष ् मातयत्र करना, इन प्रकियाओुं का तनमाधण एवुं मानकीकरण ककया िया । इस उत ् पादीत सैप का ववमभन ् न फसलों पर पररक्षण ककये िाने पर यह पाया िया कक उपि में १०-१५ प्रततशत्की वजृदद

होती है । िैव द्रव उवधरक का परीक्षण ववमभन ् न फसलों पर तथा ववमभन ् न स ् थानों पर ककया िा रहा है ।

उपभाक ्ताओुं से पाया िया कफडबॅक अत ् युंत उत ् साहवर्धक है । इसके पररणाम स ् वरुप, व ् यवसातयक रुप

से िैव द्रव उवधरक का उत ् पादन एवुं ववपणन करने हेतु तीन एम.ओ.यू. हस ् ताक्षरीत ककये िये । इस

प्रकिया के नववन ् यता के स ् वरुप, केवल भारत में ही नहीुं बजलक प ुंच अन ् य देशों में भी इसका पेंटट

फाईल ककया िया है । आने वाले वषाधकाल में इसका व ् यवसातयक उत ् पादन एवुं ववपणन अपेक्षक्षत है ।

नैसगिधक रुंिक िैसे मुंजिष ् ठा एवुं अनैटो के साथ सैप का उपयोि रुंिबुंर्क के रुप में ककया िा सकता है । इसका पूवध अभ ् यास मसरक ट, मुुंबई की प्रयोिशाला में ककया िया । इस पररक्षण के

पररणाम यह दशधतें है कक सैप ममलाने से रुंिकों के बुंर्क िुणर्मध में बढीया सुर्ार हो सकता है ।

IX

सद्यजथथतत में टेतनुंन का प्रयोि रुंिक उद्योि में आसुंिक के रुप में होता है, लेककन यह अनुमान कक

नैसगिधक आसुंिक सैप, टेतनन के बदले टेक ्सटाइल उद्योिों में उपयोि में लाया िा सकता है ।

केले के तने का मर् ् य भाि एक खादय घटक है । न.कृ.वव., नवसारी ने कॅन ् डी, आचार तथा कॅन ् डी बनाते समय बच ेहुए सरबत से आर.टी.एस. पेय िैस खादय पदाथध बनाने की प्रकिया का तनमाधण

तथा मानकीकरण ककया । बनाई िई कॅन ् डी का सी.फ.टी.आर.आय., मैसूर और एस.आय.सी.ए.आर.टी., आनुंद में पररक्षण ककया िया । पररणामों में यह दशाधया कक कॅन ् डी में अच ् छी मात्रा में Fe और B2 एवुं B5 ववटाममन होते है । इस प्रकिया का राष ् ट्रीय स ् तर पर पेटुंट आवेदन ककया है । कच ् चमेाल के तौर पर

ममष ् ठान ् न उद्योि में उच ् च पोषक तत ् व वाला केले के तने का मर् ् यभाि उपयोि में ला सकते है ।

इस पररयोिना के अुंतिधत तनमाधण की िई उत ् पादन एवुं प्रकिया प्रौद्योगिकीयों को राष ् ट्रीय

सममतत द्वारा ि ुंचा िया । इनमें से तनम ् नमलझखत तीन प्रौद्योगिकीयों का व ् यावसातयक उत ् पादन हेतू चयन ककया िया ।

1 केले के रेशों का तनष ् कषधण एवुं न न-वोवन वस ् त्र का तनमाधण ।

2 केले के तने का रस से (सैप) िैव द्रव उवधरक की तनममधती करना ।

3 केले के तने के मर् ् य भाि से कॅन ् डी बनाना ।

प्रौद्योगिकी हस ् ताुंतरण िततववगर्यों के अुंतिधत कुल आठ (ककसान ६ एवुं मदहलाऍ ुं २)

प्रमशक्षण कायधिम का आयोिन ककया िया जिसमें ४२७ ककसान सहभािी हुए । केले के तने से प्राप ् त

होने वाली उत ् पादों की िानकारी देने हेतु ववववर् कायधिमो ुं का आयोिन ककया िया िैस ेतनवेषक बैठक

(२), ममडीया बैठक (२), राष ् ट्रीय कायधशाला (१), उदयोिक पररसुंवाद (२), रेडडयो एवुं टी.वी कायधिम

(२), समाचार पत्र्(२७), इुंटरनेट (११), वेबसाईट, राष ् ट्रीय के.जहह.के. बैठक (२), िुिरात शासन द्वारा कृ वष रथ का आयोिन (३), ककसान ददवस, आिुंतूक तथा वैयजक्तक सुंपकध और प्रदशधनी ।

ववश ् व बैक द्वारा तनर्ाधररत की िई तनरीक्षण प्रकिया का कठोरतापूवधक अनूपालन करते हुए

सीआयसी (१०), सीएमयू (९) एवुं सीएसी (१०) बैठकों का तनयममत रुप स े आयोिन ककया िया ।

पररयोिना के अुंतिधत जथवकृत कायधकलापों को अमल में लाने हेत ुइस पररयोिना के सहभागियों की ववत ् तीय एवुं तकनीकी उपलजधर्य ुं सराहनीय रही ।

इस पररयोिना के अुंतिधत तनर्ाधररत सभी कायधकलापों ने पयाधवरणीय तथा सामाजिक रक्षण के

निररयों से र्नात ् मक िूण प्राप ् त ककये है । केवल यही नहीुं इस पररयोिना की इतनी क्षमता है कक वह

ग्रामीण रोििार का तनमाधण (१८३ मनुष ् य ददवस प्रतत हेक ्टर वा वषधक) कर सकता है । साथ ही यह

टेक ्सटाइ धल, कािि, फामाधमसटीकल, खाद एवुं ममष ् ठान ् न उद्योिों को पयाधवरण अनूकूल कच ् च ेमाल

का ववकल ् प देने की क्षमता रखता है । रेशें, सैप एवुं कृमी खाद के तनममधती स ेकेले की फसल करने वाले

X

ककसानों को रु ६०,००० से्७०,००० तक की वावषधक अततररक ्त आय वजृदद ममल सकती है । सुंक्षेप में यह कहा िा सकता है कक इस पररयोिना द्वारा अवशषे से लाभ िाने का रास ् ता सहीमानों में पयाधवरण-अनुकुल तरीके से दशाधया िया है । जिसमें ककसार, उद्यमम, उद्ययोिक और ग्राहकों में आगथधक लाभ का बटवारा भी हो िाएिा ।

इस पररयोिना के तहत उपलब ् र् प्रौद्योगिकीय ुं की तकनीकी आगथधक व ् यवहारीकता के

आर्ार पर यह ददखाई देता है कक, केले की खेती स ेपाया िाने वाला तने का अवशेष ये क्षमता रखता है

कक वो पयाधयी/अनुपुरक माल टेक ्सटाईल, कािि, खाद, फामाधसेटीकल और ममष ् ठान ् न उद्योिों को उपलब ् र् करा सकें । इन िततववगर्यों को सवधसमावेशक रुप से क ्लस ् टर के मार् ् यमों से बढाने की आवश ् यकता है । शासन/उद्योिक/ककसान/सहकारी सुंस ् थाओुं को केले की उपि करने वाले और

उद्योि के बीच की कडी बनकर ववश ् वास बढाना चादहये । इस ददशा में राष ् ट्रीय उद्यान कृत्रत्र ममशन,

कृवष मुंत्रालय, भारत सरकार ने इस पररयोिना की सुंपुणध िानकारी वेबसाइट पर दी है ।

BANANA PSEUDOSTEM VALUE CHAIN

1

Part-I: General Information of Sub-project

1. Title of the sub-project: A Value Chain on Utilization Banana Pseudostem for

Fibre and Other Value Added Products

2. Sub-project code : 4586

3. Component : II

4. Date of sanction of sub-project : 29 May 2008

5. Date of completion : 31 March 2014

6. Extension if granted : From 1 July 2012 to 31 March 2014

7. Total sanctioned amount for the sub-project : Rs. 732.2006 lakhs

8. Total expenditure of the sub-project : Rs. 522.2300 lakhs

9. Consortium leader (CL):

Name of CL: Dr. A. R. Pathak

Designation: Vice Chancellor

Address: Navsari Agricultural University, Eru Char Rasta, Navsari

Dist.: Navsari – 396 450 (Gujarat)

Fax: 02637 282554

Email: vc@nau.in

Website: www.nau.in

10. List of consortium partners:

Designa

tion

Name of CPI/

CCPI with

designation

Name of organization and address,

phone & fax, email

Duration

(From-To)

Budget

(Rs. in

Lakhs)

CPI Dr. R. G. Patil

Research Scientist

and Head

Soil & Water Management Research

Unit, Navsari Agricultural University,

Navsari, Eru Char rasta, Dist. Navsari –

396 450 (Gujarat)

Phone : 02637- 282771 to

282775(Ext.1113)

02637-292103 (O),

Fax : 02637- 282554

Email : rgp_swm@nau.in

29 May,

2008 –

March,

2014

461.85821

CCPI1 Dr. N.

Shanmugam

Sr. Scientist

Central Institute for Research on Cotton

Technology (ICAR)

Adenwala Road, Matunga, Mumbai –

400 019 (Maharashtra)

Phone: 022 24127273 Ext 447

Fax: 022 24130835

Email: circot@vsnl.com

29 May,

2008 –

March,

2014

211.1323

FINAL REPORT (NAIP COMPONENT – 2)

2

CCPI2 Shri. M. G. Parikh

Sr. Scientific

Officer

R & D MANTRA, Near Textile Market,

Telephone exchange, Ring Road, Surat-

395 002, Gujarat

Phone: 91261 2323211, 2337062

Fax: 2322500 Telegram: MANTRA

Email: director@mantrasurat.org

29 May,

2008 –

March,

2014

41.40516

CCPI 3 Shri. D. K. Singh

Sr. Manager

(QA & TS)

JK. Paper Ltd

Unit- Central Pulp Mills,

PO: Central Pulp Mills -394 660

Songadh, Dist. Tapi, Gujarat.

Phone:02624-220228,220278/79/80

Fax: 02624 220138

Email: cpm@cpmjk.jkmail.com

29 May,

2008 –

March,

2014

17.80497

CPI-Consortia Principal Investigator; CCPI-Consortia Co-Principal Investigator

11. Statement of budget released and utilization partner-wise (` in Lakhs):

CPI/

CCPI

Name, designation &

address)

Total budget

sanctioned

Fund released

(up to closing

date)

Fund utilized

(up to closing

date)

CPI Dr. R. G. Patil

Research Scientist and Head,

NAU, Navsari

461.86 438. 90 396.70

CCPI1 Dr. N. Shanmugam

Sr. Scientist, CIRCOT,

Mumbai

211.13 208.87 83.44

CCPI2 Shri. M. G. Parikh

Sr. Scientific Officer,

MANTRA, Surat

41.41 51.09 41.40

CCPI 3 Shri. D. K. Singh

Sr. Manager (QA & TS), JK

Paper Ltd., Songadh

17.80 15.36 15.63

Total 732.20 714.22 537.17

BANANA PSEUDOSTEM VALUE CHAIN

3

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

0

100

200

300

400

500

600

700

800

900

1991-92 1994-95 1997-98 2000-01 2003-04 2006-07 2009-10 2012-13

Area (‘000 ha) Productivity (t/ha)

Fig. 1.1: Trend in area and productivity of banana in India

Area

Pro

du

ctiv

ity

Year

Part-II: Technical Details 1. Introduction

Banana is one of the most important fruit

crops grown in India. The area under banana has

increased from 3.84 lakh ha during 1991-92 to

7.76 lakh ha during 2012-13, i.e., increase by 102

per cent (Fig. 1.1). This was also true for

productivity as it increased by 70 per cent where

the average productivity during 2012-13 was 34

t/ha. Among the states, Maharashtra, Gujarat,

Tamil Nadu, Andhra Pradesh, Karnataka and Kerala are the leading states in banana cultivation.

The major cultivars grown in different states of India are belonging to Cavendish group.

Considerable work has been done in the field of direct use and product development from

banana fruits. However, not much attention has been focused on effective utilization of the huge

waste biomass generated in the form of pseudostem, leaves, suckers etc. In India, presently this

biomass is dumped on roadside or burnt or left in situ causing detrimental effect on environment.

Though, the technologies for extraction of fibres and paper making from pseudostem are

available, yet it has not been adopted by the industries mainly due to bulky nature leading to high

transport cost. However, there exist a vast potential of extracting fibres from pseudostem. The

quantity and quality of fibres show wide variability with cultivars. The finess of fibres ranges

from 6.1 to 11.4 tex whereas its strength found in the range of 22.4 g/tex to 62.0 g/tex. The fibre

extracted from banana pseudostem could not command proper market owing to its unassured

supply and restricted use in cottage industries. There appears to be good scope for profitable use

of this fibre in textile and paper industries on commercial scale. Not only this, but number of high

value products such as handbags, non-woven felts, composites for car interiors etc., can also be

developed from banana pseudostem. Therefore, it was thought to explore possibilities of

utilization of fibre in textile and paper industries which was envisaged in this project. Similarly,

the sap (liquid) generated while extracting fibres from pseudostem is rich source of K (~ 4% on

dry weight basis) and can be recycled or enriched and use as liquid fertilizer. In addition, an

attempt has also been made to develop edible products from the central core of pseudostem. In

view of the above gaps, present project was submitted to PIU, NAIP, New Delhi for approval with

the following major objectives. Once the processes are standardized, it would not only generate

additional income for the farmers, but will also solve the disposal problem of pseudostem in an

eco-friendly way.

2. Overall Sub-project Objectives

Standardize processes for extracting textile grade fibres from pseudostem and prepare

home furnishings

Standardize processes of pulp and paper making from pseudostem, fibres and scutching

waste both at hand made and industrial levels

Develop value added edible products from central core

FINAL REPORT (NAIP COMPONENT – 2)

4

Preparation and evaluation of enriched sap and scutching waste based vermicompost

Develop linkage for marketing of pseudostem based products

3. Sub-project Technical Profile

Objective Work plan Monitoring

indicators

Expected output Expected outcome

1) Standardize

processes for

extracting

textile grade

fibres from

pseudostem

and prepare

home

furnishings

1.1 Woven fabric

Procurement and

installation of Raspador

(Nos. 24)

Installation and

commi-

ssioning of

raspador m/c

24 raspador m/c installed

and operationalized at

farmers‟ fields & NAU

Fibre extracted : 41.6 t

(NAU: 2.7 t and

farmers: 38.9 t)

Area covered: 64 ha

Evaluating quality of

fibre of different

cultivars

Identified

potential

varieties for

fibre

Fibre quality of 25

varieties evaluated &

ultra structural studies

conducted

Quality parameters

based catalogue

prepared

Moisture content in fibre Digital moisture meter

standardized & it helps

in maintaining fibre

quality during storage

Procurement and

installation of yarn

making machine

Yarn making

unit

Yarn m/c procured and

installed at CIRCOT &

NAU and modification in

yarn m/c which need

further improvisation

Improved yarn quality

suitable for weaving

fabric on looms

Preparation of yarn

Good quality

yarn

Developing CIRCOT-

Pheonix Charkha

10 modified m/c

supplied to NE hilly

region

Weaving machinery

modification for running

of banana yarn

Modified

machinery for

running of

banana yarn

Softening trials conducted

for spinning of fibre to

yarn

2.6 t of yarn prepared

Weaving of fabrics on

different types of looms

Fabrics Weaving done on power

looms, jute looms and

handlooms

350 m of different

quality fabrics prepared

and tested. Using this

febric different articles

were prepared

Analysis of gray fabrics

for quality parameters

Finished

fabrics

Quality parameters tested

Processes available for

preparing different

quality fabric

Processes standardized for

scouring bleaching,

coating, chemical

treatment, printing and

pigment printing of fabric

done

Printed, water repellent

and fire resistant fabrics

Coating and lamination Value added

apparel

products

Process standardized for

coating and lamination

Laminated fabric can be

used for sofa/seat

covers.

BANANA PSEUDOSTEM VALUE CHAIN

5

Objective Work plan Monitoring

indicators

Expected output Expected outcome

Preparation of fabric

products

Types of fabric

products

prepared

Trials conducted at

laboratory and industrial

level

Coat, apron, gloves,

caps, shoe (mojari),

vertical blinds etc., prepared at laboratory

scale.

Utility bags and mats

prepared at industrial

and handlooms scale

1.2 Non-woven fabric

Preparation of

nonwoven fabric

Quantity of

non-woven

fabric prepared

Preparation of non-woven

fabric at industrial scale

(Gloster Jute mills) using

banana fibre

3.1 tonnes of non-woven

fabric prepared

Preparation of products

from non-woven fabric

Processes for

preparing non-

woven fabric

products

Processes standardized for

preparing carpets and

composites

Processes available for

preparing carpets,

composites using non-

woven fabric and can be

used in automobiles and

railway coaches.

Carpets can also be used

for home furnishing

1.3 Other products

Preparation of Micro

Crystalline Cellulose

(MCC)

Process for

extracting

MCC from

banana fibre

Process standardized at

laboratory scale and

quality is comparable with

commercially available

MCC

Processes available for

extracting MCC from

banana fibre

Prepare handicrafts

using banana fibre and

yarn

Handy crafts

prepared

Different articles like doll,

wall hangings, key chain,

mobile covers, decorative

articles prepared

Training given to SHG

Handy crafts preparation

can generate

employment in rural

areas

2) Standardize

processes of

pulp and

paper making

from

pseudostem,

fibres and

scutching

waste both at

industrial and

handmade

levels

2.1 Industrial scale

Preparation of pulp and

paper making from

fibres and scutching

waste

Pulp from

banana fibre

and scutching

waste

Process standardized for

preparing pulp from

banana fibre and scutcher

Process available for

preparing pulp from

banana fibre and

scutching waste

can be used for

preparing kraft papers

and boards

Evaluation of bleached

and unbleached pulp

(physical strength,

optical properties and

fibre fractionation)

Quality

parameters of

bleached and

unbleached

pulp

Quality of bleached and

unbleached pulp prepared

from banana fibre and

scutching waste evaluated

Banana fibre is good for

preparing specialty

grade papers i.e.,

greaseproof, cheque &

kraft papers

Characterization of

effluent generated

during pulping and bleaching

Quality

parameters of

effluent

Quality parameters

analyzed

Effluent generated is

less hazardous as it

requires less chemicals than other raw material

FINAL REPORT (NAIP COMPONENT – 2)

6

Objective Work plan Monitoring

indicators

Expected output Expected outcome

Exploring possibility of

paper making

Preparing

quality papers

from banana

fibre

Processes standardized for

preparing cheque and anti-

grease papers and quality

tested

Processes available for

preparing cheque and

grease proof papers

from banana fibre

2.2 Handmade scale

Procurement and

installation of handmade

paper unit at NAU,

Navsari

Handmade

paper making

unit

Commissioned 100 kg/day

HMPBprocessing plant at

NAU, Navsari

Prepared different

stationary articles like

file covers (20000), box

files (6000), binders

(5000), writing pad

(200), art paper, etc.,

and marketed within the

university

Preparation of

handmade paper and

board

Handmade

paper and

board

Produced 6 t of papers and

board of different qualities

3) Develop value

added edible

products

from central

core

3.1 Edible products

Separation and cleaning

of central core from

pseudostem and

preparation of recipes

from central core

Edible

products

developed

from central

core & quality

tested

Processes standardized for

preparing candy, RTS and

pickle.

Pilot scale unit started at

NAU

Processes available for

preparing candy, RTS

and pickle form central

core. Candy is good

source of K, Fe,

digestible fibre and

vitamins.

4) Preparation

and evaluation

of enriched sap

and scutching

waste based

vermicompost

4.1 Sap

a) Liquid fertilizer

Explore possibility of

use of sap as liquid

fertilizer through field

experiments.

Experimental

results and

yield data

Tested in different crops

(sugarcane, banana,

papaya, onion)

Found to improve crop

yield, quality of produce

& maintain soil fertility.

It can also save 20%

cost of fertilizers

Enrichment of sap and

testing different crops

Experimental

results, yield

data, validation

and quantity

produced

Process standardized for

enrichment and tested in

wheat, paddy, mango,

banana, vegetable

nurseries, leafy vegetables,

garlic, okra, cluster bean,

cowpea etc.

Produced about 16000

litres of enriched sap

(International patent

filed in 4 countries).

Increases yield and

quality of produce.

b) Mordant

Development of process

for using sap as mordant

for textile dyeing

Dyed fabric

Process standardized at

laboratory scale using

natural dyes like manjistha

and annatto

Good fastening

properties observed. The

sap seems to be a good

natural mordant in

textile dyeing industry

4.2 Scutcher waste

a) Vermicompost as

manure

Preparation of vermi-

compost from scutching

waste including sap

Quantity of

vermicompost

harvested

Process standardized for

preparing scutching waste

based vermicompost

70 % scutching waste

and 30 % cow dung was

found to ideal from

nutrient point of view

BANANA PSEUDOSTEM VALUE CHAIN

7

Objective Work plan Monitoring

indicators

Expected output Expected outcome

Comparative

performance of

scutching waste based

vermicompost vis-à-vis

FYM and biocompost

Experimental

results and

yield data

Evaluated in sugarcane,

banana and papaya for 2

years and recommended to

the farmers

Pseudostem based

vermicompost is cheaper

alternative than FYM or

biocompost

Large scale testing of

liquid fertilizer (sap) and

vermicompost in

different crops on

farmers‟ fields

No. of

demonstrations

and yield data

Demonstrated on 24

farmers‟ fields

Increase in yield by 10

to15 per cent.

b) Vermicompost as

fish feed Use of scutching waste

based vermicompost as

fish feed

Experimental

results

Pelleted vermicompost

tested as fish feed

Up to 30 % of routinely

used cattle feed could be

substituted by scutching

waste based

vermicompost which

reduces the fish feed

cost by 10 per cent

5) Develop

linkage for

marketing of

pseudostem

based products

Linkages for marketing

of different products

developed for banana

pseudostem

No. of linkages

established for

marketing of

products

MoU signed with 3 parties

for commercial production

and marketing of organic

liquid fertilizer.

Production and

marketing of OLF at

commercial level will be

initiated during ensuing

monsoon season (2014).

Gloster Mills, Kolkata is

purchasing fibre from

NAU for preparing

different fabric products

4. Baseline Analysis

With a view to know the practices being

followed for disposing off the banana

pseudostem by the banana growers of Gujarat,

a systematic survey was conducted by

SWMRU, NAU, Navsari as per the guidelines

and prescribed format provided by NAIP, New

Delhi. For this purpose, a standard

questionnaire was designed and each

respondent was interviewed personally. In all

53 farmers from 36 villages were interviewed

(Fig. 4.1).

Farmers are either dumping it on field bunds (32%) or practicing in-situ incorporation (60

%). The cost of disposal of pseudostem is around Rs.15,000 to 20,000 per ha. Of all the varieties,

Grand Naine is the most popular variety. The average yield of banana fruit ranges from 46 t/ha in

rhizome to 70 t/ha in tissue culture planted crops with weighted average of 66 t/ha. At this

productivity level, the net income realized under rhizome and tissue culture planting material is

0

5

10

15

20

25

30

35

Ratooning No ratooning

22

10

12

5

1

3

Insitu incorporation/dumping on farm bund Manure preparation

Dumping on farm bund Insitu incorporation

No

. of

farm

ers

Fig. 4.1: Farmers' practice of disposing off the banana pseudostem

FINAL REPORT (NAIP COMPONENT – 2)

8

Rs. 49,800/ ha and Rs. 95,600 /ha, respectively (Table 4.1). Though, net income is good, yet the

B:C ratio is less than one.

Table 4.1: Economics of banana cultivation with two different planting materials

Particulars Planting material Weighted average

Rhizome Tissue culture plants

Yield (t/ha)* 46.00 70.00 66.00

Cost of cultivation (Rs/ha) 88,200.00 1,15,000.00 1,04,000.00

Gross income (Rs/ha) 1,38,000.00 2,10,000.00 1,99,000.00

Net income (Rs/ha) 49,800.00 95,600.00 88,600.00

B:C ratio 0.56 0.83 0.85

* Average yield was calculated considering 1.8 x 1.8 m spacing, 10% losses in tissue culture plants and 25% losses in

rhizome

Though most of the farmers know about the utilization of banana pseudostem for

vermicompost and fibre extraction, yet not a single respondent is practicing it. Of course, few

respondents are preparing manure using banana pseudostem. After explaining the content of the

project, reaction of the farmers was highly positive. After thorough understanding of the project,

they put forth the following suggestions for realizing full benefits of the project by the farmers:

- Training for extraction of fibres from pseudostem and preparation of pseudostem

based vermicompost

- Demonstrations of technologies on farmers‟ fields

- Subsidy on extraction machine

- Establish linkage for marketing of pseudostem based products

Regarding fibre extraction, manual and machine (developed by CIRCOT, Mumbai) both

are followed especially in South and western states of India. However, they are at a small scale.

Further, there is need to mechanize the existing fibre extraction machines through suitable

modification to run it more efficiently and reduce labour requirement.

In case of quality of fibre, it is more comparable to jute fibre, rather than to other existing

fibres. Some work on spinning fibre into yarn has been carried out jointly by CIRCOT, Mumbai

and NIRJAFT, Kolkata on jute spinning machines. However, concerted efforts are needed to

improve or modify the jute spinning machines to make it suitable for banana fibre. Handicrafts

from banana fibre are being made in some states and have very good export potential which needs

to be explored. Fabrics from banana fibre are being successfully made in countries like Japan and

Indonesia, whereas in India it is still on a very small scale. The present survey shows that, banana

fibre can be classified as medium quality fibre and may perform very well in combination with

other fibres for making quality fabrics, handicrafts etc.

The work on use of banana fibre as raw material for extracting microcrystalline cellulose

(MCC) and sap as mordant in taxtile dying industry is veery scanty.

In case of paper from banana waste/ fibre not much work has been done on a commercial

scale. Processing technologies are available for preparing paper at hand made scale. Literature

survey has indicated that composition of banana pseudostem is comparable with that of bagasse,

BANANA PSEUDOSTEM VALUE CHAIN

9

Modified raspador machine

Banana psueodstem cutter

machine

which is an important raw material being used in paper industry. However, there is need to

evaluate banana fibre for making different quality papers either sole or in combination with other

raw materials used in paper industry. In addition to above uses, scutcher and sap obtained during

fibre extraction can be used for preparing good quality manures.

Work on edible products with respect to central core from banana pseudostem is scanty.

Of course, some products have been developed by NRC Banana, Trichy (Tamil Nadu).

5. Research and Achievements

5.1 Objective: Standardize processes for extracting textile grade fibres from pseudostem and

prepare home furnishings

Fibre extraction from banana pseudostem: From one hectare area of banana plantation, about

60 to 80 t fresh pseudostem as waste is available. For disposing these pseudostem, farmers spend

around Rs. 15000 to 20000 per ha. The pseudostems are disposed-off on either field bunds and

burnt on drying or in nallas or road side pits. Disposal of pseudostem in this way causes

environmental problems. In present project, an attempt was made to use this pseudostem for fiber

extraction and develop some value added products from it.

5.1.1 Extraction of fibre and their characterization

(A) Standardization of process for estraction of fibre from banana pseudostem

(i) Modification in raspador machine

For this purpose, initially two raspadore machines were

procured and based on the experiences gained; following

modifications were done in consultation with CIRCOT, Mumbai.

Additional pulley attachment for operating raspadore on alternative

energy source viz., power tiller, oil engine, kerosene engine.

Attached bigger size wheel for ease in movement in field condition.

Subsequently, another 22 modified raspadore machines were

procured. Out of these, 20 machines were operationalized on farmers‟

fields along with necessary training to the farmers. The remaining 4

machines were commissioned on university farm for demonstrating to trainees, visitors etc.

(ii) Development of cutter machine for splitting pseudostem

Simultaneously, for easy and speedy separation of sheaths

from pseudostem, a cutter machine was developed by NAU, Navsari.

Based on the systematic trial conducted (Annexure 1) on manual v/s

mechanical sheath separation, it was concluded that use of cutter

machine for sheath separation was cheaper (Rs.33.32 Rs/kg of fibre)

than manual sheath separation (42.36 Rs/kg of fibre). To facilitate

speedy and cheaper sheath separation, 10 cutter machines were

procured and distributed among the farmers who were extracting fibre

FINAL REPORT (NAIP COMPONENT – 2)

10

using raspadore machines.

During the project period, in all 41.58 tonnes of dry fibre were extracted and subsequently

used for product development.

It may be noted here that the fibres extracted even from farmers‟ fields could be directly

used for preparation of yarn, woven fabric, non-woven fabric, high quality papers etc. This was

possible inspite of small quantities of pithy matter present in the extracted fibres, as this was

getting removed easily during processing for any of these final products.

(B) Preparation of catalogue for banana fibre based on their quality parameters

A comprehensive data has been lacking so far in order to have in depth study on banana

fibre. An attempt has, therefore, been made to generate information related to quality of fibre of

predominantly grown varieties for focusing their economic importance.

(i) Chemical composition of banana fibre: In order to determine the chemical composition of

banana pseudostem fibre, ten popular varieties were selected. The chemical properties viz., ash

(TAPPI-T-211), hot water soluble (T2070M-81-1981), alcohol: benzene extractable matter

(TAPPI T 204 Os – 76 -1976), lignin (T 222 Os-74-1974) and holo-cellulose (TAPPI T-9, M-54)

were determined using TAPPI standards (Table 5.1.1)

Table 5.1.1: Chemical composition of banana pseudostem fibres (dry weight basis)

Variety Ash

(%)

Hot water

soluble (%)

Alcohol:Benzene

(%)

Lignin

(%)

Holocellulose

(%)

Grand Naine 6.0 8.1 2.6 9.1 74.2

Ponchandan 4.7 4.8 1.3 11.7 77.5

Nendran 4.3 7.9 2.9 9.7 75.2

Paccakadali 5.2 8.3 3.1 9.8 73.6

Ladies Finger 3.7 7.9 2.4 10.0 75.9

Poovan 4.8 6.2 1.3 11.0 76.7

Adhar Velchi 3.1 10.4 2.0 8.8 75.7

Sugandhi 3.2 6.0 1.1 11.0 78.8

Sakar Chayna 4.4 9.3 1.9 8.9 75.5

Vannan 3.1 7.4 0.9 10.3 78.3

(ii) Tensile characteristic of banana fibre: For determining tensile parameters viz., fineness,

tenacity and extension parameters, the pseudostem of 25 widely grown varieties of banana in

India were collected from the AICRP on Banana, NAU, Gandevi (Gujarat).

The tensile parameter was tested using Tensile Testing Machine (Instron: model 400R) as

per the method described in Indian Standard 234- 1973 an IS 235-1989. It is found that the linear

density of the banana fibre ranges 6.1 to 11.4 tex and strength ranges from 24.2 to 62 g/tex,

whereas elongation ranges from 2.3 to 4.5 per cent (Annexure 2). On the basis of data generated

on quality parameters of banana fibres, grades have been framed (Tables 5.1.2 to 5.1.4).

BANANA PSEUDOSTEM VALUE CHAIN

11

Table 5.1.2: Range of fineness Table 5.1.3: Grading of strength

SN Range of

Tex Value

Grades SN Range of Tenacity

(g/tex)

Grades

1 Below 7 Extra Fine (ExF)f 1 Below 30 Weak (W)s

2 7 to 10 Fine (F)f 2 30 to 40 Normal (N)s

3 10 to 14 Medium (M)f 3 40 to 50 Strong (S)s

4 Above 14 Coarse (C)f 4 Above 50 Extra Strong (ExS)s

Table 5.1.4: Grading of extension

SN Range of Extension Grades

1 Below 2 Low (L)e

2 2.1 to 3 Medium (M)e

3 3.1 to 4 High (H)e

Considering the end use of products and processing requirements, the fibre were defined in

four groups, i.e., Group I for the fabric preparation or spinning purpose, Group II for the handy

craft, Group III for composite and non woven fabrics and Group IV for raw material for paper and

pulp industry (Annexure 3).This data base (catalogue) prepared by grading of fibres will help

spinner to decide their process parameters in spinning. Breeders to know about which varieties are

yielding good grade fibres and Research and Development workers to plan their research work.

(C) Moisture determination and ultra structural study of banana fibre

(i) Developing a method to measure moisture content in banana fibre

In the case of the natural fibre, the moisture

content has significant influence on processing

performance. The digital moisture meters are most

popular electronic device for measuring the

moisture content in natural fibre. For measuring the

moisture content in banana fibre, specially designed

moisture meters are not available. Therefore, a

study was conducted to compare the moisture

content in banana fibre determined by gravimetric

and digital moisture meter generally used for jute

fibre (Annexure 4). Using the moisture content

values obtained by both the methods, linear

regression equation was developed (Fig. 5.1.1).

Using this equation, digital moisture meter can be calibrated and used for measuring the

moisture content in banana fibre.

Fig. 5.1.1: Relationship between moisture content by

digital moisture meter and gravimetric

method

y = 1.057x - 0.690

R² = 0.944

9

11

13

15

17

19

21

23

25

9 14 19 24

Mo

istu

re c

on

ten

t b

y

Gra

vim

etr

y (

%)

Moisture content by Digital Moisture Meter

(%)

FINAL REPORT (NAIP COMPONENT – 2)

12

(ii) Ultra structural studies

The ultra structural studies were

carried out using Scanning Electron

Microscope. The fibre samples were

mounted on a specimen stub and coated

with gold in a sputter coater. The stubs

containing the coated specimens were

mounted on the specimen stage of Phillips XL30 Scanning Electron Microscope. Fibre specimens

were examined at an accelerating voltage of 10kV. Certain selected portions from the scans were

recorded. SEM micrographs of longitudinal view show that the individual cells are packed

together by lignin. Cross sectional view shows that the shape is to some extent circular.

Embedded ultimate cells show wide distribution of size.

5.1.2 Product development using banana fibre

After standardizing the process for extracting fibre from banana pseudostem, an attempt

was made to develop various products using fibre. Under this project, preparation of yarn using

modified yarn making machine, Medalari Charkha and jute spinning system was done at

laboratory and industrial scales. The yarn thus obtained was tested for its quality and woven

fabrics of different quality were developed.

Preparation of yarn and its quality testing

(A) Conversion of banana fibre to yarn by different methods

(i) Modification in yarn making machine: The CIRCOT has designed and fabricated banana

fibre processing assembly for converting banana fibre to yarn. This assembly is laboratory models

spinning unit exclusively for spinning of banana fibre which comprises five machine viz.,

mechanical softening, staple cutting, carding, gill drawing and spinning machine. After optimizing

machine parameters by conducting numbers of trials, the yarn was obtained and tested for its

quality. Based on the observations during these trials, the modifications listed here are necessary

for perfect functioning of machines.

i. The change in gearing arrangement or motor to achieve desirable speeds of back roller, front

roller and spindle of spinning machine so as to set the parameters like draft and twist for fine

count of yarn

ii. Introducing compacting guide to reduce hairiness of yarn

iii. Introduction of proximity sensors, rpm indicator for correct display in control panel

iv. Coiler mechanism to be added for laying the coils of sliver in a can which will induce the

compactness of sliver

v. The gear wheel of cutting machine has to change so as to cut the fibres of different staple

length.

vi. In the sequence of this assembly one more machine i.e., fibre opener to be added for better

removal of pithy matter from the sheath and individualization of the fibres. At present only

carding machine is unable to solve the purpose.

Longitudinal views of banana pseudostem fibres Cross sectional view of

banana pseudostem fibres

BANANA PSEUDOSTEM VALUE CHAIN

13

The above listed design modifications were completed by CIRCOT in association with the

fabricator, Trytex Machine Company, Coimbatore. Inclusion of fibre opener helped in the

assembly cleaning the fibres as desired and spinning machine could able to run for longer time

without any breakages in yarn.

After fine tuning of yarn making machines at CIRCOT, experimental trials were

conducted with different softeners (Table 5.1.5). For softening, fibres were treated with rice bran

oil (RBO) and microbial consortium before processing. Yarn prepared by both the treatments

were tested for quality parameters and results showed the best performance with rice bran oil as a

softner.

Table: 5.1.5: Tensile properties of banana fibre after softening

Samples/ Tensile properties Fineness

(tex)

Tenacity

(g/tex)

Elongation

%

TPI Count

(Ne)

Control 730 6.8 6.3 4.0 0.72

Sprayed with Rice Bran Oil 680 7.3 5.6 2.9 0.86

Sprayed with Microbial

Consortium

913 3.2 7.8 4.4 0.65

(ii) Large scale trial of yarn preparation at Kolkata

Spinning of natural fibre always involves sequence of

processes namely first cleaning the fibre, arranging fibre in a

sliver form and then drafting and twisting. Each natural fibre

spinning has their own sequence depending up on its fibre

properties. An attempt was made to spin banana fibre to yarn

using jute spinning system. The sequence followed was:

Cutting (25 cm stable length) Piling (2 days)Softening

(JBO emulsion-10%) Carding (breaker and finisher

card) Gill drawing (four drawing machine) Spinning.

The details regarding procedure followed are given in

Annexure 5. The yarn test results (Table 5.1.6) revealed that

banana fibre yarn is stronger than jute yarn with a quality

ratio of 80%. However, it was observed that the yarns are

having hairiness and more unevenness than jute yarn.

Subsequently, large scale trials were carried out at

Gloster Jute Mills, Kolkata and in all 5 tones comprising of

100 per cent banana yarn, 90:10 per cent and 80:20 per cent Banana: Jute blended yarns were

prepared.

FINAL REPORT (NAIP COMPONENT – 2)

14

An Attachment to

CIRCOT-Phoenix Charkha

Yarn prepared using CIRCOT-

Phoenix Charkha

Table 5.1.6: Yarn test results

Data Trial 1:

(50 cm cut length, 2.0 TPI)

Trial 2:

(25 cm cut length, , 3.0 TPI)

Yarn count (Actual) 16.36 18.57

MR% 17.55 18.86

Jute count (Converted) 15.87 17.81

Count cv 8.79 5.02

TPI 2.08 3.1

Twist cv 14.22 10.48

Strength (lb) 11.94 14.75

GRIST (LB) at 14% 15.87 (standard – 17) 17.81 (Standard – 17)

Strength cv 34.9 24.73

Quality ratio 73 79.44

(iii) Design and development of CIRCOT-Pheonix Charkha

Medlari charkha spinning unit is a foot operated self-

winding spinning wheel with a bobbin to collect the spun yarn. The

feeding to Medlari Charkha is done directly by hand without any

feeding unit. Hence, it is also observed that, the fineness of yarn

produced solely depend on the rate of feeding and this introduce a lot

of non-uniformity in linear density and twist in the yarn produced. To

synchronize feeding and twisting, a new drive mechanism has been

designed and incorporated. The new design of the charkha, called

CIRCOT-Phoenix Charkha. This is a pedal driven machine for

spinning coarse long-staple fibres like banana pseudostem fibres at

the cottage level. In CIRCOT-Phoenix Charkha the flyer and the

bobbin are driven independently. The differential in the RPM decides

the twist per inch (TPI) imparted to the yarn. The TPI of yarn produced can be altered by altering

RPMs of the flyer and the bobbin by changing wheels in the drive

mechanism. This charkha can produce relatively fine yarn with

sufficient uniformity from natural fibres which are other wise

difficult to spin. The fibres after extraction are cleaned and dried

before use for spinning. Fineness of the yarn produced depends on

the fineness of the fibre used, feeding rate and skill of the

operator.

An attachment has also developed to CIRCOT-Phoenix Charkha which helps in feeding

fibres, keeping twisted and non twisted portions separate. A trial was under taken after fixing the

attachment using banana pseudostem fibres. This yarn was evaluated for its tensile properties

using Instron. These modifications enable spinning of long staple fibres like banana pseudostem

BANANA PSEUDOSTEM VALUE CHAIN

15

on a peddle-driven machine that can be installed in any village household. Latest design of the

CIRCOT-Phoenix Charkha can produce finer yarns of 2.9 counts with better uniformity and can

be used for value added products at the village level.

(B) Testing quality parameters of banana fibre yarn

Yarns prepared on different spinning systems viz., Jute spinning system, CIRCOT-Pheonix

Charkha and lab model spinning unit (Yarn Making Machines installed at CIRCOT) were tested

and evaluated for quality with respect to tensile parameters and are presented in the table 5.1.7.

Table 5.1.7: Properties of yarn spun on different spinning systems

Spinning System Breaking

load

(Kg)

Breaking

extension

(%)

Fineness

(tex)

Tenacity

(gm/tex)

Twist

per

inch

U%

Large Scale using Jute

Spinning System 7.238 3.84 670 10.8 3.3 29.1

Lab Scale Using CIRCOT

Developed Machines 4.964 5.6 680 7.3 2.9 40.6

Cottage Scale Using

CIRCOT-Phoenix Charkha 2.188 2.7 166 14.6 3.1 23.5

Observations

The yarn obtained on lab scale machines and on large scale machine are almost of same

linear density.

For the same linear density, yarn prepared on large scale machines shows 46% higher

breaking load, when TPI is increase by 14%.

The breaking extension of yarn at lab scale was showing higher extension among these

methods. However, there was more variation observed in the extension value of lab

scale system.

Yarn on CIRCOT-Phoenix Charkha is reported for higher strength and fineness as

compared to other methods.

With the 9 tex fibres one can able to make a yarn of 670-680 tex in the lab as well as

large scale spinning systems. But using CIRCOT-Phoenix Charkha, one can go up to

highest level of 166 tex yarn which is hardly having 18-20 fibres to spun.

Overall it is observed that banana fibre yarn is stronger than jute yarn with a quality ratio

of 80%. However, it was found that the yarns are having hairiness and more unevenness

than jute yarns.

Three different spinning systems discussed above differ widely in terms of technology

used and scale of manufacturing. Large scale spinning of banana fibre using jute spinning is ideal

for large scale production of yarn at lower cost of production. However, such production system

requires large quantity of raw materials for becoming economically viable. Moreover, such

production system requires huge capital investments to set up. The laboratory level machines, on

FINAL REPORT (NAIP COMPONENT – 2)

16

the other hand, are ideal for small scale production units where sufficient quantity of fibre can be

sourced from the neighborhood itself. Laboratory scale machineries require comparatively less

investment to set up and operate. The CIRCOT-Phoenix Charkha is least capital intensive and last

in terms of production capacity. This peddle-driven device may be appropriate cottage level

production of yarns in the villages.

(C) Preparation of woven fabrics using banana yarn

(i) Banana fabric processing (laboratory trials): On trial basis, MANTRA had prepared four

types of blended fabrics with banana fibre yarn as weft and cotton as warp. Banana fabrics were

tested for physical parameters, the results are shown in table 5.1.8. Among these in two fabric

samples, banana fibre yarn was covered with polyester and the other with viscose. Weaving type

also changed one fabric sample as 3/1 twill, while rest were of 4 end satin. Using above banana

yarn and keeping 100 per cent cotton in warp following different banana union fabrics were

woven on a conventional loom. The quality parameters of these fabrics are given in table 5.1.9.

Table 5.1.8: Physical parameters of different quality fabrics prepared using banana fibre yarn

Sample

No.

Warp Weft Reed Pick

(Set)

R/S Remark Type of

weave

1 2/24 s

100% cotton

Banana

fibre yarn

36 S

(72/1)

15 50.00” -- 3/1

Twill

2 2/24 s

100% cotton

Banana

fibre yarn

36 S

(72/1)

17 50.00” Singed yarn 4 end

Satin

3 2/24 s

100% cotton

Banana fibre yarn

covered

with polyester

36 S

(72/1)

17 50.00” Covering of

80 den.

polyester roto

yarn

4 end

Satin

4 2/24 s

100% cotton

Banana fibre yarn 36 S

(72/1)

17 50.00” 4 end

Satin

5 2/24 s

100% cotton

Banana fibre yarn

covered with

viscose

36 S

(72/1)

17 50.00” Covering of

120 den.

viscose roto

yarn

4 end

Satin

Table 5.1.9: Quality parameters of different fabrics

Parameters Sample no.

1 2 3 4 5

Fabric direction Warp Weft Warp Weft Warp Weft Warp Weft Warp Weft

Load at break (Kg) 34.8 186.7 43.2 134.3 24.3 114.6 51.36 189.1 48.86 197.1

Actual ends/inch 36 37 37 36 36

Actual picks/inch 18 20 18 18 18

GSM 503.5 447.4 515.7 568.3 566.23

(ii) Banana fabric processing (industrial trial): About 250 m of fabric in three lots were

processed on industrial scale in local process house. The process sequence was followed are

shown in Annexure 6.

BANANA PSEUDOSTEM VALUE CHAIN

17

Grey fabric was given gas singeing with m/c speed of 70 m /min. and slit width of 2” blue

flame. Scouring and bleaching was done in an open jigger machine. This was followed by

enzymatic desizing at 70oC for 2 hrs. Peroxide bleaching was given at 90

oC for 4 hrs.

Reactive dyeing was carried out by Pad – Batch method of reactive dyeing. Chemical

finishing was given on stenter with softener and resin. This was followed by mechanical

finishing in the form of calendaring and sanforizing.

Printing of banana fabric: Banana x cotton fabric with satin weave and banana yarn facing on

one side was printed with reactive and vat dyes after pretreatment as mentioned above. The

printed fabric was dried and steamed in rapid ager at 102oC in saturated steam followed by

washing and soaping. The fabric was finished to impart softness. The fabric processing conditions

under industrial were established. Apparel made out of dyed fabric like „Jawahar coat‟ was

appreciated by all. The printed fabric can be used as curtain and sofa cover material.

Finishing of banana fabric (water repellent finish): Banana fabric was finished with

hydrophobic chemical by pad-dry-cure method. The fabric was tested for water repellency by

spray rating method. It showed good water repellence with rating 4 (rating 1 means poor and 5

means very good). Further, water repellency was achieved by eco-friendly chemical and process.

The dyed/printed water repellent banana fabric can be used for different applications like home

furnishing fabric, table mat, etc., where water repellency is important property. The product made

can be claimed as „green‟ product.

Coating of banana fabric: Banana fabric was coated with various coating chemicals to impart

functionality which can then be used as technical textile material.

PVC coating: PVC coating was applied by knife over air technique with paper release method.

Coating was done with paste containing PVC powder, DOP (Dioctyl phthalate) as plasticizer,

epoxy resin, CaCO3, stabilizer and pigment. The speed of the machine kept at 2 m/min. The

temperature set at 150ºC. PVC coated banana fabric can be used as artificial leather.

Acrylic coating: Acrylic coating was applied to banana fabric to make it hard. This acrylic coated

banana fabric can be used for window blinds like vertical blind, roman blind, etc. Coating recipe

for banana fabric vertical blind is given in table 5.1.10.

Table: 5.1.10: Coating amount used for banana fabric vertical blind

Chemical Amount

Pidicryl VB 4 kg

Pidicryl 361 M 150

Ammo. Chloride 50

Water 200

Pidicryl 260 A 150

Liq. Ammonia 25

FINAL REPORT (NAIP COMPONENT – 2)

18

Technique: Knife in air

Curing temp.: 150 – 160oC; Speed: 3 m/ min.

Two Coats on both sides of the fabric

Above recipe can be changed to produce different effects according to end use.

Banana fabric can be coated with various chemicals to have technical textile fabric with

different end uses. To produce artificial leather instead of PVC alternate chemicals like

Polyurethane (PU) and acrylics can be used to provide eco-friendly nature. The acrylic coated

banana fabric was excellent in properties and looks. The coating was done using aqueous base

chemicals (free from hazardous solvents) hence coating process was environment friendly.

Develop woven end products: In order to develop various woven end products, fabrics having

following specifications were prepared initially at Kolkata in consultation with CIRCOT.

a. Warp : Jute yarn of 20 pounds

b. Weft : Banana yarn of 17 pounds

c. Ends/dm : 42

d. Picks/dm : 44

e. Loom speed : 142 rpm (0.3 metre/minute)

f. Fabric width 0.55 metre

g. Weave plain

h. 60% banana and 40% jute (weft 100% banana and warp 100% jute)

i. Bag size – 17” x 14”

The fabric prepared was bleached using hydrogen peroxide. The bleached fabric was then

used to make hand bags of size 17 inches x 14 inches. Around 500 m of fabric was prepared and

then these fabrics used for making hand bags (1000). The hand bags were printed with floral

designs apart from printing of NAIP, ICAR, NAU and CIRCOT logos.

(D) Preparation of non-woven fabrics using banana fibre and product development

(i) Preparation of non-woven fabric: Initial trials were conducted at CICT, Bangalore for

preparation of non-woven felts from banana fibres. The prepared

non-woven felt evaluated for its strength parameters and it was

found that it has a good strength. Hence, large scale trials were

conducted at Gloster Jute Mills, Kolkata for preparation of non-

woven felts. About 3.1 t of banana fibres was converted into non-

woven fabric by needle punching method. Fabrics with linear

density of 450, 700 and 900 gram/sq m (GSM) were prepared with 2

levels of thickness for each GSM. Mechanical properties of the

fabrics are presented in table 5.1.11.

Non-woven fabric trial at Gloster

Jute mills Kolkata

BANANA PSEUDOSTEM VALUE CHAIN

19

Table 5.1.11: Mechanical properties of non-woven felt prepared at Gloster Jute Mills GSM of

nonwoven

felt

Thick

ness

(mm)

Bursting

Strength

(kg/cm2)

Weight/

m2 (gm)

Strength (gm) Elongation (%) Tearing

Strength

(gm) Draw

Direction

^

Direction

Draw

Direction

^

Direction

450 3.8 20.4 558 3460 1465 15.1 20.9 4063

700 5.3 24.5 817 4761 3050 22.3 25.9 8568

900 5.9 22.6 910 4146 3347 23.9 26.8 3150

Some exploratory work on use of these fabrics as geo-textiles has shown that these fabrics

have more life underground vis-à-vis similar jute fabrics, i.e., degradation of these fabrics is at a

slower rate as compared to that of jute. This is an advantage over jute fabrics particularly for

agro/geo-textile applications where bio-degradation of fabrics should be at a slower rate.

(ii) Product developed from non woven fabrics

A banana fibre needle punch non woven fabric was supplied by NAU to MANTRA in

three different GSM i.e. 500, 700 and 100. These fabrics were finished or coated (Annexure 7)

with different chemicals to produce non woven fabric which can be used as floor covering

material. The coated non woven fabric was tested for different properties (Table 5.1.12).

Table 5.1.12: Properties of coated nonwoven fabric

SN Test Result

1 GSM before coating 500

2 GSM after coating 653

3 Abrasion cycle before coating 422

4 Abrasion cycle after PU coating 5575

Banana needle punch nonwoven fabric can be coated or laminated to produce floor

covering mat, carpet, etc., by coating or finishing it with different chemicals like acrylics, PU and

others. The required property like abrasion resistance was obtained to a very good level of above

5000 cycles. By careful selection, a product can be made having eco-friendly nature.

Simultaneously, preparation of resin reinforced banana non-woven fabric composite was also

attempted by MANTRA.

Polyester resin: Banana nonwoven felt 30 x 30 cm (two layers) was put in a match mould and

polyester resin with chain initiator and accelerator was poured over it. The material was pressed

with hydraulic press with high pressure of 300 kg/cm2. The assembly was kept for 24 hours under

pressure and a square tile was taken out. It was further kept in open air for two days to dry up. The

sheet was cut in round shapes.

Acrylic resin: Banana nonwoven felt 30 x 30 cm was immersed in 25 per cent solution of acrylic

resin Acrodur 3550 (BASF) was padded by passing through mangle with 40 psi (3 bar) pressure

and subsequently heated at 120ºC. The semi processed sheet was kept in a mould and hydrolytic

pressure of 150 bars. The compressed sheet was heated to a temperature of 200 °C for 1 minute.

Three sheets of different thickness were prepared and it was tested for properties as shown table

5.1.13.

FINAL REPORT (NAIP COMPONENT – 2)

20

Table 5.1.13: Properties of acrylic treated sheets

Properties Sheet 1 Sheet 2 Sheet 3

Thickness mm 1.27 1.43 2.30

Density g/cc 0.69 0.73 0.73

Impact strength ISO 179-1 kJ/m2

2 3 3

Bending E - module W4 14125 N / mm2 1815 3481 1536

flexural strength N / mm2

23 34 35

Fiber reinforced composites using banana fiber and polyester resin was made which can be

used as substitute for wood. The material obtained was cut in round shape easily. The polyester

resin used does not contain formaldehyde.

The composite made using acrylic resin was light in weight with density around 0.7. This

means that it can be used for automobile applications where strength is secondary criteria and

light weight is advantageous. The composite can be easily given shape during manufacturing

An attempt at CIRCOT was also made to prepare a composite from banana non woven felt

at CIRCOT Electric press machines without using any binder. The non woven fabric of 450 GSM

was compressed with different combination of mechanical parameters and 8 types of sheets were

prepared and tested for its strength properties (Annexure 8). On the basis of the findings of this

trial, another experiment was conducted for preparation of banana fibre composite using Acrodur

DS 3515 as a binder at BASF Chemical Ltd., Mumbai. For the purpose, a non-woven felt of 500

GSM was used which was prepared at Gloster Jute Mills, Kolkata. The proportion of raw

material to binder was 75:25 and binder density of 450 g/l. Foulard parameters were maintained as

pressure of 3 bars, speed of 1.5m/min and gap of o mm. The pressing parameters were 200 C

temperature and 150 bar pressure. The two semi-finished products are compressed in the

longitudinal direction of a planar plate. The prepared semi-finished composite sheets were tested

for various parameters and are presented in table 5.1.14.

Table 5.1.14: Properties of composite sheets

Parameters Unit Sample

1 2

Plate Thickness (mm) 1.43 1.39

Density (g/cm3

) 0.72 0.85

Water Absorption after 2 hr (%) 43 (8) 26 (4)

Water Absorption after 24 hr (%) 66 (7) 47 (1)

Swelling after 2 hr (%) 19 (2) 14 (2)

Swelling after 24 hr (%) 22 (2) 18 (2)

Impact ISO 179-1/1fU (kJ/m2) 3 (0) 4 (1)

Bending E-module W2 14125 (N/mm2) 3481 (245) 3360 (171)

Flexural Strength (N/mm2) 37 (1) 33 (1)

fmax (N) 18 20

(Figures in parenthesis are Standard Deviation values)

BANANA PSEUDOSTEM VALUE CHAIN

21

Acrodur® DS 3515 (Acrylic

copolymer binder) as a binder &

non-woven felt of 500 GSM

Observations:

The surface density of the mat varies greatly, which set the

density at pressing difficult.

The impact value reported as 4 kJ/m2

which is low and it is

mainly due to the great brittleness of non-woven felt.

The modulus of elasticity is also at a low level.

The water absorption is with 47% in the target area.

Conclusion: It can be concluded that in combination of banana

with any binder, state-of-the-art lightweight composites can be

achieved–using conventional machinery. With increasing emphasis on fuel efficiency, natural

fibre such as banana based composites would enjoy wider applications in automobiles and railway

coaches. In fact, the market segments such as railway coaches and buses for public transport

system in India have vast potential, which is yet to be tapped to a good extent.

(E) Preparation of handicrafts using fibre

Apart from woven and non woven fabrics and their products, direct use of fibre for

preparing handy craft item was also attempted by NAU, Navsari and CIRCOT, Mumbai. At

Navsari, the fibres was supplied to NGO viz. Manav Kalyan Trust, Navsari for preparing wall

hangings, bags, doll, idols, keychain, mobile phone cover, mat for dining table etc. items. Such

attempt was made by CIRCOT, Mumbai by using fibre as well as yarn.

Conclusion: Based on the variety of handy craft items which can be prepared by the NGOs using

fibre and yarn, this has great potential in tribal as well as rural areas. This will generate huge

employment opportunity in rural area. In introducing this activity on large scale in tribal and rural

areas, there is need to get support from KVICs or NGOs etc., for marketing the products prepared

from fibre/yarn.

(F) Preparation of microcrystalline cellulose (MCC) using banana fibre

An effort was made to standardize a bio-chemical route for preparing MCC from banana

fibre and to compare the physical and chemical characteristics of the product obtained with that

MCC available in the market. The bio-chemical route requires less chemical and energy with

lower investment than the conventional process for preparing MCC. In other words, bio-chemical

route is environmentally safe. The MCC extracted by adopting bio-chemical route was tested for

different properties (Table 5.1.15). Details of process for preparing MCC using banana fibre is

given in Annexure 9.

Handicrafts items from banana fibre

FINAL REPORT (NAIP COMPONENT – 2)

22

Table 5.1.15: Properties of MCC extracted from banana fibre and commercial available

SN Property MCC prepared from

Banana Fibres

Commercial MCC

(Avicel®)

1. Moisture content (%) 5.3 5.0 ± 0.5

2. Ash content (%) 0.07 0.06 ± 0.005

3. Cellulose content (%) 99.0 100

4. Starch Nil Nil

5. pH value 6.4 7

6. Solubility

a. Distilled water Partially Soluble Partially Soluble

b. 1% NaOH Partially Soluble Partially Soluble

c. 1% HCl Insoluble Insoluble

d. Petroleum ether Completely Insoluble Completely Insoluble

e. Acetone Completely Insoluble Completely Insoluble

f. Ground nut oil Completely Insoluble Completely Insoluble

7. Degree of polymerization 267 157

8. Molecular weight 43254 25434

9. Particle size in µm 30-60 at 800 X 20-100 at 800 X

10. Degree of compressibility

(%)

24.9 11.0

11. X-ray crystallinity 72.1 82.1

Interpretation: The moisture content of banana fibre MCC is 5.3 per cent which is in close

agreement with 5 per cent that of commercial MCC. According to U.S. Pharmacopeia (USP)

1980, the possible effect of moisture is expected to be negligible for the moisture content below

10 per cent. The ash content of cellulose powder from banana fibre was 0.07 per cent which is in

close agreement with ash content (0.06%) of commercial sample and according to U.S.

Pharmacopeia 1980, ash content should not be more than 0.1 per cent. The starch content in

cellulose powder prepared from banana fibre is nil which is in close confirmation with the

specification given for MCC in U.S.P. The cellulose content in MCC prepared from banana fibres

is 99.0 per cent which is in close agreement with that of commercial MCC product. According to

U.S. Pharmacopoeia cellulose content should not be less than 97 per cent. Hence this product

stands well in agreement with U.S.P. specifications. The particle size of the prepared MCC is in

narrow range of 30 µm whereas commercial MCC is having 80 µm. It can be observed from the

SEM micrographs that banana MCC surface is plain without any serrations. Prepared cellulose

powder as well as commercial MCC is having similar characteristics for solubility in water, dilute

alkali, dilute acid, organic solvent and groundnut oil which is as per standards of Pharmacopoeia

of India. The pH value of prepared MCC is in close confirmation with commercial material.

Particle size depends upon the extent of degradation of cellulose molecule. The cellulose powder

prepared from banana fibres having lower molecular degradation than commercial MCC.

BANANA PSEUDOSTEM VALUE CHAIN

23

The powder X-ray diffraction spectra of both the cellulose samples showed typical of

Cellulose I structure with diffraction peaks of the 2 angles at 15 , 16.5 and 22.6 . The sharp

peak of 22.6 indicates higher crystallinity. Percentage crystallinity of cellulose powder prepared

from banana fibres is 72.1 per cent where as for commercial MCC is 82.1 per cent. The

Crystallinity Index gives a quantitative measure of the crystallinity in powders which can be

related to the strength and stiffness of fibres. High crystallinity indicates an ordered compact

molecular structure, which translates to dense particles, whereas lower crystallinity implies a more

disordered structure, resulting in a more amorphous powder. The cellulose powder prepared from

banana fibres is found to have 13.9 per cent more compressibility than commercial MCC.

Conclusion: Banana fibre is rich in cellulose and thus can be a potential raw material for the

preparation of microcrystalline cellulose. The MCC prepared from banana fibres compared

favourably with Avicel (commercial brand of microcrystalline cellulose) in most of the physical

and spectroscopic properties. The results also confirm that one can use a bio-chemical route for

preparation of MCC. Bio-chemical route is highly environmentally safe and minimizes the use of

chemicals.

In the industry MCC is prepared from wood. MCC yield from wood is about 30 to 35 per

cent. In comparison MCC yield from banana fibres is about 50 per cent. During the project period

only laboratory scale MCC production from banana fibre could be undertaken. Hence, it is very

difficult to give cost economics for preparation of MCC exclusively from banana fibres on large

scale. However, it is envisaged that the present plants producing MCC from wood pulp as raw

material can also use banana fibre for its production. Higher yield of MCC from banana fibres is

expected to increase the profit margin.

FINAL REPORT (NAIP COMPONENT – 2)

24

5.2 Objective: Standardize processes of pulp and paper making from pseudostem, fibres and

scutching waste both at hand made and industrial levels

5.2.1 Optimization of pulping conditions for banana fibre and scutcher

(A) Use of banana fibre and scutcher waste as raw material for pulping

(i) Fibre: In order to find out the economic viability of using pseudostem fibre, scutcher and

whole pseudostem as raw materials in paper and pulp industries, in present project series of trials

Summary: Banana fibre extraction and product development

After incorporating essential modifications i.e., providing additional pulley for using

alternative energy source and bigger size wheels for easy mobility in field in raspador

machines, about 42 tones of dry fibre from banana pseudostem were extracted by active

involvement of the banana growers. With the output of 25 to 30 kg dry fibre / day/machine by

employing 5 to 6 laborers, it is economically viable by considering selling price of dry fibre at

Rs.100/kg. Though, fibre extraction is economically viable, yet there is need to reduce cost of

fibre for its wider applicability.

With respect to product development, woven as well as non woven fabrics were

prepared. In woven fabrics, quality of yarn obtained has two problems i.e., protruded fibre and

coarseness with poor linearity. In spite of these problems, about 350 m woven fabric was

prepared using handlooms weaving method. This fabric was processed and varieties of

products (bags, coat, curtain, mats etc) were developed on small scale.

To overcome the problems of poor quality of yarn, non woven fabric (~3 tones) was

prepared by employing needle punching technique. The product viz., coated with resins and

composite developed from non woven fabric are potential candidates for use in automobile and

railway coaches as these products have advantage of lighter in weight than currently used

material.

For obtaining good quality yarn, peddle operated modified CIRCOT-Phoenix Medalari

Charkha has been designed and the quality of yarn prepared using charkha was much better

than yarn prepared on jute spinning system. Apart from improvement in yarn quality, it can

generate good employment in tribal and rural areas especially for women empowerment. Along

with preparing banana fibre yarn using charkha, tribal women can also prepare handicrafts

using banana fibre and earn their livelihood. Both these jobs can be performed perfectly by

tribal women who are by birth artisans. Ultimately, popularization of these activities in tribal

area may minimize migration.

Apart from the above techno-economically viable technologies, the processes for

preparing micro crystalline cellulose (MCC) using indigenously available raw material like

banana fibre and use of sap as mordant (natural adhesive) in textile dyeing have been

standardized at laboratory scale. Large scale trials are yet to be done after which it is possible

to compute the economic viability of the technology. The properties of MCC prepared by using

banana fibre are comparable with the MCC (pharmaceutical grade) available in the market.

BANANA PSEUDOSTEM VALUE CHAIN

25

were conducted at J.K. Paper Mills Ltd., Songadh (Gujarat). These trials were conducted for

optimizing the pulping, cooking time, chemical doses, temperature, bath ratio and bleaching

parameters using fibre, whole pseudostem and scutcher as raw material. The detail results are

appended in Annexure 10.

Based on results of the trials, following inferences were emerged.

Ideal bath ratio for Kraft pulping using banana fibre was found to be 1:5 with 71.0 per cent

unbleached pulp yield (unscreened) and 13.4 Kappa No. (Annexure 11)

Optimum cooking chemical dose for banana fibre appears to be 16 per cent with 55.35 per

cent unbleached pulp yield (unscreened) and 11.6 target Kappa No. (Annexure 12)

Because of higher dilution, chemical recovery is not economical. To overcome this problem,

continuous digester with plug screw feeder arrangement is suggested.

For banana fibre, soaking time of 60 minutes was found better in view of low Kappa No. and

higher twaddle of black liquor obtained (Annexure 13).

Optimum cooking temperature for banana fibre was found to be 165oC due to low Kappa No.

and cooking time of 60 minutes with better unbleached pulp yield was found to be ideal

(Annexure 13).

Subsequently, the normal pulping conditions maintained for different raw material by paper

mills vis-a- vis the optimized pulping conditions arrived for banana fibre were compared (Table

5.2.1)

Table 5.2.1: Standard pulping conditions of different raw materials

Particulars Unit Bamboo Eucaly

ptus

Subabul +

Bark Bagasse

Banana

fibre

Remarks

Active Alkali as

Na2O % 16-18 18.4 17 12.5-13 15 -16

Active alkali

requirement is

higher than bagasse

Time to temp.

(85-165oC)

Hrs. 3 3 3 -- 2 Time requirement is

less

Time at

Temp.(165oC)

Hrs. 2 2 2 1.5 1.0 Time requirement is

less

Kappa No. No. 19 20 16.8 12 ± 1 12 + 1 Less than other raw

materials

Screened

unbleached pulp

yield

% 49.3 48.9 49.4 48.5 56 -57

Yield is better than

bagasse.

Reject % 0.5 0.7 1.5 1.5 3.5 + 0.5 Rejects are higher

Total Yield % 49.8 49.7 50.9 50 59.5 – 61.0 Yield is better than

bagasse

Bleached Pulp

Yield % 41.4 45.3 43.5 45 53 + 0.25

Yield is better than

bagasse

The results clearly indicate that screened pulp yield from fibre was found to be

comparatively higher (60%) as compared to other raw material used in paper industry. Further, for

maintaining the same Kappa No. of 12±1, the active alkali requirement for banana fibre seems to

be higher (15%) only as compared to sugarcane bagasse. Similarly, bleaching conditions were

FINAL REPORT (NAIP COMPONENT – 2)

26

also optimized. The results appended suggest that banana fibre are easily bleachable and has good

bleaching response with CEpHD bleaching sequence, bleached pulp brightness achieved was 88%

ISO (Annexure 14).

(ii) Scutcher: As like fibre, scutcher waste obtained during fibre extraction was also tested as raw

material for pulping. Based on the results, it is concluded that scutcher waste require higher

cooking chemicals (22%) and also have high Kappa No. of 20.8, that too with very low

unbleached pulp yield (24.4%). It is, therefore, concluded that scutcher waste is not fit for paper

making (Annexure 15).

(B) Testing quality parameters of pulp and paper

After optimizing pulping and bleaching parameters using fibre and scutcher waste as raw

material, physical parameters of bleached and unbleached pulp and papers were tested.

(i) Pulp: Physical strength properties and fibre classification results and fibre dimensions of the

bleached pulp produced from banana pseudo stem are given in the tables 5.2.2 and 5.2.3.

Table 5.2.2: Physical properties of pulp tested at J K Paper Ltd, Unit: CPM

Particulars Unit Unbleached Pulp Bleached Pulp

Freeness of pulp °SR 40 40

GSM g/cm2

60 60

Bulk Cc/g 1.29 1.22

Breaking Length M 6978 4931

Burst Factor (kg/cm2) 88 79

Tear Factor (mN.m2/g) 86 86

Double Folds No. 3080 1389

Strength Index 2975 2776

Interpretation: The unbleached and bleached pulp physical properties are more or less

comparable in terms of bulk and tear factor, however burst factor is 88 and 80, respectively.

Breaking length in unbleached and bleached pulp is 6678 and 5931 m, and double fold 2580 and

1389, respectively. The overall strength index is 2956 and 2764 in case of unbleached and

bleached pulps. These properties indicate that the pulp quality is adequate for specialty grades of

paper i.e., greaseproof, cheque and currency paper etc.

Table 5.2.3: Classification of banana pseudostem fibre pulp

Particulars Unit Unbleached Pulp Bleached Pulp

+ 20 % 70.8 72.2

- 20 +50 % 16.8 17.6

- 50 + 65 % 2.8 2.9

- 65 + 125 % 0.68 0.65

- 125 % 8.9 6.6

BANANA PSEUDOSTEM VALUE CHAIN

27

Interpretations:

- Plus 20 fraction of banana pulp is very high at 70 to 72 per cent which indicates the

presence of long fibre pulp.

- This type of pulp is bound to give good folding endurance (double folds) indicating its

suitability for the production of packaging papers and boards.

- It is also suitable for the production of papers which needs to be preserved for long times

like Bond paper etc., where rag pulp is normally used to some extent.

- It is most suitable for the production of currency paper as it has good folding endurance

and good strength properties in view of the very high long fibre fraction

Testing of pulp quality by external agencies

The results of the paper quality tested by PAPRI, Rayagada (Orissa) is given in tables

5.2.4.

Table 5.2.4: Fibre dimensions (Tested at PAPRI –Rayagada, Orissa)

Particulars Unit Bamboo Subabul with

bark

Soft wood Banana

fibre

Fibre Length mm 1.8 -2 0.95 2.45 1.44

Fibre Diameter micron 15 15.4 20.2 18.9

Interpretation: The results showed that fibre length and fibre diameter is 1.44 mm and 18.9

micron, respectively, for bleached banana pulp. The fibre length is better than subabul (hardwood

pulp) and inferior than softwood pulp. The fibre length shows good paper making properties

potential.

(ii) Paper: Un-bleached and bleached paper samples prepared at JK Paper were sent for testing to

CIRCOT Mumbai. The results are given in table 5.2.5.

Table 5.2.5: Mechanical properties of paper samples

Paper type G.S.M

(g/m2)

Brightness

(%)

Opacity

%

Burst

factor

(kg/cm2)

Breaking

length (m)

Double

fold (No.)

Bleached 60 73.8 77.5 55.0 3210 840

Un-bleached 60 ---- 80.8 63.3 6020 1972

Interpretation: The brightness of bleached paper is

73.8 per cent i.e., low. However the pulp brightness can

be produced to level of 87-88 per cent brightness. The

paper can be made of high brightness with banana

pseudostem fibre pulp. The strength properties of hand

sheets in terms of double fold and bursting factor are

good and showing good paper making potential.

Handsheet (Bleached & unbleached pulp)

FINAL REPORT (NAIP COMPONENT – 2)

28

(iii) Physical properties of scutcher waste pulp

The results of physical strength properties of the pulp obtained from scutching waste are

given in table 5.2.6.

Table 5.2.6: Physical strength properties of paper prepared using scutcher waste pulp

Particulars Values

Chemical charge as NaOH (%) 16 18 20 22

Tear factor 51.2 53.3 49.2 50.0

Burst factor 19 17 17 14

Breaking length (meter) 4064 3981 3210 2532

Double fold (nos.) 20 17 14 10

Interpretation: This scutcher waste pulp physical strength properties are low as compared to

banana pseudostem fibre. The breaking length, double fold, burst factor is 1/3 as compared to

pseudostem fibre. Tear factor is about half as compared to banana pseudo stem fibre. This type of

pulp may be utilized only in low grade paper.

5.2.2 Exploring possibility for preparing speciality papers

Banana pseudostem fibre being costlier raw material than conventionally used raw

material, it was thought to prepare speciality paper viz., cheque book and grease proof using

banana fibre.

(A) Cheque (MICR) paper from banana fibre pulp: Cheque paper (MICR- Magnetic Ink

Character Recognition) is one of the valuable papers in Indian paper market. It is utilized by banks

to generate payment. It is prepared by adding special chemicals using special pulp. Pulp used in

manufacturing of cheque paper is prepared from some special softwood pulp. This pulp is with

higher strength properties and brightness. The pulp prepared from banana pseudostem fibre for

making cheque paper was tested for its physical properties (Table 5.2.7).

Table 5.2.7: Comparison of physical properties of pulp prepared from banana fibre to that

of other standard pulp used for making cheque papers

Particulars Unit C70+I30 C70+B30 MICR paper

standard

parameters

Banana fibre

pulp

Caliper (Thickness) Micron 110 119 110±10 112

Burst Factor Mullen 25 32 - 64

Tear Factor Eim 78 82 78 124

Breaking length Metre 3216 4628 - 5040

Double Fold MIT 35 142 - 1332

C – CPM pulp, I – Imported pulp and B – Banana fibre pulp

BANANA PSEUDOSTEM VALUE CHAIN

29

Interpretation: The physical strength properties of bleached pulp are very good in terms of tear

factor, burst factor, breaking length and overall strength index is 2764. These properties indicate

that the pulp quality is adequate for making cheque paper (MICR) is one of the valuable papers in

Indian paper market.

(B) Grease proof paper: Grease proof paper is one of the valuable papers in Indian paper market.

Grease proof paper is that impermeable to oil or grease and normally used in cooking or food

packaging. Normally grease proof papers is produced by refining the pulp stock for paper making

to a very high degree refining and thus create a sheet with very high bursting strength and low

porosity, which is the requirement for grease proof paper. The test results of the exploratory trials

on lab scale for grease proof paper prepared from banana fibre are given in table 5.2.8.

Table 5.2.8: Greaseproof paper from unbleached banana fibre pulp

Freeness

° SR

Beating

time

(min)

Tear

factor

Burst

factor

Breaking

length

(Meters)

Double

folds

Blister test Oil

transduction

period (min)

80 60 min 130 >100 8786 Very High Very Good Over 1800

90 90 min 130 >100 8736 Very High Very Good Over 1800

Interpretation: The grease proof paper produced using banana fibre is showing good bursting

strength as well as high oil absorbency time. These properties indicate good potential for making

grease proof paper from banana pseudostem fibre.

5.2.3 Characterization of effluent generated during pulping and bleaching

The effluents generated during processing of banana fibre and hardwoods were

characterized (Annexure 16). As at each step of pulping and bleaching, effluent is generated,

stage wise characterization of effluent was also done and the results are reported in table 5.2.9.

Table 5.2.9: Stage wise characterization of banana fibre effluent

Particulars Unit Chlorination Extraction Hypochlorite Chlorine dioxide

pH 5.2 10.3 6.6 3.4

TSS mg/l 60 69 43 41

TDS mg/l 1720 845 1241 1840

BOD mg/l 156 760 184 74

COD mg/l 666.4 2136 700.6 281.9

Colour Pt-Co Unit 10 60 1.7 1.7

Conductivity µ mhos/cm 2600 1288 1890 2720

Wax Pix test Sensitization test

before Sizing

Sensitization test after

SizingQuality test passed cheque paper made from banana fibre pulp

FINAL REPORT (NAIP COMPONENT – 2)

30

Interpretation: The value of pH, TSS, TDS, BOD, COD, colour and conductivity reported in

table 5.2.9 clearly prove that the effluents generated are not hazardous in nature due to less use of

bleaching chemicals.

5.2.4 Use of whole fresh banana pseudostem for paper making

For resolving the problem of high cost of banana fibre, at JK

Paper Mills Ltd., Songadh an attempt was made to use whole fresh

pseudostem for preparing paper vis-à-vis banana fibre. The results of

trials conducted at JK Paper Mill Ltd. reported in Annexures 17 and

18 indicate that the fibre obtained by depithing of whole fresh

pseudostem are having good pulpable and pulp properties which are

comparable with the fibre extracted by raspador. This was further

substantiated by the bleaching results (Annexure 19)

Bleaching results of whole pseudostem fibre extracted with

the help of raspador machine and mechanical wet depithing process are given in table 5.2.10.

Table: 5.2.10: Properties of bleached fibre extracted using raspador m/c and depithing process

Particulars Unit Banana pseudostem

fibre

Depithed whole banana

pseudostem pulp

Screened pulp kappa No. no. 15±2 15.2

Bleaching sequence -- CEpHD CEpD

Cl2 as gas % 2.5 1.3

Cl2 as Hypo % 1.5 0

Caustic (NaOH) % 1.5 1.8

H2O2 (as 100% basis) % 0.75 1.0

ClO2 % 0.7 0.5

Bleached yield % 50± 2 49.5

Brightness % ISO 89.5 86.5

Viscosity cps 7.0 16.2

PC No. no. 1.0 1.5

Unbleached paper sheet prepared

from mechanically depithed fresh

pseudostem

Depithing and pulping process using fresh banana pseudostem

Drying of pressed

pseudostem

Whole

pseudostem

(without

core)

Chopping/

cutting

Chopped

pseudostem

sample

Hydraulic press

Fibres after

depithing

Unbleached pulp

handsheets

BANANA PSEUDOSTEM VALUE CHAIN

31

Conclusions: From the overall results, it is concluded that banana pseudostem fibre can be a

potential source of raw material in pulp and paper industry. This will not only resolve waste

disposal problem of banana pseudostem, but farmers can realize additional income from this

waste. Further, if not alternative, use of banana fibre as supplemental raw material in paper and

pulp industry will reduce the tree cuttings activity. Banana pseudostem fibre gives higher pulp

yield and brightness with less chemical consumption. This extracted fibre pulp seems suitable as a

mix for preparing special grades of paper i.e., parchment, greaseproof, cheque and currency paper.

However, the cost economics seems to be an area of concerned for its commercial use by paper

industries. Fibre extraction cost from pseudostem is high due to manpower intensive which

increases the pulp manufacturing cost. Further, efforts are required to reduce the cost of fibre from

banana pseudostem through complete mechanization of the extraction process. Another option for

cost reduction of fibre is to use fresh whole pseudostem for pulping. However, there is need to

optimize the depithing parameters for fresh whole pseudostem.

5.2.5 Preparation of handmade papers and boards using fibre and their quality testing

Under NAIP, one handmade paper and board unit has been

established at NAU, Navsari (capcity: 100 kg/day). In this unit, variety

of paper and board (6 t) have been prepared using banana fibre, scutcher,

cotton rags, waste paper and paddy straw in varying proportion. The

quality parameters of these papers were tested at CIRCOT, Mumbai

(Tables 5.2.11 and 5.2.12).

5.2.11: Mechanical properties of paper samples Sample G.S.M.

(g/m2)

Burst

factor

(kg/cm2)

Tear factor

(mN.m2/g)

Breaking

length (m)

Double

fold

(nos.)

Whole pseudostem tissue paper 14.0 28.6 699.9 3158 49

Banana fibre tissue paper 26.0 51.9 470.8 6259 845

Whole pseudostem paper sheet 74.4 30.9 219.3 4450 3220

Banana fibre paper sheet 86.3 44.0 198.4 5676 5440

The quality of paper prepared both at handmade as well as at laboratory scale was quite

satisfactory when blended with banana fibre. It had excellent burst factor and folding properties.

5.2.12: Mechanical properties of paper samples

Raw materials used G.S.M.

(G/m2)

Burst factor

(kg/cm2)

Breaking

length (m)

Double fold

(nos.)

Banana fibre (Yellow) 145 31.72 4140 5000

Banana fibre (Thick- White) 309 38.83 3117 3000

Banana fibre:Cotton rags (50:50) (Thick) 513 25.34 2321 1300

Banana fibre:Cotton rags (50:50) (Thin) 146 36.99 2604 300

Banana fibre + Cotton + Paddy straw (33.3:

33.3: 33.3) 335 19.10 2334 115

Banana fibre + Cotton Rags (colour) 335 20.90 1786 320

Sheet preparing m/c at NAU,

Navsari

FINAL REPORT (NAIP COMPONENT – 2)

32

5.3 Objective: Develop value added edible products from central core

5.3.1 Standardize of process for preparing candy and testing its quality parameters

Process: Central core is inner most tender portion of the pseudostem

which is edible. It is a by-product obtained from banana pseudostem

during the process of fibre extraction. About 10 to 12 tonnes of central

core can be obtained from one hectare banana plantation. Since no

such product made from banana pseudostem central core is existing in

the market, NAU has standardized processes for developing various

edible products from it.

Quality parameters: After processing of central core into candy it becomes delicious and

palatable which is prefered by people and especially children. The product was tested at CFTRI,

Mysore and SICART, Anand for its quality. It is found to contain digestible fibres, Iron, Vitamins

B3 and B5 in appreciable amount (Table 5.3.1).

Table 5.3.1: Quality parameters of candy prepared from central core

Parameters Unit Content Parameters Unit Content

Protein % 4.1 K % 0.20

Carbohydrates mg/100 g 46.8 Na % 0.42

Calorific value k.cals/100 g 390 Ca % 1.37

Total sugars % 85.4 Mg % 2.22

Total Dietary fibre % 3.95 Fe mg/kg 643

Vitamin

(Pantothenic acid B5)

(mg/100g) 86.4 Vitamin

(Niacin B3)

(mg/100g) 34.1

It is a potential product for commercialization by the food and cottage industry. It has

opened doors for institutional suppliers like Govt‟s mid day meal scheme and nutrition

Summary of paper related work

Banana pseudostem fibre and scutcher waste were tried as a raw material for making

pulp and quality papers. The processes have been optimized for preparing good quality pulp

and high value paper like grease proof, cheque book etc., using fibre as raw material.

Though, from quality and pollution point of view, fibre is much better raw material

than other material used for paper making, yet its high cost is major problem in making large

scale use of fibre in paper industry. This problem needs to be addressed by using fibre as

blending in certain proportion and/or by using whole fresh pseudostem for pulping by

employing depithing technique. Of course, further research and development is required on

this aspect.

However, fibre is an excellent raw material for preparing handmade paper and board

at small scale/cottage industry level. This was found profitable even with 100 kg paper/day

capacity handmade paper and board unit commissioned at NAU, Navsari

BANANA PSEUDOSTEM VALUE CHAIN

33

improvement programs of UNDP and WHO. If adopted by SHGs, Mahila Mandals etc., it will

uplift rural women and boost women empowerment ultimately leading gender mainstreaming.

Hence, this business can be a very profitable and lucrative. Patent has been filed at National level

(1624/MUM/2011) as “A novel process for manufacturing banana candy from banana

pseudostem”.

5.3.2 Standardize process for preparing Ready to Serve Drink

The soft drinks are prepared from sugar syrup left out during candy

preparation as well as directly from central core sap. The drinks prepared are

fortified with flavours for which standardization has been done by NAU. Large

quantity of sugar syrup generated during processing of banana central core candy

is generally considered as waste material. The left out syrup, with 70o brix was

flavored either artificially or naturally to improve its overall acceptability. The

concentrated syrup is heated to 85ºC for 25 min followed by immediate cooling

to room temperature. The prepared RTS drink is filled into pre-sterilized glass

bottles and then hermitically sealed by crown corking machine. The bottles can

be stored at ambient temperature for 6 month.

Conclusion: Based on the quality as well as sensory parameters, banana pseudostem central core

can be processed into delicious candy and RTS which are good sources of potassium, iron and

digestible fibres. As central core is tasteless, it can be flavored using any artificial as well as

natural flavor and can have good economical value to small and medium scale entrepreneurs. The

central core seems to cheaper alternative raw material for confectionary industry.

Summary of edible products developed from central core

The central core of banana pseudostem is a edible portion. The process for preparing

candy using central core has been standardized. The candy so obtained in rich source of K, Fe

and content vitamins B3 and B5 in appreciable quantity. A pilot scale production is being done at

NAU and it was found to be profitable. This technology was also grouped under “ready for

commercialization category” by national committee of NAIP. The syrup (70% brix) obtained as

by product during candy preparation can be used for preparing RTS drink in various flavours.

This technology is also most suitable for cottage or small scale industry. Here the cost of raw

material i.e., central core is negligible.

5.4 Objecive: Preparation and evaluation of enriched sap (Organic Liquid Fertilizer) and

scutching waste based vermicompost

Banana pseudostem sap is obtained as a by-product during extraction of fibre. It is a rich

source of plant nutrients like K, Fe and plant growth regulators. Hence, experiments were

conducted to use the sap directly as a liquid fertilizer initially in different crops through soil and

foliar application. In response to its positive effect in enhancing the yields of the crops,

enrichment process was standardized and tested in different crops at NAU, Navsari.

RTS from sap of

central core

FINAL REPORT (NAIP COMPONENT – 2)

34

5.4.1: Use of sap as a liquid fertilizer (without enrichment)

(A) Separation of sap from banana pseudostem scutcher: From the

scutcher + sap collected in tray placed bellow raspador machine during

fibre extraction, sap can be separated either by squeezing the scutcher

manually or by using screw press developed by NAU, Navsari. Use of

screw press is more efficient in sap separation from scutcher than manual

squeezing. On an average, from one hectare banana plantation around

12000 to 15000 litres sap is obtained. In other words, one unit of five

raspador machines can generate about 4000 to 5000 litres sap per day.

(B) Study on variation in composition of sap: For assessing the field wise variation in

composition of sap in all 110 samples were analysed for plant nutrient and biochemcial

parameters (Table 5.4.1).

Table 5.4.1: Nutritional and biochemical composition of banana pseudostem sap (on fresh

weight basis)

Parameter Unit Content (range) Mean

N

%

0.005 – 0.032 0.015

P 0.002 – 0.007 0.0028

K 0.154 – 0.234 0.208

S Trace – 0.004 0.002

Ca 0.004 – 0.020 0.014

Mg 0.014 – 0.101 0.048

Fe

ppm

2.57 – 38.17 10.72

Mn 2.66 – 19.34 9.78

Zn Trace – 1.79 1.07

Cu Trace – 4.30 0.98

Total soluble sugars (mg/ml) 0.356 - 4.881 1.877

Total phenols (µg/ml) 2.750 - 25.19 13.803

Total amino acids (mg/ml) 0.022 - 0.232 0.129

Urease activity (U/ml/min) 1.450 - 10.14 4.676

Cytokinin (mg/l) (mg/l) 44.5

Gibberellic acid (mg/l) 13.7

The range and mean values reported in table 5.4.1 revealed that variation in the

composition of sap vary with the element which is higher in N, Cu and biochemical parameters.

Based on the mean value K, Fe, Zn and Mn are higher as compared to rest of the elements.

Among the biochemical parameters, phenol content recorded higher value in comparison to rest of

the parameters. The sap also contains plant growth regulators in appreciable quantity.

Screw press m/c for

extracting sap from

scutcher

BANANA PSEUDOSTEM VALUE CHAIN

35

55

60

65

70

75

Only RDF 80% RDF + sap@ 3

litres/plant

62

70

Fig. 5.4.1: Effect of fertilizer and sap on yield (t/ha) of banana

CD (0.05): 6.5

(C) Response of different crops to application of sap: Considering the nutrient rich

composition of sap it is suitable for direct use as liquid fertilizer. The work done during project

period on this aspect is described here.

(i) Experiment title: Evaluation of banana pseudostem sap as a liquid fertilizer through drip in

banana and sugarcane.

Methodology: An experiment was conducted at SWMRU farm, NAU, Navsari consecutively for

two years (2008-09 and 2009-10) using banana (cv. Grand Naine) and sugarcane (cv. CoN. 5071)

as test crops. In all following 9 treatment combinations were tested in FRBD with three

replications in both the crops.

Banana Sugarcane Banana Sugarcane

Sap application (l/plant) Sap application (l/ha) RDF (%) RDF (%)

S1 2 S1 5000 F1 60 F1 60

S2 3 S2 10000 F2 80 F2 80

S3 4 S3 15000 F3 100 F3 100 Note: Sap was applied in 10 equal splits through drip in both the

crops RDF 300: 90: 200 g

NPK/plant

RDF 250: 125: 125 kg

NPK/ha

Crop yields:

Banana: The two years pooled (Fig. 5.4.1)

results showed that application of RDF @ 80

per cent along with sap @ 3 l/plant in 10

equal splits recorded significantly higher

yield (70 t/ha) as compared to application of

RDF alone. This could be attributed to the

nutritional composition of sap along with

plant growth regulators applied along with

80 per cent RDF to crop. This implies that 20

per cent RDF cost in banana can be saved

that too with higher fruit yield. This treatment was also found more remunerative by recording B:

C ratio of 2.0.

Sugarcane: In the case of sugarcane, the

effect of different treatments was not

significant on cane yield (Fig. 5.4.2). This

clearly suggests that application of sap

@5000 l/ha in 10 equal splits + only 60%

RDF (low input treatment) is good enough for

getting relatively higher cane yield. Here, 40

% cost of RDF can be saved without

significant reduction in cane yield.

168

170

172

174

176

Only RDF 60% RDF + sap@ 5000

litres/ha

171

175

Fig. 5.4.2: Effect of fertilizer and sap on yield (t/ha) of sugarcane

CD (0.05): NS

FINAL REPORT (NAIP COMPONENT – 2)

36

(ii) Experiment title: Effect of sap application on yield of different crops

In addition to NAIP trials, 3 additional experiments were also conducted with onion, garlic

and leafy vegetable crops. The magnitude of increase in yield was ranging from 67 per cent in

onion to 4 per cent in leafy vegetable (Table 5.4.2). Further, in the case of onion 20 per cent

saving in recommended fertilizer dose and that on organic farm 50 per cent saving of castor cake

in garlic was also observed. These treatments are also more remunerative than control.

Table 5.4.2: Effect of sap application on yield of different crops Test crop Yield % increase over

control

Method of

application

Remark

Control Treatment

Onion

(Field)

28.75 t/ha 47.9 t/ha 67 Through drip

@1500 l/ha in 5

equal splits

20% saving of

fertilizer

Garlic

(Field)

4.58 t/ha 6.54 t/ha 43 Through drip

@2000 l/ha in 5

equal splits

50% saving of

castor cake

Leafy vegetable

(Amaranths&

Spinach)

(Poly house)

537 kg/100

sq m

559 kg/100 sq m 4 Drenching

@2000 l/ha

-

5.4.2 Develop process for enrichment of sap and study responses by different crops

(A) Development of process for preparing enriched sap (Organic liquid fertilizer)

Process: The banana pseudostem sap is collected by squeezing scutcher waste either manually or

by press obtained during the process of fibre extraction. The sap obtained is to be filtered using

muslin cloth for removing the suspended material. Mixing of different organic inputs and sap has

to be done in sequential manner (Patent, PCTIB2012053268, 1609/ MUM/2011).

The whole mixture is then filled in bio-digester and

incubated under anaerobic condition. The mixture is to be stirred

periodically. After specified period the supernatant is to be

collected, filtered and stored in air tight container.

(B) Composition of enriched sap: In order to know the variation

in composition of sap during anaerobic decomposition, periodical

samples were collected and analyzed for major and micronutrients content by adopting standard

analytical procedures. The results (Annexure 20) indicated no variation in content except N, P, Fe

and Mn which tended to increase with the time of incubation. Similarly, after completion of

incubation, ready for use enriched sap (OLF: organic liquid fertilizer) was analyzed for nutrient,

biochemical and microbial parameters (Table 5.4.3). Based on the composition of enriched sap, it

can be used as spray solution in different crops. It contains not only essential plant nutrient but

also plant growth regulators viz. cytokinin and GA3 as well as some beneficial organisms.

Enriched sap of banana pseudostem

BANANA PSEUDOSTEM VALUE CHAIN

37

0.00

0.30

0.60

0.90

1.20

1.50

Fresh sap + vermibed wash

(1:1)

Enriched sap alone

Control (No Spray)

1.291.05

0.67

Fig. 5.4.3: Effect of different treatments on final fruit retention

(% over initial) in mango (cv. Kesar)

CD (0.05): 0.26

Table 5.4.3: Composition of enriched sap ready to use

Chemical Biochemical

Parameters Unit Mean Parameters Unit Content

N

%

0.062 Total phenol mg/100 ml 48.0 – 49.1

P 0.018 Urease activity U/ml/min 63 – 81

K 0.180 Gibberellic Acid mg/l 110.2 – 205.0

Ca 0.031 Cytokinin mg/l 137.8 – 244.3

Mg 0.092 Microbe Unit Population

S 0.010 Total viable count

(CFU/ml)

1065 x 103

Mn

ppm

5.73 PSB 1025 x 102

Cu 0.40 Rhizobium 285 x 102

Zn 2.92 Azotobacter 460 x 102

Fe 109.3 Fungal count 1200

(C) Response of different crops to application of OLF

(i) Experiment title: Effect of pseudostem sap and vermi bed wash on fruit setting in mango (cv.

Kesar)

Methodology: As enriched sap contents GA3 and cytokinin, it was thought to study the effect of its

spraying on fruit retention in mango. A field experiment was conducted for two years (2009-10

and 2010-11) with seven treatments In all four sprays were done i.e., at flower initiation, 15 days

after first spray and rest two subsequently at 10 days interval. All the solutions were sprayed @ 5

per cent (v/v).

Results: The pooled results related to per cent

retention of mango fruits were affected

significantly due to different spray solutions

(Fig. 5.4.3). Among the treatments,

treatments receiving four sprays of enriched

sap alone (1.054 %), sap + vermi-wash in 1:1

ratio (1.291 %) were significantly more than

control (0.67 %). It means depending on

availability and economics, farmers can use

enriched sap or sap + vermi-wash for increasing the fruit retention in mango.

Conclusion: Spraying of sap + vermi-wash or enriched sap four times can increase the fruit

retention and ultimately the fruit yield considerably. This was also validated on farmers‟ fields

through large scale demonstrations.

(ii) Experiment title: Evaluation of sap based products on vigour of vegetable nursery.

Methodology: An experiment was conducted in polyhouse for two seasons during 2009. The

vegetable crops tested in the experiments were brinjal (cv., Surati Ravaiya) and chillies (cv.

FINAL REPORT (NAIP COMPONENT – 2)

38

0

10

20

30

40

50

T3-En. Sap (ES) T4-FS: VW (1:1) T7-Control (No spary)

Brinjal Chillies

Treatment

Fig. 5.3.4: Effect of different sprays on days to transplantable stages of

vegetable seedlings (Pooled over 2 crop season)

Brinjal Chillies

CD (0.05) 2.0 3.0

Suryarekha) with seven different treatments in RBD with 4 replications under poly house

condition. In all the treatments, concentration of spray solution was 1 % (v/v). Such five sprays

were applied at an interval of 4 days starting from two fully open leaves stage.

Results: The two seasons pooled results

clearly indicated that four sprays of either

enriched sap or sap + vermi-wash (1:1)

improved the vigour of brinjal and chillies

seedlings and there by the seedlings are

attaining transplantable stage 8 to 9 days

earlier as compared to control (Fig. 5.4.4).

Conclusion: Spraying enriched sap or sap

+ vermi-wash could save about 8 days time

of the nurserymen. This reduces the cost of

seedling production as well as facilitates timely transplanting of the crops.

(iii) Experiment title: Effect of application of enriched sap (OLF) on yield of different crops

The enriched sap was also tested in field experiment other than NAIP trials. The enriched

sap being costlier than sap, it was tested as a foliar spray in different crops (Table 5.4.4). The

results revealed that an increase in pod yield of summer vegetable crops viz., okra, cluster bean

and cowpea was 31, 30 and 20 per cent, respectively. In case of banana, an increase in fruit yield

was 23 per cent and that in cereals the increase was around 11 per cent. The wheat and paddy

crops were grown on certified organic farm. It means that the enriched sap can be used in organic

farming system also. This has special significance in organic farming, as this nutrient solution

being suitable for organic farming which are very scanty in the market.

Table 5.4.4: Effect of application of enriched sap (Organic Liquid Fertilizer) on yield of

different crops

Crops Type of

experiment

(Design)

Total no.

of

treatment

Season/

year

Yield (t/ha) Method of

application

%

increase

over

control

Control Treatment

Okra (S) Field (RBD) 5 1 1.34 1.76 4 foliar sprays

@ 1 or 2 %

(v/v)

31

Cluster bean (S) Field (RBD) 5 1 1.59 2.07 30

Cowpea (S) Field (RBD) 5 1 1.39 1.67 20

Banana Field (CRD) 21 3 81 100

Cone feeding

@120

ml/plant in 3

splits

23

Wheat Organic farm

Field (RBD) 13 2 2.15 2.42

3 foliar sprays

@1% (v/v)

13

Paddy

Organic farm

field

(RBD)

13 2 3.73 4.05 9

BANANA PSEUDOSTEM VALUE CHAIN

39

5.4.3 Use of sap as a mordant in textile dyeing

Apart from use of sap directly or after enrichment as a organic liquid fertilizer, it was also

tested for its use as a mordant in textile dyeing. The process for this was tested on laboratory scale

at CIRCOT, Mumbai. Sap was applied to cotton fabric by padding in a padding mangle to 80%

wet pick up air dried and treated with 10% alum solution in alkaline condition. Mordanted

samples were dyed with manjisth (20% owf) and annatto (7.5% owf). Colour parameters and

fastner properties are presented in tables 5.4.5 and 5.4.6, respectively. The natural dyes like

manjistha and bixa were tested for its fastening properties using fresh banana pseudostem sap.

The test results indicated very good fastening with manjistha dye along sap.

Table 5.4.5: Colour parameters of dyed cotton fabric

SN Dye Used K/S at max max (nm) L a B c H

1. Manjistha 2.33 500 58.30 27.95 13.24 30.92 25.35

2. Annatto 4.34 470 69.73 29.36 52.25 59.94 60.66

Table 5.4.6: Fastness properties of dyed cotton fabric

Dyed Used Fastness to Light Fastness to Washing

Colour Change Staining Cotton/Wool

Manjistha 2-3 4-5 4-5 / 5

Annatto 2 3-4 3-4 / 5

Interpretation: Colour obtained was darker and uniform. Wash fastness was found to be very

good for manjistha and satisfactory for annatto but light fastness needs improvement.

Summary of pseudostem sap and its uses

Organic liquid fertilizer:

The liquid portion sap obtained along with scutcher during fibre extraction from

pseudostem by raspador machine is good source of plant nutrient along with growth promoting

substances like cytokine, GA3, etc. If used as liquid fertilizer either through drip system or

drenching in crops like banana, sugarcane, papaya, onion, leafy vegetable, it can save 20 to 40

per cent dose of fertilizer with yield advantage of 10-15 per cent. This can be directly adopted by

the farmers themselves.

Apart from direct use of sap as liquid fertilizer, an enrichment process was developed

(patented) for preparing Novel Organic Liquid Fertilizer (OLF) suitable for foliar and soil

application. It was tested in mango, banana, wheat and paddy crops. Application of 3 – 4 sprays

of OLF @ 1 to 2 % (v/v), could increase the yield by 12 to 15 per cent across the crops. The OLF

has been prepared using only organic inputs and hence suitable for use in organic farming

system as liquid formulation. Looking to the techno-economic viability, three parties have signed

MoU with NAU for OLF production and marketing on commercial scale.

Sap as a mordant in textile dyeing:

Use of sap as mordant has twine advantages i.e., improves colour fastness and being

natural product it is not hazardous to the environment.

FINAL REPORT (NAIP COMPONENT – 2)

40

5.4.3 Standardization of process for preparing scutching waster based vermicompost and its

use as organic manure

As organic manure

(A) Process standardization: While extracting fibre from banana pseudostem with raspador

machine, fibre and scutcher + sap are obtained simultaneously. In general, from 1 ha banana

plantation, about 40 to 50 tonnes fresh scutcher + sap is generated. On an average, one unit of five

raspador machine can generate about 12 to 15 tonnes scutcher waste per day. The scutcher + sap

generated during fibre extraction can be used either for preparing vermi-compost or for extracting

sap. For standardizing the proportion of dung and scutcher waste to be used for preparing vermi-

compost one trial was conducted. The results of the trial revealed that 70:30 scutcher: dung is

good proportion in comparison to the 50:50 of other waste: dung used in preparing general

vermicompost. Advantage of this ratio is that, it requires 20 per cent less dung which is in short

supply.

(B) Study comparative performance of vermicompost vis-a-vis FYM and biocompost

(i) Title: Evaluation of pseudostem based vermi-compost vis-à-vis FYM and bio-compost in

banana and sugarcane.

Methodology: Integrated use of FYM or biocompost with inorganic fertilizers is recommended

for the crops like banana, sugarcane etc., so as to achieve the sustain productivity and maintain the

soil health. However, these organics are not liberally available for application to these crops. In

this project, it was envisaged to develop enriched vermicompost from pseudostem which can be a

viable alternative of either FYM or biocompost. Accordingly, the field experiments were

conducted during the year 2008-09 and 2009-10 evaluating the performance of different organics

using banana and sugarcane as test crops. The experimental details are given here.

Banana Sugarcane

T1 - FYM @ 5 kg/plant + RDF T1 - FYM @ 20 t/ha + RDF

T2 – Biocompost @ 3 kg/plant + RDF T2 – Biocompost @ 15 t/ha + RDF

T3 – Vermicompost @ 1.5 kg/ plant + RDF T3 - Vermicompost @ 5 t/ha + RDF

T4 – Vermicompost @ 3.0 kg/ plant + RDF T4 – Vermicompost @ 10 t/ha + RDF

T5 – Vermicompost @ 5.0 kg/ plant + RDF T5 – Vermicompost @ 15 t/ha + RDF

T6 - Only RDF (No organics) T6 - Only RDF (No organics)

Other details

RDF (NPK) 300 : 90 : 200 g/plant RDF (NPK) 250: 125: 125 kg/ha

Design Randomized Block

Design

Design Randomized Block

Design

Replications 4 Replications 4

Crop yield: The pooled results related to fruit yield of banana and cane yield are depicted in figs.

5.4.5 and 5.4.6, respectively.

BANANA PSEUDOSTEM VALUE CHAIN

41

0

10

20

30

40

50

60

70

80

T1 - FYM

@ 20 t/plant +

RDF

T2 - BC @

3 kg/plant + RDF

T3 - VC @

1.5 kg/ plant +

RDF

T4 - VC @

3.0 kg/ plant +

RDF

T5 - VC @

5.0 kg/ plant +

RDF

T6 - Only

RDF (No organics)

Yie

ld (t/

ha

)

CD (0.05): 8

Fig. 5.4.5: Effect of different treatments on yield (t/ha) of banana

(Pooled over 2 years)

Treatments

0

50

100

150

200

T1 - FYM

@ 20 t/ha + RDF

T2 - BC @

15 t/ha + RDF

T3 - VC @

5 t/ha + RDF

T4 - VC @

10 t/ha + RDF

T5 - VC @

15 t/ha + RDF

T6 - Only

RDF (No organics)

Yie

ld (

t/h

a)

CD (0.05): NS

Fig. 5.4.6: Effect of different treatments on cane yield (t/ha) of

sugarcane (Pooled over 2 years)

Banana: The fruit yield of banana was affected significantly due to different manurial treatments.

Among the treatments, T4 recorded conspicuously higher fruit yield of banana (71 t/ha) as

compared to T6. However, it was at par with treatments T1, T3 and T5. The result of present study

implies that banana pseudostem

based vermi-compost is an

economically viable alternative for

the routinely used FYM and bio-

compost (press mud based). Not

only this, but the quantity of

pseudostem based vermicompost

required is only 3 kg/plant as

against 5 kg/plant of FYM. This

could be due to narrow C: N ratio

of pseudostem based vermi-

compost than FYM and bio-

compost.

Sugarcane: The cane yield

recorded was not affected

significantly by the treatments of

different organics + RDF. However,

numerically higher value of cane

yield were recorded with T5 (181

t/ha), T4 (176 t/ha), T3 (175 t/ha)

and T1 (174 t/ha) as compared to T2

(163 t/ha) and T6 (163 t/ha). These

results clearly indicate that

pseudostem based vermi-compost is

comparable with FYM or bio-compost being used by the farmers.

Apart from increase in yield in banana and sugarcane, addition of organics viz. FYM, bio-

compost and pseudostem based vermi-compost also maintains the soil fertility in terms of organic

C, available P and K.

Conclusions: Based on the yield and economics, it is concluded that use of banana pseudostem

based vermi-compost is techno-economically viable alternative for FYM or biocompost in heavy

feeder crops like banana, sugarcane etc.

(ii) Experimental title: Evaluation of sources of organics in presence and absence of sap on yield

of papaya under organic farming system

Methodology: Apart from use of scutcher based vermi-compost alone, it was attempted to study

the effect of combined application of vermicompost and sap on yield of papaya on Certified

FINAL REPORT (NAIP COMPONENT – 2)

42

Organic Farm during 2009-10 and 2010-11. In all eight treatments were evaluated in FRBD with

three replications.

Results: The pooled results of fruit yield of papaya reported in table 5.4.7 revealed that only main

effects of Organics (O) and Sap (S) were significant. Among the organics, application of bio-

compost, vermi-compost and castor cake in equal proportion recorded significantly higher yield of

papaya in comparison to remaining treatments. Similarly, between two sap level, S1 (64.13 t/ha)

recorded significantly more fruit yield than S0 (57.65 t/ha). From economics point of view, O4 and

S2 showed superiority over other treatments.

Table 5.4.7: Effect of different treatments on papaya yield and income

Treatments Fruit yield (t/ha) Net income (Rs lakh/ha)

Normal price Premium price

O1= BC:CC (50:50) 52.3 1.33 3.94

O2= BC:VC (50:50) 57.5 0.96 3.84

O3= BC:VC:CC (50:25:25) 65.0 1.55 4.80

O4= BC:VC:CC (33.3: 33.3: 33.3) 68.8 1.62 5.06

CD @ 5% 2.7 - -

S0= No sap 57.6 1.20 4.08

S1= sap @8 l/plant 64.1 1.27 4.48

CD @ 5% 2.0 - -

Conclusion: Based on the results of two years, it is concluded that pseudostem scutcher based

vermi-compost is a good alternative source of organics in organic farming and it can reduce the

cost of organics also through supplementation for castor cake. Similarly, sap application was

found to be more remunerative than no sap application.

(C) Validation on farmers’ fields: In view of encouraging effect of banana pseudostem scutcher

based vermi-compost, in all 10 demonstrations were arranged on farmers‟ fields for validating the

results of field experiment. The increase in yields of the crops viz., sugarcane, banana and papaya

were 14-35, 7-19 and 8-14 per cent, respectively. The overall average increase in the yields of the

crops due to use of scutching waste based vermicompost was 15.8 per cent over control i.e.,

farmers practice. This clearly validates the results of field experiment on farmers‟ fields in

different crops.

As a fish feed

The banana pseudostem based vermicompost was also tested as a fish feed. Most of the

farmers use cattle feed in fish culture in ponds, where the cost of this feed is high. In light of this,

an experiment was planned to study the feasibility of using banana pseudostem based

vermicompost as a fish feed by partially substituting the cattle feed. Before feeding, the

vermicompost was pelleted on using a pelleting machine and dried in shade. The cattle feed was

partially substituted by 10, 20 and 30 per cent by pelleted vermicompost. The results indicated

that substitution of cattle feed up to 30 per cent with vermicompost not only reduced the cost of

feed by 10 per cent but also increased body weight of fish.

BANANA PSEUDOSTEM VALUE CHAIN

43

6. Innovations

In the project proposal, six innovations were proposed. However, during the project

period, additional three innovations pertinent to the objectives of the project were also attempted.

The status of all the innovations is mentioned here.

SN Innovations Brief information about innovations Remarks

(A) Proposed innovations

1. Garments from banana

fibre

Using the yarn obtained from jute

spinning system, garments like apron,

coat, cap, curtains etc., were prepared

and quality parameters were tested.

Laboratory scale

2. Nanotechnology for

improving fibre quality

Banana fibre being the strongest among

the natural fibres and hence, it was not

attempted.

--

3. Mircrocrystalline

cellulose (MCC) from

banana fibre

The processes viz., chemical and

biological routes were standardized.

The quality of MCC was found

comparable with that of commercially

available pharmaceutical grade MCC in

the market.

Laboratory scale

4. Sap as a mordant in

textile dyeing

Process for use of sap as a mordant was

standardized and the results are

encouraging. Sap can be used as a

natural mordant in textile dyeing.

Laboratory scale

5. Edible products from

central core

The processes for preparing candy and

RTS have been standardized. The candy

is nutritionally rich and central core is

cheaper material.

Pilot scale production

unit at NAU, Navsari

Summary of scutching waste based vermicompost

The scutcher waste which is another by-product obtained during fibre extraction from

pseudostem using raspador machine is easily degradable and found highly suitable for

preparing good quality vermicompost. The main advantage of using scutcher is it requires less

dung (30%) as against the 50 per cent in other crop residues used for preparing vermicompost.

It was tested in banana, sugarcane and papaya and found that it is comparable with the

routinely used organics like FYM, biocompost (sugar industry press mud based) etc. This is

good alternative source of organic manure for the farmers which they can prepare on their on

farms.

Further, scutcher based vemicomspost was pelleted and tested it as a fish feed.

Substitution of cattle feed up to 30 per cent with vermicompost reduced the cost of feed by 10%

and increased body weight of fish.

FINAL REPORT (NAIP COMPONENT – 2)

44

SN Innovations Brief information about innovations Remarks

6. Sap as a liquid fertilizer Tested in heavy feeder crops like

banana, sugarcane, papaya, onion etc.

Application of sap through drip or

drenching can save up to 20 per cent

cost of the RDF with added yield and

quality advantages.

Tested on farmers‟

fields

(B) Additional innovations

1. Enrichment of sap for

preparing Organic Liquid

Fertilizer (OLF)

Developed process for enrichment of

sap and tested in different crops. Foliar

application of OLF could increase crop

yield by 12 to 15 per cent. It can be

used in organic farming also.

Three parties have

signed MoU for

production and

marketing at

commercial scale.

Patented in four

countries other than

India.

2. Non-woven fabric using

banana fibre

Using needle punching technique, non-

woven fabrics of different GSM were

prepared in an industrial trial. Some end

users products were prepapred. This has

advantages over the non-woven fabrics

prepared using other fibres.

Ready for

commercialization

3. Medalari charkha CIRCOT- Phoenix Charkha for

spinning banana fibres into good quality

yarn has been developed.

This is a very good

technology capable of

generating

employment in tribal

and rural areas.

10 units supplied to

NE Hilly Region

Research Complex,

ICAR,

Barapani(Meghalaya)

BANANA PSEUDOSTEM VALUE CHAIN

45

7. Process/ Product/Technology Developed

S. No. (Process/Product/Technol

ogy Developed

Adoption/ Validation/ Commercialization,

etc.

Responsible

Partner

1. Fibre

1.1 Standardized process for

efficient fibre extraction

through development of

pseudostem cutter and

suitable modification in

raspador m/c.

Adopted by 25 farmers.

Extracted 41.6 tonnes of dry fibre (2.72 t at

NAU and 38.9 t by farmers)

NAU, Navsari

& CIRCOT,

Mumbai

1.2 Process for preparing yarn

and woven and non-woven

fabric/ products using

banana fibre

Processed and prepared 350 meters of woven

fabric and 3.1 tonnes of non-woven fabric at

industrial scale (Jute mills, Kolkata). Processes

standardized for preparing different quality

fabrics.

CIRCOT,

Mumbai,

MANTRA,

Surat and NAU,

Navsari

1.3 Process standardized for

preparing quality papers

from banana fibre

Pulping and bleaching process standardized for

making grease proof and cheque papers from

banana fibre.

JK Paper,

Songadh

Handmade paper and board From handmade paper and board various

stationary items were prepared and marketed

within the university.

NAU, Navsari

and CIRCOT,

Mumbai

2. Scutcher

2.1. Preparation of scutching

waste based vermicompost

from one acre unit

250 tonnes of vermicompost harvested

70% scutching waste and 30% cow dung was

found to be ideal from nutrient point of view.

NAU, Navsari

Quality tested and

evaluated as manure as

compared to other organics

(FYM & Biocompost).

Evaluated in sugarcane, banana and papaya for 2

years and recommended to the farmers.

Demonstrated on 12 farmers‟ fields as well.

2.2 Pelleted vermicompost also

tested as fish feed.

Substitution of cattle feed up to 30 per cent with

vermicompost reduced the cost of feed by 10%

and increased body weight of fish.

3. Sap

3.1. Process developed for

preparing organic liquid

fertilizer from banana

pseudostem sap

Tested in different crops (sugarcane, banana,

papaya, onion, wheat, paddy, vegetable nurseries

and mango for fruit setting) and found to

improve yield (10 to 15 %) and quality of

produce.

Demonstrated on 12 farmers‟ fields through drip

and 107 as spray in mango for fruit retention.

Produced about 16000 litres of enriched sap.

International patent filed in 5 countries

MoU signed with three parties.

NAU, Navsari

FINAL REPORT (NAIP COMPONENT – 2)

46

S. No. (Process/Product/Technol

ogy Developed

Adoption/ Validation/ Commercialization,

etc.

Responsible

Partner

4. Central core

4.1 Processes standardized for

prepapring edible products

like candy and RTS from

central core

Candy has been tested in reputed testing centres

(CFTRI, Mysore and SICART, Anand) for its

quality. It found to contain vitamins (B3 and B5)

along with good amount of Fe. The product has

shown good level of acceptability which are

being sold by the University during mega events

like Krishi Mahotsav and farmers day organized

by GoG and the University. These products are

also marketed by banana cooperatives.

NAU, Navsari

8. Patents (Filed/Granted)

S. No. Title of Patent Inventor(s) (Name &

Address)

Filed/Published/Gr

anted (No./Date)

Responsible

Partner

1. A Novel Process for

Manufacturing Banana

Candy from Banana

Pseudostem.

Parag Pandit,

Dr. C. S. Desai,

K. K. Patel,

Dr. S.K. Desai,

Dr. B. N. Kolambe,

Dr. R. G. Patil,

NAU, Navsari

Filed

1624/MUM/2011

1st June 2011

NAU, Navsari

2. A Novel Organic

Fertilizer of Banana

Pseudostem.

Dr. B. N. Kolambe, K.

K. Patel, S. L. Pawar,

Dr. J. M. Patel, Dr. D.

R. Prajapati, Vijay

Anand, H.B. Vaidya, Dr.

R. G. Patil

NAU, Navsari

Filed at International

level PCT/IB2012/

053268

28th June 2012

Country specific

patents filed in

Philippines, Brazil,

Indonesia & Mexico

NAU, Navsari

3. A Novel Machine for

Extracting Fibre from

Banana Pseudostem

Sheaths‟ has been filed.

Dr. R. P. Nachane

Er. N. G. Savani

Dr. R. G. Patil

Dr. B. N. Kolambe

NAU, Navsari &

CIRCOT, Mumbai

Filed

1590/MUM/2011

30th May 2011

NAU, Navsari &

CIRCOT,

Mumbai

4. Multi Sheath Feeder to

Raspador Fibre Extractor

Dr. R. P. Nachane

CIRCOT, Mumbai

Filed

901/MUM/2010

CIRCOT,

Mumbai

5. An Attachment to

Medhlari Charkha

Dr. R. P. Nachane,

CIRCOT, Mumbai

Dr. J. M. Patel, NAU,

Navsari

Filed

1371/MUM/2008

CIRCOT,

Mumbai

6. Pedal Driven Banana

Fibre Spinning System

Dr. R. P. Nachane

Mr. Vivekanandan,

CIRCOT ,Mumbai

Filed

1554/MUM/2012

CIRCOT,

Mumbai

7. Banana Pseudostem Fibre

Drawing Machine

Dr. R. P. Nachane,

Dr. N. Shanmugam,

CIRCOT, Mumbai

Filed

3464/MUM/2012

CIRCOT,

Mumbai

BANANA PSEUDOSTEM VALUE CHAIN

47

S. No. Title of Patent Inventor(s) (Name &

Address)

Filed/Published/Gr

anted (No./Date)

Responsible

Partner

8. Banana Pseudostem Fibre

Carding Machine

Dr. R. P. Nachane,

Dr. N. Shanmugam,

CIRCOT, Mumbai

Filed

3465/MUM/2012

CIRCOT,

Mumbai

9. Banana Pseudostem Fibre

Ring Spinning Machine

Dr. R. P. Nachane,

Dr. N. Shanmugam,

CIRCOT, Mumbai

Filed

3467/MUM/2012

CIRCOT,

Mumbai

9. Linkages and Collaborations

S. No. Linkages developed

(Name & Address of Organization)

Date/Period From-To Responsible

Partner

1. - The Puna Khumbaria Group

Cooperative, Fruits and Vegetable

Growers Society Limited. Krishi

Bhawan, Kela Yard, Dhumbal, Puna

Khumbaria Road, Dist. Surat

- Gadat Fruits and Vegetable Cooperative

Society, At/Post: Gadat, Tal. & Dist.

Navsari

- Jaghadia Fruit & Vegetable Growers

Cooperative, Jhagadia, Dist. Bharuch

- Fruits and Vegetable Federation,

Bardoli, Dist. Surat

- Sardar Bagayat Cooperative Society, At.

Vanesa, Tal. Palsana, Dist. Surat

- Farmers Cooperative Society, Gadat, Tal

& Dist. Navsari

- Gandevi Fruits and Vegetable

Cooperative Society, At & Post

Gandevi, Tal. Gandevi, Dist. Navsari

June 2008 -Continue NAU

2. Tapti Valley Banana Wine and Products

Coop. Society Ltd., Savda, Jalgaon (MS)

April 2011 – April 2014 NAU

3. Manav Kalyan Trust (NGO), Navsari May 2009 - Continue NAU

4. Gramin Shramik Pratishthan, Latur Sept. 2013 – Continue CIRCOT

5. Empire Jute Mills, Kolkata March 2009 to August

2010

CIRCOT

6. Gloster Jute Mills, Kolkata July 2008 to continue CIRCOT &

NAU

7. TRYTEX Machine Company, Coimbatore July 2008 to Dec 2013 CIRCOT

8. BASF Chemicals, Mumbai Jan 2013 to Dec 2013 CIRCOT

FINAL REPORT (NAIP COMPONENT – 2)

48

10. Status on Environmental and Social Safeguard Framework

Environmental Social Positive benefits Negative

benefits

Mitigation measures

for -ve effects

Positive benefits Negative

benefits

Mitigation

measures for

-ve effects

NAU - Navsari

Utilization of

pseudostem for fibre

(+ 4)

-- -- Employment

generation in rural

areas (+ 4)

Disposal of

pseudostem in eco-

friendly way

-- --

Partial substitution in

chemical fertilizer by

using scutching waste

based vermicompost

and sap as liquid

fertilizer (+ 4)

-- -- Alternative organic

source and

improves soil

health (+4)

Organic product

Increases crop yield

-- --

Partial substitution of

cattle feed with

vermicompost as a

fish feed (+ 4)

-- -- It can reduce the

cost of fish feed

without any decline

in fish production

(+ 4)

-- --

Use of central core

for edible product

(+ 4)

-- -- Candy prepared

tested in referral

labs and has found

to contain minerals

and vitamins (B3 &

B5) (+ 4)

-- --

Handmade paper and

board (NAU)

Generation

of effluent

(-2)

Use of effluent

treatment plant

Recycling of paper

waste and scutcher

and farm waste

(crop) for paper

making

Employment

generation (+3)

-- --

Quality paper at

industrial scale (JK

Paper)

Alternative raw

material can be

blended or used as

such for preparing

quality grade papers

(anti grease,

Magnetic Ink

Character

Recognition (MICR)

paper (+2)

Generation

of effluent

(-2)

Has well established

modern effluent

treatment plant.

Further, effluent

characterization

studies have shown

that compared to

presently used raw

materials like wood,

bagasse etc.) in paper

industry, pulp of

banana fibre requires

less chemicals and

cooking temperature.

-- -- --

BANANA PSEUDOSTEM VALUE CHAIN

49

Environmental Social Positive benefits Negative

benefits

Mitigation measures

for -ve effects

Positive benefits Negative

benefits

Mitigation

measures for

-ve effects

CIRCOT, Mumbai

--

Generation

of dust

while

making

yarn from

fibres on

large scale

(-2)

Workers will be

provided with

protective mask

Employment

generation as large

scale yarn will be

produced from

fibres (+2) -- --

Eco-friendly mordant

for natural dyes

(Obj.: Sap as

mordant) (+4)

-- --

Eco-friendly

mordant for natural

dyes (+2) -- --

--

Renewable

raw

material

(Obj.:

Microcrysta

lline

cellulose

from fibres)

(-2)

The BOD and COD

levels are very low and

ETP will take care

Only laboratory scale

study was conducted

Renewable raw

material (+2)

-- --

11. Constraints, if any and Remedial Measures Taken

A) During project implementation period

SN Constraints Remedial measures

1. Electric power supply available

at farmers‟ fields for irrigation

purpose and cannot be used for

running raspador machine.

- On request by University and farmers, Gujarat Electricity

Board permitted on case by case basis

- We made additional attachment to raspador machine to make

it suitable to operate on power tiller or oil engine

2. Obtained poor quality yarn

prepared on jute spinning

system from banana fibre

- Special yarn machines fabricated for spinning banana fibre.

- Prepared non-woven fabric on industrial scale, where yarn

preparation is not required

- Developed CIRCOT-Phoenix modified medhlari charkha for

spinning banana fibre to good quality yarn.

3. High transport cost as jute

spnning mills are available in

Kolkata (WB)

- There is need to establish pilot scale unit for spinning and

weaving of banana fibre in the areas where banana is

cultivated on large scale.

4. Excess availability of

pseudostem during peak period

of banana harvesting

- Pseudostem can be retained on fields for a period of 30-40

days if leaves are not removed after harvesting of bunch.

FINAL REPORT (NAIP COMPONENT – 2)

50

B) After project period

SN Constraints Remedial measures

1. Lack of assured market

demand for small quantity,

but sporadic/ occasional

demand in bulk quantity is

there for banana fibre

- Encouraging cluster based approach for fibre extraction so

as to obtain fibres in bulk quantity. Here Banana

Cooperatives / small entrepreneurs will act as a facilitator

between industry and banana growers

2. Labour shortage for fibre

extraction work during peak

periods of agricultural

operations

- There is need to increase mechanization in fibre extraction

through involving experts from Univ./ ICARinstitute/

hiring professionals.

3. High cost of fibre - Suggesting business model comprising fibre extraction,

vermicompost preparation and use of sap as liquid

fertilizer which has potential to reduce cost of fibre.

- We are encouraging the parties who have signed MoU for

production and marketing of Organic Liquid Fertilizer on

commercial scale to sell fibre @ Rs.50/kg instead of

Rs.100/kg fibre.

- Selling fibre at lower rate will create huge market demand

in paper industry, handicraft unit, non-woven industry etc.

12. Publications

A. Research papers in peer reviewed journals

S. No. Authors, Title of the paper,

Name of Journal, Year, Vol. & Page No.

NAAS

Ratings

Responsible

Partner

1. Patel, K. K., Vijay Anand, Kaswala, A. R., Italiya, A., Pawar, S. L.,

Patel, J. M., Kolambe, B. N. and Patil, R. G. (2012). Comparative

Performance of FYM, Biocompost and Banana Pseudostem Based

Vermicompost on Productivity of Banana. The Asian J. Horti. 12 (1):

140-143.

3.1 NAU,

Navsari

2. Patil, R. G. (2014). Banana Pseudostem Waste: A Source of

Additional Income for Growers. Indian Farming. 64 (2): 74-80.

-- NAU,

Navsari

3. Agarwal, N.K., Khanna, N.K., Chechi, S.K., Patel, K.I., Pawar, S.L.

and Patil, R.G. (2011). Evaluation of Banana Pseudostem Based

Fibres as Pulp and Paper Making Raw Material. International Pulp

and Paper Technical Association Journal. 23 (3): 119-124.

-- JK Paper,

Songadh

4. Nachane R.P. (2013) Banana: Utilization in Textiles. Textile Value

Chain 4: 20.

-- CIRCOT,

Mumbai

5. Shanmugam, N., Manisha Kurhade, and Vivekanandan, M. V. (2013)

–Banana Pseudostem Staple Fibre Spinning – Asian Textile Journal ,

22 (8); 38-41

-- CIRCOT,

Mumbai

6. Nachane, R.P., Kurhade, M.G., Vivekanandan, M.V. and

Shanmugam, N. (2013) - Spinning of Banana Fibres on CIRCOT-

Phoenix Charkha- Textile Value Chain, July-Sept., 35.

-- CIRCOT,

Mumbai

BANANA PSEUDOSTEM VALUE CHAIN

51

B. Books/ Book chapters/ Abstracts/ Popular articles, Brochures, etc.

S.

No.

Authors, Title of the papers

Name of Book/ Seminar/ Proceedings/Journal, Publisher, Year,

Page No.

Responsible Partner

1. Popular articles

Krishigo Vidya NAU, Navsari

Annual Report of Punakhumbaria Banana Cooperative 2008-09,

Pg. No. 38-39

NAU, Navsari

Kel Visheshank” in Souvenir during Krishi Mahotsav, 2009 NAU, Navsari

2. Brochure

Standardization of Grades for Banana Pseudostem Fibres (2013) CIRCOT, Mumbai

3. Booklet/leaflet

- Baseline survey report

- Overview of progress (2010)

- Project overview (2011)

- Business models (2014)

NAU, Navsari

- Standardization of grades for banana pseudostem fibres CIRCOT, Mumbai

13. Media Products Developed/Disseminated

S.

No.

CD, Bulletins, Brochures, etc. (Year

wise)

No. of

Copies

Distribution Responsible

Partner

1. CD: Banana fibre extraction (English &

Gujarati)

10 10 NAU,

Navsari

2. CD: Banana Pseudostem Value Chain

(English, Hindi, Marathi & Gujarati)

63 57 NAU,

Navsari

3. NAIP Display cell established in

Pseudostem Processing Unit for display of

various products developed from banana

pseudostem

1 > 5,000 visitors NAU,

Navsari

4. Trans slide boxes with light: 5 nos.

related to value added products prepared

from pseudostem (at display centre)

5 For displaying at

Conference hall, SWMRU,

NAU, Navsari

NAU,

Navsari

5. Flex posters: Related to value added

products prepared from pseudostem.

5 For display during farmers‟

day, Krishi Mahotsav,

training etc.)

NAU,

Navsari

6. Scroller screen display: Related to value

added products prepared from pseudostem

10 For display during farmers‟

day, Krishi Mahotsav,

training etc.)

NAU,

Navsari

7. New paper 24 Coverage in National and

Local news paper

NAU,

Navsari

8. e – media (Internet news/ uploaded on

different websites)

> 15 Displayed on websites NAU,

Navsari

FINAL REPORT (NAIP COMPONENT – 2)

52

14. Meetings/Seminars/Trainings/Kisan Mela, etc. organized

S. No. Details of Meetings/Seminars/

Trainings, etc.

Duration

(From-To)

No. of Personnel

participated/

trained

Budget

(`Rs.)

Organizer

(Name & Address)

(A) Workshop and seminars

1. Launching workshop 21st June,

2008

163 (including

farmers, scientists,

industrialist and

journalists)

43,467 NAU, Navsari

2. Sensitization workshop 9th March,

2009

44 (Banana

growing farmers)

20,079 All partners

Organized at NAU,

Navsari

3. National Workshop – cum –

Training Program on “Potential

Value Added Products from

Banana Pseudostem”.

2nd

and 3rd

May, 2011

50 farmers

(Gujarat, TN,

Maharashtra,

M.P., Karnataka,

Bihar)

11 entrepreneurs

34,550 All Partners

Organized at NAU,

Navsari

4. Institute – Industry Interface on

scope of banana fibre in textiles

and other industries

24th May,

2011

75 43,617 MANTRA, Surat &

NAU, Navsari

(B) Meetings

5. Meeting with Chairman‟s of

Banana Cooperatives on to discuss

regarding demonstration of NAIP

activities

29th Oct.,

2009

12 21,553 NAU, Navsari

6. Cost committee meeting involving

Chairman‟s of Banana

Cooperatives and Scientists of

consortia to finalize cost of fibre

4th Jan.,

2010

10 49,947 NAU, Navsari

7. Meeting organized with Textile

industries

5th March,

2013

51 11,720 MANTRA, Surat &

NAU, Navsari

8. Mass media meet organized at

NAU, Navsari in collaboration sub

project on- “Mobilizing mass

media support for sharing agro-

information”

27th Aug.

2013

22 -- NAU, Navsari in

collaboration with

DMAPR (ICAR),

Boriavi, Anand

(Gujarat)

(C) Training to farmers

9. Rajpipla, Bharuch District 17-12-09 37 23,534

NAU, Navsari

10. Dhamdod, Surat district 28-01-10 45 2,700

11. Bhamod, Surat district 27-03-10 54 15,361

12. Banana Cooperative, Mukthiapur,

Jalgaon (Maharashtra) 15-07-10 80 6,957

13. Gadat Vibhag Sahakari Mandali

Ltd., Gandevi taluka, Navsari 29-09-10 67 33,316

14. Uchediya, Bharuch district 24-09-11 127 20,000

BANANA PSEUDOSTEM VALUE CHAIN

53

S. No. Details of Meetings/Seminars/

Trainings, etc.

Duration

(From-To)

No. of Personnel

participated/

trained

Budget

(`Rs.)

Organizer

(Name & Address)

(D) Training to women/ SHGs

15. Handicraft

training at NAU,

Navsari

Rajpipla,

Jhagadia

28th to 29

th

Jan., 2011

17

15,918

NAU, Navsari

Bardoli, Surat 25-01-13 25 7,925

(E) Other awareness activities

16. Visit of farmers to Handmade

Paper Research Institute,

Sanganera, Jaipur (Rajasthan)

22nd

to 26th

March,

2009

21 (Banana

growing farmers)

35,317 NAU, Navsari

17. During Krishi Mahotsav 2009,

special session on banana was

organized

1st to 3

rd

June, 2009

About 400 banana

growers

participated.

--

NAU, Navsari

18. One day awareness programme on

Handmade paper and fibre

extraction at Rajpipla

2nd

Dec.,

2010 42 Organized by KVIC,

Ahemdabad

19. Entrepreneur training – lecture

delivered at summer school,

Vallabhvidya Nagar, Anand

22 May,

2012 25 -- Dr. B. N. Kolambe

20. Attended Khedut Shibhir (farmers

meeting) of the Gadat Cooperative

Society, Gadat, Navsari

4th Sept.,

2010 72 Gadat Cooperative

Society, Gadat

15. Participation in Conference/ Meetings/Trainings/ Radio talks, etc.

S. No. Details of Meetings/Seminars/

Trainings etc. (Name & Address)

Duration

(From-To)

Budget

(`Rs.)

Participant

(I) NAU, Navsari

(A) Conference/seminars/workshops attended

1. “Scope and Potential Use of Banana Fibres in

Textile Industries”. Paper presented in 22nd

National Convention of Textile Engineers &

National Seminar on Textiles: Prospects &

Growth Beyond 2020, Organized by, The

Institution of Engineers (India) South Gujarat

Local Centre in association with Department of

Textile Technology, Sarvajanik College of

Engineers & Technology, Surat

5th & 6

th Feb.,

2009

16,569 R. G. Patil,

B. N. Kolambe,

J. M. Patel &

S. L. Pawar

2. Seminar organized by Gujarat Agro. Industry,

Ahemdabad

27th March,

2010

1,195 B.N. Kolambe

3. Fibre to Fashion Expo 2009 Seminar as a Keynote

Speaker on “Multiple uses of Banana Fibres”,

Organized by Southern Gujarat Chamber of

Commerce & Industries, Surat.

17th to 20

th

April, 2009

-- R. G. Patil, B. N.

Kolambe, S. L.

Pawar, J. M.

Patel

4. Global conference on Meeting the Challenges in

Banana & Plantain for Emerging Biotic and

Abiotic Stresses, held at Thiruchirapalli, Tamil

Nadu

10th to 13

th

Dec., 2010

15,471 R. G. Patil, B.N.

Kolambe, Chirag

Desai

FINAL REPORT (NAIP COMPONENT – 2)

54

S. No. Details of Meetings/Seminars/

Trainings etc. (Name & Address)

Duration

(From-To)

Budget

(`Rs.)

Participant

5. Paper presented, “Marketing Strategy for Banana

Pseudostem Based Products in Gujarat”, 24th

National Conference on Agricultural Marketing to

be held at NAU, Navsari

23rd

to 25th

Nov., 2010

-- R.G. Patil

6. National Conference – KVK, 2010 held at

MPUAT, Udaipur

22nd

- 24th

Dec., 2010

4,800 S.L.Pawar &

K.K.Patel

7. Swadesh Prem Jagriti Sangosthi-2011, National

Conference on “HortiBusiness - Linking Farmers

with Market”, organized by Lt. Amit Singh

Memorial Foundation, New Delhi and Sardar

Vallabhbhai Patel University of Agriculture,

Meerut in collaboration with Amity University,

Noida at Dehradun, Uttrakhand

29th

-31st

May, 2011

36025 R.G. Patil & S.L.

Pawar

8. Seminar on Cultivation of Banana – Using Tissue

Culture and Hi-Tech Horticulture, Organized by

PDC Centre, Reliance Industries Ltd., Baroda and

Shri. Gujarat Bagayat Vikas Parisad, Baroda,

during at Vadodara, Gujarat.

16th July,

2011

3,987 S.L.Pawar &

K.K.Patel

9. National conference – Advances in Natural Fibres

held at CIRCOT, Mumbai

25th April,

2011

12,602 Vijay Anand

10. National Conference on KVKs-2011 held at

JNKVV, Jabalpur

3rd

-5th

Dec.,

2011

R.G.Patil

11. Asian Symposium of the Global Natural Fibre

Forum (GNFF) initiated by the Commonwealth

Secretariat held at Bangalore

25th to 27

th

Sept. 2012

19,220 R. G. Patil

12. Workshop on “Agro waste management and value

addition” organized at “Community Science

Centre” at Sardar Patel University, Vidyanagar,

Anand

31st Oct, 2012 1,348 B. N. Kolambe

& S. L. Pawar

13. National Seminar on Tropical and Subtropical

Fruits held at NAU, Navsari

9th to 11

th

Jan., 2013

-- B. N. Kolambe

14. Confederation of Horticulture Association of

India, Paper presented on “Converting Banana

Waste to Wealth – Issues and Strategies” at

Coimbatore

29th & 30

th

Feb., 2013

R. G. Patil and

B. N. Kolambe

(B) Trainings attended

15. Course on improving administrative efficiency and

financial management, Organized by Director of

Finance, NAIP at NAARM, Hyderabad

16th to 23

rd

July, 2008

-- R.G. Patil, B.N.

Kolambe &

U.P.Chaudhari

16. Monitoring and Evaluation organized at NASC

Complex, New Delhi

19th & 20

th

Sep., 2008

-- R.G. Patil &

B.N. Kolambe

17. Procurement related matter and finance

management system, organized at CIFE, Mumbai

5th & 6

th Jan.,

2009

3043 R.G. Patil, B.N.

Kolambe &

U.P.Chaudhari

18. Quality testing of handmade paper and board

testing at CPPRI, Saharanpur related HMPB

during

23rd

to 25th

March, 2009

16000 K.K. Patel &

Vijay Anand

19. Developing edible products from central core of

banana pseudostem at CFTRI, Mysore

7th to 18

th

Sep., 2009

49790 K.K. Patel,

Saunak Desai

BANANA PSEUDOSTEM VALUE CHAIN

55

S. No. Details of Meetings/Seminars/

Trainings etc. (Name & Address)

Duration

(From-To)

Budget

(`Rs.)

Participant

20. Handmade paper and board making from banana

waste at Kumarappa HMP Institute, Sanganera,

Jaipur

3rd

to 8th

Aug., 2009

11432 Vijay Anand &

K.K. Patel

21. Vermicompost preparation from banana and other

agro waste at Central Plantation Crop Research

Institute, Kasaragod, (Kerala).

1st to 10

th

Dec., 2009

9873 Saunak Desai

Manoj Gami &

Anand Kaswala

(II) CIRCOT, Mumbai

22. “Banana Fibre Extraction and Utilization” paper

presented in National Conference on Banana

organized by Director, Horticulture Maharashtra

State

17th Jan.,

2009

A.J. Shaikh &

R.P. Nachane

(CIRCOT,

Mumbai)

23. “Extraction and Utilization of Fibre from

Banana Pseudostem” paper presented in 11th

Agricultural Scientist and Farmers Congress organized by Bioved Society at Allahabad.

13th Feb.,

2009

R. P. Nachane

(CIRCOT,

Mumbai)

24. Attended seminar on " Value Added Apperals and

Home Textiles Made of Natural Fibres" , in

Mumbai

Paper presented entitled "Banana Pseudostem

Staple Fibre Spinning: Various Approaches,

Presented two posters on ;

- Preparation of cellulose powder from

banana pseudostem fibres,

- Value addition of banana pseudostem

2nd

& 3rd

March, 2012

Dr. R.P.

Nachane, Dr. N.

Shanmugam,

and Mrs.

Manisha

Kurhade

(III) JK Paper, Songadh

25. Zonal Seminar on “Raw material –

Handling/Plantation/Storage & Usage, organized

by International Pulp and Paper Technical

Association (IPPTA) at Lucknow

4th & 5

th

August, 2011 N. K. Agarwal,

Sanjay Chechi &

Kamlesh Patel

16 . Foreign Trainings/Visits:

S.

No.

Name,

Designation,

Address

Study tour, Organization

and Duration (From-To)

Dates of Seminar

Delivered and Report

Submitted

Total Cost

(Rs.)

1. Dr. B. N. Kolambe (CoPI)

Professor, ASPEE

College of Horticulture

and Forestry, NAU,

Navsari

Study tour, University of

Philippines, Los Banos,

College of Agriculture, Crop

Science Cluster, Laguna,

Philippines

11th to 17

th March, 2012

Seminar delivered on 18th

June, 2012

Report submitted, 17-07-

2012

2,33,312

2. Dr. R. P. Nachane (CCPI)

Principal Scientist and

Head (QEI, Division),

Central Institute for

Research on Cotton

Technology, Adenwala

Road, Matunga, Mumbai

– 400 019

-do-

Lecture delievered on 6th

July, 2012.

2,33,312

FINAL REPORT (NAIP COMPONENT – 2)

56

17. Performance Indicators (As per the enclosed format in Appendix-1)

S. No. Indicator Total No.

1. No. of production technologies released and/or adopted 4

2. No. of processing technologies released and/or adopted 6

3. Number of technologies/products commercialized based on NAIP

research 3

4. No. of new rural industries/entreprises established/ upgraded 3

5. No. of product groups for which quality grades developed and agreed 1

6. Total no. of private sector organizations (including NGOs) participating

in consortium 8

7. No. of farmers involved in consortia activities 594

8. Total number of farmers‟ group developed for marketing and processing --

9. Number of patent/intellectual property protection applications filed based

on NAIP research 9

10. Number of patents/intellectual property protections granted/published

based on NAIP research 1

11. Number of scientists trained overseas in the frontier areas of science --

12. Number of scientists trained overseas in consortium-based subject areas 2

13. No. of scientists participated in conference/seminar etc. abroad --

14. Success stories 1

15. Incremental employment generated (person days/ha/year) from fibre

extraction, vermicompost preparation and sap

Baseline Final

0 183

16.

Increase in income of farmers cultivating banana (`Rs./ha/ annum)

from banana pseudostem (Through fibre extraction, vermicompost

preparation and use of sap)

Baseline Final

0 60,000 to

70,000

17. Number of novel tools/protocols/methodologies developed 6

18. Publications

Articles in NAAS rated journals 1

Articles in other journals 5

Book(s) --

Book chapter(s) --

Thesis 4 M.Sc & 4 Ph.D.

Popular article(s) (English) 1

Newspaper article(s)/ e-media 24

> 15

Seminar/Symposium/Conference/Workshop Proceedings 8

Technical bulletin(s) --

Manual(s) 3

CDs/Videos 2

Popular article(s) in other language 3

Folder/Leaflet/Handout 8

Report(s) 5

Success stories 1

BANANA PSEUDOSTEM VALUE CHAIN

57

18. Employment Generation (man-days/year)

S. No. Type of Employment Generation Employment

generation up to

end of sub-

project

Responsible

Partner

1. Fibre extraction (41.58 tonnes, covering area

of 60 ha) @ 183 mandays/ha/year

7137 mandays NAU, Navsari

19. Assets Generated (details of equipments and works costing more than` 10,000/-)

(i) Equipment

S. No. Name of the Equipment with

Manufacturers Name, Model

and Sr. No.

Year of

Purchase

Quantity

(Nos.)

Total cost

(Rs. in

lakhs)

Responsible

Partner

1. Raspador machine (Mac Well

Engineering Works, Mumbai)

Modified raspador fabricated at

Shree Umiya Eng. Works,

Shapar, Rajkot

07.10.08

26.10.09

09.03.10

26.03.10

02.12.09

2

10

9

2

1

1.88775

7.66462

10.10002

2.30159

0.82500

NAU, Navsari

Total for raspador -- 24 22.77898

Handmade paper and board unit

(Sitson India Pvt. Ltd., Thane,

MS)

Dye-Punching machine

04.02.10

15.03.10

1 14.26702

22.08498

5.75000

NAU, Navsari

Total for HMPBU -- 1 42.10200

Yarn making machine (Trytex

Machines Company, Coimbatore,

Tamil Nadu)

Carding machine

29.03.10

26.03.10

1

1

38.01000

0.60000

NAU, Navsari

Banana pseudostem cutter

machine, Shree Umiya Eng.

Works, Shapar, Rajkot

23.03.10 10 4.50000 NAU, Navsari

Forklift machine (Godrej &

Boyce Mfg. Co. Ltd.)

31.12.08 1 8.13750 NAU, Navsari

Tractor (John Deere) with trailer 03.10.08 1 5.83650 NAU, Navsari

Mini-tractor, trailer with

accessories (Mitsubishi Shakti

180)

06.10.08 1 2.69605 NAU, Navsari

Hydraulic trailer (for tractor),

Gayatri Agro Industries, Atak

Pardi

07.01.09 1 1.19700 NAU, Navsari

FINAL REPORT (NAIP COMPONENT – 2)

58

S. No. Name of the Equipment with

Manufacturers Name, Model

and Sr. No.

Year of

Purchase

Quantity

(Nos.)

Total cost

(Rs. in

lakhs)

Responsible

Partner

Trolleys – Hydraulic pallet, Shri.

Modi Materials handling Co.

25.03.09 2 0.31050 NAU, Navsari

Miscellaneous (costing < 1 lakh)-

Utensils, pseudostem crusher,

pedestal fan

-- -- 0.59000 NAU, Navsari

Universal Engineering India/

Paper Tensile Tester/ UEC-1005-

E

23.03.09 1 6.155 CIRCOT,

Mumbai

Trytex Machine Company / Yarn

Making Machines

18.02.10 1 28.71 CIRCOT,

Mumbai

High Speed Automatic Weaving

Machine for Weaving Heavy

Fabric

08.02.10

1 8.74

MANTRA,

Surat

Laboratory Jigger Machine 12.11.09 1 2.15 MANTRA,

Surat

Digital Bursting Tester Bursting

Strength

02.02.10 1 0.98 MANTRA,

Surat

Flexometer for Flexing test De

Mattia Flex Tester and

Flexometer for Flexing Test

Schildknecht Flex Tester

21.11.09 1 1.12 MANTRA,

Surat

Digital pH Meter 03.02.10 1 0.07 MANTRA,

Surat

Analytical Electronic Balance 03.02.10

1 0.65 MANTRA,

Surat

Twist Tester TT-MCT-Electronic 08.03.10 1 0.53

MANTRA,

Surat

Laboratory six bomb digester,

Universal Engineering

Corporation, Saharanpur

May, 2008 1 4.25 JK Paper,

Songadh

Laboratory Somerville screen

system

May, 2008 1 1.25 JK Paper,

Songadh

(ii) Works

S. No. Particulars of the Work,

Name and Address of

Agency Awarded the Work

Year of

Work

Done

Quantity (Nos.) Total Cost

(Rs. in

Lakh`)

Responsible

Partner

1 Shed for hosting raspador

machines, Handmade paper

and board unit and Yarn unit

2009 Shed = 100 x 50 feet

Yard = 80 x 40 feet

25.0 NAU,

Navsari

BANANA PSEUDOSTEM VALUE CHAIN

59

(iii) Revenue Generated

S. No. Source of Revenue Year Total

amount

(`lakh Rs.)

Responsible

Partner

(A) From sale of products developed from

banana pseudostem

Stationary articles from handmade paper

and board; Scutching waste based

vermicompost; Banana fibre; Organic

liquid fertilizer; Candy from central core

2012 to

2014 10.78

NAU, Navsari

(C) Patents (licence fee) 2013 10.50

(D) Training fee 2014 0.30

Total 21.58

20. Awards and Recognitions

S. No. Name,

Designation,

Address of

the Person

Award/ Recognition (with Date) Institution/

Society

Facilitating

(Name &

Address)

Responsible

Partner

1. Dr. R. G. Patil

(CPI) & Mr. M. G.

Parikh (CCPI)

Appreciation certification from

for Contribution made in the

project

ICAR, New Delhi NAU, Navsari

& MANTRA,

Surat

2. Dr. R. G. Patil

(CPI)

Award for best paper presentation

on “Development in banana

pseudostem based value added

products in Gujarat” Global

conference on Meeting the

Challenges in Banana & Plantain

for Emerging Biotic and Abiotic

Stresses, held at Tiruchirapalli,

Tamil 10th -13

th Dec., 2010

National Research

Centre on Banana

and Association

for Improvement

in Production and

Utilization of

Banana (AIPUB)

NAU, Navsari

3. Dr. R. G. Patil

(CPI)

Award for best paper presentation

on “Potential Value Added

Products from Banana

Pseudostem- A Source of

Additional Income (NAIP,

Compt. 2), National Conference

on “HortiBusiness - Linking

Farmers with Market” held at

Dehradun, Uttrakhand 29-31 May

2011.

Late Amit Singh

Memorial

Foundation

NAU, Navsari

FINAL REPORT (NAIP COMPONENT – 2)

60

S. No. Name,

Designation,

Address of

the Person

Award/ Recognition (with Date) Institution/

Society

Facilitating

(Name &

Address)

Responsible

Partner

4. Dr. R. G. Patil &

Dr. B. N. Kolambe

(CPI)

Kadali Puraskar by Association

for the Improvement in

Production and Utilization of

Banana , on 1st March, 2014

Association for

the Improvement

of Production and

Utilization of

Banana

NAU, Navsari

5. Dr. R. G. Patil Confederation of Horticulture

Association of India (CHAI)

Fellow on 29th May 2014, Navsari

CHAI, New Delhi NAU, Navsari

6. Mrs. Manisha

Kurhade (RA)

Poster Awarded 2nd

Position

which was presented on Hindi

day celebration

CIRCOT,

Mumbai

21. Steps Undertaken for Post NAIP Sustainability

All the infrastructures created under NAIP will be utilized in state funded plan scheme viz.,

Enhancing Total Factor Productivity of Banana Farming System (BH: 12026).

The activities related to production of enriched sap, vermicompost, handmade paper and

candy/RTS being self sustainable will be carried out under revolving fund.

Training related to banana pseudostem processing will be given on charge basis.

Amount received through transfer of technology, signing MoU (Licence fee) and royality.

CIRCOT has given a research proposal under the Natural Fibre Platform in XII Plan. The

facilities developed in present project will be maintained by taking research programs

under fibre Platform project.

22. Possible Future Line of Work

Fibre extraction

At present about 25 to 30 kg of dry fibre can be extracted on one raspador machine per day

in a shift of 8 hours. Considering the labour cost, asset value, overheads (electricity, water) etc.,

cost of extraction of fibres on farmers‟ fields is approximately Rs.60/ kg. It means if fibres are to

be sold in the market with some profit margin, cost of dry fibre per kg cannot be less than Rs.70.

Since the fibre is similar to jute fibres and can be used to produce items which are normally

produced using jute fibres, it is expected that cost of banana pseudostem fibres should be

comparable to that of jute fibres. The present cost of jute fibres is about Rs.30 to 35 per kg. In

view of this constraint if fibre extraction from banana pseudostem has to become commercial

venture, cost of production has to be considerably reduced. This may be possible by modification

of raspador to get more fibre output keeping all the requirements for extraction same, such as

labour, cost of electricity etc. Two attempts tried under the project viz., multisheath feeder for

raspador and direct sheath feeding appears promising but requires more research in that direction.

BANANA PSEUDOSTEM VALUE CHAIN

61

Yarn quality improvement

Under the project yarn was prepared using two different approaches, one was yarn

spinning on newly developed CIRCOT Phoenix charkha and the second was using spinning

assembly developed at CIRCOT.

First approach is peddle operated and requires feeding of fibres by hand. It has been

possible to spin finner and more uniform yarn of reduced hairiness. However, the quality of this

yarn and quantity produced depends mainly on the expertise developed by the artisan who is

spinning yarn on this charkha. It is expected that more and more person start using it and develop

expertise which can then be passed on to as many interested persons as possible.

In the other attempt to produce yarn on industrial scale, machineries have been developed

consisting of treatment for softening, staple cutting, carding, gill drawing and spinning. Carding

machine has been further modified with increasing the number of pins for improving fibre

separation and removal of nonfibrous materials. Sliver prepapred is also introduced with a small

twist to hold fibres together. Spinning assembly has been further modified to control speed of

feeder rollers, draw ratio and twist introduced. This has resulted in improvement in the production

of yarn on yarn making assembly. At present yarn of 1‟s cotton count can be produced. But it is

envisaged that after adjusting the spinning parameters one will be able to get yarn of up to 4‟s

cotton count. However, many more trials are required to be conducted varying different

parameters in the assembly lines to optimize spinning conditions for better quality yarn. One of

the important requirements in machine spinning of these fibres is process of softening of fibres to

make them more pliable for spinning. During the project work it was observed that use of rice

bran oil (RBO) as softener gave better results as compared to that of Jute Batch Oil (JBO). Also

piling fibres after softening treatment for 72 hours seemed to be better than that for 48 hours. But

many more softening agents can be tried to get better results. Different staple lengths of fibres can

also be studied for optimization.

Once good quality yarn is produced weaving it into fabric is easily possible on handlooms.

Depending on the quality of yarn it may be even possible to use it on powerlooms for high

productivity.

In the initial stages of the project fibre extraction was considered as the main activity. To

enthuse farmers to extract fibres from banana pseudostem they were promised that all the fibres

extracted by them would be purchased by the project. To work out cost of extraction of fibres, the

entire cost of extraction was considered for recovery from sale of fibres only. But during

extraction other byproducts of value are also available such as scutcher waste, sap and central

core. Each of these can be utilized for preparation of value added products. For e.g., scutcher

waste can be used for preparation of vermicompost. Sap can be used as it is, as liquid fertilizer or

can be converted into enriched sap using the technology developed. It can be sold as Novel

Organic Liquid Fertilizer of high value. If income from these products is also considered, the cost

of fibres can be brought on par with that of jute fibres.

FINAL REPORT (NAIP COMPONENT – 2)

62

Replacement of imported pulp with banana fibre pulp for cheque paper making

As had been mentioned under item 5.2.2 (Exploring possibility of preparing speciality

papers) in the report, quality of cheque paper (MICR) from banana fibre pulp was found to be

much better than that prepared using imported pulp. Here for comparison both imported and

banana fibre pulp was used to the same proportion with respect to CPM pulp. At this level (30%)

of use of banana fibre pulp the cost of cheque paper will be higher as compared to that being

produced using imported pulp, but it may be noted that there is scope to reduce percentage of

banana fibre pulp may be to 20 per cent or even 10 per cent and still get the paper qualities

comparable to the normally produced cheque paper. This optimization of use of banana fibre pulp

will be able to reduce the cost of cheque paper to the present level or even less.

NAU, Navsari

1. Adoption of cluster based approach for fibre extraction and holistic way i.e., prepare more

number of products rather than concentrating on one product only.

2. Increase the fibre output efficiency of existing raspador machines, for reducing the cost of

extracting fibre.

3. Creating awareness among different stakeholders‟ through trainings and workshop.

CIRCOT, Mumbai

1. Preparation of Composites and development of its products

2. Use of yarn Knotters and development of hi-value shirtings

3. Study the efficacy of banana MCC in pharmaceutical industry

4. Preparation of finer count yarn in banana spinning machinery

5. Development of Automatic feeder for CIRCOT-Pheonix Charkha

23. Personnel

Personnel From – To (DD/MM/YYYY)

Research Management (CL), NAU, Navsari

1. Dr. R. P. S. Ahlawat, Vice Chancellor 29/05/2008 to 28/04/2009

2. Dr. H. C. Phatak, Vice Chancellor (Incharge) 29/04/2009 to 30/01/2010

3. Dr. A. R. Phatak, Vice Chancellor 31/01/2010 to 31/03/2014

Scientific (CPI, CCPI, others)

Lead Centre – NAU, Navsari

1. Dr. R. G. Patil (CPI), Research Scientist 29/05/2008 to 31/03/2014

2. Dr. B. N. Kolambe (CoPI), Professor (Soil Sci.) 29/05/2008 to 31/01/2014

3. Dr. S. P. Shukla, Engineer (PHT) 29/05/2008 to 31/03/2014

4. Dr. J. M. Patel, Assoc. Res. Scientist (SWM) 29/05/2008 to 31/03/2014

5. Shri. S. L. Pawar, Asstt. Res. Scientist (Soil Sci.) 29/05/2008 to 31/03/2014

BANANA PSEUDOSTEM VALUE CHAIN

63

Personnel From – To (DD/MM/YYYY)

6. Er. N. G. Savani, Asstt. Res. Scientist (Agril. Eng.) 29/05/2008 to 31/03/2014

7. Dr. C. S. Desai, Asstt. Res. Scientist (PHT) 01/07/2007 to 31/03/2014

8. Dr. D. R. Prajapati, Assoc. Res. Scientist (Agron.) 29/05/2008 to 31/03/2014

9. Er. Parag Pandit, Asstt. Res. Scientist (PHT) 29/05/2008 to 31/03/2014

10. Dr. Ruchira Shukla, Assoc. Prof. (ABM) 29/05/2008 to 31/03/2014

Consortium partner-1, CIRCOT, Mumbai

11. Dr. A. J. Shaikh (CCPI), Principal Scientist 01/06/2008 to 31/05/2012

12. Dr. R. P. Nachane (CCPI), Principal Scientist 01/06/2008 to 31/12/2012

13. Dr. N. Shanmugam (CCPI), Senior Scientist 01/06/2008 to 31/03/2014

14. Dr. S. K. Dey, Senoir Scientist 24/08/2013 to 31/03/2014

15. Dr. P. K. Mandhyan, Chife Tech. Officer 14/06/2013 to 31/03/2014

16. Dr. M.V. Vivekanandan, Asst. Chief Tech. Officer 14/06/2013 to 31/03/2014

17. Shri B.R. Pawar , Asst.Chief Tech. Officer 14/06/2013 to 31/03/2014

Consortium partner-2, MANTRA, Surat

18. Dr. S. R. Naik (CCPI), Deputy Director 29/05/2008 to 28/02/2011

19. Shri. M. G. Parikh (CCPI), Jr. Scientific Officer 01/03/2011 to 31/03/2014

Consortium partner-3, JK Paper Pvt. Ltd., Songadh

20. Shri. K. Radhamohan (CCPI), Deputy General Manager 29/05/2008 to 30/04/2011

21. Shri. Sanjay Chechi (CCPI), Sr. Manager 01/05/2012 to 31/12/2012

22. Shri. D. K. Singh (CCPI), Sr. Manager 01/01/2013 to 31/03/2014

Contractual

1. A. R. Kaswala, RA (Soil Science) 06/09/2008 to 14/06/2010

2. K. K. Patel, SRF/RA (PHT) 11/09/2008 to 16/08/2012

3. S.K. Desia, RA (PHT) 29/05/2009 to 19/05/2011

01/09/2013 to 31/01/2014

4. H.B. Vaidya, SRF/RA (Biochemistry) 29/05/2009 to 31/03/2014

5. H.P. Shah (Floriculture) 23/06/2009 to 14/06/2010

6. Vijay Anand, RA (Fruit Science) 14/06/2009 to 09/12/2011

7. H. M. Patel (Soil Science) 01/09/2010 to 28/10/2010

8. C. S. Desai (PHT) 01/09/2010 to 31/03/2011

9. P. S. Patel (Soil Science) 03/11/2010 to 01/03/2013

10. R. J. Makwana (Floriculture) 19/05/2011 to 15/08/2012

11. C.D. Desai (PSMA) 25/09/2012 to 31/03/2014

12. P. P. Bhalerao (Fruit Science) 01/10/2012 to 01/03/2013

13. Rajkishore (Soil Science) 01/09/2013 to 31/12/2013

14. Mrs. Manisha G. Kurhade 19/08/2008 to 31/03/2014

15. Mrs. Kanchan Patil 25/10/2013 to 31/03/2014

FINAL REPORT (NAIP COMPONENT – 2)

64

24. Governance, Management, Implementation and Coordination

A. Composition of the various committees (CIC, CAC, CMU, etc.)

S. No. Committee

Name

Chairman

(From-To)

Members

(From-To)

1. CIC &

CMU

Dr. R. P. S. Ahlawat

(29/05/08 to 28/04/09

Dr. H. C. Pathak

(29/04/09 to 30/01/10)

Dr. A. R. Pathak

(31/01/10 to 31/03/14)

Director of Research

Dr. H.C. Pathak (29/05/08 to 28/04/09)

Dr. C. L. Patel (29/04/09 to 30/01/10)

Dr. A. N. Sabalpara (31/01/10 to 31/03/14)

Director of Extension

Dr. R. B. Patel (29/05/08 to 31/08/10)

Dr. M. S. Purohit (01/09/10 to 24/01/12)

Dr. Derasari (25/01/12 to 31/03/14)

CIRCOT, Mumbai

Dr. A. J. Shaikh (29/05/08 to 31/05/12)

Dr. R. P. Nachane (29/05/08 to 31/12/12)

Dr. N. Shanmugam (29/05/08 to 31/12/12)

MANTRA, Surat

Dr. S. R. Naik (29/05/08 to 28/02/11)

Shri. M. G. Parikh (01/03/11 to 31/03/14)

JK Paper Ltd., Songadh

Shri. Radhamohan (29/05/08 to 30/04/11)

Shri. Sanjay Chechi (01/05/12 to 31/12/12)

Shri. D. K. Singh (01/01/13 to 31/03/14)

Account Officer cum Comptroller

Shri. U. P. Chaudhari (29/05/08 to 30/06/13)

Shri. D. T. Chaudhari (01/07/13 to 31/03/14)

Dr. S. P. Shukla (Executive Engineer)

(29/05/08 to 31/03/14)

Dr. B.N. Kolambe (CoPI)

(29/05/08 to 31/01/14)

Dr. R. G. Patil (CPI & Member secretary)

(29/05/08 to 31/03/14)

2. CAC Dr. P. Rethinam

(29/05/08 to 31/03/14)

Consortium Leader

Dr. R. P. S. Ahlawat (29/05/08 to 28/04/09)

Dr. H. C. Pathak (29/04/09 to 30/01/10)

Dr. A. R. Pathak (31/01/10 to 31/03/14)

National Coordinator (Component 2)

Dr. J. P. Mittal

Dr. R. K. Goyal

Dr. Ezeikiel

BANANA PSEUDOSTEM VALUE CHAIN

65

S. No. Committee

Name

Chairman

(From-To)

Members

(From-To)

Director of Research

Dr. H.C. Pathak (29/05/08 to 28/04/09)

Dr. C. L. Patel (29/04/09 to 30/01/10)

Dr. A. N. Sabalpara (31/01/10 to 31/03/14)

Other Members

Dr. R. S. Gandhi (29/05/08 to 31/03/14)

Dr. M. M. Mustaffa (29/05/08 to 31/03/14)

Shri. Dinesh Zaveri (29/05/08 to 31/03/14)

Shri. Arvind K. Naik (29/05/08 to 31/03/14)

Shri. Jagdish Z. Patel (29/05/08 to 01/02/10)

Shri. Ashwin B. Patel (02/02/10 to 31/03/14)

Shri. Deepak S. Patel (29/05/08 to 31/03/14)

Smt. Deepa T. Patel (29/05/08 to 31/03/14)

Dr. B.N. Kolambe (29/05/08 to 31/01/14)

Dr. R. G. Patil (29/05/08 to 31/03/14)

B. List of Meetings organized (CIC, CAC, CMU, etc.)

S. No. Details of the meeting Date Place & address of meeting organized

1. CIC 08-11-2008 SWMRU, NAU, Navsari (Gujarat)

22-02-2009 JK Paper, Songadh (Gujarat)

03-10-2009 SWMRU, NAU, Navsari (Gujarat)

04-01-2010 SWMRU, NAU, Navsari (Gujarat)

04-08-2010 SWMRU, NAU, Navsari (Gujarat)

22-12-2010 SWMRU, NAU, Navsari (Gujarat)

10-03-2011 SWMRU, NAU, Navsari (Gujarat)

26-08-2011 SWMRU, NAU, Navsari (Gujarat)

21-02-2012 SWMRU, NAU, Navsari (Gujarat)

27-08-2013 SWMRU, NAU, Navsari (Gujarat)

2. CAC 21-06-2008 SWMRU, NAU, Navsari (Gujarat)

26-02-2009 SWMRU, NAU, Navsari (Gujarat)

24-08-2009 CIRCOT, Mumbai (Maharashtra)

18-03-2010 SWMRU, NAU, Navsari (Gujarat)

23-12-2010 SWMRU, NAU, Navsari (Gujarat)

22-11-2011 SWMRU, NAU, Navsari (Gujarat)

06-03-2012 SWMRU, NAU, Navsari (Gujarat)

08-01-2012 SWMRU, NAU, Navsari (Gujarat)

07-10-2013 SWMRU, NAU, Navsari (Gujarat)

21-03-2014 APMC, Surat (Gujarat)

FINAL REPORT (NAIP COMPONENT – 2)

66

S. No. Details of the meeting Date Place & address of meeting organized

3. CMU 22-02-2009 JK Paper, Songadh (Gujarat)

07-07-2009 SWMRU, NAU, Navsari (Gujarat)

04-01-2010 SWMRU, NAU, Navsari (Gujarat)

31-07-2010 SWMRU, NAU, Navsari (Gujarat)

22-12-2010 SWMRU, NAU, Navsari (Gujarat)

10-03-2011 SWMRU, NAU, Navsari (Gujarat)

26-08-2011 SWMRU, NAU, Navsari (Gujarat)

21-02-2012 SWMRU, NAU, Navsari (Gujarat)

27-08-2013 SWMRU, NAU, Navsari (Gujarat)

BANANA PSEUDOSTEM VALUE CHAIN

67

Part-III: Budget and its Utilization

STATEMENT OF EXPENDITURE (Final)

(Period from 29-05-2008 to 31-03-2014) (Date of start) (Date of completion)

Sanction Letter No.: F.No.1(5)/2007-NAIP dtd. May, 29, 2008

Total Sub-project Cost Rs. 600.983 lakhs Sanctioned/Revised Sub-project cost (if applicable): Rs. 732.2006 lakhs

Date of Commencement of Sub-project: 29-05-2008 Duration: From 29-05-2008 to 31-03-2014 (DD/MM/YYYY)

Funds Received in each year (Lakh Rs.)

I Year (2008-09) 253.65 III Year (2010-11) 52.67 V Year (2012-13) 31.59

II Year (2009-10) 102.63 IV Year (2011-12) 66.76 VI Year (2013-14) 183.90

Bank Interest received on fund (if any) ` Rs. 16.09 lakhs, Amount Refunded to PIU, NAIP: Rs. 177.22

Total expenditure ` Rs. 522.23 lakhs

Expenditure Head-wise (Rs. in lakhs): Sanctioned Heads Funds

Allocated

(*)

Funds Released Expenditure Incurred Total

Expend

iture

Balance

as on

date

Amount

refunded

to PIU

NAIP

Req. of

additio

nal

funds

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

A. Recurring Contingencies

(1) TA 10.56 1.56 1.24 1.02 0.92 1.69 1.38 0.92 1.19 1.22 2.08 1.78 2.11 9.29 -1.48 1.48

(2) Workshops 5.19 4.60 -2.83 -2.59 1.26 0.36 0.00 1.29 0.48 0.76 1.48 0.36 0.41 4.77 -3.97 0.50

(3) Contractual Services/RA/SRF 105.86 12.42 13.02 15.52 22.01 8.60 12.75 4.10 12.43 18.15 27.06 12.72 15.33 89.79 -5.46 7.63

(4) Operational cost 237.45 32.89 45.03 32.56 36.40 19.22 36.95 25.66 21.55 40.07 35.90 23.34 35.71 182.22 20.83 20.67

Sub-Total of A (1-4) 359.06 51.47 56.47 46.52 60.59 29.87 51.08 31.97 35.65 60.20 66.52 38.19 53.55 286.07 9.92 30.28

B. HRD Component

(5) Training 2.18 1.30 0.22 1.08 0.90 0.00 0.00 0.36 0.93 0.37 0.51 0.00 0.00 2.17 1.32 0.00

(6) International Training 4.31 0.00 0.00 0.00 5.31 0.00 0.00 0.00 0.00 0.00 4.31 0.00 0.00 4.31 1.00 0.00

(7) Consultancy 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of B (5-7) 6.49 1.30 0.22 1.08 6.21 0.00 0.00 0.36 0.93 0.37 4.82 0.00 0.00 6.48 2.33 0.00

C. Non-Recurring

(8) Equipment 293.77 173.00 37.00 0.00 0.00 0.00 128.70 32.56 98.63 51.46 0.00 0.00 0.00 182.66 156.04 0.00

(9) Furniture 2.94 2.90 0.10 0.00 0.00 0.00 0.00 2.84 0.10 0.00 0.00 0.00 0.00 2.94 0.06 0.00

(10) Works (new renovation) 24.97 20.00 5.00 0.00 0.00 0.00 0.00 19.97 5.00 0.00 0.00 0.00 0.00 24.97 0.03 0.00

(11) Others (Books & Journaletc.) 1.79 0.90 0.70 0.60 0.30 0.00 0.00 0.72 0.76 0.10 0.20 0.00 0.00 1.79 0.71 0.00

(12) North East Plant 18.7 0.00 0.00 0.00 0.00 0.00 18.70 18.21

Sub-Total of C (8-11) 342.17 196.80 42.80 0.60 0.30 0.00 147.40 56.09 104.49 51.56 0.20 0.00 0.00 212.36 175.54 0.00

D. Institutional Charges* 24.49 4.09 3.14 4.47 3.97 1.71 4.12 1.12 3.79 3.24 2.11 1.96 1.83 14.05 7.46 2.15

Grand Total (A+B+C+D) 732.21 253.65 102.63 52.67 71.07 31.59 202.60 89.54 144.87 115.37 73.66 40.15 55.38 537.18 177.04 177.32 32.43

* Institutional charges will be 10% of the recurring contingencies for the Lead Consortium and 5% for Consortia Partners.

Name & Signature of CPI :

Date:16/06/2014

68

PART-IV: DECLARATION

This is to certify that the final report of the Sub-project has been submitted in full

consultation with the consortium partners in accordance with the approved objectives and

technical programme and the relevant records, note books; materials are available for the same.

Place: Navsari Signature of Consortium Principal Investigator

Date: 16/06/2014

Signature & Date

Consortium Co-Principal Investigator

Signature & Date

Consortium Co-Principal Investigator

Signature & Date

Consortium Co-Principal Investigator

Signature & Date

Consortium Co-Principal Investigator

Comments & Signature of Consortium Leader

Date: 17/06/2014

i

Appendix I

Performance Indicators for Component- 2

S. No. Indicator Total No.

1. No. of production technologies released and/or adopted 4

2. No. of processing technologies released and/or adopted 6

3. Number of technologies/products commercialized based on NAIP

research 3

4. No. of new rural industries/entreprises established/ upgraded 3

5. No. of product groups for which quality grades developed and agreed 1

6. Total no. of private sector organizations (including NGOs) participating

in consortium 8

7. No. of farmers involved in consortia activities 594

8. Total number of farmers’ group developed for marketing and processing --

9. Number of patent/intellectual property protection applications filed based

on NAIP research 9

10. Number of patents/intellectual property protections granted/published

based on NAIP research 1

11. Number of scientists trained overseas in the frontier areas of science --

12. Number of scientists trained overseas in consortium-based subject areas 2

13. No. of scientists participated in conference/seminar etc. abroad --

14. Success stories 1

15. Incremental employment generated (person days/ha/year) from fibre

extraction, vermicompost preparation and sap

Baseline Final

0 183

16.

Increase in income of farmers cultivating banana (`Rs./ha/ annum)

from banana pseudostem (Through fibre extraction, vermicompost

preparation and use of sap)

Baseline Final

0 60,000 to

70,000

17. Number of novel tools/protocols/methodologies developed 6

18. Publications

Articles in NAAS rated journals 1

Articles in other journals 5

Book(s) --

Book chapter(s) --

Thesis 4 M.Sc & 4 Ph.D.

Popular article(s) (English) 1

Newspaper article(s)/ e-media 24

> 15

Seminar/Symposium/Conference/Workshop Proceedings 8

Technical bulletin(s) --

Manual(s) 3

CDs/Videos 2

Popular article(s) in other language 3

Folder/Leaflet/Handout 8

Report(s) 5

Success stories 1

ii

Annexures of Research Achievements and Summary

Annexure 1

Details regarding processing of 100 kg pseudostem (average of 5 groups)

SN Particulars Unit Manual Mechanical

1 Time required for splitting of pseudostem in two

halves

min 2.65 0.82

2 Time required for separation of sheath from halves min 12.6 12.8

3 Rate for extraction of fibres from sheath gm/min 38 49

4 Time required for extraction of fibres from sheath min 21.3 19.0

5 Total weight of sheaths kg 52 55

6 Total weight dry fibres kg 0.81 0.93

7 Sheath recovery from pseudostem % 52 55

8 Fibre recovery from sheath % 1.55 1.69

9 Fibre recovery from pseudostem % 0.81 0.93

Total cost per kg of fibres extraction from pseudostem (Rs/kg)

S N Particulars Manual Mechanical

1 Fixed cost * 2.21 1.81

2 Labour cost of pseudostem splitting in two halves 2.73 0.37

Labour cost of sheaths separation 13.64 11.65

Labour cost of fibres extraction 11.52 9.33

Electricity cost 12.26 10.16

Total variable cost 40.15 31.51

3 Total cost fibres extraction from pseudostem (1+2) 42.36 33.32

* Machine cost (Rs 35000 for cutter machine, Rs 100000 for raspador machine), Depreciation

(15 years), Interest (12 %) and R &M (2 %)

Annexure 2

Tensile properties of banana pseudostem fibres Variety Fineness

(tex)

Tenacity

(g/tex)

Extension

(%)

Variety Fineness

(tex)

Tenacity

(g/tex)

Extens

ion

(%)

Pacha Kadali 6.9 40.6 2.5 Chetty 10.1 33.4 3.1

Grand Naine 6.2 48.0 3.2 Annai 9.0 40.3 3.0

Ladies Finger 7.3 41.8 2.5 Cherapunji 8.9 62.0 3.2

Poovan 8.2 31.1 2.8 Champa 9.4 37.7 2.5

Robusta 8.8 49.7 3.7 Nendran 10.8 51.6 3.9

Vannan 6.9 42.1 3.0 Adhapuri 11.4 48.2 4.5

Raja Balac 9.9 38.8 2.7 Kali 11.0 49.6 3.0

Kosta Bontha 7.2 52.9 3.1 Collection 97 10.1 37.5 2.6

Sakar Chayna 6.1 22.4 2.0 Sughandhi 7.6 52.3 2.6

Gandevi Selection 6.9 43.4 4.0 Hybrid-2 10.5 45.3 3.6

Ponchandan 7.7 57.5 3.2 Nalla Bontha 8.7 54.1 3.2

Ney Poovan 8.1 45.8 3.0 Adhar Velchi 8.6 34.3 2.4

Vadakkan Kadali 9.2 35.5 2.3

iii

Annexure 3

Detail description of groups

Group End use Requirement of

fibres

Grading

Combinations

Varieties

Group I Fabric

preparation:

spinning

purpose

Extra fine to

fine, stronger

and high

extensible fibres

ExFf - ExSs - He

ExFf - ExSs -Me

ExFf - Ss - He

ExFf - Ss - Me

Ff - ExSs - He

Ff - ExSs - Me

Ff - Ss - He

Ff - Ss - Me

Pacha kadali ,Grand

Naine, Ladies finger,

Robusta, Vannan,

Kosta Bontha, Gandevi

Selection, Ponchandan,

Ney Poovan, Annai,

Cherapunji, Sughandhi,

Nalla Bontha

Group II Handicrafts Fine, strong and

medium

extensive

ExFf - ExSs - Le

ExFf - Ss - Le

ExFf - Ns - He

ExFf - Ns - Me

Ff - ExSs - Le

Ff - Ss - Le

Ff - Ns - He

Ff - Ns - Me

Mf - ExSs - He

Mf - ExSs - Me

Mf - Ss - He

Mf - Ss - Me

Mf - Ns - He

Cf - ExSs - He

Cf - Ss - He

Poovan, Raja Balac,

Chetty, Champa,

Nendran, Adhapuri,

Kali, Vadakkan Kadali,

Hybrid-2, Adhar Velchi

Group III Composites

and non-

woven fabric

Coarse, normal

to weak with

medium

extensive

ExFf - Ns - Le

ExFf - Ws - He

ExFf - Ws - Me

Ff - Ns - Le

Ff - Ws - He

Ff - Ws - Me

Mf - ExS - Le

Mf - Ss - Le

Mf - Ns - Me

Mf - Ns - Le

Collection 97

Group IV Raw material

for paper and

pulp industry

Coarser, weak

and medium to

low extensive

ExFf - Ws - Le

Ff - Ws - Le

Mf - Ws - He

Mf - Ws - Me

Mf - Ws - Le

Cf - ExSs - Me

Cf - ExSs - Le

Cf - Ss - Me

Cf - Ss - Le

Cf - Ns - He

Cf - Ns - Me

Cf - Ns - Le

Cf - Ws - He

Cf - Ws - Me

Cf - Ws - Le

Sakar Chayna

iv

Annexure 4

Moisture content values obtained using digital moisture meter and gravimetric method

Experimental Trials Moisture content (%)

By digital moister meter By Gravimetric Method

1 9.9 8.7

2 10.3 11.4

3 11.2 11.6

4 12.5 12.6

5 12.9 13.4

6 13.4 12.8

7 14.7 15.2

8 15.7 16.1

9 16.4 15.0

10 21.2 22.4

Annexure 5

Details regarding procedure followed in yarn preparation at Kolkata

The banana fibre, softened using jute batch oil emulsion at a concentration of 10 per cent

and kept for 2 days, is used for spinning on large scale spinning machines. Softened fibres are

processed through the sequence of machines as given below.

The fibre are cut to 25 cm staple length using manual cutters and piled for 2 days for

softening. During piling, the temperature inside the banana fibre went up to 55 degrees centigrade

due to bacterial action and results in softened of fibres. The softened fibres are than processed

through two sets of carding machines namely breaker card and finisher card. Manual feeding was

done at breaker card. Ten laps were taken from breaker card and fed to finisher card and finisher

card lap was produced. The finisher card lap had hank of 11.47 lbs/100yds with 30% moisture

content. The coefficient of variation of lap weight of 5 yard length was 23.8%. The delivery

speed of the finisher card was kept at 200 ft/minute and a draft of 8.3 was given at breaker card.

The finisher card sliver properties: 9.6% CV, 6.6 lbs/100 yds.

The slivers obtained from finisher card were processed through four drawing machines

and the machine settings and hank details are given in table 5.1.12. The fourth drawing sliver was

fed to bobbin spinning and a TPI of 3.0 was given at flyer speed of 3200 rpm.

Drawing machine hank details

Drawing 1 Drawing 2 Drawing 3 Drawing 4

Doublings 4 4 3 2

Draft 3.7 5.5 8 7.92

Delivery speed (ft/minute) 7.4 100 100 150

Sliver weight (lbs/100 yds) 6.14 5.38 3.39 118

CuttingGill

drawingSpinningSofteningPiling Carding

v

Annexure 6

Banana fabric process sequence: bleaching and dyeing

Grey fabric

Scouring with 2.0 g/l non-ionic detergent at 85˚C/30 min followed by Cold Wash

Bleaching with:

5 volume Hydrogen Peroxide (Due to high colouring matter)

5 g/l sodium silicate, 2 g/l soda ash

1 g/l NaOH (pH 10.5), 1 g/l NID, 1 g/l TRO

Bleaching at 85˚C/345 min. followed by Cold wash and hot wash

Dyeing with:

X% Dye

Y g/l common salt as per class of reactive dyes

For fixation add Zg/l soda ash as per class of reactive dyes

After treatment

1. Cold overflow rinse for 10 min.

2. Hot rinse at 70˚C for 10 min.

3. Soaping at 95˚C for 10 min.

. 4. Hot rinse at 70˚C for 10 min. followed by Cold rinse.

Annexure 7

Procedure followed in dyeing coating of non-woven fabric

Dyeing of non woven fabric: Dyeing was done by reactive dye cold pad batch method. Banana

nonwoven web was dipped in cold brand reactive dye solution containing salt and alkali. It was

batched for 4 to 6 hours and rinsed with water.

Coating of banana nonwoven: The banana nonwoven, dyed and finished fabric was wound on

let off roller of pilot coating and laminating machine. The heating zone temperature was set to

150oC. The coating paste containing mixture of PU and acrylic dispersion with thickener was

applied with gap setting of 2.5 mm with knife over cylinder technique. Coating trials with

different combination of PU with acrylics were also conducted.

vi

Annexure 8

Strength properties of composite of banana fibres

SN Pressure

(bar)

Temp.

(oC)

Thickness

(mm)

GSM Density

(g/cm3)

Strength (kg) Elongation (%)

Width

way

Length

way

Width

way

Length

way

1 12.5 160 1.10 496 0.44 3.21 14.25 1.4 2.0

2 12.5 160 0.70 319 0.45 4.75 16.35 1.3 1.1

3 12.5 160 0.90 481 0.56 5.83 140.8 1.5 1.1

4 20.0 160 0.80 437 0.54 3.00 14.90 1.4 1.2

5 20.0 180 0.90 493 0.55 3.24 12.54 0.7 1.1

6 20.0 180 0.70 369 0.52 4.40 13.85 1.1 1.2

Without any moisture

7 12.5 160 1.60 523 0.31 4.75 1.63 1.3 13.5

8 12.5 180 1.20 381 0.33 3.71 4.05 0.8 18.0

Annexure 9

Details of process for preparing MCC using banana fibre

Dry banana fibres weighing about 500 g were cut into pieces of 2-3 cm and were soaked

in 5 % (v/v) nitric acid at room temperature for 24 h keeping material to liquor ratio at 1:10. The

fibres were washed thoroughly with water and subjected to anaerobic treatment for 7 days. The

fibres were transferred to ten litre capacity bottles containing stabilized microbial consortium.

The bottles were stoppered with rubber corks and sealed with paraffin wax. From the side arms,

rubber tubes were connected as air traps to prevent the entry of air. After the incubation period,

the sample was taken out and washed with water followed by open boiling with 1 % (w/w)

sodium hydroxide for 15 min. The fibres were again washed with water, neutralized with 0.2%

(v/v) acetic acid and bleached. The bleaching was carried out using hydrogen peroxide (0.3%

w/v), along with sodium hydroxide (0.1 % w/v) and sodium silicate (0.15 % w/v) as stabilizer at

90-95o C for 30 min with material to liquor ratio 1:20. The bleached sample was then subjected to

acid hydrolysis using 2.5N hydrochloric acid. The hydrolyzed material was filtered, washed free

of acid, dried and powdered using pulveriser of 0.053 mesh size. The obtained product was

MCC.

Annexure 10

Optimization of pulping conditions: Kraft Pulping

Particulars Unit Set-1 Particulars Unit Set-1 White liquor

analysis Unit Set-1

OD raw material gm 200 Unbleached

pulp yield

unscreened)

% 62.4

Active alkali gpl 86.8

Active alkali charge % 14 Sulphidity % 15.7

Bath ratio -- 1:5 Kappa No. -- 11.0

Soaking time min 60 Twaddle °TW 12

100 to 160 °C min 60 RAA gpl 4.96

At 160 °C min 90 pH -- 12.25

Cooking temperature °C 160 Total Solids % NM

vii

Annexure 11

Optimization of bath ratio for Kraft pulping using banana pseudostem fibre

Particulars Unit Set-1 Set-2 Set-3 Set-4

OD raw material gm 150 150 150 150

Alkali charge as NaOH % 15 15 15 15

Bath ratio -- 1:4 1:4.5 1:5 1:5.5

Soaking time min 60 60 60 60

100 to 160 °C min 60 60 60 60

At 160 °C min 90 90 90 90

Cooking temperature °C 160 160 160 160

Unbleached pulp yield

(unscreened) % 69.5 70.8 71.0 72.4

Kappa No. -- 17.4 16.6 13.4 13.4

Twaddle °TW 8.5 7.0 6.0 3.0

RAA gpl 1.86 1.86 1.24 0.62

pH -- 10.5 11.0 10.8 10.7

Annexure 12

Optimization of cooking chemical requirement for Kraft pulping of banana pseudostem fibre

Particulars Unit Set-1 Set-2 Set-3 Set-4

OD raw material Gm 150 150 150 150

Alkali charge as NaOH % 14 15 16 17

Bath ratio -- 1:5 1:5 1:5 1:5

Soaking time Min 60 60 60 60

100 to 160 °C Min 60 60 60 60

At 160 °C Min 90 90 90 90

Cooking temperature °C 160 160 160 160

Unbleached pulp yield

(unscreened) % 68.3 56.9 55.35 53.55

Kappa No. -- 21.6 15.9 11.6 11.0

Twaddle °TW 5.0 5.0 6.6 6.0

RAA Gpl 1.86 1.86 2.48 3.1

pH -- 9.66 9.9 10.32 10.75

Total solids % 8.9 10.0 10.4 9.6

viii

Annexure 13

Optimization of time and temperature for Kraft pulping using banana pseudostem fibre

Particulars Unit Set-1 Set-2 Set-3 Set-4 Set-5 Set-6

OD raw material gm 150 150 150 150 150 150

Alkali charge as NaOH % 15 15 15 15 15 15

Bath ratio

1:5 1:5 1:5 1:5 1:5 1:5

Soaking time min. 60 -- 60 60 60 60

100 to 160 °C min. 45 45 60 60 60 60

At 160 °C min. 60 60 90 60 60 90

Cooking temperature °C 160 160 150 150 165 165

Unbleached pulp yield % 67.4 71.2 59.4 63.9 56.0 57.25

Kappa No.

17.5 18.5 18.9 22.7 12.2 11.7

Twaddle °TW 6.5 5.0 3.0 4.0 4.5 6.0

RAA Gpl 2.48 1.86 1.86 1.86 1.86 1.86

pH

11.15 10.96 11.91 11.97 11.37 11.27

Total solids % 11.4 10.47 8.2 9.8 11.7 14.4

Annexure 14

Optimization of bleaching conditions of pulp of banana fibre

Particulars Unit Results

Chlorination (Ambiant temp., 30 min, 3.0% Cy.)

Cl2 applied as Cl2 % 2.5

End pH -- 5.5

Residual chlorine ppm 95

Extraction (70°C, 120 min, 10% Cy.)

NaOH added % 1.5

H2O2 (gpl basis) % 0.75

End pH -- 10.7

Residual H2O2 ppm Nil

Extraction stage brightness % 57.4

Hypo (Calcium hypochlorite)-42°C, 150 min, 10% Cy.

Hypo applied as Cl2 % 1.5

End pH 7.1

Residual chlorine ppm 50

Chlorine dioxide (76°C, 180 min, 10% Cy.)

ClO2 applied as ClO2 % 0.6

End pH -- 2.7

Residual Cl2 as ClO2 ppm 90

Brightness Hypo Pulp % 78.6

Brightness Final Pulp % 87.9

Pulp Viscosity Cps 12.6

ix

Annexure 15

Pulping condition for scutcher waste

Particulars Values

Soda Charged, as NaOH (%) 16 18 20 22

Cooking temperature (°C) 160

Time to temperature 160°C (min) 60

Time at cooking temperature (min) 90

Bath ratio 1:5

Kappa no. 24.4 22.8 22.0 20.8

Reject (%) 8.0 8.0 8.0 8.0

Screened yield (%) 27.1 25.8 25.1 24.4

Annexure 16

Characteristics of effluent generated during processing of banana fibre and hard wood

Properties Unit Banana fibre

(black liquor)

Weak black liquor

(bamboo:

hardwood)

pH - 9.91 -

Specific gravity at 80° C - 1.035 1.09

Total solids % w/w 11.0 17.6

Organics (on dry solid) % 61.4 63.28

Inorganic (on dry solid) % 38.6 36.72

Sulphated ash (on dry solid) % 29.5 46.0

TTA as Na2O (As such basis) % 0.62 25.36

Viscosity at 80° C spindle: 1& rpm: 50 cp 4.5 -

Gross caloric value K. cal/Kg 3109 2989

Swelling volume Index ml/gm 18.0 -

Silica as SiO2 (on dry solid) % 1.12 0.28

R203 (on dry solid) % 0.63 0.18

Sodium as Na (on dry solid) % 16.85 -

Potassium as K (on dry solid) % 1.4 4.53

Chloride as Cl (on dry solid) % 3.17 1.2

Calcium as Ca (on dry solid) % 0.074 0.063

x

Annexure 17

Characteristics of banana fibre extracted by raspador machine and mechanical depithing methods

Particulars Unit Banana fibre

pulp (fibre by

raspador

machine)

Dry Whole

pseudostem

pulp

Scutcher

waste pulp

Green whole

pseudostem pulp by

Mechanical depithing

& pulping

Soda Dosage % 15 18 18 15

Cooking Time Hrs 4.15 4.15 4.15 4.15

Kappa No. No 15 24 23 15.5

Screen Unbleached

yield % 56.5 22.9 25.8 57.0

Rejects % 3 11 8 3.0

Total Yield % 59.6 33.9 33.8 60.7

Initial freeness ⁰ SR 25.3 Not

measurable

Not

measurable

21.0

Final freeness ⁰ SR 40.3 -

Tear factor 86 Due to the

presence of

pithy material

hand sheets

preparation

was not

possible. The

presence of

pithy material

is not desirable

for pulp

&paper

making.

53 114

Burst Factor 88 17 61

Breaking Length meter 6678 3981 5851

Double Fold No. 2580 17 2540

Observations Easily

preparation of

hand sheets on

sheet making

machine, very

good pulp

properties

Here pulp

yield is very

low and

presence of

pithy

material

affects the

hand sheets

preparation.

The result indicates fibre

obtained by depithing of

whole pseudostem is

also having good

pulpable properties and

pulp properties are also

same as pulp from

raspador made fibres.

Annexure 18

Fibre yield using depithing method of dry and fresh pseudostem sheaths

Parameters Whole dry

pseudostem

(1-5 cm)

Whole dry

pseudostem

(2-3 cm)

Whole dry

pseudostem

(5-7 cm)

Whole green

pseudostem

(3-5 cm)

Pulpable fibre % 32.7 29.3 47.7 27.9

Pithy material % 30.0 33.0 13.6 37.0

Total % 62.7 62.3 61.3 64.9

Observations Still pith

present

Pith not

separated

completely

Pith not

separated

effectively

Good separation

of pith

Colour appearance Fibres have

blackish colour

appearance

Fibres have

blackish

colour

appearance

Fibres have

blackish

colour

appearance

Appearance like

fibre as made by

raspador machine

xi

Annexure 19

Properties of bleached fibre extracted using raspador m/c and depithing process

Particulars Unit Banana

pseudostem fibre

Depithed whole banana

pseudostem pulp

Screened pulp kappa No. no. 15±2 15.2

Bleaching sequence -- CEpHD CEpD

Cl2 as gas % 2.5 1.3

Cl2 as Hypo % 1.5 0

Caustic (NaOH) % 1.5 1.8

H2O2 (as 100% basis) % 0.75 1.0

ClO2 % 0.7 0.5

Bleached yield % 50± 2 49.5

Brightness % ISO 89.5 86.5

Viscosity cps 7.0 16.2

PC No. no. 1.0 1.5

Annexure 20

Periodical content of different elements in sap during anaerobic incubation

Element Unit Days after incubation

0 7 14 21

Total N % 0.245 0.723 0.845 0.857

P % 0.0142 0.0162 0.0174 0.0175

K % 0.077 0.100 0.114 0.115

S % 0.0016 0.0019 0.0020 0.0020

Ca % 0.029 0.034 0.040 0.040

Mg % 0.116 0.124 0.130 0.131

Fe ppm 37.74 42.33 44.05 44.19

Mn ppm 6.53 12.12 12.19 12.50

Zn ppm 3.35 3.77 3.94 3.98

Cu ppm 0.68 0.71 0.72 0.72

xii

Annexure 21

Value chain analysis

Based on the baseline survey, it can be stated that before the start of the project there was

no value chain existing as far as utilization of banana pseudostem is concerned. A very small

quantity of fibre was being extracted and is even now extracted by hand scrapping mostly in

southern part of the country. This may not be even more than 10 tonnes per annum. All these

fibre is used for preparation of handicrafts mostly for the foreign tourist market. Proposed value

chain at the beginning of the project is as given below.

Proposed value chain flow chart

With the progress of work and experienced gained, it has been proved that banana

pseudostem is potential raw material for textile, paper, manure and confectionary industries. The

details are given in flow chart.

Banana pseudostem

FibreScutching

wasteSap

Central core

Mordant for textile dyeing

Enrichment of manure

PaperYarn

making

MCC & Cellulose powder

Vermi compost

Paper and

board

Edible products

Marketing of products

Weaving and home

furnishings

xiii

Flow chart of the value chain after NAIP interventions

xiv

Two way table – Result framework analysis

Sustainability - Assured market demand and

supply of fibre - Management of scutcher

waste in eco-friendly

way and availability of

good quality organic

manure

- Banana pseudostem sap

waste converted into

Organic liquid fertilizer

which are available for the

farmers’

- Suitable for small and

medium scale

entrepreneurs

- Disposal problem

solve Impact - Farmers can realize an

additional income of Rs.

25,000 to 30,000/ha through

fibre extraction

- Use of pseudostem in eco-

friendly way

- Farmers’ can prepare and

sale/use them self

- Alternative organic

manure available for

crops production

- Improvement soil health

(saves 20% chemical

fertilizer)

- Increase in yield 10-15 per

cent

- Three parties sign MoU

for production and

marketing on commercial

scale

- Cheaper and ample

available raw

material for

confectionery

industries

Outcome - Availability of natural raw

material for

textile/paper/pharmaceutical

industries/ handicrafts

- Waste utilization in

profitable way

- Alternative source for

organic manures (FYM

& Bio-compost)

- Good supplement for fish

feed

- Saving in chemical

fertilizer requirement

- Enrichment technology

patented and ready for

commercialization

- Sap can be use as mordent

- Process for candy and

RTS standardize

- Contain Fe and

vitamin B3/B5

- RTS from left-out

syrup obtained during

candy preparation Intervention - Extraction of fibre using

modified raspador m/c

- Developing different

products from fibre

- Preparing good quality

vermicompost

- Vermicompost as fish

feed

- Use as liquid fertilizer (as

such or after enrichment)

- Use as natural dye in

textile dying

- Process

standardization for

preparing edible

products

Reasons - Dumping and burning of

pseudostem on field bunds,

nallas and road side causing

environmental problems

- Spending Rs.15000 to

20000/ha for disposal or

cleaning their field

- Scutcher- 30-35 t/ha - Sap- 15000-20000 l/ha - Central core- 8-10

t/ha

Issues - Banana pseudostem is

absolute waste

Disposal of scutching waste + sap and central core obtained during pseudostem

processing

xv

Some statistics:

Pseudostem availability – 60 to 80 tonnes/ ha

Area under banana cultivation – 8 lakh ha

Total pseudostem availability in the country – 64 million tonnes

Fibre availability – 6.4 lakh tonnes (0.64 million tonnes)

Sap availability – 14 million tonnes, i.e., 14 billion litres

Scutcher waste – 21 million tonnes

Central core – 7 million tonnes

It may be noted that value of the raw material viz., fibre (Rs.30/kg), sap (Rs.1/litre),

scutcher waste (Rs.0.50/kg) and central core (Rs.1/kg) will be approximately Rs. 5150 crorers.

With value addition this may become manifold. For extraction alone, one unit of five raspadors

requires at least 30 persons. The unit can produce about 30 tonnes of fibres per annum. For

utilization of the entire pseudostem available, 20000 such units will be required, that too, in rural

areas where banana cultivation takes place. Thus, employment generation will be approximately

six lakh persons or in man days it will be 120 million man days (6*10^5*200 with the assumption

that units will be working for 200 days in a year). In the conversion of fibres to fabric and end

products, sap to enriched sap, scutcher waste to vermicompost, central core to edible products,

etc., there will be additional employment generation. It means value of raw material generated per

manday will be Rs.425. After paying labour charges and other overheads even to the tune of

Rs.350 per manday an entrepreneur will be able to earn Rs.75 per person employed per day. An

entrepreneur establishing one unit of 5 raspadors will therefore be able to earn Rs.2250 per day.

Even if the unit works for 25 days in a month his total earnings per month will Rs. 56250.

As has been mentioned earlier disposal of banana pseudostem is a big problem for banana

growers. By utilization of the technologies generated in the project not only this disposal problem

is solved but there will be substantial employment and wealth generation.

xvi

Annexure 22

BUSINESS MODELS

The three technologies recognized by ICAR which are ready for commercialization.

- Fibre extraction using raspador machine and preparation of non-woven fabric

- Preparation of organic liquid fertilizer from banana pseudostem sap

- Preparation of candy from central core of banana pseudostem

To establish and operationalized a unit on a commercial scale, business models for the three

technologies are described here in detail

(I) Fibre extraction using raspador machine and preparation of non-woven fabric

Establishment of banana processing unit: For establishing Banana Pseudostem Processing

Unit (BPPU), identify banana growing cluster of about 40 to 50 ha area. Wherever possible,

the site for BPPU should be either at the centre of cluster or within the cluster area so that the

lead should not be more than 10 km. For an ideal BPPU, one should have to select around 0.3

to 0.4 ha area (Fig. 1) with three phase power connection facility. If power connection is not

available, then alternative energy sources viz., power-tiller, oil engine and Honda engine

(Fig. 2) may be used for extracting fibre from banana pseudostem.

Fig. 1: Layout of the BPPU

Fig. 2: Raspador machine with alternate power supply

Engine operated raspador Power-tiller operated raspador Diesel engine operated raspador

xvii

Methodology

After establishment of BPPU, the next step is collection of pseudostem and its

processing. While extracting fibre from pseudostem using raspador machine four components

viz., fibre, scutcher, sap and central core are simultaneously obtained. The details of

processing banana pseudostem are given here.

Fibre extraction and its uses

Step 1: Collection of banana pseudostem

After harvest of banana bunch at appropriate stage, the stem needs to be cut manually

at least 6” as above the ground level. Similarly, remove the leaves at the base of lowest or

oldest leaf petiole or 12” from the apical point. In either case, after cutting pseudostem, it

should be transported to BPPU by using tractor with hydraulic trolley.

Normally, banana pseudostem processing should be done immediately after harvest of

bunch. However, if excess pseudostems are available, then pseudostem can be kept standing

in the field up to 8-10 days after removing the top leaves or 15-20 days without removal of

the leaves. This period may vary with the season i.e., fewer days during summer and more

during winter or monsoon seasons. Further, after cutting the pseudostem, it can safely be used

up to 2-3 days, so as to avoid the deterioration in pseudostem.

Step 2: Processing of banana pseudostem

Splitting of pseudostem: Banana pseudostems are to be splitted into two halves for separating

sheaths from it. The splitting can be achieved either manually using knife (Koyta) or

mechanically by using Pseudostem Cutter machine developed by NAU, Navsari under

NAIP (comp II). The mechanical splitting is cheaper, faster and more efficient than manual

xviii

splitting. One pseudostem cutter machine is good enough to provide sheaths for 4 - 5

raspador machines.

Preparation of sheaths for fibre extraction: Once the

pseudostem is splitted in to two halves, the sheaths are

separated easily. After peeling out each sheath from

pseudostem, it should be cut at the both ends so as to

remove dry or rotten part. Similarly, remove the thin

portion longitudinally present on either side of sheath with

knife (Koyta). This ensures cleaner fibre output than non

removal of thinner portion.

The prepared sheaths should be stacked properly on the table behind raspador to

enable extraction of fibre more efficiently.

Step 3 Fibre extraction using raspador machine:

After preparation of sheaths, the fibre extraction is done by using raspador machine

developed by CIRCOT, Mumbai and subsequently modified during NAIP period. The

licensed manufacturer for raspador machine is Mac Well Engineering Works, Mumbai. The

prepared sheath is to be fed in between two rollers of raspador machine by holding one end

sheath firmly. The sheath is fed and pulled back to get clean fibres. The fibre should be rinsed

in the water thoroughly and air dried. The dried fibre should be collected and bundles are to

be prepared. The dried fibres are stored in dry room (damp free). From one hectare banana

plantation approximately 600-800 kg dry fibre are obtained.

Splitting of pseudostem using cutter machine and separation of sheath

Fibre extraction, rinsing, drying and storing the dried fibres in bundles

xix

Potential commercial uses of fibre:

- Raw material for textile industry for preparing yarn and fabrics (woven and non woven)

- Handmade and high quality paper

- Microcrystalline cellulose (MCC- pharmaceutical grade)

- Handicraft, ropes etc.

Non-woven fabrics

Trials were conducted at industrial level at Gloster Mills, Kolkata for preparing yarn

and non-woven fabrics where jute fibres are used currently. The non-woven fabrics of

different GSM were prepared successfully. The non-woven fabric was tested and used for

preparing various products on a laboratory scale. The potential commercial uses identified for

non-woven fabric are

acoustic /Sound Absorption,

insulator in automobiles,

wall paneling,

carpeting,

technical textile industries

The advantages of fibre extraction and non-woven fabric preparation are:

Use of banana pseudostem (presently waste) in eco-friendly way

Additional monetary benefit to the farmers

Employment generation in rural and urban areas

Alternative natural fibre for different industries

Alternative material for organic manures (from scutcher and sap)

The details of the cost economics of fibre extraction covering 40 ha of banana plantation

using one unit consisting of five raspador machines

Total no. of pseudostems available : 3400/ha

Extractable fibre : 200 g /pseudostem

Area covered by one unit comprising of five raspador machines : 40 ha

Total no. of pseudostems available : 3400 x 40=136000

Fiber extracted from 40 ha : 27200 kg

Realizable revenue : Rs. 29.1 lakhs

Raw materials obtained during fibre extraction and their cost details

Component Rate (Rs./kg) Quantity (t) Amount (Rs. in lakhs)

Fibre 50.00 27 13.5

Scutching waste 0.60 1600 9.6

Sap 1.00 600 6.0

Total 29.1

xx

Cost details of fibre extraction

Fixed cost Cost (Rs.

lakh)

Man

power Nos. Cost/

month (Rs. lakh)

Cost/ 6 months (Rs. lakh)

Variable

costs (Rs. lakh)

Per

month (Rs.

lakh)

For 6

months (Rs. lakh)

Raspador M/c (5) 5.00 Manager 1 0.10 0.60 Fuel (eng.) 0.25 1.50

Cutting m/c (1) 0.50 Driver 1 0.05 0.30 Fuel (trac.) 0.18 1.08

Diesel M/c (1) 0.75 Labour 25 0.90 5.40 P’ stem 1.13 6.80

Tractor tailor (1) 8.00

Civil work 5.00

Total 19.25 6.30 9.38 *Note: Above calculations are based on 180 working days

Total cost for first year= Rs.19.25+6.3+9.38= 34.93 lakhs

Cost details for transportation and processing of fibre to non-woven fabric

Recovery : 80% of 27.2 t

Processing and transport cost : Rs. 50 per kg

Selling price : Rs. 150 per kg

Revenue : Rs. 32.64 lakhs (21.76 t nonwoven fabrics)

(a) Year wise cost and returns for fibre extraction (Rs. lakhs)

Particulars Year

1st 2

nd 3

rd 4

th 5

th

Cost 34.93 18.25* 20.07 22.08 24.29

Revenue 29.10 32.01 35.21 38.73 42.61

Profit -5.83 7.93 15.14 16.65 18.32

B:C 0.83 1.75 1.75 1.75 1.75

* Variable cost = 9.38 + manpower = 6.30 + interest on fixed cost (12%) + M & R =2% of

fixed cost

(b) Year wise cost and returns for fibre extraction + non-woven fabric (Rs. lakhs)

Particulars Year

1st 2nd 3rd 4th 5th

Cost 48.53* 31.85 35.04 38.54 42.39

Revenue 48.24$ 53.06 58.37 64.21 70.63

Profit -0.29 20.92 23.34 25.67 28.24

B:C 0.99 1.67 1.67 1.67 1.67

* Fibre extraction (Rs. 34.93 lakh) + Processing & Transport (Rs. 13.60 lakh) $ Revenue from nonwoven (32.64 lakhs) + Sap (6.0 lakhs) + Scutcher (9.6 lakhs)

The cost-economics have been worked out as per the experimental trials conducted

during the project period on needle punching machines at Kolkata. The cost for transportation

of fibre to the industry will vary as per the distance and transportation facilities available. The

cost economics are calculated are tentative and will vary as per demand by the industry and

supply of fibre by the banana growers.

xxi

(II) Preparation of Organic Liquid Fertilizer (OLF) from Banana Pseudostem Sap

Banana pseudostem sap is obtained as a byproduct during extraction of fibre. It is a

rich source of plant nutrients and growth regulators. This can be enriched with organic inputs

through anaerobic incubation.

The details of facilities required and processes followed for extraction of sap are

given described here.

Establishment of sap enrichment Unit:

For establishing unit of enrichment of sap (1 lakh litres capacity per year) following

facilities are required.

1. Land requirement: 200 m2

2. Shed: Suitable infrastructure may be constructed as per the local condition

3. Specification of bio digester: For preparing 1 lakh litres enriched sap, two

biodigesters each of 5000 litres capacity are required. Using two biodigester each of

5000 litres capacity and 10 batches per year one can produce about 1 lakh litres of

enriched sap (Organic liquid fertilizer)

4. Filter unit: After enrichment, the sap is required to be filtered using filter press

machine

5. Bottling plant: The filtered sap is to be bottled suitably (PET bottle of different

capacity) and sealed in appropriate packing. The bottle needs to be labeled

appropriately.

6. Packaging for transport and marketing: The labeled and sealed bottles are to be

packed in cartoon boxes for easy transport to marketing outlet.

Separation of sap from scutcher: From the

scutcher with sap collected in tray placed below

raspador machine during fibre extraction, sap

can be separated either by squeezing the

scutcher manually or by using screw press

developed by NAU, Navsari. Use of screw

press is more efficient in sap separation from

scutcher than manual squeezing. On an average,

from one hectare banana plantation around 12000 to 15000 litres sap is obtained. In other

words, one unit of five raspador machines generates about 4000 to 5000 litres sap per day.

Filtration and storage of sap: The sap obtained during fibre extraction should be filtered

using muslin cloth. The filtered sap can be stored in plastic tank.

Uses of Sap

Can be injected directly through drip system in any crop.

Can be used in all crops

Reduces the use of chemical fertilizers

Suitable for use in organic farming system also

xxii

A patented technology available of organic liquid fertilizer from banana pseudostem sap. For

commercial production and marketing of OLF, will have to get license from NAU, Navsari

Cost economics for OLF covering 40 ha area

• Sap available: 6 l/pseudostem

• Number of pseudostem : 3400/ha

• Area covered with one unit of five raspador machines : 40 ha

• Number of pseudostem available : 136000 (3400*40)

• Total sap available: 8,16,000 litres

• With 10,000 litres capacity / month x 12 months : 1.20 lakhs

litres

• Recovery of enriched sap @ 80% : 96000 litres

• Revenue realizable : 96,000 litres *120 : Rs. 115.20 lakhs

• Cost and profit statement: Total Project cost (first yr)=40+75.8+4.46=120.26 lakhs

Cost breakup for organic liquid fertilizer unit of 10000 liters capacity per month

Fixed cost Rs. in

lakhs

Variable cost Rs. in

lakhs

Manpower Rs. in

lakhs

Land and

building

10 Sap @ Rs. 5/l

(1.2 lakh l)

06.0 Manager @ Rs.

20000 per month

2.40

Digester 10 Additives @ Rs. 25 per

liter

30.0 Skilled labours (2)

@ Rs. 3600 per

month

0.86

Bottling plant 15 Labeling, packaging @

Rs.15 per liter

14.4 Supervisor @ Rs.

10000 per month

1.20

Storage Tank 05 Marketing and

advertising

4.0

Transport 2

Trade margin 19.2

Misc. (Electricity etc.) 0.2

Total fixed

costs

40 Total variable cost 75.8 Total (manpower) 4.46

Total project cost (first yr) 120.26

xxiii

Raw Central core

Cutting/Dicing

Blanching

Addition of Sugar (Day 1)

Addition of Citric acid

Brix adjustment by adding sugar

Washing of candy

Drying

Packing &Storage

Washing

(a) Year wise cost and returns for organic liquid fertilizer (Rs. lakhs)

Particulars Year

1st 2

nd 3

rd 4

th 5

th

Cost 120.26 85.86* 94.45 103.89 114.28

Revenue 115.20 126.72 139.39 153.33 168.66

Profit -5.06 40.86 44.95 49.44 54.38

B:C 0.96 1.48 1.48 1.48 1.48

* Variable cost = 75.8 + manpower = 4.46 + interest on fixed cost (12%) + M & R =2% of fixed cost

(III) Candy from central core of Banana Pseudostem

Central core is a by-product obtained from

banana pseudostem during the process of fibre

extraction. From one hectare banana plantation about

12,000 to 15,000 kg central core is obtained. It is rich

in digestible fibres, iron, vitamins B3 and B5. Further,

it is colour and tasteless edible part which can be

blended with any fruit pulp. After processing of central

core into candy it becomes delicious and palatable and liked by people and children

especially. This is unique product for the consumers as well as for processor. At present no

such product made from banana pseudostem central core exists in market. Hence this

business can be a very profitable and lucrative.

Basic requirements/ inputs to start business with technology

banana plantation

cabinet drier

packaging and storage facilities

Process: The standardized process for preparing candy using central core is given here in

flow chart.

Composition: After preparing candy, it was sent to CFTRI,

Mysore and SICART, Anand laboratories for nutritional analysis

and value are given below.

Nutritional content of candy prepared form central core

Parameters Unit Content

Protein % 4.1

Carbohydrates mg/100 g 46.8

Calorific value k.cals/100 g 390

Total sugars % 85.4

Total Dietary fibre % 3.95

Vitamin (Pantothenic acid B5) (mg/100g) 86.4

Vitamin (Niacin B3) (mg/100g) 34.1

Fe mg/kg 643

xxiv

The major advantage of central core candy is it contains vitamins B3 and B5 in

addition to appreciable quantity of Fe.

Scope: The central core is cheaper raw material for confectionary industry. It being

colourless and tasteless can be blended with any fruit with improvement in nutritional quality

as added advantage. Still there is scope of improvement in the quality as well as product

diversification.

Application and use of the technology

Banana pseudostem central core can be used for preparing candy

Suitable for SHGs, Mahila Mandals etc.

Creation of employment opportunities in rural areas

Cost breakup for 10000 kg/year candy and 2500 liters RTS processing capacity

Fixed cost Rs. in

lakhs Variable cost Rs. in

lakhs Manpower Rs. in

lakhs

Land and building 15.00 Electricity bill 1.10 Skilled @ Rs. 6000 per

month 0.72

Cabinet drier 20.00 Central core 0.40 Unskilled labours (5)@ Rs.

625 per day 2.25

Utensils, etc. 03.00 Sugar 08.00 Packaging 10.00 Misc. 02.00 Total fixed costs 38.00 Total variable

cost 21.50 Total (manpower) 2.97

Total project cost (first yr) 62.47

Business potential including cost and profit projections

(10000 kg/year candy and 2500 litres RTS processing capacity)

Year wise cost and returns for candy and RTS (Rs. Lakhs)

Years 1 2 3 4 5

Cost 62.47 24.47 26.92 29.61 32.57

Revenue 47.50 47.50 52.25 57.48 63.22

Profit -14.97 8.06 33.39 27.87 30.65

B:C 0.76 1.94 1.94 1.94 1.94 Note: Selling price: Rs.450/kg candy and Rs.100/litre RTS

xxv

Annexure 23

STATEMENT OF EXPENDITURE (Final)

Lead Centre: Navsari Agricultural University, Navsari Sanctioned Heads Funds

Allocated

(*)

Funds Released Expenditure Incurred

1st

Year

2nd

Year

3rd

Year

4th

Year

5th

Year

6th

Year

Total 1st

Year

2nd

Year

3rd

Year

4th

Year

5th

Year

6th

Year

Total

A. Recurring Contingencies

(1) TA 7.15 1.15 0.50 0.84 0.75 1.05 0.88 5.16 0.67 0.90 0.84 1.48 1.02 1.30 6.20

(2) Workshops 5.19 4.60 -2.83 -2.59 1.26 0.36 0.00 0.80 1.29 0.48 0.76 1.48 0.36 0.41 4.77

(3) Contractual

Services/RA/SRF

64.96 9.35 5.62 8.28 17.35 7.06 6.05 53.71 2.51 8.37 12.90 15.65 7.04 7.73 54.20

(4) Operational cost 181.32 21.09 32.96 24.92 33.72 16.24 27.50 156.42 21.09 18.21 31.28 25.75 19.50 21.37 137.19

Sub-Total of A (1-4) 258.61 36.19 36.25 31.44 53.07 24.71 34.43 216.09 25.56 27.95 45.78 44.35 27.91 30.81 202.36

B. HRD Component

(5) Training 2.16 1.05 0.47 0.54 0.28 0.00 0.00 2.34 0.36 0.93 0.36 0.51 0.00 0.00 2.16

(6) International Training 4.31 0.00 0.00 0.00 4.31 0.00 0.00 4.31 0.00 0.00 0.00 4.31 0.00 0.00 4.31

(7) Consultancy 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of B (5-6) 6.47 1.05 0.47 0.54 4.59 0.00 0.00 6.65 0.36 0.93 0.36 4.82 0.00 0.00 6.47

C. Non-Recurring

(8) Equipment 128.93 94.00 37.00 0.00 0.00 0.00 18.70 149.70 20.65 62.68 45.60 0.00 0.00 0.00 128.93

(9) Furniture 2.74 2.75 0.00 0.00 0.00 0.00 0.00 2.75 2.74 0.00 0.00 0.00 0.00 0.00 2.74

(10) Works (new renovation) 24.97 20.00 5.00 0.00 0.00 0.00 0.00 25.00 19.97 5.00 0.00 0.00 0.00 0.00 24.97

(11) Others (Animals, Books,

etc.)

1.62 0.75 0.60 0.60 0.30 0.00 0.00 2.25 0.72 0.60 0.10 0.20 0.00 0.00 1.62

(12) North East Plant 18.70 18.70 18.70 18.21 18.21

Sub-Total of C (7-10) 176.97 117.50 42.60 0.60 0.30 0.00 37.40 198.40 44.08 68.28 45.70 0.20 0.00 18.21 176.48

D. Institutional Charges 19.81 3.32 2.46 3.35 3.73 1.46 3.44 17.76 1.09 2.63 2.98 1.61 1.56 1.52 11.39

Grand Total (A+B+C+D) 461.86 158.06 81.78 35.94 61.69 26.16 75.27 438.90 71.10 99.79 94.81 50.99 29.47 50.54 396.70

xxvi

STATEMENT OF EXPENDITURE (Final)

Partner 1: Central Institute for Research on Cotton Technology, Mumbai Sanctioned Heads Funds

Allocated

(*)

Funds Released Expenditure Incurred

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total 2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total

A. Recurring Contingencies

(1) TA 2.11 0.15 0.40 0.15 0.15 0.25 0.30 1.40 0.15 0.16 0.30 0.29 0.46 0.57 1.93

(2) Workshops 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(3) Contractual

Services/RA/SRF

23.70 2.12 4.86 4.67 3.47 0.53 2.81 18.45 1.34 2.49 3.47 6.57 2.55 4.36 20.77

(4) Operational Cost 36.47 9.00 7.73 5.00 -2.71 1.20 9.25 29.47 2.73 0.80 2.48 3.77 0.32 13.59 23.68

Sub-Total of A (1-4) 62.27 11.27 12.99 9.82 0.91 1.98 12.36 49.32 4.22 3.45 6.24 10.63 3.33 18.51 46.39

B. HRD Component

(5) Training 0.00 0.00 0.00 0.00 1.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(6) International Training 0.00 0.00 0.00 0.00 1.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(7) Consultancy 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of B (5-6) 0.00 0.00 0.00 0.00 2.00 0.00 0.00 2.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

C. Non-Recurring

(8) Equipment 145.21 45.00 0.00 0.00 0.00 0.00 110.00 155.00 6.16 22.39 6.66 0.00 0.00 0.00 35.21

(9) Furniture 0.20 0.15 0.10 0.00 0.00 0.00 0.00 0.25 0.10 0.10 0.00 0.00 0.00 0.00 0.20

(10) Works (new renovation) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(11) Others (Animals, Books,

etc.)

0.17 0.15 0.10 0.00 0.00 0.00 0.00 0.25 0.00 0.17 0.00 0.00 0.00 0.00 0.17

Sub-Total of C (7-10) 145.58 45.30 0.20 0.00 0.00 0.00 110.00 155.50 6.26 22.66 6.66 0.00 0.00 0.00 35.58

D. Institutional Charges 3.28 0.57 0.44 0.40 -0.07 0.10 0.62 2.05 0.00 1.00 0.10 0.30 0.08 0.00 1.48

Grand Total (A+B+C+D) 211.13 57.13 13.63 10.22 2.84 2.08 122.98 208.87 10.48 27.10 13.01 10.93 3.41 18.51 83.44

xxvii

Partner 2: Manmade Textile Research Association, Surat STATEMENT OF EXPENDITURE (Final)

Sanctioned Heads Funds

Allocated

(*)

Funds Released Expenditure Incurred

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total 2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total

A. Recurring Contingencies

(1) TA 0.83 0.13 0.27 -0.03 -0.08 0.39 0.10 0.78 0.05 0.07 0.02 0.08 0.25 0.17 0.64

(2) Workshops 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(3) Contractual

Services/RA/SRF

7.68 0.63 1.30 1.12 -1.18 1.02 1.30 4.19 0.25 0.41 0.34 2.16 1.80 2.16 7.12

(4) Operational cost 18.52 2.50 3.84 2.46 5.40 1.78 0.10 16.08 1.31 2.46 6.00 6.24 3.52 0.54 20.07

Sub-Total of A (1-4) 27.03 3.26 5.41 3.55 4.14 3.19 1.50 21.05 1.61 2.94 6.36 8.48 5.57 2.86 27.82

B. HRD Component

(5) Training 0.01 0.25 -0.25 0.54 -0.38 0.00 0.00 0.16 0.00 0.00 0.01 0.00 0.00 0.00 0.01

(6) International Training 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(7) Consultancy 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of B (5-6) 0.01 0.25 -0.25 0.54 -0.38 0.00 0.00 0.16 0.00 0.00 0.01 0.00 0.00 0.00 0.01

C. Non-Recurring

(7) Equipment 13.56 29.00 0.00 0.00 0.00 0.00 0.00 29.00 0.00 13.56 -0.80 0.00 0.00 0.00 12.76

(8) Furniture 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(9) Works (new renovation) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(10) Others (Animals, Books,

etc.)

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of C (7-10) 13.56 29.00 0.00 0.00 0.00 0.00 0.00 29.00 0.00 13.56 -0.80 0.00 0.00 0.00 12.76

D. Institutional Charges 0.79 0.16 0.18 0.17 0.19 0.16 0.02 0.88 0.03 0.16 0.15 0.15 0.16 0.16 0.81

Grand Total (A+B+C+D) 41.40 32.67 5.34 4.26 3.95 3.35 1.52 51.09 1.64 16.66 5.72 8.63 5.73 3.02 41.40

xxviii

Partner 3: JK Paper Pvt. Ltd., Songadh STATEMENT OF EXPENDITURE (Final)

Sanctioned Heads Funds

Allocated

(*)

Funds Released Expenditure Incurred

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total 2008-09 2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Total

A. Recurring Contingencies

(1) TA 0.48 0.13 0.08 0.06 0.10 0.00 0.10 0.46 0.04 0.06 0.07 0.23 0.05 0.07 0.52

(2) Workshops 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(3) Contractual

Services/RA/SRF

9.52 0.33 1.24 1.46 2.38 0.00 2.59 7.98 0.00 1.17 1.44 2.68 1.33 1.08 7.70

(4) Operational cost 1.14 0.30 0.50 0.19 0.00 0.00 0.10 1.09 0.53 0.09 0.31 0.15 0.00 0.21 1.28

Sub-Total of A (1-4) 11.13 0.75 1.81 1.70 2.48 0.00 2.79 9.53 0.57 1.31 1.82 3.06 1.38 1.36 9.50

B. HRD Component

(5) Training 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(6) International Training 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(7) Consultancy 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of B (5-6) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

C. Non-Recurring

(8) Equipment 6.07 5.00 0.00 0.00 0.00 0.00 0.00 5.00 5.75 0.00 0.00 0.00 0.00 0.00 5.75

(9) Furniture 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(10) Works (new renovation) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(11) Others (Animals, Books,

etc.)

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Sub-Total of C (7-10) 6.07 5.00 0.00 0.00 0.00 0.00 0.00 5.00 5.75 0.00 0.00 0.00 0.00 0.00 5.75

D. Institutional Charges 0.61 0.04 0.07 0.55 0.12 0.00 0.04 0.83 0.00 0.00 0.01 0.05 0.16 0.15 0.37

Grand Total (A+B+C+D) 17.80 5.79 1.88 2.25 2.60 0.00 2.83 15.36 6.33 1.32 1.83 3.11 1.54 1.51 15.63

*****