1

“Linear Low Density Polyethylene Drip Irrigation Pipes” – Ms Poorvi C. Desai, Sr. Manager, Business Development - Polymers,

– Ms Davneva Phira, Manager, Polymers Reliance Industries Limited

The Indian Plastic Industry witnessed a sweeping change from 1970’s to 2000 with increasing number

of entrepreneurs entering the plastic business. An entrepreneur can start with a low investment in

various projects. Achievements of the plastic industry have led to gains to the common man.

The range of plastics products begin at our doorstep with a Linear Low Density Polyethylene milk

pouch. Throughout the day we come across various products that offer functionality, convenience,

hygiene and safety.

Plasticulture products lead to higher yield (productivity) of plants. These products include LLDPE mulch

film, LLDPE drip irrigation pipes, HDPE raschel bags and HDPE agrishade nets. A robust distribution

pattern with more number of products would lead to a much more viable business.

Pipes form one of the major sectors in plastic processing industry & contribute to very great extent in

achieving high volumes of sales. Further, expansion of the pipe units is taking place at a rapid pace

& these pipe processors are well placed with a wide distributor/dealer network.

Linear Low Density Polyethylene Drip Irrigation pipes can be manufactured by a Polyolefin pipe

extruder which manufactures High Density Polyethylene Gas pipes. A High Density Polyethylene pipe

extruder can manufacture Polypropylene pipes on the same extruder with modifications in the

machinery.

2

Need for Plasticulture

The need for increasing food production to meet the increasing demands of the expanding population

by reducing resource base of cultivable land and water and hence effective and efficient use of these

resources is a necessity. Growth in agricultural production will have to be based on productivity

improvement by application of technologies like drip irrigation etc. To remain self sufficient in food

grains, we need another green revolution, or rather, a greener, revolution.

Plasticulture

Plasticulture is the use of plastics in Agriculture, horticulture, water Management, food grains storage

and related areas: -

Plasticulture in water management

Drip Irrigation

Controlled Environment Agriculture

LDPE Film Mulching

3

The factors that will lead to growth of Plasticulture in India are :-

Increase in population

Higher rate of urbanisation

Dual Income families & Economic Liberalisation

Economic Growth

Fruits prevents disease such as heart, diabetes & cancer

India ranks No.2 & No.3 producer of fruits & vegetables in the world - India, currently produces about

50 million tonnes of fruit & about 90 million tonnes of vegetables, a huge potential exists for LLDPE

Drip Irrigation Pipes

Monetary gains to the farmers and entrepreneurs :

Benefits to Farmers – Increase in productivity (yield) to the crops

Benefits to Entrepreneurs – High Value Added Products

- Flexibility of high Product Mix

- High Capacity Utilisation

- High Net Profitability

HDPE Crates, PP Leno bags, HDPE Raschel bags,

HDPE Agrishade Nets, HDPE Woven sacks, HDPE

& PVC Pipes, LLDPE Mulch film, HDPE Tarpaulins

4

Indian Trend – Drip Irrigation Examples of innovative adaptations of low cost systems by farmers to suit their needs show that drip

technology made simple and flexible can work in ways that are more dynamic.

Recurrent drought and scarce water resource has led to inefficient water use. What a farmer needs is higher productivity (yield), savings in water and fertilizer; what an entrepreneur

needs is an increase in net profitability. The use of the versatile plastic product, Linear Low Density

Polyethylene Drip Irrigation pipes has led to gains, both to farmers as well as entrepreneurs and

therefore the industry.

A farmer aims to reduce cost through effective use of fertilizers and water by the use of plastic products

(plasticulture). Plastics pipes vary from very small diameter used in drip irrigation pipes to large

diameter water supply pipes for irrigation.

Drip Irrigation

Drip irrigation is a technique in which the water is filtered, conveyed through PVC or HDPE mainlines,

LLDPE lateral lines and then let out in droplets through drip nozzles or microtubes placed directly at the

rootzones of the plants. The quantity and rate of water application can be matched to varying crop

requirements.

Besides conveying water, linear low density polyethylene drip irrigation pipe leads to uniform

distribution of water and fertilizer. Since the system is further bifurcated into submain line, laterals and

emitter/dripper, there is water saving by use of drip irrigation technique.

5

Micro irrigation helps to economize water use, reduce the irrigation cost per unit land and increase the

yield per unit area and unit quantum of water.

The laying of LLDPE Drip Irrigation pipes becomes difficult in monsoons. Advantages of Drip Irrigation Systems 1. About 50% saving in water consumption

2. Uniform distribution of water and fertilizer

3. Over 30% increase in yield

4. Reduced weed growth

5. Suitable for poor soil and water

Drip irrigation system includes the Main Line, Submain line, Laterals & Emitters/Drippers

1. Mainline is made up of PVC & HDPE which are of 65 mm diameter and above.

2. Submain conveys the water uniformly to lateral lines and are made up of PVC, HDPE or LDPE

which are of diameter 32 mm to 75 mm

3. Laterals convey water uniformly by means of drippers or emitters and are made up of LDPE or

LLDPE and are of internal diameter 10,12 & 16 mm

4. Emitters reduce the pressure head 0.5 to 1.5 atmospheres to zero atmospheres

6

Micro Irrigation

By converting 1 lakh land area under micro irrigation

• Total water saving is 347 million Cu. Meters / annum.

• Fertilizer saving of Rs. 105 cores

• Saving of 271 lakh KWH of energy per year worth Rs. 7crores by pumping less water.

Benefits • Better water use efficiency (60-70%)

• Increase in yield (30 – 100%)

• Saving in Fertilizer usage (40%)

• Cultivation in saline land possible.

Status in India • One million Ha under Drip Irrigation

• Two million Ha under Sprinkler Irrigation

• There is a potential of about 50 million Ha under drip and 20 million Ha under

Sprinkler Irrigation

7

Objectives of Micro Irrigation System

- Save Water & Electricity

- Multi cropping for higher returns

- Efficient use of fertilisers

- Solution for water/soil problems

- Maximize crop productivity

Comparison between Conventional Irrigation v/s Microirrigation

1. The yield in microirrigation can be increased upto 15-150% in comparison to lower crop yield in

conventional irrigation

2. 40-70% water saving in microirrigation compared to conventional irrigation where losses occur

due to evaporation, percolation and runoff

3. Effeciency of water in microirrigation is high about 80-95% in comparison to conventional of 30-

50%

Manufacturing Process Pipe extrusion is defined as a process of forcing the polymer melt through a die. The extrudate from

the die is sized, cooled and the formed pipe is pulled to the winder or a cut off device with the aid of

haul off device. Prior to this, polymer is fed into a hopper, conveyed by a rotating screw through a

barrel. This is subjected to high temperature and pressure.

Crop Increase in yield %

Water Saving %

Tomato 25-50 40-60Sugarcane 50-60 30-50Okra 25-40 20-30Potato 20-30 40-50Cabbage 30-40 50-60Brinjal 20-30 40-60Chilli 10-40 60-70Bottle Gourd 20-40 40-50Cauliflower 60-80 30-40

8

PE Piping system has many advantages :

- Light weight

- Flexible

- Long lasting

- Economical

- Easy for transportation & installation

Applications – Irrigation Drip, Sprinkler and Lift Irrigation

Drip Laterals are flexible tubings used in drip irrigation system. A single screw extruder suitable for

processing LLDPE. Melt temperature is 2150 C to 2250 C. Incorporating of processing aid and screen

pack with a mesh of 100/80/60 is recommended. Advantages of using LLDPE

• Flexibility: LLDPE pipes have specific elastic properties and can take a wide range of curvatures.

Long lengths can be transported as coils.

• They are corrosion proof

• Suitable for handling most types of corrosive acids and alkalis.

• Offer excellent chemical resistance properties.

Business with Plasticulture – Monetary gains to the farmers along with an increase in productivity

(yield) by the use of plastic products would lead to a growth in this industry. The loss which the farmers

would otherwise have made by not using these products is huge. The benefits of these plastic products

and the gain in terms of productivity (yield) of the crops by using these plastic products need to be

communicated to the farmers.

Local people who can communicate in the local language to these farmers are required. These people

could be “commission agents”. These commission agents will bring in a faster market penetration and

wider usage of these products. These products also need to be marketed parallely through dealers who

market other agricultural plastic products in their shops. Thus, a robust distribution pattern with these

elements is needed.

9

The major axis on which the pipe business lies is on the dealers. Good quality products to the farmers

which mean 100% virgin material create a good brand for the processor. Inferior quality product with

pipe failures in a short time would lead to product rejection by the farmers harming the image of the

dealer as well as the processor.

The high market potential for agricultural plastic products and lower number of manufacturers of these

products in the country would bring in more number of entrepreneurs in this business. A higher product

mix can increase the average selling price of the final product and lead to higher net profitability. Net

profitability depending on factors such as capacity utilization can be met by this high market potential in

the country.

Increase in capacity utilization and a product mix would help entrepreneurs in eliminating the risk of the

seasonality of products such as pipe business for irrigation. A product mix with applications such as

high density polyethylene pipes for gas applications etc would eliminate the risk of seasonality of these

products.

Besides this, the versatility of the extruder capable of producing all polyolefins on the same pipe

extruder brings in other end uses of high density polyethylene pipes such as drinking water,

submersible pipes and jet pumps.

Polyethylene Pipes for Entrepreneurs Pipe business with high volumes is a good business for entrepreneurs. This is a gain for both the

industries as well as agriculture. By increasing product mix, the project approaches a higher

profitability.

Pipes, known as a tube for conveying media such as water, fuel, liquids for numerous enduses such as

agriculture, automotive, medical, electrical fields. New enduses such as sewerage brings in a new

horizon for the entrepreneurs in this business.

10

Single and double walled corrugated pipes, which are at an infant stage in the country, are available

for numerous end-uses and end-users. Plastics pipes ranging from small diameter to large diameter

such as outer diameter 1000 mm are manufactured in the country.

Water is needed for survival of human beings; clean water needed for drinking can be provided by

plastic pipes. Plastic pipes offer excellent corrosion resistance and ensures clean delivery of water.

Corrosion resistance of plastic pipes brings in multiple endusers in food processing industries. Plastic

pipes are needed for survival of plants (crops) and help farmers with better monetary gains. Productivity

increases for farmers by use of plastic pipes, while productivity increases for entrepreneurs by use of

larger diameter plastic pipes.

Entrepreneurs who manufacture other plastic products use the same distribution/ network for Linear

Low Density Polyethylene Drip Irrigation pipes. Diversification in a field similar to the existing business

is a strategy used by most of the entrepreneurs to help them market the products with the existing

distributor/dealer network.

The existing pipe processors who are well established in the business for many years are now looking

at other alternatives in the pipe business. Eg. The processors of LLDPE Drip Irrigation pipes now look

at diversification into HD/PP Pipes so that they can use the same distribution/dealer network.

An increase in the net profitability of the pipe business due to more number of machines & higher

volume of business has resulted in expansion units. The existing processors also have their own team

of marketing graduates in agriculture and who visit the farmers for supplying pipes to them directly.

Project Financials

Project Startup

Project Writeup

New ProjectsUnder the

Guidance of Entrepreneur Development

Programme Cell, Reliance Industries

Limited

11

Today, entrepreneurs are keen to set up a pipe unit mainly due to the fact that the pipes can be

marketed through distributors/dealers making their business easy with one single operation i.e.

manufacturing. However, some of the processors have opened their own shops & deal directly with

farmers eliminating one intermediary step of distributors/dealers.

Some processors now aim at expanding their current manufacturing capacities, fully aware of the

demand of these pipes through direct deals with the farmers without distributors/dealers.

Entrepreneur Development Programme (EDP) Cell, Reliance Industries Limited Entrepreneur Development Programme Cell of Reliance Industries Limited leads projects from seed to

fruition. With its help, plans of expansions/diversifications can be drawn up. Support is given by this

Entrepreneur Development Programme Cell from Project Identification Stage to Implementation Stage.

Achieving low payback periods, high product mix, new applications, and new enduses can be

developed with the help of the EDP Cell. EDP helps in climbing steps of success for entrepreneurs.

Conclusion Pipe business is one such business that has a high market potential in the country. This business

involves projects with very low investments making it possible for entrepreneurs to start business in a

small way. New entrants in this business need to look at a higher product mix to help them achieve a

higher net profitability, eg. HDPE Gas pipes & LLDPE Drip Irrigation pipes. Good quality Linear Low

Density Polyethylene Drip Irrigation pipes of virgin material would help farmers have faith in a brand of

pipes of that processor and also lead to lower rejections in distribution network and higher sales.

Reference:

http://agri.mah.nic.in

http://www.cseindia.org

http://www.ncpahindia.com