skim processing issue of processing powdery skimclinic.rubberboard.org.in/pdf/ircpdf/gi-07 santosh...
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![Page 1: SKIM PROCESSING ISSUE OF PROCESSING POWDERY SKIMclinic.rubberboard.org.in/PDF/ircpdf/GI-07 Santosh kumar IRC... · 12 Hp Captain with rotavator. 02‐11‐2012 17 CONCLUSIONS Conventional](https://reader031.vdocuments.us/reader031/viewer/2022012000/6070089f01e1e936a232f6a6/html5/thumbnails/1.jpg)
02‐11‐2012
1
INNOVATIVE APPROACHES IN FIELD AND FACTORYAN HML EXPERIENCE
SANTOSH KUMAR
Vice President, HML
SKIM PROCESSING‐ISSUE OF PROCESSING POWDERY SKIM
AN INNOVATIVE APPROACHSANTOSH KUMAR
Vice President‐ HML
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SKIM
Forms between 8‐10% of production.
The skim Serum has low rubber content 4‐
5%
The serum has high concentration of
Ammonia,NR solids, higher concentration of
trace elements and microbes.
Quality of skim is seasonal in nature
The rollability of skim is dependent on factors like
Age of latex.
Seasonal stability of latex .
The Quality of skim is greatly influenced by the degree
of oxidation it suffers on account of prolonged storage
under processing
IT IS IMPORTANT TO CARRY OUT DAILY PROCESSING
OF SKIM TO MAINTAIN QUALITY AND CONSISTENCY
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MOOPLY SKIM PROCESS
IMPACT
Timely Rolling of skim has resulted in
Improved recovery and reduced process loss.
Improved quality of Processed skim
Reduce inventory of skim for processing
Reduce work load ,labour and electricity consumption
Reduce load on Effluent Treatment Plant,
Increase NSA.
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LOSS % Including SLUDGE IN HML
0
0.5
1
1.5
2
2.5
3
2008‐09 2009‐10 2010‐11 2011‐12 Sept 2012‐13
%
%
SKIM ROLLING AND PROCESSING
• Dedicated to Mr Jayakrishnan and Team
Mooply CTC factory
• comprising of
Mr Bijineesh
Mr Rebi Abraham
Mr Abraham Mathew
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MANAGING LARGE REPLANTINGS CHALLENGES AND NEED FOR INNOVATION
CHALLENGES IN REPLANTINGS
RAISING QUALITY PLANTING MATERIAL.
ENSURE UNIFORM SURVIVAL AND GROWTH.
ENSURE REDUCED GESTATION PERIOD.
ENSURE 80 % TREES ARE OPENED FOR TAPPING IN 6 years.
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QUALITY PLANTING
• What is a standard Plant?
• Methods of propogation?
• How do we ensure that all plants produced are vigorous growing and meets standards?
• Choice of clones and Planting material?
• Location specific approach to plant selection and planting?
• Future strategies?
COLLAR GIRTH ‐5.5 cm
1st whorl‐7‐8 leaves
2nd whorl ‐8‐9 leaves
Girth at Bud union‐4.5 cm
2nd internode length35 cm
1st internode length‐30 cm
STANDARD PLANT
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METHODS OF PROPGATION
Direct seeding in polybags
Seedlings in ground bed and transplant to Polybags
18 month plant
Root trainer plants
Out of these 4 methods the first 3 remain our
main source of plants.
KEY ‐REPLANT MILESTONES
Planting to be over in June.
80% of plants to branch by December.
100% of plants to be branched by 1st year.
Plant growth to be in line with girth parameters in the girth chart.
Analysis of girth readings every quarter and corrective action.
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ROAD TO GIRTH CARD
0
10
20
30
40
50
60
End of 1st year 2nd year 3rd year 4th year 5th year 6th year
GIRTH (cm)
GIRTH (cm)
80% plants to reach 50 cm
0
10
20
30
40
50
60
1st year 2nd Year 3rd year 4th year 5th year 6th year
TARGET (cm)
ACTUAL (cm)
TARGET VS ACTUAL – ROAD TO GIRTH
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PLANT GROWTH AND UNIFORMITY
ZONE 2
18 month/ Normal Polybag.
RR11 400 series.
Erosion prevention
measures/Revetments/Vetiver.
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MONITORING GIRTH PARAMETERS
• Individual plant census is taken quarterly.
• This involves 20 girth measurements in an immaturity phase of rubber plant
• 10000 girth readings per hectare
• 3.6 crore readings to be taken in an area of 3650 hectares.
• Manpower required @ 500 trees/person
• 73000 mandays – Rs 3.28 crores
This is a huge expenditure.
DATA CAPTURE AND TRANSFER PROCESS
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EXPLORE FURTHUR USES
• GPS BASED MONITORING.
• INDIVIDUAL PLANT TAGGING‐RF OR BAR CODE.
• INDIVIDUAL PLANT VARIANCE REPORTS.
• DATA LOGGING CUM MARKING TOOL.
• GPS BASED SECTORAL DIFFERENCIATION.
• WORKER MOVEMENT AND CONTROL.
0
5
10
15
20
25
30
35
2002‐03
2003‐04
2004‐05
2005‐06
2006‐07
2007‐08
2008‐09
2009‐10
2010‐11
2011‐12
2012‐13
RAINFALL –DEVIATIONS AND DISTORTIONS
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0
20
40
60
80
100
120
MIN (cms)
MAX (cms)
MEAN(cms)
RAINFALL –MIN ,MAX & MEAN OVER LAST 10 YEARS
0
5
10
15
20
25
30
MIN (cms)
MAX (cms)
MEAN (cms)
WET DAYS‐MIN.MAX & MEAN OVER LAST 10 YEARS
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USE OF SUPERABSORBANT AND SLOW RELEASE GELS
PRECISION FARMING
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0
10
20
30
40
50
60
70
80
90
>90 80‐90 <80
%
%
IRRIGATED FIELDS‐UNIFORMITY IN GIRTH
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USE OF UV RESISTANT POLY FILMS ON TERRACES
ECONOMICS OF UV RESISTANT FILM APPLICATION ON TERRACES
• COST
• MATERIAL COST – Rs 21600
• APPLICATION COST ‐ Rs 8000
• TOTAL COST ‐ Rs 29600
• SAVINGS
• WEEDING COST/Hectare in 2 YEARS – RS 25000
• MULCHING COST/Hectare ‐ RS 5000
• TOTAL ‐ RS 30000
• THE COSTS ARE EXPECTED TO BE RECOVERED IN 2 YEARS.
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The use of this poly film on terraces combined with drip
irrigation and fertigation may be a promising technology of
the future which will give additional benefits of
Higher water use efficiency.
Higher fertilizer use efficiency and lower fertilization
costs.
Higher ability to combat changing weather conditions
and ensuring faster growth.
EVALUATION OF TRACTORS FOR FARM OPERATIONS IN RUBBER
24 Hp Swaraj with rotavator24 Hp Swaraj with Cultivator
12 Hp Captain with rotavator
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CONCLUSIONS
Conventional Higher HP tractors may not be required to carry out our normal
operations.
A reduction of 10‐15 Hp is easily possible.
12 Hp tractor though useful for spraying etc has problems of clearence
and negotiating slope and thus is only suitable for level lands.
26 hp tractors have 22% less fuel and operating costs compared to34 hp tractors.
Tractor of the range 24‐26 Hp is capable of all operations like
Rovator attachment
Post hole digger
Levelling
Spraying applications
THE INTERCROPPING DEBATE
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INTERCROPPING
• From our experience of intercropping for the last 10 years
It is more an issue of crop management and space management than compatibility.
There are significant potentialities of co‐existance and economic benefits .
One crop should not be neglected at the cost of another.
0
10
20
30
40
50
60
YEAR 1 YEAR 2 YEAR 3 YEAR 4 YEAR 5 YEAR 6
WITH INTERCROP
WITHOUT INTERCROP
GIRTHING IN RUBBER FIELDS‐WITH INTERCROP & WITHOUT INTERCROP
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0
5
10
15
20
25
1st Year 2nd Year 3rd year
BANANA
PINEAPPLE
BANANA VS PINEAPPLE
While we have succeeded in establishing a very good ground cover in all our non interplantedfields,we have not been successful in Intercrop Fields.
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A NEED FOR BRINGING MORE CROPS IN THE INTER CROPPING BASKET
COCOA AS INTER CROP
ALTERNATE CROPSCOFFEENUTMEGRHIZOMES
MEDICINAL AND AROMATIC CROPS
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INSITU WATER CONSERVATION
INSITU WATER CONSERVATION
OWNERSHIP MODELS
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PROJECT FIREFLIES
A REVIEW
• This initiative was launched by HML 3 years
ago
Popularising and implementing very early
morning tapping
Use of proper /improvised headlights and
tapping gear
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Benefits
Improved yields from fields under Headlight
tapping.
Improved productivity/Tapper.
Significant reduction in FC%.
Significant increase in Tapper income.
• Today Head light tapping has been extended
to almost 55% of the area in the company
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0
5
10
15
20
25
INCREASE IN YIELD REDUCTION IN FC% INCREASE IN TAPPER INCOME
%
%
THANK YOU