Serals - ICRISAT (e

Transcription

Serals - ICRISAT (e

IMlMP1UGAPHIC INPUT SHEET
/
Serals
.'UJECT
-AN20-0000-GG0
Food production and nutrition--Farm equipment--Tropics
. TITLE AND
SBTITLE
Rice machinery development 'and industrial extension; semi-annual progress
report ,Jan.-June,1978
3. AUTHORIS)
(101) IRRI
4. DOCUMENT DATE
1978
S."UMBER OF PAGES
t.
70p.
ARC NUMBER
ARC
7. REFERENCE ORGANIZATION NAME AND ADDRESS
IRRI
8. SUPPLEMENTARY NOTES (Sponeuing Organt.allons Publhe,. A venaliflty
(Research summary)
9. ABSTRACT
10. CONTROL NUMBER
St. PRICE OF DOCUMENT
PN-AAG- 204
12. DESCRIPTORS
Agricultural machinery
Intermediate technology
'Rice
IV. PROJECT NUMBER
14. CONTRACT NUMBER
AID/ta-C-1208 GTS
15, TYPE OF DOCUMENT
AID 590-1 14-74)
67
"
Semiannual Progress Report No. 26
January I - June 30,1978
IUEMmNRYEVLOPMEN
AOD
INDUSRIL EXTE-NSION
IIDIto -C-1208
AGRICULTURAL, ENGINEERING DEPARTMENT
THE
INT.RNRTiONRL
IME REUEIROH' INTITUTli
P.O13CX 933
MANILA'
PHtLIPPINES
ISSN 0115-2610'
IPRl'Rice Machinery Development
Primary objectives of the machinery development program are increasing the income
and welfare of small rice farmers and fostering farm equipment manufacturing in developing
countries. Improved mechanical technologies contribute directly to these goals by increasing
food production through increased yields, reductions in field and post-production losses,
increased cropping intensity, and improvement in quality and value of agricultural p;oducts.
Appropriate machines can also reduce costs - a direct benefit to the low-income rice consumer. Mechanization based on local production conserves foreign exchange, expands oppor
tunities in rural-based industries, strengthens linkais between agriculture and other sectors
of the economy. and enhances training opportunities in small-scale manufacturing.
Program procedures begin by developing machines that satisfy two major conditions.
First, designs must be compatible with the technical and economic needs of small farmers
who use them. Second, the manufacture and servicing of the machines must be within the
technical capabilities of indigenous small and medium-scale machine shops. Drawings, design
information, and limited technical support are given free of charge to manufacturers who
want to produce IRRI designs on a commercial basis, agree to the conditions of a Memoran
ium of Agreement, and provide information on their manufacturing facilities and marketing
plans. IRRI retains worldwide distribution and patent rights for all designs developed at
IRRI and does not grant exclusive manufacturing rights or licenses.
Training opportunities include a two-week engineering course that is conducted semi
annually. Participants are expected to develop competency in the operation, maintenance,
and manufacturing aspects of IRRI designs. Enrollment is limited to 12 persons per class.
Financialsupport for the development program comes from the IRRI budget which is
funded by the Consultative Group on International Agricultural Research. Industrial exten
sion projects in Pakistan, Philippines, and Thailand are supported by a United States Agency
for International Development cont~act.
Location of the main research and development facility is the International Rice
Research Institute, Los Bafios, Philippines, with national liaison links found in countries
throughout Asia, Latin America, and Africa. Reports describing program activities are issued
semiannually and may be obtained upon request.
Agricultural Engineering Department
International Rice Research Institute
P. 0, Box 933, Manila, Philippines
LIAISON OFFCeS
IRRI/PAK Machinery Program
c/o LAPSA, P.O. Box 1237
Islamabad, Pakistan -
IRRI/THAI Machinery Program
P.O. Box 2453
Bangkok, Th .iland
TABLE OF CONTENTS
Page
Title
Introduction and Summary
1
Design and Development
4
6-8 hp tiller
Rotary tiller attachment for 6-8 hp tiller
Load-sensing tool carrier
Rice transplanter
Multi-crop upland seeder
Double-acting piston pump
Axial flow pump
Plow-sole granular chemical applicator
Portable thresher
Axial flow thresher
Harvester attachment for power tiller
Producer gas generator
Rice hull furnace
Improvement of the Engleberg rice mill
Tables and figures
25
Mechanization Research
Compacted soil studies
Plow-sole applicator laboratory and field trials
Threshing cylinder performance tests
Dryer fan performance tests
Storability of grain dried by the vertical bin dryer
Tables and figures
Mechanization Systems
Personnel List
33
34
36
37
38
38
39
40
52
Industrial Extension
extension
extension
extension
extension
figures
25
25
26
26
27
28
33
Mechanization consequences project
IRRI/UPLB/BRBDP rice post production technology project
Household and village storage studies
Rice hull weight analysis
Analysis of paddy drying systems
Thresher survey
Power tiller survey
Tables and figures
Industrial
Industrial
Industrial
Industrial
Tables and
4
4
5
6
7
8
8
8
9
10
10
11
12
12
14
in the Philippines
in Thailand
in Pakistan
in Indonesia
52
54
54
56
58
65
INTRODUCTION AND SUMMARY
The vertical bin dryer was released to manufacturers during
this reporting period. New development projects initiated include
a load-sensing tool carrier for the power tiller, axial flow pump,
a redesigned axial flow thresher with dual, oscillating cleaning
screens, and a rice hull furnace for the vertical bin dryer. Work
continues on the rice transplanter, multicrop seeder, and rotary
tiller and harvester attachments for the power tiller.
The compacted soil study is in its eleventh season. The 4-wheel
tractor was again able to till its plot without excessive mobility prob
lems. The depth at which the cone indices were measured increased in
some cases, probably due to lack of a drying period between crops be
cause of regular rains. Comparative field trials showed use of the
plow sole applicator produced higher yields than a Japanese deep place
ment applicator and traditional fertilizer application methods. Com
parative performance tests of alternative threshing cylinders and dryer
fans were conducted to obtain information to guide design improvements
and to advise manufacturers on selection of components.
The United States Agency for International Development has approved
a three-year study in Pakistan, Indonesia, Thailand and the Philippines
that will evaluate the impact of small rice farm mechanization on employ
ment, incomes, and production. Implementing agencies have been identified
in each country and a training program for the field staff will begin in
July, 1978. The project to evaluate technical and economic characteristics
of alternative rice post production systems in the Bicol River Basin,
Philippines, was completed in March. Comprehensive surveys, combined
with technical evaluation trials and monitoring activities were used to
examine the performance and economics of a range of operations at the
farm and mill level. Research on farm and household storage practices
in the Philippines reveals a wide range of techniques used for the pre
servation of paddy, although there is little evidence of large losses
from storage on the farm.
Threshers continue to be the most popular IRRI design and the
Philippine Extension Project concentrated on assisting manufacturers
in correcting problems with their prototype threshers and giving advice
for more efficient plant layout and operation. Thresher production in
Thailand totalled 356 units during the first half of 1978 compared to
65 during the same period in 1977. The Pakistan Staff has completed
modification of the IRRI threshers to include a wheat threshing capa
bility and good acceptance by farmers is expected. They also cooperated
with the Pakistan government in the adaptation of a North Korean trans
planter to suit Pakistan Conditions. P. Stewart Barton has resigned
his position in Thailind to return to Australia and V. R. Reddy has been
retained to head a new industrial extension program in indonesia.
Twelve engineers attended the 2-week training course in March
and 11 are invited to the course planned for October. One issue of the
2
IRRI Farm Machinery Newsletter was distributed and operator's manuals
for the portable grain cleaner and vertical bin dryer were published
during this period.
Papers and publications
Camacho, I.,P. Hidalgo, E. Lozada and B. Duff. 1978. "A Technical
Evaluation of Alternative Rice Processing Systems in the Bicol
Region of the Philippines." Paper No. 78-01.
Maranan, C. L. and B. Duff. 1978. "Farm Level Post-Production Systems
in the Bicol Region of the Philippines." Paper No. 78-02.
Duff, B. 1978. "Technical and Economic Factors Affecting the Efficiency
of Mechanization in Rice Post-Production Systems." Paper No. 78-03.
Kuether, D. 0. 1978. "Agricultural Machinery Development and Extension
at the International Rice Research Institute." Paper No. 78-04.
Duff, B. 1978. "Augmenting Human Energy Supplies for Agricultural
Development." Paper No. 78-05.
Camacho, I., P. Hidalgo, B. Duff and E. Lozada. 1978. "A Comparison
of Alternative Rice Milling Systems in the Bicol Region." Paper
No. 78-06.
Arboleda, J. R., H. T. Manaligod and J. S. Policarpio. 1978. "Vertical
Bin Dryer: A Product Developed Through Value Analysis." Saturday
Seminar Paper. May 27.
Takai, H., L. Ebron and B. Duff. 1978. "Nature and Characteristics
of Farm Level Paddy Storage in Luzon, Philippines." Saturday
Seminar Paper. June 3.
Kiamco, L. and J. McMennamy. 1978. "Reflection of the Energy Require
ments of a Small Scale Farmer." Saturday Seminar Paper. June 10.
Manalili, I. C. and J. McMennamy. 1978. "Rice Transplanter Development."
Saturday Seminar Paper. June 17.
3
PROGRESS REPORT NO. 26
January 1 to June 30, 1978
The following projects were active during the reporting period:
Design and Development (C.Moss, J. McMennamy)
6-8 hp tiller
Rotary tiller attachment for 6-8 hp
tiller
Load-sensing tool carrier
Rice transplanter
Multi-crop upland seeder
Axial flow pump
Portable thresher
Axial flow thresher
Producer gab generator
Rice hull furnace
I. Manalili,
R. Dayrit
I. Manalili, G. Espiritu
M. Aban
I. Manalili, S. Labro
M. Aban
G. Salazar
G. Salazar
G. Salazar
J. Policarpio
J. Policarpio
G. Espiritu
L. Kiamco
L. Kiamco
A. Caballes
Mechanization Research (D. Kuether)
Plow-sole applicator laboratory
and field trials
Storability of grain dried by the
vertical bin dryer
F. Cabrales
S. Labro
R. Dayrit
J. Arboleda
J. Arboleda, H. Takai
Mechanization Systems (B. Duff)
IRRI/UPLB/BRBDP rice post production
technology project
Thresher survey
Power tiller survey
B. Duff
I. Camacho, P. Hidalgo,
C. Maranan, M. Sumiran
H. Takai, L. Ebron
M. Sumiran
R. Echevarria
F. Juarez
F. Juarez
Industrial Extension (A. Khan, J. McMennamy, V. Reddy)
Industrial extension
Philippines
in the
in Thailand
in Pakistan
in Indonesia
S. Gutierrez, N. Langam,
H. Manaligod
Project Staff (table 13)
Project Staff (table 13)
V. Reddy
4
DESIGN AND DEVELOPMENT
6-8 hp tiller
The effects of steering clutch shock loads on the tiller
transmission during dynamometer testing of alternative clutch designs
was reported in Semiannual Report No. 24.
Two intermediate shafts and several final reduction chain
failures occurred during these tests. 1830 hours of field test on
two production prototypes produced three intermediate shaft failures
and two chain failures. In all cases, the intermediate shaft failed
at the weld joint of the shdft and driven sprocket.
The high failure rate of this shaft required action to improve
its service life. The dynamometer was used to compare a standard
production intermediate shaft assembly (2.54 cm dia), a production
assembly with larger weld fillet radius, and an assembly which used
brazing instead of welding to Join the shaft and sprocket. Each shaft
failed in less than 10 hours of test at a constant input of 3 hp and
a total steering clutch engagement rate of 37 times per minute. A
shaft of 3.32 cm diameter with the sprocket welded to the shaft was
tested under the same conditions and satisfactorily completed 50 hours.
This shaft design is now specified on the production drawings.
Although the failure rate of the final reduction chain was not
considered as serious as that of the shaft, it could become serious
when the tiller is used in dry soil. Our field tests were conducted
in wetland where the shock loads encountered during clutch engagement
are probably cushioned somewhat by the saturated soil.
The dynamometer evaluation of the use of springs to reduce the
clutch engagement shock loads resumed. Springs with rates of 197, 76
and 23 kg/cm were tested at power inputs of 1.5, 3, and 5 hp. Figure
1 shows representative oscilloscope traces of clutch engagements. The
springs evaluated thus far have had little effiect on reducing the peak
shock loads that are about five times the steady engaged load. Springs
with lower spring rates will be evaluated.
Rotary tiller attachment for the 6-8 hp tiller
Field testing of the rotary tiller was resumed after redesign
of the rotavator but the dog clutch failed after 115 hours of operation.
The clutch jaws, which were made of cold-rolled steel, were badly worn.
It was replaced by a clutch made of heat-treated medium carbon steel
5
and having a higher clutch spring force. The size of the roller chain
used in the rotavator intermediate drive was increased from No. 40 to
No. 50 so it is the same size as the chain used in the rotavator final
drive, to reduce spare parts requirements.
Excessive slippage was experienced on the second belt ot the
multi-speed primary drive causing the belt to fail prematurely. Use
of premium quality belts did not increase life to an acceptable level
so a two-speed chain drive that uses two sets of sprockets wi.th dif
ferent speed ratios will replace this second belt. A toggle mechanism
will loosen the chain when the chain is moved from one sprocket set to
the other for speed changes. The chain drive will be a more positive
drive with longer life, be more compact and provide the present over
all speed ratios.
Load sensing tool carrier
Single axle tractors (power tillers), when used to develop draw
bar pull, exhibit a weight transfer to the rear as implement draft
force increases. Unless a reaction member, such as a tail wheel is
present, the operator must counteract this reaction by applying an
upward force on the handlebar. Counterweights are often placed at
the front of the tiller to keep the force applied by the operator
within an acceptable range. This reduces the upward force applied
by the operator for a given draft force, but a downward force may be
required at no draft conditions.
The objective of this project is to develop a tool carrier
that uses the weight transfer effect to sense draft and automatically
compensate for excessive draft conditions by reducing the working
depth of tools mounted on the carrier frame. A prototype system was
designed, fabricated, and limited field testing was conducted.
The tool carrier consists of a spring loaded tail wheel assembly
which is connected to a tool bar assembly by a link (fig. 2). The
link connecting the two assemblies is positioned so that the tool bar
raises when the upward reaction on the tail-wheel exceeds the spring
force holding it in the no-draft position. By adjusting the preload
on the spring, the sensing linkage is inactive until the draft exceeds
a given value, for example, that corresponding to excessive wheel slip.
In theory the spring rate will then determine the rate at which the
tool is raised as a function of increasing draft.
Initial field tests demonstrated that the working depth of the
tool can be controlled by draft, but the spring rate chosen for the
first prototype was too low, and sufficient preload could not be obtained
6
to maintain full working depth at even small draft loads. Springs
with higher rates will be tested.
Rice transplanter
The prototype of te manually-operated transplanter described
in Semiannual Report No. 25 was field tested with traditional wet bed
seedlings. The machine did not uniformly singulate the seedlings,
sometimes several plants are remov3d from the tray causing the pickers
to miss on the succeeding stroke. This problem was attributed to
loosely packed seedlings because gravity feeding was used. A wooden
weight was placed on top of the seedling stack, but it only to.nded to
compress the seedlings without insuring positive feeding to the pickers.
Loose packing not only resulted in non-uniform singulation but also
caused the seedlings to frequently drop off the pickers before they
were planted.
To overcome this problem, feeder-fingers were installed to mecha
nically feed the seedlings to the pickers. This required the install-
ation of a feeding frame (fig. 3) to hold the moving tray. The frame
provided exit holes on the front side for the seedlings and another
set of holes at the-rear for entry and withdrawal of the mechanical
feeder-fingers.
The five feeder-fingers consist of 3 mm x 13 mm steel strips
rigidly mounted on a common frame supported by levers at both ends.
The lower end of the levers is hinged to the main frame. A lirk
connects each lever to the pivot arm of the planting frame so raising
of the planting handle causes the feedc:-fingers to move forward
through the holes of the feeding frame to push the seedlings into the
path of the pickers. When the planting handle is pushed down the
feeder-fingers withdraw totally out of the frame to permit the lateral
movement of the seedlings with the seedling tray.
The performance of the picking mechanism was studied in the
laboratory. During initial tests the pickers had a tendency to com
press the seedlings because the seedling exit is restricted to the
size of the hole in the feeding f7.ame. To minimize this a cam was
installed along the travel path of the picker holder to alter its
motion.
Several test runs were then conducted in the field. The machine
and
worked satisfactorily only if the seedlings were separated by hand to
add
will
and
consuming
time
carefully aligned on the tray. This is
from
the already large amount of labor spent in pulling the seedlings studied,
being
is
problem
the nursery bed and washing their roots. This
7
and we intend to try the machine with mat-type seedlings, grown in
soil-filled trays (similar to the Japanese method). It is important
that the seeds are evenly distributed in the tray to avoid missing
hills during transplanting. The presence of soil is expected to
effect a more uniform seedling singulation and protect the roots from
damage by the transplanter.
Multicrop upland seeder
Field trials with the multicrop upland seeder uncovered the
following problems:
1. An excessive amount of
between the hopper bottom and the
the clearance between these parts
due to the uneven surfaces of the
blies.
seed and fertilizer leaked out
oscillating seedplates - even when
was carefully adjusted. This was
hopper bottom and seedtube assem
2. The sponge material used as a seal between the hopper
bottom and seedplate wore rapidly.
3. The seedplate thickness must be the same for all five rows.
This is not desirable when intercropping where seed size and rate may
be different in adjacent rows.
4. Lateral adjustment of the presswheels on the axle to vary
row spacing was time consuming and the set screws that hold the press
wheel and cam assemblies on the axle were difficult to keep tight.
To solve the first two problems, the seedplate arrangement was
redesigned to use individually spring-loaded seedtubes. This arrange
ment was similar to the first prototype except the spring support was
improved. Laboratory tests showed no improvement in the leakage problem.
If one seed worked its way into the space between the hopper bottom and
the seedplate, it kept these parts apart creating a space for additional
seeds to leak out. The leakage problem was eventually solved by using
a narrower seedplate enclosed on the sides by spacers (fig. 4). Use
of seedplates and spacers in sets allow use of seedplates of varying
thickness.
The fourth was solved by using a square axle shaft made by weld
ing two angle bars together.
Field tests and laboratory life tests are planned to insure that
no major performance or durability problems exist in the machine.
8
Although the first prototype performed satisfactorily, some
improvements were made that resulted in the design shown in Figure 5.
The concrete legs were eliminated to simplify the concrete mold and
the location of the water inlet was changed from the bottom to the
top side of the casing to make the pump "self-priming". This design
also reduced the height of the pump centerline. A prototype is being
built for performance and life tests.
Axial-flow pump
The objective of this project is to develop an efficient, low
cost portable axial-flow pump that can lift water 1-4 meters from
lakes, rivers, or irrigation canals and be driven by an internal com
bustion engine or electric motor.
The first prototype consisted of a bamboo discharge tube, 4.2 m
long and 12 cm in diameter, fabricated steel impeller coupled to a
lineshaft of 1.9 cm (.75 nominal) pipe, a bamboo stator casing, and
a 1800 steel elbow. The lineshaft is supported by wooden bearings
fixed by clamp-type bearing holders to the bamboo tube. The pump is
driven by a 5 hp gasoline engine through a flexible coupling (see
Fig. 6). Preliminary tests showed that the pump is capable of pumping
up to 1350 1/min of water at 1.5 m lift.
The pump performed satisfactorily during a 100-hour test but
cracking and deflection of the bamboo tube and excessive bearing wear
were observed. This led to the development of a second prototype
using a steel discharge tube and redesigred wooden bearings (fig. 7).
Inlet guide vanes and diffusion vanes were incorporated to increase
the efficiency and an oblique entrance was added to reduce inlet
head loss.
Improvement of the plow-sole granular chemical applicator con
tinued. The drive chain frequently jumped off the sprocket and the
small capacity of the hopper required frequent loading of fertilizer.
To remedy these defects, the drive wheel position was changed from
the furrow bottom to the landside (see Fig. 8). This design allowed
coupling of the drive wheel to the metering roiler, thereby eliminating
the chain. Hoppercapacity was increased from 3 kg to 12 kg of urea.
Instead of one adjustable width fluted metering roller, a set of meter
ing rollers witi grooves of different lengths was made to give various
rates of fertilizer discharge. To improve the removal and cleaning of
9
the roller and hopper, the metering roller was made a slide fit to
the main shaft and is retained by a hitch pin. The revised plow-sole
applicator performs satisfactory in the field without major problems.
Field trial results are reported in the Mechinization Research section.
Portable thresher
The cleaning system for the portable thresher mentioned briefly
in Semiannual Report No. 25 was completed and is now being performance
tested (fig. 9).
The cleaning system of the first prototype consisted of a cen
trifugal blower, oscillating screen and a stationary grain chute. It
uged a cominon drive shaft for the blower and oscillating screen similar
to that of the portable grain cleaner. The blower gave adequate air
delivery at 800 rpm, but the 2 cm stroke was too long at this speed.
An idler shaft was added to reduce the speed to about 400 rpm and the
screen perfurmed well. To reduce cost, a larger blower was used which
runs at 600 rpm so the common drive arrangement design could again be
used.
Wood strip screen hangers were initially used, but their service
life was not satisfactory. Hangers made of three sheets of light
gauge sheet metal, bolted together, arv% now being tested.
The concave area is .20 m2 larger than the portable thresher and
a 7 hp engine is used instead of a 5 hp engine. Consequently the
threshing capacity is increased. Performance tests of 3 min duration
produced capacities of up to 850 kg/ha with separation losses of about
0.5% and blower/screen losses approaching 1.0%. Purity was 95%. Blow
back of straw and chaff at the feed inlet was encountered during initial
tests. An open threshing drum was installed and reduced the problm.
A novel screen design was incorporated in the thresher to mini
mize the length of the oscillating screen. When a perforated screen
is located directly under the concave, straw falls through the holes
which reduces screen efficiency ano tends to clog the screen. Normally,
a solid sheet is used under the concave to orient the straw horizontally
and avoid this problem. The new screen has a corrugated surface with
holes in the forward side of each corrugation. About 20% of the grain
falls through the corrugated screen section thus increasing the capacity
of the screen system. The thresher will now be subjected to long term
durability tests.
10
Axial flow thresher
The axial flow thresher has been in commercial production since
1973. The latest modification reported was the addition of an oscilla
ting conveyor-screen in place of the rotary screen and grain delivery
components (Semiannual Report No. 22). Most versions of the axial flow
thresher made by IRRI cooperating manufacturers use one oscillating
screen for cleaning. The IRRI-PAK version for threshing wheat has two
screens which run at the same speed ana in the same direction (Semi-
annual Report No. 24). This system requires a long screen assembly to
compensate for the distance traveled by the naterial on the top screen
before it drops on the second screen.
A continuing problem with any oscillating screen system is the
clogging of the screen holes, especially when threshing high moisture
material. This problem can be reduced by using larger diameter holes
but this approach decreases grain purity.
A new version of the axial flow thresher with two oscillating
screens under the full-length of the concave is under development
(fig. 10). The screens run at the same speed but in opposite directions
to reduce imbalance of the oscillating assembly. The top screen has
large holes to remove large impurities. Then the grain falls through
an air stream provided by two centrifugal blowers onto an inclined,
adjustable wind board and moves onto the second screen which performs
of
the final cleaning. An auger conveys the cleaned grain to one end
the thresher. An eccentric cam on the auger shaft oscillates the
cage
screens at 320 cycles per minute with a 2.5 cm stroke. An open
concave.
grill
bar
round
a
type threshing drum is used with
Standard material sizes was considered during the design of this
prototype. In the original IRRI design, a 122 cm long threshing drum
com
was used as the basis for sizing the machine. Consequently, many
sizes.
material
raw
ponents exceeded 122 cm, requiring non-standard
the
The length of the frame is used as the primary basis for sizing
new thresher so material usage will be more efficient.
The prototype harvester is complete, except for the cutterbar.
with
The IRRI 6-8 hp power tiller used with the harvester was fitted
the
of
requirement
power
added
the
meet
a 10 hp gasoline engine to
harvester (fig. 11).
The drive and conveyor mechanism was tested by manually feeding
the
cut paddy into the feed auger. Initial tests showed clogging in under
the
to
entrance
the
area between the end of the auger flight and
in
feed conveyor. The design of the conveyor system is rather unique
conveyor are on
that the auger and the front pulley of the underfeed
harvesters.
combine
on
used
a common shaft whereas separate shafts are of the
portions
lower
Initially, the open area between the upper and
perpendicular
attached
conveyor belt was covered by a sheetmetal shield
the end of the
to the back of the auger housing. Clearance between
this shield that
at
auger flight and this shield was .6 cm, and it isto 5.0
cm to reduce
clogging occurred. This clearance was increased
the shield. This did not
the amount of paddy the auger pushed against
the time before clog-
completely eliminate the clogging but it increased
rate the material
ging interfered with operation. At a reduced feeding
were cleared by the conveyor fingers.
paddy was pulled
Later tests showed that at times half a stalk of
still engaged by the
by the conveyor belt while the other half was point was changed to
auger flight. The sharp corner at this transfer
the straw during
a 10 cm radius which provided a smooth passage for
appears to
modification
This
transfer from the auger to the conveyor.
have eliminated the clogging problem.
and conveyor
After successful trials on the cutterbar, auger
begin.
systems have been completed, field testing will
Producer gas
generator
several
lests conducted on the dual mode gas generator revealed by LPG
of preheating
major problems. The generator requires one hour
in the com
uniformly
burns
and
gas before the volatile matter ignites
due to failure
bustion chamber. The volatile matter was not distilled
through the
upward
flow
to
of the hot gases from the combustion chamber
this
inside
installed
then
was
distillation chamber. A heat exchanger
separate
to
added
was
plate
chamber to improve distillation and a baffle
to prevent the vola-
the reduction chamber from the distillation chamber
(fig. 12). The
chamber
tile matter from flowing down into the reduction
0
at about 400 0 C.
stops
and
C
volatile matter starts vaporizing at about 90
failed to ignite.
Several test runs were made but the producer gas
excessive C02 and
This means a poor quality gas, probably containing
slightly burned
water. In the reduction chamber, the carbon was only was not attained
which indicates that the reaction temperature (1000'C)
chamber, heat ex
due to a high temperature drop across the combustion
changer and reduction chamber.
progress and
Because of the above problems, a dcsign study is in
distillation and
the gas generator is being modified by installing the
to minimize
combustion chambers directly above the reduction chamber
to
considered
being
is
heat loss (fig. 13). The continuous process
reduce the generator size.
12
Rice hull furnace
A manually operated rice hull furnace was designed and constructed
for the 2-ton vertical bin dryer. The furnace walls are made of 1.20 mm
(i8ga) ASTM-304 stainless steel sheet and 3 mm (11 ga) mild steel sheet
instead of fire bricks, to reduce the cost by about 30% and the weight
by 70%. An air duct is built around the furnace walls to prevent the
furnace from overheating and to minimize wall warping (fig. 14). Feed
ing and the combustion rate are controlled by shaking the two grates.
The furnace is designed to operate for about 6 hours (normal drying time
for one batch of grain) before the ash must be removed.
This furnace operates on a downdraft and updraft combustion pro
cess, to more completely burn the volatile matter (Lar, oil, CH4 ) and
the fixed carbon in the rice hull char, which results in a white ash.
In the downdraft process the rice hull is carbonized, or charred, above
the grate as the air flows downward across the fuel bed and burns the
volatile matter below the steel grate. The high temperature generated
allows the simultaneous combustion of the fixed carbon as air moves
upward across vhe char (updraft process).
In early tests, channeling in the fuel bed allowed too much air
for combusion and caused smokey exhaust gases but they were eliminated
by reducing t2,e clearance between grate bars from 6 nn to 2.5 mm and
installing a simple rake above the fuel bed to level and break any par
tially fused char. From the glass window, a bluish flame and red chars
were observed, which indicates efficient combustion. Several trials of
six hours of continuous operation showed that 8 kg/h of rice hull is
required to maintain an air drying temperature of 450 C at an airflow of
100 cu. m/min. The resulting ash consisted of 90% white ash.
The furnace is being prepared for a final performance tests and
durability tests.
A redesigned rotor (fig. 15) for the Engleberg rice mill has been
fabricated and tested. It has been designed to create a two-stage effect
with a single rotor because two-stage milling (the hull is removed first
by a huller and the bran and germ removed by a whitener or a polisher),
is the most efficient milling system. Grain breakage in the Engleberg
occurs largely at the point where the paddy is hulled.
The new rotor was compared to a standard mill rotor at Flected
blade clearances. Three trials of three runs with IR36, nine runs with
IR38, and nine runs with IR38 were made. Each trial used homogenous
grain and a standard screen (0.75 mm x 12 mm staggered slots), PVC blade,
13
machine
and weight loaded outlet. A power recorder was used to observe
was no
there
until
adjusted
were
gates
response. The inlet and outlet
peak
a
at
was
consumption
power
the
unn1illed rice in the output and
per run,
without erratic surges. Twenty kilos of paddy were milled
had
machine
the
after
right
one
and two one-minute samples were taken,
samples
The
run.
the
of
been set and another before the completion
taken
were used in the laboratory analyses. Paddy samples were also
milling
potential
and
from each run to check purity, moisture content
recovery.
On all the trials the new rotor design improved the total rice
0.9%
recovery by an average of 1.17% (1st trial by 1%, 2nd trial by
(fig.
and 3r by 1.6 ) at approximately the same degree of whiteness
16).
' increase in head rice
The new rotor gave an average of 12.5
3 d
recovery (12.76% 1st trial, 12.23% 2nd trial and 12.5% for the
effect
stage
two
the
by
explained
be
trial). This improvement may
tends
of the rotor and the smaller pitch of the feeding screw which
ne
still
is
improvement
more
to move the grain gradually. However,
the
and
70%
over
is
recovery
cessary because the potential head rice
increase was only from 37.98 to 50.47,.
The capacity of the new rotor is 12% lower than the old rotor.
This may be the effect of the single thread one-inch pitch continuous
feeding which meters the paddy as it enters the mill chamber.
The
decrease in power consumption is approximately the same as the de
crease in capacity when compared to the standard mill.
,-LOAD SENSING MECHANISM
SPIN -HITCH
'/ /
RAISED PIN -IMPLEMENT
POSITION---2---,-,--
RAIDEEP
DEEP
,,:RALWE
"/
NORMAL DEPTH
-
POSITION---------
----"
Fig 2 Schematic drawing of the load sensing hitch/tool carrier
showing the upword displacement of tool implement during
wheel slippage
OF OPrDATION
FEEDER FINGERER
r)J
1-dCtjr
ipl
tori
iini
LEGEND:
NI~fh
$'A,
S~
NI
HFL'
NERMEiA
A9
L
UE
CA"
AL
V
CO
Fig 7 Schematic drawing of a
19
F.
P1I~
f J.
P't
**\
..
-~~~
'n
1
t
i'
r
I
I
i
n(i
20
UPPER SCREEN
GRAIN FLOW
Fig.
I0
Axial flow tlhresher-witih
(oulil,-,croenl cleaninq system.
Relr-Feeder
c-iger
I-Cutter bar
Engine
Conveyo, housirg
Fig. II
thresher
PoertllrPortable
Schematic of power tiller
LGroin
pon
attached harvester.
22
LEGEND:
Plate cover-strow inlet
-0 Wi0ilemattv CH4 ,TAR,O
2 ,CnHA
(50- 150Cl
10001C
- Fle ge C02 ,02 ,N2 (50OOC0Proucer ga CON 2 (300C-6OO'C)
___
tube
VM-Gas collector
strow
Rice
Air
VM-Gas inlet got& valve
55gal drumfulchaomber
Air inlet
stock/1 Flare
=upo--ubGlow plug- igniter
Charging door
VM-Gas combustion ciamber
Gratz
r
Reduction chambe
collector
frCO-Gos
C+C'2Cln
Ashes
Fig. 12. Experimental producer gas generator.
Char grate drive
Feed hoppor
Air inlet ..
Carbonizing chamber
Insulation
-i
Combustion chamber
Producer gas
Ipection hole-
outlet
Ash
Ash
chamber
rateReduction-rate
-- .aedi
-------
-
.
Ash .-.
Ash grate drive
tnspction hole
Fg.
ScdAw
Ash port
3
pot
,I
Fig,13 Schematic drawing of gas generator.
23
NEW
60
ROTOR
STANDARD
76.24
ROTOR
POTENTIAL
700
71.71
70
/
6895
6.22
600
6
60
50.47
500
5
40 4
300 3
50
40
3.98
30
264
223
200 195
2
20
0
m
0i
TOTA L
RECOVERY
M%)
H EAD
R IC E
M%)
CAPACITY
(KILO-PADDY/HR.)
AMOUNT OF
POWER USED
(FOR
20 KG SAMPLE)
FIG.16 COMFARISON OF NEW ROTOR VS. STANDARD ROTOR
24
A......
,
I ts,
-
T GA5
/t
FIG 14 RICE HULL FURNACE
Fig. 15
Two-s taleI
0
1o'
1 llqrl'
IntI!1
I 'c.
I,1
25
MECHANIZATION RESEARCH
The compacted soil study is in the eleventh cropping season.
Depths at which a cone index of 2.46 kg/cm 2 was measured generally
remained constant when compared to similar readings for the tenth
crop, with the exception of the 4-wheel tractor plot where "after
tillage" depths increased almost 2 cm to over 7 cm for the "before
tillage" readings (fig. 17).
Depth increases at a cone index of 4.92 kg/cm 2 were less and
significant only inthe 10 hp tiller Flot where the "after tillage"
depth increased 6 cm.
The plots were not irrigated during the one-month fallow
period but about 200 mm of rain fell during the period so the soil
never dried out completely as it had between crops 9 and 10. The
4-wheel tractor successfully completed the tillage of the 4-wheel
tractor plot.
Plow sole applicator laboratory and field trials
The plow sole applicator was subjected to laboratory tests to
determine if metering rates vary with a change in operating conditions.
Eight metering rollers calibrated to give different application rates
ranging from 30 to 120 kg N/ha were tested at different speeds of
rotation. No significant variation in metering rate per revolution
occurred with speed changes, thus the fertilizer metering rate is
proportional to speed so the application will maintain a constant
application rate per hectare, independent of machine ground speed.
The discharge rate is also independent of the depth of ferti
lizer in the hopper. There was no appreciable change in delivery rate
with the hopper full, half full, and one-quarter full of fertilizer.
Similarly, a metering rate test conducted with the hopper tilted at
200 to 30' forward, backward, and to each side showed no effect on
delivery rate.
Life tests will be conducted to determine possible metering
rate variations with time due to wear of the metering components.
The plow sole applicator was compared in dry season yield trials
with a Japanese deep placement applicator, incorporation at final harrow
26
ing, and a best split application (2/3 incorporation at final harrow
ing and 1/3 broadcast at panicle initiation). An application rate of
90 kg 14/ha was used on all plots. Each fertilizer application method
was replicated three times for a total of 12 individual plots, each
witi an area of about 460 sq m. IR-36 was planted in one-half of
each plot and IR-42 planted in the other half. Fertilizer was applied
with the plow sole applicator 20 days before transplanting and the
Japanese deep placement machine applied the fertilizer 10 days after
transplanting. Common weed and insect control was applied to all plots.
The yield results are shown in Table 1. The plow sole aoplicator method
produced the highest average yields. While incorporation at final har
rowing (basal) produced the lowest yield. The test will be repeated
during the wet season using a fertilizer application rate of 30 kg N/ha.
Several Filipino manufacturers have adopted an open threshing
cylinder in place of the closed cylinder specified on IRRI drawings
(fig. 18). The open cylinder can reduce costs in some manufacturing
situations and provides for more convenient pegteeth replacement and
easier straw removal when the thresher is plugged.
The open and closed cylinders were evaluated to determine if
one cylinder design possesses better performance than the other. Each
cylinder was used in an IRRI portable thresher to thresh combinations
c' long, short, wet, and dry batches of IR-36. The procedure was re
peated with the new prototype portable thresherwith cleaning system
and IR-42 (fig. 9).
The results are shown in Table 2 and indicate that although some
individual tests showed differences no significant overall difference
in performance was noted. The open cylinder reduced blowback of material
and dust out of the feeding entrance and into the face of the operators
which is a plus for the thresher crew. Although not enough tests were
conducted to evaluate statistically, generally the results agreed with
previous data which shows a marked reduction in threshing capacity as
straw length increases. Average capacity was reduced by almost one-half
when the straw length increased from the 45-60 cm range to 71-90 cm.
Wet paddy did not effect capacity as much as long paddy, probably be
cause moisture content affects cleaning capacity more than threshing
capacity and only threshing capacity was compared in these trials.
Numerous requests for information on the capabilities of the IRRI
batch dryers in cereals other than rice and the questionable need for two
different blower designs for the two dryers prompted a series of tests
27
to compare performance under varied operating conditions. The blower
from the University of the Philippines-Los Baios (UPLB) dryer was
included in the tests.
The IRRI It flat-bed dryer (B01) uses a vaneaxial blower and
the IRRI vertical-bin (BD2) and the UPLB dryers have tube axial blowers.
The UPLB fan is a standard automotive-type used in engine cooling sys
tems.
Each blower was installed in the appropriate test duct and
powered by an electric motor. Air flow, air temperature and humidity,
and electric power consumption were measured at selected fan speeds
and static pressures. The results are shown in Figure 19.
Under most of the conditions tested, the BD2 fan was more than
twice as efficient as the other fans. The BD2 blower could replace
the BDI blower and provide the required 50 cu m/min air flow at a
power requirement of less than 1 hp compared to about 1.7 hp required
by the BDI blower under similar conditions. Although the BD2 blower
is more efficient than the othe^ two blowers, it is still much lower
than average for this type of blower, thus it is being redesigned to
improve efficiency.
Storability of grain dried by the vertical bin dryer
[he moisture gradient between the heated air inlet and discharge
sides of the vertical bin dryer varied from 4.5 to 3 percentage points
and could affect the storability of the grain.
To determine this effect, if any, four bags of dried grain from
the final test of the dryer (3%moisture gradient) were randomly select
ed and stored for 3.5 months and sampled monthly for fat acidity value
(FAV) analysis. An increase in FAV indicates a reduction in grain
quality but the FAV did not increase during the 105 day storage period,
indicating good storability if proper drying procedures are followed.
The grain was stored during the dry season so the results could differ
for wet season storage.
28
Table
Variety
IR-36
IR-42
1. Fertilizer yield trials.
Fertilizer application
method
Rep 1
Plow-sole
7.00
5.48
6.13
6.20
Best split
5.98
5.48
5.32
5.39
Basal
Japanese machine
4.40
6.10
3.58
6.14
4.88
5.65
4.29
5.96
Plow-sole
7.03
7.70
8.54
7.76
Best split
6.75
6.80
7.05
6.87
Basal
6.48
5.33
6.08
5.96
Japanese machine
5.80
7.25
8.10
7.05
Rep 2 Rep 3 Ave.
(t/ha at 14% M.C.)
29
Table 2. Performance of closed and open threshing cylinders.
Cylinder
Paddy length (cm)
Moisture content 3
Closed
Capacity in kg/h
451
711
602
952
1
iR36,
2 1R42,
Open
(Separation loss in %)
Wet
669 (1.3)
524 (1.6)
Dry
815 (1.5)
777 (1.5)
Wet
344 (1.0)
353 (1.1)
Dry
.55 (0.9)
339 (1.1)
Wet
845 (0.4)
590 (0.4)
Dry
740 (0.4)
859 (1.1)
Wet
363 (1.8)
330 (3.5)
Dry
308 (2.1)
575 (0.6)
IRRI portable thresher, 5 hp engine, capacity and loss averaged from
three 3-minute runs in each condition.
IRRI portable thresher with cleaning system, 7 hp engine, capacity and
loss averaged from two 3-minute runs in each condition.
3Wet, +30%
MC, folage wetted to simulate threshing during or shortly after rain.
Dry, 20-25% MC, threshed on day of harvesting, sunny weather.
2
4 92 k9/cm
2.46 kg/cM2
AVO o bfe
bMd prgpoton
AV@e afi kind pplutea
45-
40"
35
1
IHP
TILLER
15
I
2
5
6
7
812
2
3
4
CROPPING SEASON
Fig 17 Compacted layer depth under different tillage systems
5
6
7
8
9
10
It
2
OPEN THRESHING
CYLINDER
"
"..
A
Po.e (k.)
O ,eron effcew c -(V
FowL% Iw..
)
-30
PoE".ecv
...
C
22,
-'-
P
e
N.)
ie f -c.i..1
)
w
3
2
ei i e tctn cyl% )
--
L
--
-- E
3
--t
4-
,,e ~
--9
a
4______20 ~

lo.-___•
- 7
2k
0
soI€wce
I" " H lO)
s t ic
S
gerentvI H 2 01
510?.c
3
Sloli p
e e
H2 01
____
0 1750 rpm
3
750 pm
Sa 2050- rpm
0
220 0r pm
1 0
O
300
AA
25[-A
0
15
,
,
2
I
'
25
,
'
00
2200vm;
0o
65
isj
1
75
05
1
903
105
-9
115
125
20
25
Fig. 19
0
45
3
3
Airflow (m /mtn)
Airflow m /mmii
Awflow, power consumption ard overall efficiency of BD2 blower
at 00,1900, 2200 rpm moving ambient ar
3
30
of D1 blower
nd
overall effice.n
Airflow, power consumption
rpm moving ambient oar
.,20r"2200
art I
IRRI and IJPLB dryer blower performance.
0
W
W
05
1
: f
--------------
Ariflo(m
3
/rm n)
Arflow, power consumption and overall efficiency of UPLLB blower
at 1750,1950,2050 rpm moving arriient air
33
MECHANIZATION SYSTEMS
Funding has been approved by the United States Agency for
International Development for a three year, four country study to
examine the impact of small rice farm mechanization on production,
employment, and income. The project will cover two survey sites in
Indonesia, Pakistan, Thailand, and the Philippines. Associated with
the cross sectional surveys will be expPrimental engineering trials
to examine the technical characteristics of alternative techniques
for operations such as tillage, seeding, threshing, and drying. Work
has begun on a cross national comparison of the historical development
of mechanization in Asia.
Affiliations have been developed in each country with the follow
ing agencies:
Thailand:
Faculty of Economics, Tharinasat University
Dr. Dow Mongkolsmai
Statistical Section, Planning Division
Ministry of Agriculture & Cooperatives
Ms. Sanga Duangratana
Pakistan:
Indonesia:
Economic Research Institute, Lahore
Dr. Dilawar A. Khan
Rural Dynamics Group (for East Java Study)
Agro Economic Survey, Bogor
Dr. Rudolph Sinaga
Department of Economics (for South Sulawesi Study)
Husanuddin University, Ujung Pandang
LPPM (Agricultural Research Institute), Maros
Dr. Ibrahim Manwan
Philippines:
International Rice Research Institute
A two month training program at IRRI will begin in July, 1978
for the project field staff from each country. The objectives are to:
refine and complete the data instruments for the field surveys, develop
research design and sampling procedures, develop the analytical and
operational procedures for the assembly and analysis of the field survey
data, and compile a set of management and accounting guidelines for the
34
country research projects. Following the training program and a
three day workshop at IRRI in September, field surveys are scheduled
to begin in November, 1978.
IRRI/UPLB/BRBDP rice post production technology project
This report completes the semiannual reports on the Bicol River
Basin rice post production project. Earlier reports summarized find
ings on the comparative labor requirements of traditional and improved
rice post production systems, harvesting and threshing losses, milling
recovery rates, ana common post production practices.
Farmers derived several benefits from improved threshing and
drying techniques as shown in Tables 3 and 4. Mechanical threshing
yielded the highest return per ton of paddy using either actual or
contractual labor rates utilized in the analysis, although the axial
flow thresher continued to have mobility and maintenance problems.
The adoption of mechanical drying increased cash outlay mostly due
to high fuel cost, thus increasing total post production expenses per
ton. These increased expenses have decreased the farmer's willingness
to adopt mechanical drying.
Reducing the length of time from harvesting to drying increased
yields and improved grain quality because of a reduction in spoilage.
The mechanized system produced a lower number of damaged kernels and
immature grains than the traditional system. Almost 40% of the farmers
interviewed used mechanical threshers on their farms, most of which
were owned by contract operators. Several felt this practice would
become more widespread as cropping intensity and yields increased.
Sixty three percent of the farmers interviewed sold their wet
paddy immediately after threshing, because of the lack of economic
incentives for drying and the immediate need for cash. These farmers
saw little benefit from drying paddy mechanically except during periods
of inclement weather and for the production of good quality seed. Farm
ers used highways, basketball courts, and other concrete surfaces for
the sun drying of paddy.
Marketable surplus, defined as the operator's share of the harvest
less that for home consumption and seed requirements, averaged 41.4% in
the three pilot areas, ranging from 27.0 to 49.2% (table 5) and increases
significantly with total production (fig. 20a). A proportionate relation
ship appears to exist between marketable surplus and the operator's share
(fig. 20b). Figure 20c shows a proportionate relationship between the
surplus and effective rice area, although the linear relationship is not
statistically strong. The paddy retained for home consumption ranges
35
from 20 to 35% of total production (table 5). With improved post
production facilities, this share may decrease as reduced post pro
duction losses increase the share available for sale.
The Bicol project mill level systems trial and monitoring
activities were completed in March, 1978, and an analysis of com
parative costs and revenues concluded the evaluation. Semiannual
Report No. 25 presented technical assessments which included milling
estimates for alternative farm level threshing-frying systems.
Eighty-two percent of all rice mills in the Bicol River Basin
are steel hullers and process about 46% of the paddy crop. The other
18% are cone-type units which mill the remaining 54% of the paddy.
Diesel engines are the main source of power, averaging 11 hp for
steel hullers and 42 hp for cone-type mills. The average age of the
steel hullers is 13 years and cone-type units average 11 years (table
6). Cone-type mills generally service rice traders, while steel hull
ers provide for the household requirements of farmers, usually milling
small lot sizes. Cone-typemills are generally bette- equipped than
mills using steel hullers, and provide a wider range of services such
as drying and storage.
Farmers say proximity and accessibility are important factors
in their choice of steel-huller mills. High milling recovery and
quality of milled rice may, however, induce farmers to patronize cone
type mills.
Steel-hullers and cone-type mills were monitored to assess their
operational characteristics. The results indicate a high utilization
level for cone-type mills relative to steel hullers. The largest cone
type rice mill recorded the highest utilization rate at 97% followed by
a rubber roll-steel huller combination mill with a 77% rate. The steel
hullers, centrifugal hullers, and stone disc-steel huller combination
mills generally showed low utilization levels (table 7).
Seventy-one percent of t;ie paddy samples analyzed were of low
quality and only 29% were considered as being of high standard grade
(fig. 21). Comparing laboratory milling yields, high grade paddy dif
fered significantly in quality from samples with a high incidence of
immature, cracked, and fermented grains. Cone-type mills (fig. 22) produced
high quality milled rice relative to steel huller units but physical
condition and characteristics of paddy also affected milling perform
ance. Better milling performance was obtained with short grained
varieties than with long grained or mixed varieties. Rubber huller
units provided the highest overall milling efficiency.
The relative costs and revenues associated with different mill
involving village- and commercial-level milling units were
systems,
ing
36
analyzed. At the village level, the steel huller had the lowest
average total cost at all four levels of utilization, while the
single-pass rubber roll unit had the highest (table 7), reflecting
the low investment and maintenance costs of steel huller units and
the high investment and replacement costs of rubber huller units.
The rubber roll-steel huller combination mill recorded the highest
average revenue (table 8), indicative of a high milling recovery rate
and a high degree of utilization (77%). It also reported the highest
average profit per ton of milled rice.
A field survey of existing facilities and practices wa3 conducted
in 10 provinces of Luzon in December, 1977. Seventeen farmers were
interviewed and 28 storage facilities were included in the technical
evaluation phase of the study. Both container-type facilities (sacks,
wooden boxes, bamboo baskets) and granary-type facil;ties (wooden, bam
boo, sheet metal and concrete warehouses) were included in the study.
The interviews revealed that none of the respondents had chemical
ly treated their facilities before storing grain. Most simply dry-swept
or washed their facilities with water. No farmer treated paddy while in
storage. Only one farmer inspected his storage periodically, the rest
assumed the stored paddy to be always dry and safe.
Farmers consider moisture content at storage time and type of
storage facility as the two most important factors affecting the safe
storage of paddy. Satisfaction with present facilities, limited Daddy
production and lack of capital are some reasons why no farmer was in
terested in improving his storage facilities.
Damage to the storage facility and paddy handling errors were the
sources of quantitative losses. According to farmers' estimates, the
amount of paddy lost from containers was 1.4 kg per sack (45-50 kg) and
from granaries, 0.6 kg per sack. The estimated loss due to rat damage
was 0.4 kg per sack. Although no respondents complained of fungus or
insect damage all paddy samples collected were infected with fungi and
60% were infested by insects.
The size of paddy reserves for home consumption depends on family
size. The relationship can be expressed by the equation: Y = 16.2 +
5.6X, where Y is home reserve in sacks per year and X is household size.
The average annual reserve was 49 sacks for households averaging 6 mem
bers.
Paddy reserves for double-cropped farms lasted frei:J 4 to 8 months.
Few single-cropped farms kept stocks until the succeeding harvest because
immediate cash requirements forced many farmers to sell.
37
A number of trials were conducted to determine the general
condition and quality of paddy samples taken from on-farm storage
facilities. Relevant agronomic, biological and technical criteria
were specified in their assessment as shown in Table 9.
No serious deterioration took place during the storage period,
averaging about 8 weeks. This indicates the paddy was properly dried
prior to storage and that it had not been exposed to conditions that
would bring about moisture condensation. The average fungi infection
rate was 38% for field fungi and 2% for storage fungi. Seventeen out
of 28 samples (61%) showed the presence of live insects, insect damage,
and frass material. Paddy moisture content ranged from 11 to 17%,
averaging 13.9%. Half of the samples had a moisture content above 14%.
The ratio of cracked grains, which is mainly the result of the
drying method, was 20%. All farmers sun-dried thcir paddy, so very
little control was exercised over drying speed, drying tim and tem
pering, resulting in a very wide variation in the cracked grain ratio
average. Average grain damage, which included broken and husked grain,
was 1.6%. The level of purity was generally low, averaging 96.5%. To
obtain nearly 100% purity while minimizing cleaning losses, an improve
ment of existing cleaning methods is required.
A multiple regression model was specified and tested to determine
the main variables that determine grain spoilage. Field fungi infcctior
and chalky grains showed significant influence on the level of spoiled
grain. The regression coefficient for moisture content was not signi
ficantly different from zero per the t test. To obtain a significant
coefficient for moisture content, more samples will be required. Re
gression results for field infection and chalky grain level are shown
in Table 10. About 55% of the causes for spoiled grain were explained
by these two factors. The effects of varietal differences, temperature,
humidity changes, field conditions, and storage facilities on storability
were not studied in detail. These factors may also influence the degree
of spoilage of stored grain.
Rice hull usually constitutes about 20% of paddy weight but it can
range from 18 to 26% depending on variety. A study was conducted to
determine hull weight differences of 10 varieties selected at random from
the IRRI collection of promising lines grown during the 1977 wet season.
Their hull weight percentage was determined using the formula:
of brown rice
Hull weight (%) = weight of paddY - weight
paddyX10
weight of
x 106
38
Four replications of each variety gave the results shown in
Table 11. Hull weight percentage varied from 19.2 to 21.9%, a range
of 2.7%. Statistical analysis showed highly significant differences
among varieties, with varietal differences accounting for about 78%
of the variation. The coefficient of variation was 2.25%. In addi
tion, sample variety means were significantly different when using
Duncan's multiple range test.
An elementary conceptual model of the farmer's decision to
harvest before, during, or after the agronomically prescribed harvest
ing date, depending on rainfall expectations, was developed to assess
the benefits and costs of solar relative to mechanical drying. Expected
loss values due to immature grain, shattering, and moisture content were
measured for wet and dry seasons and comp-tred with mechanical drying.
The results indicated the advantage of mechanical drying ever sun drying
in the Bicol River Basin regardless of season.
Further development of the model will require more detailed rain
fall and solar radiation data, estimates of paddy storage losses under
different moisture regimes, and the specification of a larger range of
farmer decision alternatives that encompass specific regional patterns
within the Philippines and in Asia.
Thresher survey
A study of thresher adop4 in and utilization in irrigated and
rainfed rice growing areas of Iloilo, Philippines will cover three or
four villages, primarily in areas covered by IRRI's Cropping Systems
field research program. The sample will include users ani non-users,
owners and non-owners. Surveys will be conducted at one year inter
vals for a period of three to four years to evaluate changes in use
patterns over time.
A 1978 presurvey assessment of the introduction of IRRI portable
threshers in this area, formerly characterized by manual threshing, in
dicated rapid adoption and widespread use beginning late in 1977. The
presurvey also showed:
1) Farmers recognize the advantages of threshers and felt more
threshers were needed in the area. There were indications that faster
threshing gave rainfed farmers time to maximize use of available rain
fall for a second rice crop. In irrigated area, turnaround time may
be shortened to allow the planting of more than two crops per year.
39
2) High labor demand durin. the harvesting and planting seasons
often results in a shortage of labor for planting because farm labor
earns more in harvesting and threshing than in transplanting.
3) Renting of threshers is common. Customers complained of
the lack of threshers and owners found it difficult to schedule
operations to accommodate all customers.
A similar presurvey conducted in Laquna during 1978 showed a
in threshers over the past two years. In both Iloilo
increase
large
purchase of more machines by farmers is restricted by
the
Laguna,
and
capital.
a lack of
Power tiller survey
The results of a 1976-77 study of 122 power tiller owners and
non-owners in 20 villages in Laguna Province and 21 villages in southern
Nueva Ecija was reported in Semiannual Reports No. 24 and 25.
The survey information has beer. analyzed in more detail to deter
mine:
1. patterns of tiller utilization for owner-field work, contract
work, transport, and other purposes
2. effects of tiller ownership on prestige, incolme, yield, crop
ping intensity, and the effective use of other farm resources
3. problems relating to service, performance and credit
4. future tiller demand in terms of desired perfomance and
new features
5. other farm machinery wants and needs of the farmer
A final report of the survey results will be availaule soon.
40
Table 3. Estimated costs for alternate post production systems
based on observed!/ labor inputs and contractual labor
rates, Bicol River Basin area, 1976-77.
System b/
II
III
IV
actual contractual retail cost
$/ton-C
HARVESTING EXPENSES
Cash!/
Non-cashe/
-
_f/
_/
-
7.17
7.17
THRESHING EXPENSES
Cash
Non-cash
19.61
19.61
2.08
2.21
2.08
2.21
1.61
6.30
0.65
1.61
6.30
0.65
Cash
Non-cash
21.22
6.30
20.26
2.08
10.99
8.38
10.03
TOTAL
21.22
26.56
13.07
18.41
DRYING EXPENSES
Cash
Non-cash
TOTAL EXPENSES
i/Actual labor cost was imputed at $1.35/8 h-day
Y/System
I II III IV -
traditional threshing and sun drying
traditional threshing and mechanical drying
mechanical threshing and sun drying
mechanical threshing and mechanical drying
S/Based on exchange rate of P7.40/US$1.
!/Cash cost includes cost of fuel and oil, depreciation, interest on
capital investment, repair, and maintenance.
t/Non-cash cost includes cost of labor usually paid in kind.
Y/Included in threshing fee.
41
Table 4. Estimated cost and returns for alternate post production
systems, based on observed and contractual labor inputs,
Bicol River Basin area, 1976-77.
Systemai
I
III
II
IV
actual contractual retail cost
$/tonW/
All sites
Returns
Costs
Net returns
120.41
21.22
99.19
118.92
26.56
92.36
133.79
13.07
120.72
127.84
18.41
109.43
121.89
19.04
102.85
93.65
24.44
69.21
121.89
14.06
107.83
110.00
19.46
90.56
139.73
18.73
121.00
138.24
24.07
114.17
130.81
19.83
110.98
123.38
25.17
98.21
124.87
19.78
105.09
120.41
24.96
95.45
121.89
12.25
109.64
121.89
17.43
104.46
105.54
26.21
79.33
110.00
31.69
78.31
138.24
11.00
127.24
129.33
16.48
1!2.85
Libon-dry
Returns
Costs
Net returns
Libon-wet
Returns
Costs
Net returns
San Jose
Returns
Costs
Net returns
Buhi
Returns
Costs
Net returns
!/See Table 3 for description of systems.
Y/Based on exchange rate of P7.40/US$1.
Note:
Returns have been adjusted to reflect the quantity of paddy
recovered after deducting grain loss incurred for each system at each
site. Price of paddy was at $0.14/kg.
Cost estimates for the first two post production systems have
been based on the amount of labor required to perform each operation.
With an imputed wage of $0.17/ which was the prevailing wage rate in
the area.
42
Table 5. Production and disposal of paddy by 137 rice farmers in
the Bicol River Basin area, 1976-77.
Village
Libon
Buhi
Effective rice area
per farm (ha)
3.97
1.58
3.73
2.71
Production per farm
(tons)
11.16
5.16
13.66
8.59
San Jose Ave.
(percent)
H/T sharea/
Seed
Other Landlord's share
Operator's share
Home consumption
Seed
Other Sold
Marketable surplus b/
12.5
0.3
0.3
15.2
71.7
16.0
0.8
1.2
18.0 64.0
12.4
0.1

20.5
67.0 13.5
0.4
0.5
17.8
67.8
19.7
2.3
8.!
40.5 35.0
2.0 8.5
18.5
20.0
1.8
13.4
31.8
24.5
2.2
10.1
31.0
49.2
27.0 45.2
41.1
a/H/T share - harvester/thresher's share as payment for their labor.
b/Marketable surplus is equal to operators' share less seed and home
consumption.
43
Table 6. Characteristics of rice mills by type and capacity, Bicol River
Basin Area, 1976-77.
Steel huller-
/
Cone type -/
Grand
1
C2
C3
All
Total
4
4
5
13
-
-
-
-
-
1
1
50
2
1
14
39
4
4
-
-
-
5
1
13
-
4
5
9
12
13
-
-
2
2
1
3
-
1
2
3
1
1
7
5
All
K1
K2
K3
10
-
14
1
13
1
37
2
-
-
-
10
15
-
-
1
4
5
4
6
5
Type of ownership
Sole proprietorship
Partnership
Corporation
Power
Diesel
Electric
1
52
1
Years mill in operation
Before
1951 1961 1971 -
1950
1960
1970
1976
-
1
1
8
6
10
19
18
(mean values)
10
15
14
39
4
4
6
14
53
Size of power units (hp) 7
14
Years in operation
10
16
11
18
37
61
42
19
12
11
12
7
16
10
11
12
No. reporting
Distance to mill from
main road (km)
Distance to mill from:
main sourne of
paddy (km
farthest source
(kin)
main market outlet
(kin)
farthest market
outlet (kin)
1.8
4.4
0.5
2.3
3.9
0.4
0.1
1.3
2
0
0.1
0.5
0.2
0.3
3.1
4.2
2.8
0.9
1.4
3.7
4.9
3.5
5.3
12.5
21.2
14.3
6.4
-
b/
7.5
17.3
15.7

-
b/
7.5
23.3
25.5

b/
b/
b/
b/
b/
a/ K = steel huller mills or Engelberg type rice mill
C = cone type mills
Mill capacity in tons per 12 hours of operation:
K1 = below 1.2
K2
=
1.2 - 2.3
C1
C2
K3
=
above 2.3
C3
_/ Engaged only in custom milling
- below 3.2
a 3.2-- 8.1
' above 8.1
44
Table 7. Average total costs for alternative milling system at actual and
assumed utilization levels.!/
Milig
yte
ilingsystem
No. of
N. f
observations
Actual
utilizautt 1z-/tonb/
rate
actual
/ob
25%
50%
75%
100%
1. Steel huller
4
12
10.80
6.91
5.00
4.41
4.09
2. Rubber roll single
pass
1
25
13.30
13.30
8.91
7.30
6.59
3. Rubber roll-steel
huller combination
1
77
6.50
11.80
7.91
6.50
5.91
4. Stone disc-steel
huller combination
1
6
25.91
9.50
6.91
6.00
5.59
5. Multiple steel
huller
1
12
18.09
10.91
7.59
6.41
5.91
6. Centrifugal huller
1
6
21.70
9.59
7.70
7.09
6.76
(3)
51
11.30
18.86
11.50
9.00
7.70
1
1
1
97
18
38
6.80
25.11
16.04
17.39
19.20
21.79
10.19 7.89
11.70 9.20
13.50 10.69
6.69
8.00
9.30
7. Cone type (ave.)
a) large
b) medium
c) small
Cost/t
=
fixed cost per ton + average variable cost.
Based on exchange rate
P7.40/US$i.
Table 8. Revenue and profit per ton for alternative milling systems- / , Bicol River Basin Area, 1976-77.
Milling system
Number
of
tosrv
tos
Milled
Milling
fee
rice b/
b
sto p
/
otmo.
($/t)c/
Revenue
from milling
i$/mo.g
Revenue
per ton
($/t)
Profit (S/t) at utilization rate
actujT
25%
50%
75%
100%
Steel huller/Engelberg
type
4
8.5
13.51
114.86
8.36 (2.43)
1.46
3.36
3.96
4.27
Rubber roll single pass
1
11.9
13.51
160.8i
9.12 (4.18)
(4.18)
0.22
1.82
2.53
Rubber roll-steel huller
combination
1
47.8
13.51
645.95
9.24 2.74
(2.55)
1.34
2.74
3.34
Stone disc-steel huller
combination
1
4.4
13.51
59.46
8.50 (17.41)
(1.00)
1.60
2.50
2.91
Multiple steel huller
1
5.9
13.51
79.73
8.57 (9.53)
(2.34)
0.97
2.16
2.66
Centrifugal type
1
6.6
13.51
89.19
8.59 (13.11)
(1.00)
0.89
1.50
1.84
(3)
56.3
13.51
760.81
9.03 (2.27)
(9.84)
(2.47)
0.03
1.32
large
medium
1
1
162.6
21.0
13.51
13.51
2,197.30
283.78
8.92 2.12
9.12 (15.99)
(8.47)
(10.08)
(1.27) 1.03
2.23
(2.58) (0.08) 1.12
small
1
17.6
13.51
237.84
9.05 (12.74)
(4.45) (1.64) (0.24)
Cone type (av)
(6.99)
a/ Revenue is derived from milling fee only.
b/ Paddy input x milling recovery from monitoring data.
c/ In actual practice rubber roll mills charge US$2.70/t more than other mills.
d/ Profit/t = revenue/t - total costs/t; values in parentheses indicate losses.
u1r
46
Table
9. Statistic of distribution of factors indicating condition
and quality of paddy in farm storage in Luzon.
Mean
Factor
S. D.
Coefficient of
variation (%)
Percent matured grain
Sound + spoiled grain
(Varietal purity> 99%)
%
%
89.6
(91.2)
5.8
(2.8)
Spoiled grain
Percent green kernel
%
2.7
1.5
56
%
5.3
3.1
59
Percent chalky grain
%
3.6
2.3
64
Varietal purity
Percent discolored grain
Percent fungal infection
%
98.1
3.8
Field fungi
Storage fungi
Insect infestation
Frass material
No. of infested
grains
Insect population
Moisture content
%
0.07
0.19
3.9
271
61.7
38.1
23.5
%
2.2
4.8
218
%
0.05
0.06
120
No/t00 g
1.6
3.7
231
No/100 g 1.4
13.9
% w.b.
4.7
1.5
336
11
%
Crack ratio
Percent damaged grain
%
%
19.5
1.6
19.2
1.1
Purity
%
96.5
1.9
days
12.2
7.4
Duration, harvest
storage
6.5
(3.1)
98.5
69
2.0
61
Table
10. Results of multiple regression analysis on the effects of field fungi infection (F.F.),
percent chalky grain (C.G.) and moisture content (M.C.), on quantity of spoiled grain
(S.G.) in stored paddy.
(S.G.) = 1.4503 + 0.0358 p__(F.F.) + 0.2738 a_/(C.G.) - 0.0781ns(M.C.)
Equation
4- 1
t-value
R2 ./
3.0011
- 0.5838
0.0087
0.0909
O.i337
(S.G.) = 0.3290 + 0.0356 _ (F.F.) + 0.2846 a_/ (C.G.)
Equation
t-value
R2 S/
4.1175
0.545
Std. error
4- 2
Statistic
Item Model No.
4.1586
3.2430
0.0086
0.0878
0.558
Std. error
Note:
a/ Significant at 1% level
b/ Significant at 0.1% level. c/ Value with adjusted degrees of freedom
No. of samples - 26.
48
Table 11. Paddy hull percentage by weight, by variety.
Replications
Mean*
1
2
3
4
IR4711-259-3-3-3
21.8
21.7
21.8
22.2
21.875 a
IR32
23.0
21.4
21.4
20.8
21.65 ab
IR42
21.6
21.4
21.4
22.1
21.625 a b
IR3518-106-2-2-2-2
21.0
20.8
21.3
21.2
21.075 bc
IR5815-59-2-2
21.0
21.1
20.6
21.0
20.925 bcd
IR4422-164-3-6
20.6
20.6
21.0
20.8
20 .75cde
IR4432-28-5
21.0
20.2
21.0
20.6
20 .7cde
IR5793-110-2-1-2
20.0
19.8
21.4
19.6
20.2de
IET 5118
20.2
19.9
20.2
20.2
2C.125e
IR36
18.8
19.8
19.1
19.1
19.2 f
Variety
*Variety mean estimates with at least one common letter superscript
are not significantly different as in Duncan's multiple range test.
49
M.S. (Tons)
25
15
MS =-23.63+0 52
(TP) 7< TP < 1091
r2 = 0 7544
10
5-
.
1I
0
15
10
5
20
25
I
I
30
.
35
40
35
40
a. Total Production (Tons)
MS.(Tons)
MS =- 18.7 + 0.59(OS) 4 <OS < 955
./' __
r 2 = 0.7972
15
15
0
I
10
5
15
20
25
30
b. Operator's Share (Tons)
MS. (Tons)
20
MS=-11.68 + 29.34 (A) 0.1 < A< 15
r2 = 0.5164
15
10
-.
-
5
2
8
6
4
c. Effective Rice Am (Ha)
t0
12
Fig. 20. Effect of total productian,operator's shore and effective rice area
on marketable surplus.
(t2%)
V0
to
p
(61.33%
(9-1%
.?
6 6 %)
Fig.21
Results of paddy analysis,150 samples collected
from If rice mills,
Bicol River Basin Area,1976.
(30)
(0))0
(0%
1
SUBSTANARD
t40%)
30%)(6%
(4%
S.
0
)0.
40
STEEL MULLER
CENTRIFUGAL TYPE
STONE DISC -STEEL HULLER COMBINATION
SUB_
APO
(9%)
ANST-NDARD
0
(6%
0
(37%)
(45%)
a
o
RUBBER ROLL-SINGLE PASS
RUBBER ROLL- STEEL HULLER COMBINATION
CONE TYPE
Fig. 22 Grade distribution of milled rice samples by milling system,BEicol River Basin Area, 1976 -77
52
INDUSTRIAL EXTENSION
Industrial extension in the Philippines
Cooperating manufacturers in Metro Manila were visited four times
and three companies received assistance with quality control problems
encountered on the axial-flow and portable threshers.
Companies in the Visayas and Mindanao were visited twice as part
of the project's technical assistance program and they received help
with production problems of IRRI designs. During two visits, Bicol
region companies received help in improving portable thresher perform
ance, which included a performance test of a prototype thresher made by
a new cooperator. Another company added a blower to the portable thresh
er for winnowing threshed grain and needed assistance with minor perform
ance problems resulting from the modification. During the reporting pe
riod, a cooperating manufacturer in Davao expanded his plant and con
structed a sales office with display center. Additional shop tools and
equipment were acquired and the work force was doubled to meet the in
creased demand for power tillers and threshers.
Three new cooperators in the Bulacan region were visited and one
firm was assisted with a method and work simplification study. The
second firm ha3 its own industrial engineering department w:-ich is
performing some of the activities of IRRI's technical consultancy services,
thus assistance may only be needed on specific problems relating to IRRI
designed machines. The third firm, a small backyard shop, was given
advice on production and business management.
In the past, extensive methods and work simplification studies
and cost reduction plans were offered to commercial producers of IRRI
designs. Manufacturers welcomed this assistance for increasing their
manufacturing efficiency and improving product quality, but followup
visits made to assess improvements showed that most recommendations were
not implemented. This situation is particularly true among the smaller
firms with strict financial limitations and a lack of skilled personnel
to implement, control, and maintain the improvements. To increase the
effectiveness of the program, a survey will be conducted to assess the
capability of cooperators to implement our recommendations, the speci
fic type of assistance needed, and the relative degree of urgency for
assistance.
During this period the project staff participated in seven Depart
ment of Agrarian Reform seminar-workshops held in different regions of
the country. The seminar-workshops train staff in the government's program
on agricultural mechanization and development. These meetings provide an
53
effective forum for the dissemination of information on IRRI's Rice
Machinery Development Program as well as other modern rice production
techniques.
The project staff presented lectures to participants of the
2-week engineering course held in March. A new topic on plant and
equipment layout for the manufacture of IRRI machines was included
and was well received by the trainees. Handouts on the techniques
and principles for designing a factory layout and evaluating improve
ments for an installed layout were distributed and some trainees were
given assistance in improving the layout of their research machine
shops or manufacturing plants. As in the past, trainees visited Manila
area IRRI cooperating manufacturers to observe manufacturing techniques
used in the production of IRRI design machines.
An engineer employed by a cooperating manufacturer in the Visayas
area was given a two-day training program which included topics on
des 4 gn, fabrication, and manufacturing techniques, plus operation
and maintenance aspects of the tiller. This company plans to produce
the IRRI power tiller and requested training.
A layout was designed for a proposed paddy procurement and drying
station in the Bicol region. The pilot drying station will be used to
test the technical and economic feasibility of procuring and drying pad
dy at the village level. It is believed that small farmer's incomes can
be increased through local procurement by reducing transportation and
handling costs.
An operating cost analysis of the vertical bin dryer was prepared
to assist in assessing its marketability and competitive status. A
comparison of annual and per-ton costs for the IRRI flat bed dryer (BDl)
and the vertical bin batch dryer (BD2) are shown in Table 12. The cal
culations show that BD2 drying costs per ton of paddy are lower than for
the BD1 dryer. The relationships of drying cost and breakeven volume
of the vertical dryer (BD2) are shown in Figure 23. Using the Philippine
National Grains Authority (NGA) drying fee of US$3O.60/t of paddy with
24% initial moisture content, the breakeven volume is 35 t per year.
This is only 12% of the dryer's estimated annual capacity of 75 operating
days per year. Figure 24 shows the volume of paddy necessary for break
even at different drying fees and machine costs.
Another economic study (based on the results of the trials dis
cussed in the Mechanization Research section) was made on the profit
generating potential of the plow sole fertilizer applicator compared
with a Japanese fertilizer applicator, basal, and best split methods
of fertilizer application. The results show that the profit realized
from the use of plow sole applicator is higher than when the other
methods are used (fig. 25).
54
Bills of material and manufacturing process charts were prepared
for the portable grain cleaner and vertical bin dryer. Cost estimates
are now available for the Thai 4-wheel tractor, multicrop upland seeder,
and plow sole fertilizer applicator.
Industrial extension in Thailand
Production of the IRRI axial-flow thresher increased substantially
during the reporting period, with 356 machines produced during the first
half of 1978 compared with 65 during the same period in 1^77. In pre
vious years, a much larger number of threshers were produced during the
second half of theyear, due to the seasonal nature of the market in
Thailand.
There is increased interest in dry seeding of rice in the rainfed
areas of northeastern Thailand. There appears to be good potential for
producing two crops of rice per year under rainfed conditions, but early
establishment of the first crop and a short turnaround time between crops
is a prerequisite. An IRRI multicrop upland seeder was fabricated and
will be evaluated in experiments conducted in cooperation with the
Thailand Rairifed Rice Improvement Project.
Considerable time was spent by the project staff on training
activities. A 3 day course on the design, manufacture, and operation
of field machinery was given to five students from the Department of
Agricultural Machinery, Korat Technical College. Lectures and equipment
demonstrations were also given to officers from the Accelerated Rural
Development (ARD) Program. These people advise farmers on the selection
of farm machinery. Both training programs were supported by and conducted
in cooperation with the Agricultural Engineering Division, Department of
Agriculture. Collaborative work with the Industrial Service Institute
and other organizations described in earlier reports continued.
Mr. Stewart Barton resigned his position effective March 3, 1978,
after serving the project for 2 years to accept a position with the
Australian Extension Service.
Industrial extension in Pakistan
The axial flow thresher has been successfully modified to thresh
wheat and other small grain crops. Eight companies have fabricated pro
totype units and these were extensively tested during the last harvest
ing season. A threshing output of 320 kg/h of wheat with a total grain
loss of 0.36% was obtained in these tests, compared to reported losses
of 4 to 5% with conventional threshing methods. Two of the above com
panies have begun marketing the IRRI thresher.
55
Problems were encountered in removing light impurities from
the grain, so the aspiration system was redesigned with a larger fan
and duct to improve cleaning performance. The machine can now satis
factorily thresh wheat with 99% cleaning efficiency. A manufacturer
is
in Mian Channu, Punjab, has incorporated these improvements and
season.
threshing
rice
coming
the
in
now producing 60 units for sale
The mini axial flcw thresher has an axial-flow threshing drum,
It is
centrifugal blower, and dual screen oscillating grain cleaner.
manner
a
in
fields,
into
mounted on two wheels for convenient movement
paddy,
similar to a wheel burrow. This machine was tested in wheat,
encountered
were
sorghum, soybeans, and corn in 1977. Some problems
in obtaining satisfactory cleaning performance so a new grain aspira
the
tion system was developed to remove the lighter impurities from 120 kg/h
of
threshed grain. The improved machine has a threshing output
Three
of wheat with a total loss of 1.4% and a 99% cleaning efficiency.
to
companies have completed prototypes of this machine and are planning
market it for US$350-450 without engine. A 5 hp gasoline/kerosene en
gine costing US$100-150 can power the machine. Most farmers who have
and
observed the machine's operation are impressed with its versatility
have shown interest in purchasing it.
About 250 power-operated, six-row paddy transplanters have been
imported into Pakistan from the People's Republic of North Korea. These
machines encountered some operational problems during the 1977 transplant
ing season. A project was organized in February, 1978, by the IRRI-PAK
Program in cooperation with the University of Agriculture, Faisalabad,
and the Rice Research Institute, Kala Shah Kaku, to adapt the machines
also
to Pakistan conditions. The services of three Korean experts wereproblems
main
obtained through the Pakistan Tractor Corporation. The two
with these machines were:
1. inability to transplant seedlings in water greater than 5 cm
deep. In Pakistan, the water depth at transplanting is
generally 5 to 10 cm.
2. planting an excessive number of seedlings per hill and too
many missing hills (above 18%).
Over a period of 4 months,a number of design modifications were
incorporated and tested on these machines. The problems of transplant
ing in 10-15 cm of water were solved. Some improvement was also achieved
in reducing the number of seedlings per hill and missing hills. After
these improvements, the machines were tested in farmer's fields at six
locations in the Punjab to study their performance under varying soil
conditions. The results showed a missing hill range of 3.8 to 10.5%
and plants per hill ranged from 1.70 to 3.13. The overall average of
eight field tests at six locations was 8.1% missing hills and 2.25 plants
56
per hill. A report on the modification of the Korean transplanter in
English and an instruction manual in Urdu are available from the IRRI-
PAK Program. A one-week training program on the use of these machines
was organized b' the Rice Research Institute, Kala Shah Kaku, for machine
operators, farmers, and government engineers.
The project staff made over 50 visits to cooperating manufacturers
in Pakistan and provided 30 man-days of assistance in checking, modifying,
and improving the IRRI machines fabricated by them. Field demonstrations
of some of the machines were held in various locations for farmers, manu
facturers, and government officials. The project participated in fairs
of Chakwal, Kala Shah Kaku, and Rawalpindi and demonstrated the IRRI
machines. Two project officials, Dr. Amir U. Khan and Mr. Abdul Shakoor
Khan participated in an "International Seminar on Low-Cost Farm Structure"
held at Peshawar and presented papers on small scale farm mechanization
and rural industrialization.
Afghanistan was visited in April, 1978 to introduce the IRRI-PAK
machines to local manufacturers and government officials. Drawings of
the mini thresher were given to one company which is now fabricating a
prototype. Two engineers from this company recently visited the IRRI-
PAK office for 10 days of training and orientation which included visits
to some cooperating manufacturers. Their company is planning to manu
facture the axial flow and mini threshers.
India was also visited to study the latest agricultural machinery
developments and to encourage production of IRRI machines. Almost all
threshers manufactured in Irdia are suitable for wheat but cannot be
used for paddy. Many manufacturers showed interest in producing the
threshers adapted by the IRRI-PAK Program. Drawings have been given to
cooperating IRRI organizations and some manufacturers in India.
Industrial extension in Indonesia
Subsequent to the short-term consultancy that was reported in
Semiannual Report No. 25, USAID, Jakarta has funded the IRRI-Indonesia
agricultural machinery program for 1 year with the likelihood of conti
nuation for a longer term in collaboration with Bina Produksi INDONESIA.
Mr. V. R. Reddy has been retained as Agricultural Engineering Consultant
for this program. He arrived in Jakarta in May, 1978, after spending a
few weeks at IRRI.
The work plan during the first year will include:
1) reviewing current policies and the philosophy of the Indonesian
government relating to farm equipment, specially with regard to importa
tion, pricing, credit, and incentives to local industry,
57
2) preparing an inventory of local manufacturing and distribution
activities in the farm machinery industry,
3) identifying specific areas for concentration of this extension
project where the need for mechanization ismost urgent and conduct short
agri
surveys in these areas to determine power requirements for various
organizations
cultural operations, local manufacturing capabilities, and
willing and capable of developing machinery contract services,
4) providing support in the planning and implementation of the
IRRI research project, "The Consequences of Small Rice Farm Mechaniza
tion on Production, Incomes, and Rural Employment in Selected Countries
of Asia",
5) investigating ways of cooperating with other internationally
funded small farm development projects.
During this reporting period, assistance was given to a coopera
ting manufacturer in Bandung who is manufacturing IRRI vertical-type
bin dryers for the National Seeds Center of Indonesia. These dryers
are being located in various provinces for drying seed.
Visits to South Sulawesi and West Sumatra were nade to study the
present status and the future needs of farm mechanization in these
provinces. Machinery extension programs for these areas are being
organized and will be implemented before the end of 1S78.
58
Table 12. Comparative cost analysis for IRRI batch dryers, BD-1 and
BD-2.1
Assumed values:
Interest on investment z 12%
Repair and maintenance cost - 30% of initial cost 2
Tax and insurance - 12% of initial cost
Salvage value - 10% of initial cost
Life of equipment - 5 years
Items Initial co-t of investment
Capacity, ton(s)/batch
Capacity, tons/year
Drying hours/batch
No. of batches/day
Operating days/year
BD-1 BD-2
P7,450.003
($1,006.00) s
1
150
5
2
75
P5,800.004
($ 783.78)
2
300
5
2
75
A. Annual fixed costs.
1.
2.
3.
4.
Depreciation cost
Interest on investment
Repair and maintenance
Tax and insurance
$181.22
66.49
60.41
24.19
$141.08
51.76
47.03
18.78
Total fixed cost/yr
$332.30 $258.65
B. Annual variable (operating) costs
1.
2.
3.
4.
Labor Gasoline Kero.ene Lubricant $374.05
122.43
220.05 16.76 $380.07
244.76
309.22
16.76
Total variable cost/yr
$742.30 $950.81
'BD-1 rurers to the 1-ton IRRI flat bed dryer design and BD-2 refers
to the new 2-ton dryer.
2 Dryers
have few moving parts, hence 30% is used compared to 45% used
for power tiller cost analysis.
3Based
on IRRI cooperating manufacturer's list price with 3 hp gasoline
engine, burner assembly and accessories.
4 Based
on IRRI cooperating manufacturer's list price with 5 hp gasoline
engine, burner assembly and accessories.
BUSS = P7.40
59
Table 12 (cont'd)
SUMMARY
BD-2
BD-1 Items C. Total annual cost
$332.29 742.30
$258.65
950.81
$1,074.59 $1,209.46
$742.30/yr
150 ton/yr
$950.81/yr
300 ton/yr
= $4.95
= $3.17
Fixed cost Variable cost Total drying cost/yr
D. Drying cost per ton
1. Variable cost/ton
2. Total drying cost/ton
$1,074.59/yr $1,209.46/yr
150 ton/yr 300 ton/yr
=
Breakeven point (BEP):
BEP
=
$7.16
fixed cost
10.60 - 3.17
=35 t
=
$4.03
Drying fee at US$10.60/t (NGA data)
Income/ton - variable cost/ton
258.65
,
60
Table 13.
Industrial Extension Project Staff
Name Position
Philippines
John A. McMennamy Simeon Gutierrez Nemelito Langam Rodulfo Angco Enrique Macatangay Estrella Castro Industrial Liaison Engineer
Senior Research Ahsistant
Senior Research Assistant
Draftsman
Shop Assistant
Secretary
Thailand
P. Stewart Barton I Suwit Bunyawanichkul Chalit Choensombat Vacharachai Pumarin Juthaporn Charoenpravat Industrial Extension Engineer
Research Assistant
Technician
Draftsman
Secretary
Pakistan
Amir U. Khan Malik M. Shafiq Mohd. Ilyas Jameel Ahmed Mohannad Jameel
Zahoor Ahmed
Industrial Extension Engineer
Administrative Assistant
Research Assistant
Draftsman
Shop Supervisor
Bench Mechanic
Indonesia
V. R. Reddy 'Resigned March 3, 1978.
Agricultural Engineering
Consultant
61
Table 14.
Industrial Extension Subcontract Program Officers
Dr. K. M. Badruddoza
Executive Vice-Chairman
Bangladesh Agricultural
Research Council
130-C Road 1, Dhanmandi
Dacca-5, Bangladesh
Dr. Sung Kum Han
Director
Institute of Agricultural
Engineering & Utilization
Office of Rural Development
Suwon, Korea
Ing. Rolf Kaeser
Mechanical Engineer
Asistencia Tecnica
a la Industria
Apartado Aereo 8053
Cali, Colombia
Dr. M. Hashim Noor
Assistant Director
Malaysian Agricultural Research
and Development Institute
P. 0. Box 208, Sungai Besi
Serdang, Selangor, Malaysia
Dr. K. N. Singh, Head
Agricultural Engineering
Department
G. B. Pant University of
Agriculture & Technology
Pantnagar, Distt. Nainital
Uttar Pradesh, India
Mr. B. B. Khadka
Director General
HMG Department of Agriculture
HMG of Nepal, Kathmandu
Nepal
Mr. M. M. Suri
President
Suri Research Foundation
B-14 Greater Kailash
New Delhi - 48
India
Mr. R. Dadang Tarmana
Project Director
Directorate of Food Crops
Production
Department of Agriculture
Pasar Minggu, Jakarta
Indonesia
Mr. S. Kathirkamathamby
Superintending Engineer
Engineering Research
& Development Division
Department of Agriculture
Peradeniya, Sri Lanka
62
55
50
45
40
(0 BREAK-EVEN POINT
3
35
U)
U)
I-30-
0
-J
25
W
Cr
20
RETAIL PRICE 1 783.78)
15 -
-DRYING CHARGE/TON OF PADDY
WITH INITIAL M.C. OF 24 % (NGA)
-
I
I0
I
I
0o
5
10
I
I
I
I
d
I
*
1
15
20
25
30
35
40
45
50
I
100
I
I
I
150 200 250 300TNS
ANNUAL USE
Fig.23.Relationship between drying cost and annual use
of the vertical dryer.
1100
/ ///
,I
7-'!
/
*0
800
M
.C
1//"
Custom drying fee at:
U.S.$ 14.00/ton
C700 -
S/
I
S600
001
10.00/ton
/U.S.$
i
/
/
8.00/ton
/U.S.$
/-
500 -I
ii
400 t
U.S.$ 12.00/ton
.....
/
-U.S.4
6.00/ton
U.S.$ 5.00/ton
-
!
OTT
20
40
60
80
100
120
140
160
180
Annual break-even volume in tons
Fig.24.Determination of break-even volume for IRRI vertical bin dryer
under different investment cost and custom drying fees.
200
300
64
700
EI
IR-36
600
IR-42
500
0
Vi 400
0
Z
('300-
Z
200
/
/
I00"
BASAL
BEST SPLIT
JAPANESE
PLOW SOLE
APPLICATOR
APPLICATOR
ANNUAL OR 2 CROP YIELD/ha
Fig.25.Profit comparison of different method
of fertilizer application.
65
Personnel List*
C. Moss
B. Duff
D. Kuether
I. Manalili
J. Policarpio
H. Takai
K. Lee
A. Resurreccion
J. Arboleda
P. Carbonell
S. Labro
M. Aban
A. Caballes
F. Cabrales
I. Camacho
R. Dayrit
M. Diestro
L. Ebron
R. Echevarria
G. Espiritu
P. Hidalgo
F. Juarez
L. Kiamco
H. Manaligod
C. Maranan
G. Salazar
M. Sumiran
V. Tiangco
L. Banquilis
L. Pua
F. Jalotjot
N. Mufiez
R. Pabustan
N. Rivera
J. Reyno
A. Bagalso
H. Rada
E. Suhaz
L. Bahfez
Agricultural Engineer & Department Head
Agricultural Economist
Associate Agricultural Engineer
Assistant Engineer
Assistant Engineer
Post-Doctoral Fellow
Research Scholar
Research Scholar
Research Assistant
Research Assistant
Research Assistant
Research Assistant (PA)**
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Research Assistant (PA)**
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Research Assistant
Statistical Aide
Statistical Aide
Drafting Supervisor
Draftsman
Draftsman
Office Assistant
Office Aide
Secretary
Secretary
Secretary
Clerk Typist
*Please see Table 13 for Industrial Extension staff.
**Project assignment.
66
E. Dungo A. Barot Z. Borja A. Camacho M. Castro R. Dignadice A. Dizon M. Fabellar C. Flojo M. Macatangay D. Manalo P. de Mesa M. Salac R. Santos G. Ladra F. de Leon L. Villegas N. Ongkiko E. Principe R. Tobias P. Aldemita R. Capule A. Llerena Shop Supervisor
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Shop Assistant
Field Assistant
Field Assistant
Field Assistant
Field Aide
Field Aide
Laboratory Aide
Laborer
Laborer
Laborer