A Shift Towards Ready-made Cattle Feed.
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Irrespective of the current economical trend the dairy industry is showing significant growth and it holds potential for investment by government or non government or private sector as the demand of dairy based products is growing worldwide. It has extreme potential to provide employment opportunity to millions of professionals and labor. Scope of production is present in liquid milk, milk based products (ghee, curd, paneer etc) cattle feed and supplement. Scope of research is present in animal keeping activities (good animal keeping practices can be significantly developed), animal feed, disease control and cost cutting. Quality control and assurance practices opens up vital scope for professional as well. Whereas if we only talk about cattle feed production under MSME type, extensive potential to engage professionals can be observed. According to analyst Mr. Abhinav Gaur “in coming future cattle feed production industries will compete with pharmaceutical industries for professional workers”.
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A Shift Towards Ready-made Cattle Feed.
- 1. Dairy Industry : A Shift Towards Ready-made Cattle Feed. By : Abhinav Gaur1 and Shaurya Goyal2 for Yuvaan Foundation. 1. M.Sc Chemistry and B.Sc Biotechnology with Skill Enhancement Course in Environmental Science, Nursery Management and Gardening, Sericulture, Intellectual Property Rights, Bio-ethics, Bio-safety and Pesticidal Chemistry. 4 years + experience in social work and education. 2. B. Tech. Safety Engineering (Health Safety and Environment). Member Fire & Security Association of India, Member American Society of Safety Engineers and 4 years + experience in social work and industrial safety. Abstract : India is leading producer and consumer of dairy products in entire globe since late 90s with a sustained growth in the availability of milk and milk products via improvement in animal husbandry practices and technology related to dairy farming. India is highest producer of milk in the entire globe and therefore also called as “oyster” of the globe. Back in 2001 India produced 84.6 million tons of milk and reports suggest that the industry has been continuously growing by rate of 5% per annum. The Indian dairy industry holds tremendous potential for value-addition and overall development. According to the latest report by IMARC Group, titled “Dairy Industry in India 2019 Edition: Market Size, Growth, Prices, Segments, Cooperatives, Private Dairies, Procurement and Distribution”, the dairy market in India reached a value of INR 9,168 Billion in 2018. Dairy industry is the major source of rural employment with more than 8.47 million people involved among which 71% are women as per the available formal data. The with development in technologies and with improvement in quality control and quality assurance practices the dairy industry is also engaging professionals with procurement, production, storage and distribution practices nation wide. Most of the produced milk and milk products are domestically consumed, their distribution based on consumption can be understood by help of following chart :- Demand of milk and milk products is contentiously on a rise in India and India also has potential to become spark exporter of milk and milk products in the globe. Although we consume more than 97% of produced milk and milk products domestically and therefore generating exporting potential is still a mythical dream. By economic point of view dairy industry can be related to following sub-sections like :- agriculture, pharmaceutical, chemical and FMCG. According to reports due to certain changes in governance, world wide economic slow down scenario and other internal / external factors following is the current trend in related sub-sections :-
- 2. Agriculture sector on a peak slow down with reports of farmers committing suicide daily, Pharmaceutical industry in loss of about 24% and FMCG showing lowest growth in past two decades. Hence we can conclude that due to some economic factors the dairy industry is also facing a slow down or a halt in growth which alarm us to develop new improved technologies and animal husbandry particles to cut the cost of production to its minimum and simultaneously improve quality and quantity of yield. Role Of Cattle Feed Industry :- As we all know that land is a limited resource nowadays and farmers can not depend on grass lands to feed their cattle as well as scope of growing (farming) cattle feed is also unrealistic as agriculture land is getting extinct due to rapid urbanization. And hence ready made feed is an ultimate option that has number of advantages which can be summarized as :- 1. Easily available and cheap raw materials. 2. Easy to produce, easy to transport and easy to feed. 3. Offer balanced nutrition and required diet to the animal. 4. Medicinal and immunity building diet can be served easily. 5. Reduce cost and improve production The advantages of cattle feed (ready made) over traditional feed also highlight the requirement of developing advance methods of production, quality control and research work on cattle feed and supplements and hence a potential to involve chemical/biological/pharmaceutical professionals.
- 3. CASE STUDY Objective : To understand the functioning, production process, production capacity, demand .vs. supply, QC, QA, R&D operations, labour and professional employee requirement at cattle feed industry. Undertaken At “Shri Sudharma Industries” Shri Sudharma Industries, G.T Road, Village Kauri, Khanna, Punjab - 141401 Dated : 28th August 2019 With Special Thanks To Industrialist Mr. Akshit Goyal Director / Owner Shri. Sudharma Industries Project Documented By ABHINAV GAUR Founder, COO - Yuvaan Foundation
- 4. CONTENTS 1. Introduction 2. Production Process 2.1 - Raw Material 2.2 - Weighing 2.3 - Mixing 2.4 - Pallet Making 2.5 - Challenges 3. Quality Control 3.1 - Waste 3.2 - Methods 4. Research & Development 4.1 - Feed Types 4.2 - Composition Balance 4.3 - Feedback Analysis 5. Employment Potential 6. Summary 7. Sources
- 5. 1. INTRODUCTION Mr. Abhinav Gaur with Mr. Akshit Goyal Er. Shaurya Goyal with Mrs. Savita Goyal Shri Sudharma Industries, situated on the G.T. road at village Kauri Khanna, holds very old place in cattle feed industry supplying nutritious feed under the brand name of Sardar to dairy farmer of Punjab, Haryana, Himachal Pradesh, Rajasthan, Jammu and Kashmir, Uttar Pradesh, Gujarat, Uttrakhand and many other states. This unit was started in 1984 by Late Sh.Ramesh Goyal. It has been using the latest technology in making cattle feed. With the feed back from the market Shri Sudharma Industries is elated as dairy farmers and other cattle owners have appreciated its Sardar brand. Since last 34 years ''SARDAR'' came up as a brand in the cattle feed industries. At that time there was no concept of a brand in this field. In late and early 1990 ''SARDAR'' was a brand using professional marketing channel like dealer conferences, advertising with good modelling, attractive packaging etc. It was a time when cattle feed was regarded as a low profile product. It needed the visionary like Shri Ramesh Goyal to launch a successful brand. He wanted to bring white revolution in Punjab through the concept of balanced feed. His untimely death did not stop his work as his wife took over the mantle to take the company to greater heights of success. Mrs.Savita Goyal deserves credit for maintaining high quality in feed at a time when price war had taken a heavy tool of many units. She attributes her success to inspiration she has drawn from a doyen of cattle feed industries in Punjab. Awards :- 1. Many awards the company's founder had won, bear testimony to his contribution to the feed industries in Punjab. AMONG OF THEM ARE :- 2. Gold medal by the Institute of Quality Control and National Character, Faridabad. 3. Udyog Shree Award presented by union labour and social welfare minister Ram Vilas Paswan in Hyderabad in 1990. 4. Lok Shree Award presented by Commerce minister Dr.Subramaniam Swami in Mumbai in 1990. 5. Udyog Rattan award by Punjab governor Surendra nath in Chandigarh in 1993.
- 6. 2. PRODUCTION PROCESS SARDAR cattle feed is processed under high standard specifications. All the ingredients are thoroughly pre-tested in the laboratory and pass through various quality control analyses before use. Next, they are proportionately dozed, well ground and mixed carefully to produce a homogenous, balanced blend which has the best possible bio chemical composition and is free of fungus as well as insect infestation. The subsequent grinding, molassing and palleting is done by special machines capable of even dispersal of ingredients. Thus, each pallet is a complete feed in itself. SARDAR cattle feed is packed in clean HDPE bags. 2.1 - Raw Materials A) Maize : B) Broken Pulses : C) Rice Polish :
- 7. D) Rice Bran : E) Cotton Doc : F) Soya Doc : G) Whole Millet Seed (Bajri) :
- 8. H) Jowar Grains : I) De oiled Cakes : J) Binding Agents (Natural) and Feed Supplement (As Per Feed) 2.2 Weighing In Shri Sudharma Industries the process of weighing involves preparation of 1000kg batch including all the required raw materials in specific concentration based on feed type. The industry uses underground collector and weighing balance specifically designed to prepare feed stock batch based on industrial composition standards. The process is carried out by labors under supervision of an expert who cross check the concentration of raw material weighed according to pre set standards of industry. Different feeds differ in concentration of required raw material so weighing process require proper quality control and quality standardization methodology.
- 9. 2.3 Mixing Shri Sudharma Industries uses customized industrial mixtures designed to crush different type of organic raw materials into fine particles of 6 to 10 micrometer thickness. Industry ensure that mixing process remain moisture free and temperature is regulated using heaters using proper temperature control methodology. Supplements based on feed type are added in this process. 2.4 Pallet Making Based on feed type, 4mm to 6mm pallets are prepared under condition of temperature and pressure by pallet making machines. After formation of pallet the feed is restored to normal temperature and then packed manually in 50kg bags. PROCESS OUTLINE
- 10. 2.5 Challenges The major challenge for the industry is to acquire raw materials as different raw materials are available in different agricultural season. Therefore to avoid seasonal unavailability of certain raw material, its mass purchase in tons and storage is vital. Proper storage of acquired raw material and its protection from insects, fungus and rats without using any hazardous chemical pop up as a major challenge. On the other hand moisture can also degrade raw material so temperature treatment and controlled atmosphere storage is practiced that also increases the cost. Since raw material is such that it can catch fire easily even due to increase in temperature thus it has to be kept away from heavy machines which produce heat. Shri Sudharma Industries keep their raw material in specially built sheds that has proper entrance, exists and emergency exists in case of fire. Proper availability of fire extinguishers is noted. Factory workers are trained to use fire extinguishers and they are found aware about emergency protocol.
- 11. 3. QUALITY CONTROL Raw material reach directly from agricultural field and hence it contain numerous types of impurities. Proper treatment before use in manufacturing process is must to improve quality of product. 3.1 Waste a) Dust : Fine, dry powder consisting of tiny particles of earth or waste matter lying on the ground or on surfaces or carried in the air. Introduced to raw material during gathering and transportation. b) Metallic Particles : Small metal particles usually iron. Introduced to raw material during harvesting, separating and transportation process. c) Plastic and Other : Small plastic particles. Introduced to raw material during packing process or via broken tools. 3.2 Methods a) Manual Separation : Larger metallic or plastic materials are separated by industrial workers during weighing process. b) Magnetic Separation : Multiple magnets are present on collection chamber that separate metallic particles. Mixing machines consist of magnets which separate last left metallic impurities. c) Suction : During mixing, dust is collected by a suction machine and dust free raw mixture goes for pellet making process. d) Safety : Heavy machines are kept at proper distance to avoid fire and related damage, they are connected via suction pipe lines to transfer raw material. Heat regulators are present to maintain temperature and proper frames are built to control vibration. Sound reduction is also practiced. e) Product Quality : Composition analysis is done for every batch. Detection of heavy metal impurity is done using laboratory methods. pH, pOH test is performed. NOTE : 1. Good industry practice : Keep heavy machines at proper distance to avoid fire. 2. Good industry practice : Regulate temperature of machines, cover heating parts with insulation, wear heat resistance suit during work. 3. Good industry practice : Reduce vibrations of machine by proper framing. Vibration may cause injury to factory workers. 4. Good industry practice : Reduce noise and wear ear protection during work. (we have specific details about equipment required in laboratory for QC lab set up.)
- 12. 4. RESEARCH & DEVELOPMENT 4.1 Feed Type Based on nutritional composition following feeds are produced :- Sr. No Feed Type For 01 Cow Feed For milk yielding cows which give 10L+ milk everyday. 02 Buffalo Feed For milk yielding Buffalo which give 10L+ milk everyday. 03 Calf Feed For new born and early stage calf. 04 Growing Calf Feed For non milk yielding buffalo and cows. Following are the brand products by Shri Sudharma Industries :-
- 13. 4.2 Composition Research and development projects were carried out by Shri Sudharma Industries involving veterinary doctors, post graduates, research scientists and others for the formulation of best suitable cattle feed as per required. Industry ensure that its product must deliver all nutritional requirement to the animal at minimum cost on the pocket of dairy farmer. Based on different composition of fats, carbohydrates, proteins and minerals different products are produced as mentioned in 4.1 and 4.2 section.
- 15. 4.3 Feedback Bases on feedback from farmers and observations made by professionals the feeding schedule has been decided as :- Cows (per day) BUFFALOES (per day) 1.5 kg Plus 1 kg for every 2.5 litres of Milk yield. 2 kg Plus 1 kg for every 2.5 litres of Milk yield.
- 16. 5. EMPLOYMENT POTENTIAL Although meanwhile the industries are mainly dependent on uneducated labour but any micro or small or medium scale industry that is involved in production of compost feed have potential to offer employment to following set of persons according to analyst Mr. Abhinav Gaur. (other than sales - marketing and management). No. Of Person/s Required Factory Work Description Educational Background Salary Range 2 Store (raw material). Any - 6000 - 10000 2 Store / Packing (final product). Any- 6000 - 10000 2 Weighing and inspection of raw material for metallic and plastic waste. Any- 6000 - 10000 1 To super-wise the weighing process according to industrial standards. Graduate (B.Sc - with chemistry as one of the main subjects) 10000 - 12000 1 Safety officer to super-wise entire process of production. Graduate (B.Tech in fire safety or B.Sc - with chemistry as one of the main subjects) 12000 - 15000 1 QC officer to control impurity and assure best quality of product. Post Graduate (M.Sc - biochemistry / pharma chemistry / organic chemistry / etc.) 12000 - 15000 1 Helper to QC officer and Safety officer. Graduate (B.Sc - with chemistry as one of the main subjects) 10000 - 12000 If industries undertake research and development activities to improve quality, improve effect or to decrease cost then extreme employment potential is present for veterinary doctors, post graduates, researchers and labour.
- 17. 6. SUMMARY Irrespective of the current economical trend the dairy industry is showing significant growth and it holds potential for investment by government or non government or private sector as the demand of dairy based products is growing worldwide. It has extreme potential to provide employment opportunity to millions of professionals and labour. Scope of production is present in liquid milk, milk based products (ghee, curd, paneer etc) cattle feed and supplement. Scope of research is present in animal keeping activities (good animal keeping practices can be significantly developed), animal feed, disease control and cost cutting. Quality control and assurance practices opens up vital scope for professional as well. Whereas if we only talk about cattle feed production under MSME type, extensive potential to engage professionals can be observed. According to analyst Mr. Abhinav Gaur “in coming future cattle feed production industries will compete with pharmaceutical industries for professional workers”.