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Final Report of NAIP Sub Project onA Value Chain on Lac and Lac Based Products for Domestic and Export Markets

Indian Institute of Natural Resins and GumsNamkum, Ranchi – 834 010 (Jharkhand)

2014

Final Report

A Value Chain on Lac and Lac based Products forDomestic and Export Markets

National Agricultural Innovation Project(Indian Council of Agricultural Research)

Indian Institute of Natural Resins and Gums, Ranchi

Printed on : June, 2014

Component : 2 (Production to Consumption System of Research)

Citation : Prasad, N. 2014. Final Report of NAIP sub-project on “A Value Chain on Lac and Lac based Products for Domestic and Export Markets”. Indian Institute of Natural Resins and Gums, Namkum, Ranchi 834 010.

Copyright : Indian Council of Agricultural Research (ICAR)

Disclaimer : Materials of this publication are collective research work of all consortia partners.

Published by : Dr. R Ramani

Director

Indian Institute of Natural Resins and Gums, Namkum

Ranchi-834010 (Jharkhand)

Phone - 09934140899

E-mail- [email protected]

Website : http://ilri.ernet.in

Edited by : Dr. Niranjan Prasad

Compiled by : Er. Sanjay Kumar Pandey

Dr. Soumen Ghosal

Dr. Satish Chandra Sharma

Dr. Sanjay Srivastava

Hindi translation : Dr. Anjesh Kumar

Cover page photographs

: Plantation of F. semialata (Left side)

Lac crop on ber (Right side)

______________________________________________________________________________

Printed atSpeedo Print, Ranchi

i


Foreword

The NAIP Sub-Project on A Value Chain on Lac and Lac Based Products for Domestic and Export Markets was launched in April, 2009 with the objective of playing a key role in transforming lac value chain with due emphasis on innovation in all aspects that contribute to the overall improvement of lac production, processing and value addition scenario in the country. The specific objective of the sub-project was to develop working model of sustainable lac value chain by involving stake holders from different organizations including private and NGOs and facilitating their collaboration in a consortium mode. The joint efforts of all the stake holders involved in this sub-project have resulted in promoting high yielding kusmi lac cultivation on ber, lac cultivation on plantation basis on ber and Flemingia semialata, primary processing of lac at village level, lac handicraft making, recovery of improved quality lac dye from effluent of lac processing industry etc. My complements to Dr. Niranjan Prasad, CPI and his team consisting of CCPIs, RAs and Office Assistant for the good work done in the project and bringing out this Final Report of the Sub-project. I would like to thank Dr. N.S.L. Srivastava, CAC Chairman for his keen interest and able guidance and members for their valuable suggestion during execution of this sub-project.

(R. Ramani)

Director & Consortium Leader

Ranchi

June, 2014

Hkkjrh; izkd`frd jky ,oa xksan laLFkkuIndian Institute of Natural Resins and Gums

(Hkkjrh; d`f"k vuqla/kku ifj"kn)(Indian Council of Agricultural Research)

ukedqe] jkWaph & 834 010Namkum, Ranchi - 834 010

Ph.: 0651-2261156, EPBX: 0651-2260117, FAX: 0651-2260202, E-mail: [email protected] Quality Evaluation Laboratory for Natural Resins and Gums

iii


Preface

The NAIP Sub-Project on A Value Chain on Lac and Lac Based Products for Domestic and Export Markets covered all stake-holders, which included lac producers, who were involved in lac production; processors, who added value to commodities, and consumers, who were looking for better quality products. In this sub-project, the emphasis was on promoting high yielding kusmi lac cultivation on ber, lac cultivation on plantation basis on ber and Flemingia semialata, primary processing of lac at village level, lac handicraft making, recovery of improved quality lac dye from effluent of lac processing industry etc., so that all the stake holders benefit leading to an overall improvement in their income and quality of life. Besides, issues such as women empowerment, environment protection, institutional pluralism, linkages with markets and sustainability were also addressed.

This Final Report documents sub-project implementation and highlights achievements. Valuable and helpful suggestions from Dr. Rama Rao and Dr. B. Baboo, National Directors, NAIP; Dr. J.P. Mittal, Late Dr. R.K. Goyal and Dr. R. Ezekiel, National Coordinators (Component -2); Dr. NSL Srivastava, Chairman, CAC and CAC Members have been the source of inspiration for effective implementation. Constant encouragement, support and guidance of Dr. B. Baboo and Dr. R. Ramani, Directors, IINRG have been helpful in successful implementation of the sub-project. The sincere efforts of Consortia Partners, Co-Consortia Principal Investigators, participating industries, NGOs and farmers in carrying out the project works as planned are very much appreciated and thankfully acknowledged. The contribution to the sub-project by my colleagues Dr. S. Ghosal, Dr. S.K. Giri, Er. S.K. Pandey, Dr. S. Srivastava, Dr. G. Pal and Dr. S.C. Sharma is thankfully acknowledged. The financial management contribution by the Finance and Accounts Section and administration and procurement support provided by Administration Section are placed on the record with thanks. The support of Research Associates and Office Assistants in sub-project implementation is also acknowledged.

(Niranjan Prasad)

Consortia Principal Investigator

Ranchi

June, 2014

v


CONTENTSForeword .................................................................................................................................................... i

Preface ...................................................................................................................................................... iii

dk;Zdkjh lkjka'k ..............................................................................................................................................1

Executive Summary/ Key words ...............................................................................................................4

Part-I: General Information of Sub-project ................................................................................................7

Part-II: Technical Details

Introduction ...............................................................................................................................................9

Overall Sub-project Objectives ................................................................................................................10

Sub-project Technical Profile ...................................................................................................................11

Baseline Analysis .....................................................................................................................................14

Research Achievements ...........................................................................................................................25

Innovations ..............................................................................................................................................54

Process/Product/Technology Developed .................................................................................................61

Patents (Filed/Granted) ............................................................................................................................62

Linkages and Collaborations ....................................................................................................................62

Status on Environmental and Social Safeguard Aspects ..........................................................................62

Constraints, if any and Remedial Measures Taken .................................................................................64

Publications ..............................................................................................................................................65

Media Products Developed/Disseminated ...............................................................................................67

Meetings/Seminars/Trainings/Kisan Mela, etc. organized ......................................................................67

Participation in Conference/ Meetings/Trainings/ Radio talks, etc. .......................................................69

Foreign Trainings/Visits ...........................................................................................................................69

Performance Indicators ............................................................................................................................70

Employment Generation ..........................................................................................................................71

Assets Generated ......................................................................................................................................72

Awards and Recognitions .........................................................................................................................73

Steps Undertaken for Post NAIP Sustainability .....................................................................................74

Possible Future Line of Work ..................................................................................................................74

Personnel ..................................................................................................................................................74

Governance, Management, Implementation and Coordination ...............................................................76

Part-III: Budget and its Utilization ..........................................................................................................80

Part-IV: Declaration .................................................................................................................................84

vi


List of abbreviation AOAC Association of Official Agricultural ChemistsBRIAT Bioved Research Institute of Agriculture & TechnologyCAC Consortium Advisory Committee CCPI Consortium Co- Principal InvestigatorCFTRI Central Food Technological Research InstituteCIC Consortium Implementation CommitteeCL Consortium leaderCMU Consortium Monitoring UnitCPI Consortium Principal InvestigatorDoI Date of InoculationFYM Farm Yard ManureF. semialata Flemingia semialataGMP Good Manufacturing PracticesHDPE High Density Poly EthyleneHYPR Half Yearly Progress ReportICAR Indian Council of Agricultural ResearchIINRG Indian Institute of Natural Resins and GumsIRF Institute Research FarmISO International Organization for StandardizationITK Indigenous Technological KnowledgeJASCOLAMPF Jharkhand State Co-operative Lac Marketing and Procurement FederationLDPE Low Density Poly EthyleneMoC Material of constructionNAIP National Agricultural Innovation project NBJK Nav Bharat Jagriti KendraNGO Non Government OrganizationOFT On Farm Training PCO Public Call OfficePDU Product Demonstration UnitPDS Public Distribution SystemPHC Public Health CentrePIU Project Implementation UnitPP Poly PropyleneQEL Quality Evaluation LaboratoryRA Research AssociateSISO Small Industries Service OrganizationTOT Transfer of TechnologyWB West BengalZ. mauritiana Ziziphus mauritiana

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dk;Zdkjh lkjka'kyk[k ewY; ds fofHkUu eqn~ns] yk[k dh de mRikndrk] b/kj&m/kj QSys yk[k ifjikydksa dk izca/ku] vi;kZIr vkSj ?kfV;k chguyk[k (yk[k cht)] mRikn dk de ewY;] yk[k izlaLdj.k m|ksx ds mRiknksa dk mi;ksx u gksuk ,oa yk[k mRiknu rFkk izlaLdj.k esa izf'kf{kr ekuo lalk/ku dk vHkko ds fujkdj.k }kjk fVdkÅ yk[k ewY; Jà[kyk ds fodkl ds fy, Hkk-Ï-u-ifj- dh mi&ifj;kstuk **?kjsyq ,oa fu;kZr cktkj ds fy, yk[k ,oa yk[k vk/kkfjr mRiknksa dh ,d ewY; Jà[kyk** dk dk;kZUo;u fd;k x;kA yk[k ewY; Jà[kyk ds fofHkUu eqn~nksa ds lek/kku gsrq feydj dk;Z djus ds fy, Hkk-izk-jk-xksa-la-] jk¡ph] loZJh rtuk 'ksysd izk- fy-] [kawVh] loZJh xqIrk cznlZ 'ksysd] cqaMq] jkaWph] czk;V] bykgkckn ,oa ,u- ch- ts- ds-] [kwaVh dks dUlksZfV;e lk>hnkj cuk;k x;kA >kj[kaM ds jkaWph ftys ds ifj;kstuk {ks= ds xzkeksa esa ifj;kstuk dh yk[k mRiknu xfrfof/k;ksa ds fdz;kUo;u ds fy, LoSfPNd lk>hnkj ds :Ik esa pkj xSjljdkjh laxBuksa dh lgk;rk yh xbZA bl iz;kl esa jk-Ï-u-ifj- us vfuok;Z foÙkh; lgk;rk iznku dhA Qjojh 2009 ls ekpZ 2014 rd dh vof/k esa bl mi&ifj;kstuk ls izkIr Kku ,oa rduhdh miyfC/k;ka fuEuor gS%&

• vuqnku dh igyh izkfIr ds volj ij Hkk-izk-jk-xksa-la-]jkaWph esa ifj;kstuk 'kqHkkjaHk dk;Z'kkyk dk vk;kstu fd;k x;k rFkk lHkh lk>snkjksa ds fy, dk;Z;kstuk rS;kj dh xbZA ifj;kstuk ds xfrfof/k;ksa ds dk;kZUo;u ds fy, jkaWph ,oa [kwaVh ftyksa dh igpku dh xbZA izf'k{k.k ,oa izn'kZu ds fy, Hkk-izk-jk-xksa-la-] jkaWph ds vuqla/kku iz{ks= esa ,d y?kq yk[k izlaLdj.k bdkbZ dh LFkkiuk dh xbZA

• igpku fd;s x, xzkeksa dk vk/kkjHkwr losZ fd;k x;k rFkk fjiksVZ tek dh xbZA

• csj ij dqleh yk[k dh [ksrh ds fy, :fp j[kus okys fdlkuksa dh igpku dh xbZ rFkk Hkk-izk-jk-xksa-la-] jkaWph esa oSKkfud fof/k ls yk[k dh [ksrh dk izf'k{k.k fn;k x;kA csj ij dqleh yk[k dh [ksrh ds izkS|ksfxdh dks muds csj ds o`{kksa ij mUgsa lkFk ysdj iznf'kZr fd;k x;k rFkk xq.koÙkkiw.kZ chguyk[k] midj.k@e'khu rFkk dhVuk'kh miyC/k djk, x,A fdlkuksa dks Qly dh ifjiDork ds mijkUr mls dkVus fn;k x;k rFkk ckn dh Qly ds fy, chgu yk[k (yk[k cht) ns fn;k x;kA bl izkS|ksfxdh dks vaxhdkj djus ds fy, izksRlkfgr djus gsrq vkl&ikl ds xzkeksa ds fdlkuksa dks Qly fn[kk;k x;kA ifj.kke Lo:Ik jkaWph vkSj [kwaVh ftys ds fdlkuksa us csj ij dqleh yk[k dh Qly mxkuk vkjEHk fd;k gSA bu ftyksa esa 2008&09 ds 875 Vu dh rqyuk esa 2012&13 esa yk[k mRiknu c<+dj 4250 Vu gks x;kA

• ckxku vk/kkfjr yk[k dh [ksrh dks izksRlkfgr djus ds fy, ,u- ch- ts- d-s [kawVh dh lgk;rk ls bPNqd fdlkuksa dh igpku dh xbZ rFkk Hkk-izk-jk-xksa-la-] jkaWph esa **yk[k ifjikyd mxkuk ,oa ckxku vk/kkfjr yk[k dh [ksrh** dk izf'k{k.k fn;k x;kA vkjEHk esa ckxku rS;kj djus dh xfrfof/k;ksa ls izf'kf{kr fdlkuksa dks lkFk ysdj ,Q- lsfe;kyrk ds rhu rFkk csj ds nks ckxku rS;kj fd;s x,A fdlkuksa dks ckxku rS;kj djus ds fy, ikS/ks+s ,oa moZjd fn;s x,A pwafd ,Q- lsfe;kyrk ,oa csj dks tkuoj [kk tkrs g]Sa vr% ekWMy izn'kZu IykWV dks ifj;kstuk ds [kpZ ls lqj{kk ?ksjk yxk fn;k x;kA

• ikWap ekWMy cxkuksa esa ls dsoy nkss] ,d ,Q- lsfe;kyrk dk vkSj ,d csj dk ckxku fVd ldk rFkk fdlkuksa us mlesa yk[k Qly ysuk 'kq: dj fn;k gSA tkuojksa ls iz;kZIr lqj{kk ugha gksus rFkk fdlkuksa }kjk leqfpr /;ku ugha nsus ds dkj.k vU; foQy gks x,A

2


• xzkeh.k Lrj ij yk[k ds izlaLdj.k dks izksRlkfgr djus ds fy, izf'k{k.k rFkk izn'kZu ds fy, Hk-izk-jk-xksa-la- vuqla/kku iz{ks= esa y?kq Lrjh; yk[k izlaLdj.k bdkbZ LFkkfir dh xbZA yk[k dh oSKkfud [ksrh ,oa mi;ksx ds mUur rjhds ds vUrxZr laLFkku ds fu;fer izf'k{k.k xfrfof/k;ksa esa y?kq Lrjh; yk[k izlaLdj.k bdkbZ ({kerk&100 fd-xzk-@fnu) ds ckjs esa ,d O;k[;ku lg izn'kZu dks 'kkfey fd;k x;kA LFkkfir bdkbZ ds }kjk yxkrkj izf'k{k.k ds vUrxZr m|ferk fodkl dk;ZØe tkjh gSA o"kZ 2011&14 dh vof/k esa 3130 fdlkuksa@ykHkqdksa dks y?kq Lrjh; yk[k izlaLdj.k bdkbZ ij izf'k{k.k fn;k x;kA

• loZJh le`f¼ bUVjizkbZtst] ds'ko uxj] dqekjVksyh] jkaWph uked ,d okf.kfT;d bdkbZ esa IykfLVd m|ksx esa mi;ksx gksus okys bDlVªwMj esa xeZ pkSjh ds Nkuus dk ijh{k.k fd;k x;kA ijh{k.k ds nkSjku fi?kys gq, yk[k dh rjyrk dk fujh{k.k fd;k x;kA bDlVªwMj ds gkWij Hkkx (eq[k) esa yk[k ds eqyk;e gksus dh leL;k ns[kh xbZ] ftlls pkSjh dk tkuk dqN nsj ds ckn cUn gks x;k ,oa Nuuk :d x;kA ,slh leL;k blfy, vkbZ D;ksafd yk[k ds eqyk;e gksus dk rkieku 40&500 ls- rFkk nzo.kkad 700 ls- gS] tcfd IykfLVd dk nzo.kkad 700 ls- gSA v/;;u ls fuLd"kZ fudyrk gS fd bDlVªwMj dk mi;ksx dj piM+k cukus fd fy, cSjsy ds fMtkbu esa dqN lq/kkj dh t:jr gSA

• fojaftr yk[k ds lkFk eq[; leL;k ;g gS fd bldks j[kus ij xq.koÙkk [kjkc gksrh gSA bldh ?kqyu'khyrk esa rsth ls àzkl gksrk gS rFkk ;g lkexzh tYnh gh mi;ksx ds yk;d ugha jgrh gSA fojaftr yk[k esa Dyksjhu (1&3-5%) gksus ds dkj.k HkaMkj.k ds le; blesa fLFkjrk ugha jgrh gSA fojaftr yk[k ds fuekZ.k ds fy, mUur fojaftr vfHkdkjd dh igpku dj bl leL;k ds fujkdj.k ds fy, v/;;u fd;s x,A bl v/;;u ds vk/kkj ij gkbZMªkstu isjksDlkbM ,oa lksfM;e gkbiksDyksjkbM ds la;kstu dh mUur fojaftr vfHkdkjd ds :Ik esa igpku dh xbZ gS] ftlls fojaftr yk[k dh xq.koÙkk esa lq/kkj gqvk vkSj HkaMkj.k vof/k esa Hkh lq/kkj ns[kk x;kA mUur fojaftr vfHkdkjd dh izkS|ksfxdh dk loZJh rtuk 'ksysd] [kawVh esa izn'kZu fd;k x;k vkSj vPNh xq.koÙkk ds fojaftr yk[k ds fy, bl izkS|ksfxdh dk loZJh xqIrk cznlZ ('ksysd)] cqaMq esa nks ckj okf.kfT;d ijh{k.k fd;k x;kA

• yk[k jatd yky jax dk cgqr izfl¼ o iqjkuk lzksr gSA Åu o js'ke dh jaxkbZ] xzkeh.k {ks=ksa esa lkSUn;Z izlk/ku ds :Ik esa iSj dks jaxus rFkk vFkoZ osn lfgr izkphu lkfgR; esa dqN ijEijkxr vkS"kf/k;ksa esa iz;ksx tSls dbZ rjg ds mi;ksx iqjkus le; ls Kkr gSaA ,UFkzkDohuksu ls mRiUu yk[k jatd dk jklk;fud uke ySdsbZd vEy gSA bls vUrZjk"Vªh; O;kikj esa izkÏfrd yky 25 (lh vkbZ la[;k 75452) ds :Ik esa tkuk tkrk gSA laLFkku us bl ifj;kstuk ds vUrxZr /kksou ty ds 'kq¼ Js.kh dk yk[k jatd fudkyus dh izkS|ksfxdh dks loZJh xqIrk cznlZ ('ksysd)] cqaMq dks iznf'kZr ,oa gLrkarfjr fd;k gSA mUur rjhds dh vko';drk ds vuq:Ik yk[k jatd la;a= esa :ikUrj.k@lq/kkj ds Ik'Pkkr~ izfr"Bku us mlls yk[k jatd cukuk vkjaHk fd;k gS rFkk izfro"kZ vkSlru 200 fd-xzk- yk[k jatd rS;kj dj :- 2500@fd-xzk- ewY; dh izkfIr gks jghA bl rjg loZJh xqIrk cznlZ ('ksysd)] cqaMq yk[k jatd dh fcØh ls izfr o"kZ :- 5 yk[k vftZr dj jgk gSA bl iz;kl ls jatd dh xq.kork esa lq/kkj gqvk rFkk mRikn dks cktkj esa ilUn fd;k x;k o vklkuh ls fcØh gqbZA vPNh xq.koÙkk ds yk[k jatd fudkyus dh bl izkS|ksfxdh dks loZJh xqIrk cznlZ ('ksysd)] cqaMq }kjk vaxhdkj dj fy;k x;k gSA

3


• yk[k jky esa egRoiw.kZ ?kVd ds :Ik esa mifLFkr ,Y;wfjfVd vEy dh mifLFkfr 35% rd gksrh gS ,oa bls okf.kfT;d egRo ds dbZ ifj"Ïr jlk;uksa tSls lqxa/kh ;kSfxdksa (vkblks,EczwVksykbM] flosVksu] bDtkyVksu] ,fEczVksykbM) dhV&fyax Qhjkseksu ;kSfxdksa] jkuh eD[kh Qhjkseksu] tqosukby] gkWjeksu ,ukykWXl bR;kfn ds la'ys"k.k esa vkjaHkd lkexzh ds :Ik esa mi;ksx fd;k tkrk gSA ,Y;wfjfVd vEy dh ekax lqxU/k ,oa vkS"kf/k m|ksx esa yxkrkj c<+ jgh gSA mRÏ"B mRiknu (pkSjh ds otu dk 18%) ds lkFk ,Y;wfjfVd vEy dk okf.kfT;d ijh{k.k ifj;kstuk ds dkWulksfVZ;e ds Hkkxhnkj m|ksxksa loZJh rtuk 'ksySd] [kawVh ,oa loZJh xqIrk cznlZ cqaMq ds le{k lQyrkiwoZd iznf'kZr fd;k x;kA

• fofHkUu izdkj dh iSdsftax lkexzh (,p Mh ih bZ] ,y Mh ih bZ] ih ih] ,ywfefu;e ysfir ikWyhFkhu) dk mi;ksx dj lkekU; fLFkfr;ksa essa HkaMkj.k v/;;u ds fy, iz;ksx fd;s x,A rqjUr rS;kj fd;k x;k yk[k jatd Ø; fd;k x;k rFkk mldh vkjafHkd xq.koÙkk ekunaMksa dh eki dh xbZ yk[k jatd ds uewuksa dk fofHkUu iSdsftax lkexzh tSls ,y Mh ih bZ (200 ,oa 400 xst)] ,p Mh ih bZ (200 xst)] ikWyhizksfiyhu (200 xst)] ,ywfeuh;e ¶ok;y ySfeusV ,oa dkxt ds cSx esa iSd fd;k x;k rFkk buds ewY;kadu ds fy, lkekU; fLFkfr;ksa esa HkaMkj.k fd;k x;kA Hkk-izk-jk-xksa-la-] jkaWph ds xq.koÙkk ewY;kadu iz;ksx'kkyk esa ,d o"kZ rd rhu eghus ds vUrjky ij jatd dh ek=k ,oa jax tSls xq.koÙkk ekudksa dk fu/kkZj.k fd;k x;kA izkIr ifj.kke ds vuqlkj fofHkUu izdkj dh iSdsftax lkexzh esa j[ks yk[k jatd ds uewuksa esa dksbZ mYys[kuh; fHkUurk ugha ikbZ xbZ bl rjg lcls lLrk iSdsftax lkexzh tSls ,y Mh ih bZ esa yk[k jatd ds HkaMkj.k dh vuq'kalk dh xbZA

• xzkeh.k Lrj ij yk[k gLrf'kYi fuekZ.k dks izksRlkfgr djus ds fy, ch vkj vkbZ , Vh] bykgkckn dks ifj;kstuk ds dlksfVZ;e ikVZuj ds :Ik esa tksM+k x;kA ch vkj vkbZ , Vh] bykgkckn us ifj;kstuk {ks= ds xzkeh.k ;qodksa dks yk[k gLrf'kYi fuekZ.k dk izf'k{k.k fn;k rFkk bu {ks=ksa esa pkj izf'k{k.k lg izn'kZu dsUnz LFkkfir fd;kA ch vkj vkbZ , Vh] bykgkckn }kjk 20 yksxksa dks yk[k gLrf'kYi fuekZ.k dk izf'k{k.k nsdj ekLVj Vsªuj cuk;k x;kA mUgsa ckn esa [kwaVh ([kwaVh ftyk) ,oa cukcq:] lks/kk ,oa drkjh ckxku (jkaWph ftyk) esa izf'k{k.k&lg&mRiknu dsUnz esa ykHkqdksa dks izf'k{k.k dk dk;Z fn;k x;k rFkk muyksxksa ls 175 ykHkqdksa us izf'k{k.k izkIr fd;kA

• 40 ykHkqdksa dks yk[k gLrf'kYi fuekZ.k ds fy, pkj LFkkfir izf'k{k.k&lg&mRiknu dsUnzksa esa dke ij yxk;k x;k ,oa mUgksaus vizSy 2013 ls vxLr 2013 dh vof/k esa :- 4-86 yk[k ewY; ds gLrf'kYi dk mRiknu fd;kA

dqy feykdj bl mi ifj;kstuk dks fofHkUu Js.kh ds lk>hnkjksa dks lkFk ysdj ,d lQy yk[k ewY; J`a[kyk dk fuekZ.k dj dq'kyrk ls dk;kZfUor fd;k x;kA lEiw.kZ ewY; J`a[kyk dh vkfFkZdh dk v/;;u fd;k x;k rFkk vk/kkjHkwr fjiksVZ rS;kj fd;k x;kA ifj;kstuk ds xfrfof/k;ksa ds ifj.kke Lo:Ik >kj[kaM ds jkaWph ,oa [kwaVh ftys esa yk[k ds mRiknu esa o`f¼ gqbZA yk[k mRikndksa us vc ckxku vk/kkfjr yk[k dh l?ku [ksrh ds fy, yk[k ifjikyd ckxku yxkuk vkjEHk dj fn;k gSA yk[k dk leFkZu ewY; ,oa vuqdwy ewY; (yk[k dh [ksrh o xzkeh.k Lrj ij yk[k ds izkFkfed izlaLdj.k ds fy, vkStkj@e'khu dh ykxr gsrq vuqnku) yk[k ds mRiknu esa yxkrkj o`f¼ gsrq lgk;d gksxkA mlh izdkj ewY;of¼Zr mRiknksa tSls fojaftr yk[k] ,Y;wfjfVd vEy] vkblks,EczsVksykbM ds mRiknu rFkk fu;kZr ,oa yk[k m|ksx ds mRikn dh izkfIr ij T;knk tksj nsus dh t:jr gSA

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Executive SummaryThe NAIP sub- Project on “A value Chain on Lac and Lac based Products for Domestic and Export Markets” was implemented to develop a sustainable lac value chain by addressing various issues in lac value chain, encompassing low lac productivity, management of scattered lac hosts, inadequate and inferior quality of broodlac (lac seed), low price of produce, non utilization of by product of lac processing industry and lack of trained human resource in lac production and processing. To achieve this, a consortium of partners IINRG, Ranchi; M/s Tajna Shellac Pvt. Ltd., Khunti; M/s Gupta Brothers Shellac, Bundu; BRIAT, Allahabad and NBJK, Khunti was formed to work cohesively to address various issues in lac value chain. The support of four NGOs as voluntary partners was also taken in implementation of lac production activities in villages of project area in Ranchi and Khunti districts of Jharkhand. NAIP provided the necessary funding support to the consortium in this endeavor. The technical achievement and lessons learned in the sub project during February 2009 to March 2014 are briefly presented hereunder.

• Upon receiving the first grant, a project launch workshop was organized at IINRG, Ranchi and work plans were developed for all partners. Ranchi and Khunti districts were identified for implementation of project activities. A small scale lac processing unit was established in Research Farm of IINRG, Ranchi for training and demonstration.

• A baseline survey was conducted in the targeted villages and report was submitted.

• Farmers interested in kusmi lac cultivation on ber were identified and trained on scientific method of lac cultivation at IINRG, Ranchi. Technology of kusmi lac cultivation on ber was demonstrated on their ber trees by involving them in lac demonstration activities and inputs like quality broodlac, tools/machines and pesticides were provided. The farmers were allowed to harvest the crop an maturity and use brood lac (lac seed) for taking subsequent lac crop. The demonstrations were shown to farmers of near by villages for motivating them for adoption of technology. As a result farmers have started taking kusmi lac crop on ber in Ranchi and Khunti districts. In these districts, lac production has increased from 875 tons is 2008-09 to 4250 tons in 2012 –13.

• To promote lac cultivation on plantation basis, interested farmers were identified with the help of NBJK, Khunti and trained on “Raising Lac Host Plantation and Lac Cultivation on Plantation Basis” at IINRG, Ranchi. Initially three plantations of F. semialata and two of ber were raised involving trained farmers in plantation raising activities. The farmers were provided inputs like seedlings and fertilizer for raising plantation. As F. semialata and ber are prone to grazing, the model demonstration plots were fenced with financial support from project. Out of five model plantations, only two – one of F. semialata and one of ber could sustain and farmers have started taking lac crop. Others failed due to inadequate attention by farmers in protecting the plot from grazing and providing proper care.

• To promote primary processing of lac at village level, a small scale lac processing unit was established at IINRG Research Farm for training and demonstration. A lecture-cum-demonstration of Small Scale Lac Processing Units (Capacity – 100 kg/day) was included in the regular training activity of the institute under scientific lac cultivation and improved method of utilization. The installed units were continuously used to impart training programme of the institute and entrepreneurship development. About 3130 farmers/beneficiaries were imparted training on small scale lac processing unit during 2011-2014.

• Trial for hot filtration of seedlac was carried out in extruder used in plastic industry at a commercial unit M/s Samriddhi Enterprise, Keshav Nagar, Kumartoli, Ranchi. During trial excess fluidity of melted lac was observed. Problem of softening of lac was also encountered at hopper section (feeding

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point) of extruder which resulted in non feeding of seedlac with passage of time and further filtration was stopped. Problem may be due to reason that lac has softening temperature 40-500 C and melting above 700 C, whereas plastic has only melting temperature above 700 C. The study suggested that improvement in design of barrel is needed for filtration of lac for making shellac using extrude.

• The main drawback associated with bleached lac is its poor keeping quality. The solubility of the material falls rapidly and the material soon becomes unfit for use. The poor storage stability of bleached lac has been attributed to the combined chlorine (1-3.5%) usually present. To address these problems further studies were conducted to identify improved bleaching agent for making bleached lac. Based on the study, improved bleaching agent i.e. combination of hydrogen peroxide and sodium hypo-chlorite was identified, which improved the quality of bleached lac and resulted in improvement in its shelf life. The technology of improved bleaching agent was demonstrated at M/s Tajna Shellac, Khunti and commercial trials of this technology for better quality of bleached lac were carried out two times at M/s Gupta Brother (Shellac), Bundu of this technology.

• A very popular and old source of red dye is lac dye. It has several age old known applications like dyeing of wool and silk, as skin cosmetic besides colouring of feet by villagers and certain traditional medicinal uses reported in old literatures including in Atharva veda. The chemical name of lac dye, an anthraquinone derivative is laccaic acid. It is known as Natural Red 25 (CI Number 75452) in international trade. The institute has successfully demonstrated and transferred the technology of recovering pure grade lac dye from wash water to M/s Gupta Brother’s (Shellac), Bundu under this project. After modification/refinement in lac dye plant as per requirement of improved method, firm started making lac dye using the modified lac dye plant and producing on an average 200 kg lac dye per year and getting price of Rs. 2500/kg. Thus M/s Gupta Brothers (shellac), Bundu is earning Rs. 5 lakhs per year from sale of lac dye. The intervention improved dye quality and product was preferred in the market and sold easily. The technology of recovery of lac dye of improved quality is now adopted by M/s Gupta Brother’s (Shellac), Bundu.

• Aleuritic acid is a major constituent acid present to the extent of about 35% in the lac resin and can be utilized as starting material for the synthesis of a number of fine chemicals of commercial importance such as perfumery compounds ( isoambrettolide, civetone, exaltone, ambrettolide), Insect-sex pheromone components, Queen-bee pheromone, Juvenile hormone analogues etc. is a continuous growing demand of aleuritic acid in the fields of perfumery and pharmaceuticals. The commercial trials of aleuritic acid with improved yield (18% of seedlac weight) were successfully demonstrated to the industries of consortium partners of project namely M/s Tajna Shellac, Khunti and M/s Gupta Brother, Bundu.

• Experiments were carried out for storage study of lac dye using different packaging materials (HDPE, LDPE, PP, Aluminium coated polythene, Paper bags) and storage in ambient condition. Freshly prepared lac dye was purchased and its initial quality parameters were measured. Lac dye samples were than packed in different packaging materials viz LDPE (200 & 400 gauge), HDPE (200 gauge), polypropylene (200 gauge), aluminium foil laminate and paper bag and stored in ambient conditions for evaluation. The quality parameters i.e. dye content and color were determined at 3 months interval for one year from Quality Evaluation Laboratory, IINRG, Ranchi. The results obtained indicated no appreciable difference in quality parameters for lac dye samples stored in different packaging material. Thus cheapest packaging material i.e. LDPE was recommended for storing lac dye.

• To promote lac handicraft making at village level, BRIAT, Allahabad was associated as consortium partner in the project. BRIAT, Allahabad trained the rural youth from project area on lac handicraft making and established four training-cum-production centres in these areas. 20 persons were trained

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to become as Master trainers for making lac handicrafts by BRIAT, Allahabad. They were later engaged in training beneficiaries at training-cum-production centre established at Khunti (in Khunti district) and Banaburu, Sodha and Kataribagan (in Ranchi district) and they trained 175 beneficiaries.

• 40 trained beneficiaries were engaged for making lac handicrafts at four established training-cum-production centers and they produced handicraft of value Rs. 4.86 lakhs during April, 2013 to August, 2013.

On the whole, the sub project was implemented in letter and spirit to build a successful lac value chain with a range of interventions involving a variety of partners. Economics of the entire value chain was studied and baseline report was prepared. Project interventions has resulted in enhanced production of lac in Ranchi and Khunti districts of Jharkhand. Lac growers have now started raising lac host plantation for intensive lac cultivation on plantation basis. Favourable policy intervention in terms of minimum support price for lac and stalk pricing (subsidizing tool/machinery cost to the farmers for lac cultivation and primary processing of lac at village level) will help in sustainable increase in lac production. Similarly, more emphasis is needed on increasing the production & export of value added products i.e. bleached lac, aleuritic acid, isoambrettolide and recovery of by product of lac industries.

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Part-I: General Information of Sub-project1. Title of the sub-project : A Value Chain on Lac and Lac based Products for Domestic and Export Markets

2. Sub-project code : --

3. Component : 2 (Production to Consumption System of Research)

4. Date of sanction of sub-project : February 3, 2009

5. Date of completion : March 31, 2014

6. Dateoffirstreleaseoffund : March 12, 2009

7. Date of launch workshop of : April 30, 2009 the sub-project

8. Extension if granted : From June 30, 2011 to March 31, 2014

9. Total sanctioned amount for : 193.71 lakhs the sub-project:

10. Total expenditure of : 112.53618 lakhs the sub-project:

11. Consortium leader : Dr. R Ramani, Director, IINRG, Ranchi

Director Indian Institute of Natural Resins and Gums Namkum, Ranchi-834 010. Jharkhand. Ph-09934140899 Email- [email protected]

List of consortium partners:

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

1. Dr. Niranjan Prasad

PS & Consortium Principal Investigator

IINRG, Namkum Ranchi-834010

2. Dr. S Srivastava

Consortium Co-Principal Investigator


3. Er. S K Pandey



4. Dr. S Ghosal



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5. Dr. S C Sharma



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

Consortium Partner Total budget sanctioned

Fund released(up to closing date)

Fund utilized(up to closing date)

IINRG, Ranchi 137.51 208.58761 89.96480M/s Tajna Shellac, Khunti 10.09 2.79771 1.53836M/s Gupta Brothers (Shellac), Bundu

9.55 6.01175 2.59625

NBJK, Khunti 11.13 10.23467 9.06008BRIAT, Allahabad 25.43 11.64000 9.37669Grand Total 193.71 239.27174 112.53618

13. Sub-project website address (URL): http://ilri.ernet.in/~iinrg/naip.html

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Part-II: Technical Details 1. IntroductionLac is a natural, renewable, bio-degradable, versatile and non-toxic resin produced by the colonies of a tiny insect known as Kerria lacca (Kerr). These insects thrive on the tender branches of specific host trees viz., palas (Butea monosperma), ber (Ziziyphus mauritiana), kusum (Schleichera oleosa), Ficus spp. etc. It serves as an important source of income to more than one million tribal families in India as well as foreign exchange earner for the country. Cultivated by poor, marginal and tribals in the sub-hilly tracts of Jharkhand, Chhattisgarh, Madhya Pradesh, West Bengal, Maharashtra, Assam and Orissa, lac is grown in and outside of forest areas contributing 20-30% of the grower’s annual income. As a renewable source of resin, dye, and wax, lac has a bright future. World demand of this natural resin of insect origin is increasing due to enhanced awareness on use of safe, natural products for human contact and consumption.

India, producing 20-22 thousand tons of lac annually and having installed processing capacity of about 40,000 tons, leads in the world in production, processing and export of lac. About 80 per cent of the produce is exported to more than 70 countries throughout the world. There was declining trend in lac production during 2007-11 in India due to various reasons, widening the gap between demand and supply. There is spurt in demand of lac in the country and substantial amount of raw lac (~ 7000 tons) was imported to fulfil this demand in order to run the domestic lac processing units in the country. There is availability of improved technologies that ensures sustained lac production and also vast untapped areas in the country which are ecologically favourable for lac production. These areas possess the potential lac host plants which, if exploited properly in scientific and systematic manner are liable to enhance the lac production to fill this gap. Tapping the traditional production catchments having suitable climate for lac production and their revival will have advantage of broodlac availability for other areas also.

The Ranchi and Khunti districts of Jharkhand had been a potential lac growing catchment with a good number of lac host plants. Some of the strengths/advantages of the catchment with regards to lac value chain are highlighted below:

• All conventional lac hosts viz. kusum, palas and ber trees are available in plenty.

• More than 50% of lac growers in the area have 50-500 numbers of lac host trees.

• The catchment is dominated by kusmi lac host tree species which is able to produce best quality of lac in the world.

• The catchment is rainfed area and agricultural activity is meager and unable to provide economic security to the farmers.

• About 20% of total income and 30% of agricultural income of lac growers come from lac.

• The catchment has 14 processing units with an installed processing capacity of approximately 4000 tons.

• The industries have facility to produce value added products from lac viz. shellac, bleached lac, aleuritic acid and lac dye.

• The only Cooperative on lac i.e. Jharkhand State Co-operative Lac Marketing and Procurement Federation (JASCOLAMPF) is in operation in the catchment.

• In the past lac production was able to provide livelihood for 3-4 months in a year to the lac growers in this catchment area.

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Nevertheless, the production in this catchment is slowly decreasing over the years due to unscientific method of cultivation, lesser profitability, shortage of broodlac etc. The lac processors in the area were compelled to import inferior quality raw lac from other countries like Indonesia and Thailand to run their industries. Hence, there was need to improve the lac value chain comprising lac production, processing, handling, storage, export and quality parameters with the objective of augmenting production, profitability and income of lac growers and ultimately increasing export earnings for the country. The value chain aimed to reduce deforestation to a large extent by increasing profitability from lac cultivation, thus helping in conservation of natural resource of lac host plants and insects for commerce. The focal theme was ecological approach for economic development.

Indian Institute of Natural Resins and Gums undertakes research and develops technology for increasing lac production, its quality, processing and product development by assessing the technology intervention requirements. As such there was no formal link between all stakeholders in the region and abroad. The project aimed to develop formal links in the production to consumption system involving farmer, industry and exporter.

2. Overall Sub-project Objectives(i) Production:

• To promote cultivation of high yielding lac insects (kusmi) for continuous supply-chain management.

(ii) Processing:

• To promote primary processing of lac at village level.

• To reduce losses during processing, improve quality, develop suitable packaging for lac (shellac) and lac based products (bleached lac and aleuritic acid) for domestic and export markets.

(iii) By-products value addition:

• To recover and purify the byproduct of lac industry (lac dye from wash water) for economic benefits.

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3. Sub-projectTechnicalProfile(Indicate briefly objective-wise work plan, monitoring indicators, expected output and expected outcome)

Workplan and monitoring indicators

Sl. No. Objective Activities Expected Output Expected

Outcomes1. To promote

cultivation of high yielding lac insects (kusmi) for continuous supply-chain management.

Production

• Cultivation of high yielding lac insect on existing host trees.

• Promotion of intensive lac cultivation on plantation basis.

• Collecting indigenous technological knowledge and refinement of technologies.

• About 30% increase in adoption of scientific lac cultivation by farmers. Presently it is about 20%.

• Establishment of lac host plantation in production catchment for scientific and sustained lac cultivation. These does not exist at present.

• Enhanced lac production of up to 30 %.

• Enhanced income of lac cultivators up to 20 %.

• Employment generation in forest and sub- forest areas of about 60 man-days from ten lac hosts in a year.

2. To promote primary processing of lac at village level.

Processing

• Establishment of model small scale lac processing unit for training, demonstration and entrepreneurship development.

• Imparting training on primary lac processing to rural entrepreneurs/lac grower.

• Establishment of primary processing units for making seedlac from sticklac at village level. Presently everything is done by industry.

• About 25 % of lac produced is likely to be processed in rural area enhancing the employment and net returns to the farmers.

• There is likely increase in the value of products by about 10 % and hence net return to lac processing industries.

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OutcomesTo reduce losses during processing, improve quality, develop suitable packaging for lac (shellac) and lac based products (bleached lac and aleuritic acid) for domestic and export markets.

Shellac

• Assessment of yield of shellac and economics of shellac manufacturing in existing process and machinery.

• Evaluation of quality parameters of shellac.

• Modification in the pressure system of existing shellac manufacturing process.

• Study on alternate filtration technique for shellac manufacturing.

• Standardization of measures and packaging materials to enhance shelf life of shellac.

• Cost / economic analysis of shellac manufacturing by modified/ improved method.

• Development/ Documentation of Good manufacturing processes.

• Improvement/refinement in present system of shellac manufacturing for enhanced recovery/ quality of shellac.

Bleached Lac

• Assessment of quality requirement of bleached lac for different application areas in Global market, price scenario, present and potential areas.

• Evaluation of quality parameters of bleached lac.

• Improvement in manufacturing process of bleached lac for improving its quality.

• Standardization of measures and packaging materials to enhance keeping quality of bleached lac.

• Improvement/refinement in the process/machinery for improving quality and quantity of bleached lac and enhancement in its keeping quality.

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OutcomesAleuritic Acid

• Assessment of quality requirement of aleuritic acid for different application areas in Global market, price scenario, present and potential areas.

• Evaluation of quality parameters of aleuritic acid produced in India.

• Improvement in yield of aleuritic acid and reduction in duration of preparation of aleuritic acid.

• Cost analysis of aleuritic acid.

• Development/ Documentation of Good manufacturing processes.

• Improvement/refinement in the process/machinery for improving quality and quantity of aleuritic acid.

To recover and purify the byproduct of lac industry (lac dye from wash water) for economic benefits.

Lac Dye

• Assessment of production potential of lac dye for possible use in dyeing and food industry.

• Evaluation of quality parameters like dye contents, presence of heavy metals.

• Improved Primary lac processing ( lac washing) technology and refinement in plant for enhance recovery of lac dye.

• Standardization of measures and packing materials to enhance shelf life of lac dye.

• Cost analysis, consumer preference evaluation and market testing of Natural lac dye.

• Development/ documentation of Good manufacturing processes.

• Improvement/renovation in plant for enhanced recovery and improved quality of lac dye with higher dye content.

• There is likely increase in the value of products by about 10 % and hence net return to lac processing industries.

• Establishment formal linkage among all stockholders for maintaining India’s leadership and competitive edge in International market.

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4. Background status of project based on baseline survey (Baseline Analysis) (Baseline data on the pre-project situation supported by tables, charts, photographs)

Ranchi and Khunti districts of Jharkhand were selected for the study as these are two leading lac producing districts in the state. Considering the lac host viz. kusum, palas and ber trees availability and lac host holding of lac growers one village in Ranchi district and four villages in Khunti district were selected purposively for the present study. The total sample size of village and lac growers was 5 and 60 respectively. The relevant information were collected from selected lac growers through a pre- tested questionnaire / schedule by survey method for the year 2007-08 and 2008-09.

4.1GeneralprofileAccess of facilities- Accesses to household needs were available in only four villages and the shops were very small and provides very limited items. In case of flour mill, this facility was available in three villages only. Basic health facilities viz. PHC and private clinic were not available in any of the surveyed villages. The public distribution system (PDS) was available for 4 villages. Access to both agro centre and veterinary clinic facilities were not available for all 5 villages. No cottage and small industries were found in the all 5 surveyed villages. Access to facility of Post Office was available for 3 villages within 2 km of area. The access to facility of PCO was available for 1 village. Primary cooperative society, veterinary services and financial facility were not available in any of the surveyed villages. The facilities which were not available in the villages, people have to travel nearby town or city.

Educational institutions- Out of five villages surveyed, four villages have primary education facilities. The other educational Institutes i.e. Secondary schools, Sr. Secondary schools, ITI, College were not available in the surveyed villages. Students travel 2 to 12 km for education above primary level as these institutions available in nearby area or town.

Transportation facilities - All the villages were not well connected by tar roads to approaching town and district head quarters for marketing of their produce. Marketing depends upon the crop which the farmers were cultivating. In case of lac, the harvesting and transportation was done by the farmers themselves. Generally stick lac was marketed in small quantity (2 to 10 Kg) in nearby “haats”. Farmer used bicycle or by walking approaches the haat. Broodlac was marketed in bulk quantity. The major means of transportation for broodlac was truck or tempo, while bullock cart were seldom used. In the case of marketing of cereals and vegetables, most of the farmers marketed their produce through middle man or wholesaler. Some of the farmers marketed their produce by using tractors, tempos or truck as a means of transport. In case of cereals and pulses, farmers market their produce either to the nearest local market or mandi located in the nearest town or district which ever was nearest from the village.

Family size and type of family- Family size of the surveyed respondents varied from 2 to 14 members. The farmers falling in group < 4, 5-9 and > 10 members were 40.0 percent, 53.3 per cent and 6.7 per cent respectively. In case of type of family 58.3 per cent families lived as joint and 41.7 per cent families as separate family.

4.2AgricultureandeconomicprofileLeasing system - Leasing system of land was prevailing in the study area and the rent was half of the total crop produce. This practice was followed in both the cases i.e. agricultural land and lac host plants.

Cropping pattern - There was wide variation in the cropping pattern depending on the climate, soil type and water availability. In the surveyed villages, during kharif, crops like paddy, maize, madua, brinjal,

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cluster bean, okra, gourds etc., were grown and that during rabi wheat, cauliflower, cabbage, chillies, tomato, potato etc., were being cultivated. Lac was used as cash crop and two crop of each strain i.e. rangeeni (baisakhi and katki) and kusmi (jethwi and aghani) are taken in a year.

Milk production- Jharkhand was poor state in production of milk. There were 52 per cent deficits of milk in relation to demand in the state. In the villages surveyed, the production of milk was also poor and very few farmers have milch animals and the whole produce was consumed in household requirements.

Irrigation - About 9 percent of the area in Jharkhand was irrigated. The state receives rainfall 1200-1600mm/ annum at rainfall. Winter season precipitation was meager and highly variable. The state has an average 130 rainy days in a year and on 75 days rainfall was below 2.5 mm. In 55 rainy days evaporation level was more than 2.5 mm per day. In the villages surveyed there are no source of irrigation like canal and tube-well. There were open dug wells but hardly used for irrigation purpose. Sometimes these wells were used to give life saving irrigation to vegetable crops. Agriculture in these villages was mostly rain-fed.

Farm Equipments and Machinery- The mechanization level in the surveyed village was very poor. The irrigation equipments (diesel engines) were available only in two villages. Wooden plough was used to a maximum extent as compared to iron plough. Iron plough was mainly used in heavy textured soils and wooden plough in light/ shallow soils.

Land Holding - Land holding of selected growers shows that 18.3 per cent have marginal holding (< 1 ha.) with average size 0.68 ha, 41.67 have small holding (1-2 ha.) with average size 1.52 ha and 40.0 per cent have large holding (> 2.0 ha) with average size 4.72 ha.

Family household incomes- With respect to information on different income source, there was wide variation in income considering only agriculture occupation of all the farmers. Agriculture was the main source of income for majority of the farmers. It ranged from less than Rs. 10.0 thousand to more than 30.0 thousands per annum. The income from animal husbandry and business was comparatively lesser in comparison to agricultural income. Around 6.7 per cent farmers have total income less than Rs. 12,000, 68.3 per cent have total income Rs. 12,001 to 20,000, 18.3 per cent have total income Rs. 20,001to 30,000 and only 6.7 per cent farmers have total annual income more than Rs. 30,000. In the study area around 55.0 farmers have no income from lac because of complete lac crop failure in the previous years. Around 30.0 per cent farmers have annual income from lac was up to Rs. 5,000. Around 3.3 per cent farmers have annual income from lac was more than Rs. 20,000. With respect to occupation, of the total 60 farmers surveyed, 17 were dependent only on agriculture while rest of the farmers have subsidiary source of income in addition to agriculture. Agriculture also include lac cultivation. 38 farmers families were engaged in both agriculture and animal husbandry. Families of 2 farmers were involved in all the three occupations i.e., agriculture + animal husbandry + business and three in agriculture + business (Table 4.1).

Table 4.1 Occupation of the farmers

Type of occupation No. of farmers Farmers (%)Agriculture 17 28.3Agriculture + Animal Husbandry 38 63.4Agriculture+Animal Husbandry+Business 2 3.3Agriculture + Business 3 5.0Agriculture + Service 0 0Total 60 100

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4.3LacprofileTools in lac cultivation- Majority of lac growers dauli, pruning knife, axe for lac cultivation operations (pruning and harvesting). Gatur sprayers were used by the farmers for spraying of insecticide and fungicide and used on group basis (generally group of 5 families used one sprayer). The lac cultivation related implements like tree prunner, phunki hook, scraping machine etc., were not in practice in the study area (Table 4.2).

Table 4.2 Lac cultivation tools availability with farmers

Implements Lac growers (%) Average numberTree prunner 0.00 0.00Secateur 80.00 1.31Dauli / pruning knife 91.66 2.03Axe 66.67 1.11

Lac host holding- Regarding availability of lac host trees with farmers, palas (Butea monosperma) and ber (Ziziphus mauritiana) trees were available with 100 per cent of the farmers, while kusum (Schleichera oleosa) host trees were available with 66.67 per cent of farmers. Regarding availability of palas trees for lac cultivation, 60.00 per cent lac growers have host holding less than 50 trees with average holding 16.5 trees. 26.67 per cent lac growers have host holding in the group 50-100 with average holding 66.25 trees (Table 4.3). Around 13.33 per cent lac growers have host holding more than 100 with average size holding 222.20 trees.

Regarding availability of ber trees for lac cultivation, 63.33 per cent lac growers have host holding less than 25 with average holding 12 trees. 26.67 per cent lac growers have host holding in the group 25-50 with average holding 32.67 trees. 10.00 per cent lac growers have host holding more than 50 with average size holding 102.30 trees. Regarding availability of kusum trees for lac cultivation 33.33 per cent lac growers have no kusum trees for lac cultivation. 40.00 per cent lac growers have host holding up to 5 with average holding 2.92 trees. 26.67 per cent lac growers have host holding in the group >5 with average holding 13.75 trees.

Table 4.3 Lac host holding according to different size of host holding

Host availability in number

Percentage of lac growers in different groupsPalas (Butea monosperma)

Ber (Ziziphus mauritiana)

Kusum (Schleichera oleosa)

<50 60.00 (16.50) 63.33 (12.00) 33.33 (00.00)50-100 26.67 (66.25) 26.67 (32.67) 40.00 (2.92)>100 13.33 (222.20) 10.00 (102.30) 26.67 (13.75)

Figures in parentheses are average number of host holding

Utilization of lac host trees- The utilization of host trees for lac cultivation in the study area were 4.34 per cent for palas, 41.36 per cent for ber and 22.41 per cent for kusum. The utilization of host for rangeeni lac cultivation in the area was very less. The utilization of palas host was very less due to continuous rangeeni lac insect mortality in the area. Majority of ber and all kusum trees were used for kusmi lac cultivation. There was greater scope for increasing lac production by utilizing more hosts for lac cultivation. The reasons for

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low utilization of hosts were shortage of fund for purchase of broodlac, uncertainty in production, height of hosts, scattered host plant, high cost of broodlac and difficulty in management of large scale hosts.

Lac production status –The rangeeni lac production on palas tree in the study area was meager due to continuous rangeeni lac crop failure. Majority of production in the study area comes from ber and kusum. Lac production from ber constitutes 81.20 per cent of total production while kusum constitutes 18.10 per cent in total production. Farmers of the study area were more interested in production of broodlac as it was more profitable than sticklac production. Per tree production of broodlac from palas, ber and kusum was 3.0, 14.3 and 24.76 kg. respectively.

Adoption of technologies- As regards to adoption of improved techniques in lac cultivation, majority of lac growers had adopted improved lac cultivation techniques. More than 75 per cent farmers have adopted pruning of lac hosts, selection of good quality broodlac, broodlac bundling and tagging on plant, spray of insecticide and pesticide. About 50 per cent farmers have adopted coup farmers have adopted broodlac treatment and use of synthetic net. In the study area no farmers has planted lac hosts for the purpose of lac cultivation. Lac cultivation is done on naturally occurring host trees.

Cleaning, grading, processing and disposal- In case of lac crop, farmers try to sell the broodlac as such. In case when it was not sold on proper time, they scrap the lac from its stick and sell in the local market. Scraped lac was cleaned and graded as per the impurities getting added during harvesting and scraping. Regarding processing no farmer was involved even in the processing that can be done at village level.

4.4 Key indicators and their baseline levels of sample respondents from project area Lac production

As this project involves only lac and lac based value added products, the baseline levels of key indicators with special reference to lac cultivation are given here for Ranchi-Khunti area.

Key indicators Unit Baseline status Remarks

Lac productionLac production in the target districts TonsRanchi 380 2008-09Khunti 495 2008-09Lac production in target villages TonsRanchi 8.9 Broodlac productionKhunti - Crop failure in previous yearAverage broodlac production per tree KgPalas 3.00Kusum 24.76Ber 14.30Utilization of host trees for lac cultivation %Palas 4.34 Due to crop failure, there was shortage

of broodlac. Hence, less utilization

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Kusum 22.41Ber 41.36Input-Output ratio of broodlacPalas 0.47Kusum 4.9Ber 4.2Adoption of lac cultivation techniques in target areaAdoption of coupe system % 50.0Pruning of lac host % 83.0Selection of good quality Broodlac % 80.0Broodlac treatment % 8.33Bundling of Broodlac and tagging on plant % 95.0Phunki removal % 96.7Spraying of insecticide % 75.0Use of synthetic net % 5.0Spray of fungicide % 75.0Lac cultivation on plantation basisArea under lac host plantations Ha Nil

Lac processing and by product recovery

Seedlac, and shellac are basic products of lac, whereas, bleached lac and aleuritic acid are value added products from lac and lac dye is by-products of commercial importance. The baseline levels of key indicators are given below for based on data collected from lac processing units in Ranchi and Khunti districts.

Key indicators Unit Baseline status Remarks

Lac processingQuantity of sticklac processed in Ranchi-Khunti area in 2007-08 Tons

4,800Primary lac processing at village levelSeedlac production Tons 0.00SeedlacYield/recovery from sticklac % 50-60ShellacYield/ recovery from seedlac % 80-83Quality parameters

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- Flow mm 40-50- Life minutes 35-40Bleached lacYield/ recovery from seedlac % 80Quality parameters- Flow mm 6-10- Acid value - 80-85- Colour Colour

index 1-5

Drying period at 300C hours 24-36Storage life month 6Selling price (export quality) Rs./kg 225-250Aleuritic acidYield/ recovery from seedlac % 12-14 No firm making pure aleuritic acid Melting point 0C 95-97Purity % 98Selling price Rs./kg 1000Lac dyeYield/ recovery from wash water (by weight of sticklac) % 0.1-0.15 Firm manufacturing lac dye for

dyeing of wool & silk.Dye content % 20-50Ash content % 2-3Selling price Rs/kg (600-1000)

4.5 Rationaleoftheprojectandlikelybenefits,Diagramofexistingvaluechainand proposed value chainLac is the natural resin of insect origin and is commercially very important as a versatile raw material for various purposes viz. paint & varnishes, cosmetic, adhesive, pharmaceutical, perfumes, food, leather, electrical industries. Besides versatility, shellac possesses other merits i.e. it is natural, non-toxic and eco- friendly. India, Indonesia and Thailand are the main areas in the world where lac is cultivated. About 75% of Indian Lac comes from the States of Jharkhand and Chhattisgarh. Lac cultivation is one of the traditional occupations of the tribal communities of this area. Even today more than 80 % of lac growers are tribal, and most of the lac growing families in Jharkhand are among the poorest in the state. Many of the blocks where lac is cultivated in significant scale are among the most backward in the state in terms of infrastructure, poverty level, literacy levels etc.

One of the major problems of this sector in the recent past has been the instability in production and prices of lac. Despite good unrealized demand for lac (both domestic as well as overseas), the lac production growth had not been very healthy. Just 2-3 years back Jharkhand was the leading producer (> 55% of

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national production) of the lac. However, recently, lac production has shown a declining trend in the state. Experts in this field say that the Indian lac industry is totally dependent on the export market and the uncertainty of production leading to the uncertainty of prices make foreign buyers wary to enter. Many of the lac processing units are not able to sustain themselves in this situation. This has led to lack of interest among the poor traditional lac growing tribal families to take up lac cultivation and the production has come down drastically in the recent past.

Besides West Singhbhum, Gumla, Simdega, Latehar, Palamau and Garhwa districts, Ranchi and Khunti districts of Jharkhand are the major lac producing areas. In these areas the principal host plants for the lac cultivation are palas (Butea monosperma), kusum (Schleichera oleosa) and ber (Ziziphus mauritiana). Most of these host plants are in the forest area and are scattered over large areas making farm activities difficult and non-productive. Rapid deforestation in the lac catchment area due to various developmental activities in village vicinity is also affecting lac production. Soil of the area is mainly lateritic, which is low in soil organic matter, nitrogen and phosphorus. Due to undulating topography, high runoff is the characteristic feature of the area. These constraints have made the region agriculturally backward. On the other hand, Jharkhand has 29.7% land under forest cover. So, also the region has considerable amount of forest cover. Lac host like palas is distributed all through the region while kusum trees are concentrated in certain pockets. Ber trees are mainly concentrated in the village areas. Considerable amount of income can be generated if the resources are tapped properly. Farm income can be enhanced considerably, if high value enterprise like lac is integrated to general agriculture. Such system can ensure production of food grains for food in one hand and inflow of money in the other hand. Lac host like F. semialata and ber can be suitably integrated in such system. Due to inadequate planning of lac cultivation or crop failure, seed material (broodlac) becomes scarce as a result of which lac cultivation is discontinued. Lac cultivation through coupe method can assure broodlac to the farmers throughout the year.

This scenario is coupled with the low level of penetration of the training, capacity building and extension efforts on improved technology for lac production by the various promoting institutions engaged in this sub-sector i.e. NGOs, resource institutions and the State Government agencies. One needs to appreciate and understand that without intervention to stabilize the production, prices cannot be stabilizing. Simply intervening in the market through procurement and other methods of price administration are not sufficient. Thus, to bring in a stability to the entire sub-sector, stabilization of production through intervention in technology availability with the community coupled with backward (brood lac producers) and forward linkages (community based lac procurement agents) would be the key. This endeavor will require convergence of efforts for resource institution (IINRG), grassroots action organization (NGOs/CBOs) and the lac processing units.

This process of manufacturing shellac involves Filter press, Hydraulic pumps (low pressure & high pressure), Shellac sheeting rollers and Boiler for steam heating. There is also need for study on alternate method of filtration (like the method used in plastic part manufacturing) which will help in further development of machine more compact with higher efficiency and better quality of product because the present old indegeneous process of making shellac by bhatta process (hand made process) which is practiced at cottage industry level is diminishing slowly due to unavailability of skilled worker and associated health hazard and non availability of its charcoal fuel and mechanized method using filter press is bulky and requires boiler for which capital investment is high.

Bleached lac or white lac forms the major share of world’s consumption of lac. Nearly half of the world output of lac is estimated to be converted into bleached lac. The product is thus of considerable commercial importance. It is mainly used in surface coating industry and pharmaceutical industry. In surface coating application, it is used for polishing of wooden items as it provides transparent films on wooden surface.

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Bleached lac, in view of its poor keeping qualities in dry state, is sometimes, marketed in forms of hanks, particularly when it is intended for use in aqueous varnishes or emulsions. Bleached lac is also sold as a coarse white powder. Major issue related to bleached lac is its poor keeping quality. When produced in powder form its life is not more than 6 months and after this it’s solubility in alcohol decreases which is not desired. The problem is more serious in hot climate.

Other reasons associated with this are improper removal of used chemicals like sodium hypochlorite for bleaching and acid for precipitation of bleached solution of lac. Even small traces of these compound deteriorate life of the product. There is ample scope for refinement in the process of making Bleached lac. There is a need to address issues i.e. improvement in quality of this product prepared from lac for improving its keeping quality (for storing longer period), to develop suitable packaging for long distance transit and to determine optimum storage condition requirements. Realizing the benefits and scope of improved bleached lac with higher storability research, development, and extension efforts are needed. As the success and sustainability of any product demands acceptance in the market, profitable marketing and commercialization need focused strategies

Aleuritic acid is isolated from lac resin by saponification and several separation and filtration steps. Aleuritic acid is mainly used in the perfumery industry, as a starting material for the preparation of “musk” aroma compounds as well as medicinal and bioactive compounds. Foreign consumers, in recent years are also preferring to import value-added lac-based products in order to reduce production/processing costs in their country. Under this changed scenario, many lac processors of our country are showing growing interest in manufacturing value added products from lac, and they insist for appropriate technologies of manufacturing of these products. The Institute has technology of isolation of aleuritic acid through laboratory scale demonstrations, where a yield of around 17-18% of the weight of seedlac can be obtained. However, the manufacturers at present are able to recover only around 12-13% of it, resulting in less profit margin. Sometimes the quality of the products is not upto the standards and not acceptable to foreign buyers. Hence, some basic researches on improvement in process and machineries are required so as to increase the yield and purity and to reduce the duration and cost of production.

Lac dye, a by-product of lac industry, is generally lost in the effluent during washing of sticklac in primary processing of lac. Lac dye is used in textile as mordant dye for dyeing animal fibres like wool and silk. Since it is non-toxic, it is also being used as food colouring material. It is reported that Japan, China and Thailand are using pure lac dye for colouring beverages and products like ham, sausages, bears, jams etc. The present consumption of pure grade lac dye in Japan is reported to the tune of 5-6 tones per year. So, this natural dye has also immense potential for food application besides dying of wool and silk. India, at present, produces about 20,000 tonnes of lac annually. Considering the amount of production, nearly 200 tonnes of lac dye is lost in effluents during washing. Thus, an enormous potential exists for recovery of the dye as by-product of lac industry. Even if half of the potential is exploited, it will be possible to turn trade of lac dye into highly profitable business, as an export item with an assured foreign market. Moreover there has been an upsurge in demand for such natural dye for colouring food items.

The IINRG has developed a standardized process for the recovery of technical grade lac dye from wash water obtained during washing of sticklac and its purification. Recently, a pilot plant has been developed and installed in IINRG that can produce upto 2 kg of technical lac dye from the wash water. The recovery of this dye has received little attention, restricting to only by few lac industries of lower dye content (below 50%). Such type of dye is used only for dyeing purpose and due to lower dye content, this fetches lower price (Rs. 500-600/kg.) in the market. The condition of preparation of this dye in lac industries results in presence of heavy metals (Fe, Pb, As etc.) which restricts its use for further purification for making it food colouring material. There is a need to increase dye content (above 50%) and improve machineries for

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production of lac dye with permissible limit of heavy metals so that it can fetch higher prices (Rs. 2500-3000/kg). Attention on such by products is required to promote large scale production.

Diagram of existing value chain and proposed value chainIn the beginning of project lac value chain consisted of lac growers, lac traders, lac primary and secondary processors, exporters and consumers within the country and abroad. IINRG, Ranchi didn’t had direct role in the value chain. It helped lac grower’s in training on scientific method of lac cultivation and lac industry in solving their problem as and when required. After the intervention of project IINRG, Ranchi played role as one of the important link in the value chain at different levels. The value chain at the beginning of project, intervention of project and new value chain and value chain analysis are presented below.

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Lac Value Chain Analysis Sustainability

Horizontal expansion of scientific lac cultivation

Horizontal expansion of lac cultivation on plantation basis

Horizontal expansion of progressive lac growers involvement in broodlac production

Horizontal expansion of primary processing of lac at village level

Continuing the recovery of by-product by lac industry

Continuing linkages developed among farmers, processors & markets

Continuing training of lac growers and rural youth

Impact

Jharkhand regained its number one position in lac production (Production > 4000 tons per year)

Adoption of lac cultivation on plantation basis (>50 Ha) In Khunti project of Rs. 61.88 lakhs sanctioned

Broodlac production in Ranchi and Khunti districts has increased (>1000 tons annually meeting requirement)

> 50 Small scale lac processing units established (with installed capacity 1500 tons per year)

Industry started production of improved quality lac dye fetching higher price (> Rs. 2500/kg)

Assured market

Better return

Increase in lac productivity, increase in income of lac growers and employment generation for rural youth at village level

Outcome

Adoption of kusmi lac cultivation on ber using scientific method lac production in Ranchi & Khunti districts > 4000 tons mark against average 2000 tons at the time of start of project

Model lac host plantation of F. semialata and ber for lac cultivation on plantation basis established by 83 beneficiaries in 63 villages of Ranchi & Khunti

1100 lac growers were trained on scientific lac cultivation including quality broodlac production.

Established Model Lac Processing unit for training and demonstration4 lac handicraft making Demonstration-cum-production centres established

Improvement in lac dye recovery unit by one industry in Ranchi district

Lac growers liked with lac processors/exporters for marketing of their produce

>1100 lac growers trained on scientific lac cultivation

>1000 beneficiaries trained on primary processing of lac and

> 300 rural youth trained for making lac handicrafts

Interventions

Promotion of high yielding kusmi lac cultivation on existing lac host (ber)Training on scientific lac cultivation to farmer

Promotion of lac cultivation on F. semialata and ber on plantation basis

Training on quality broodlac production to lac growers

Promotion of lac processing at village level Training on lac processing Promotion of making lac handicraft

Promotion of process for recovery of improved quality lac dye

Lac growers were liked with the lac processors/exporters

Training imparted on scientific lac cultivation, processing and handicraft making

Reasons

Traditional method of lac cultivation Lac insect mortality

Lac cultivation on scattered lac host

Lack of knowledge on quality broodlac production

No value addition at village/ lac growers level

Lack of awareness on by-product utilization

Unorganized marketing

Lack of awareness and training

Issues

Low productivityLow Production

Difficulty in management of scattered lac host

Inadequate and inferior quality of beedlac (lac seed)

Low price of produce

Non-utilization of by product

Poor market access

Lack of trained human resource in lac production and processing

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5. Research Achievements5.1 Lac Production

5.1.1 Promotion of high yielding kusmi lac cultivation on existing host treesLac cultivation is an age old practice for the farmers of Jharkhand. Earlier, farmers used to collect lac, growing naturally on lac host trees. Later they started lac cultivation on trees available in their field or field bunds following traditional practices. New interventions like use of quality broodlac, pesticides and new hosts can increase lac yield and thereby total income of farmers significantly. Usually farmers use ber trees for cultivation of immature rangeeni lac in summer season. This practice is not remunerative, as lac yield is very less due to sparse settlement of rangeeni lac on the branches (Fig. 5.1). Productivity of resin per unit length from rangeeni lac is almost half than that of kusmi lac (Fig. 5.2). Further, broodlac production is not possible from summer season rangeeni lac. As a result farmers fail to get good price due to their inability to produce rangeeni broodlac. Profitability can be increased, if same ber tree is used for kusmi lac production, as market price of the same is higher than that of rangeeni lac.

Fig. 5.1 Typical encrustation of rangeeni lac with sparse encrustation

Fig. 5.2 Typical encrustation of kusmi lac with dense encrustation

Ber is a unique tree which can host both the strains of lac insects i.e. rangeeni and kusmi. However, IINRG recommends cultivation of kusmi lac in winter season instead of rangeeni lac in summer season. Normally kusum trees due to its dense canopy are less suitable for winter season lac cultivation. Therefore, kusum trees are recommended for brood production in summer season. Ber trees are abundant in rural areas and can be used successfully for kusmi broodlac production in winter season (Fig. 5.3).

Sometimes, lac crop fails due to different reasons. Lac cultivation using scientific approaches nullifies the causes of lac failure. The project aimed in (i) facilitating the farmers to produce good quality broodlac, so that they can produce their own requirement for the next season and (ii) motivating farmers to develop lac host plantation of ber and F. semialata. Following measures were taken for promotion of kusmi lac cultivation on ber and kusum trees.

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Fig. 5.3 Lac crop on Ziziphus mauritiana (ber)

(a)Identificationofpotentialfarmers

Farmers are the key component in lac production system. Success in achieving the objective depends mostly on choosing able and interested farmers. For choosing such farmers, help of five NGOs was taken. A total of 994 farmers from 48 villages were selected by the local NGOs and progressive farmers during the project duration. 365 farmers were from 27 villages of Ranchi district whereas 629 farmers were from 21 villages of Khunti district. During early phase of the project, aim was to cater limited number of villages for demonstration. As a result, benefit of the project remained confined to very limited pockets. In contrary, the later phase of the project (since 2011) concentrated in dissemination of technologies in more number of villages. Therefore numbers of beneficiaries in a village were limited, but number of villages was higher.

(b) Capacity building

Residential and On Farm Training programmes organized

A total of 264 lac growers obtained one week residential training on scientific lac cultivation against the target of one hundred (Table 5.1) & 840 farmers participated in one day “On Farm Training” programme (Fig. 5.4), against the target of five hundred (Table 5.2). The farmers belong to 14 villages of Ranchi & Khunti districts. A workshop at village-Lupungdih in Khunti district was also conducted for progressive farmers which in turn disseminated technology of scientific lac cultivation in their adjoining villages passively (Fig. 5.5).

Table 5.1 One Week Training Programme on Scientific Method of Lac Cultivation organized

Sl. No. Duration Venue No. of

Participants Name of the Villages

1. 12.10.2009 to 16.09.2010 IINRG, Namkum, Ranchi 59

Mangubandh, Digri, Lupungdih, Mile buru, Bara Salga, Saparum, Bhusru, School Salga, Barka Silda, Rui Tola, Rai, Ghaghra Bera, Kajibaru, Nawadih

2. 29.12.2009 to 02.01.2010 -do- 423. 10.10.2011 to 16.102011 -do- 314. 06.02.2012 to 10.02.2012 -do- 425. 13.02.2012 to 18.02.2012 -do- 266. 12.08.2013 to 17.08.2013 -do- 347. 26.08.2013 to 31.08.2013 -do- 30

Total 264

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Table 5.2 On Farm Training Programme organized

Sl. No. Year No. of

Villages Name of the Villages No. of Trainees

1. 2009 02 Mangubandh (Ranchi) and Siyankel (Khunti) 108

2. 2010 05 Lupungdih, Barka Silda, Bara Salga, School Salga (Khunti), Mangubandh (Ranchi) 277

3. 2011 03 Rai, Rui Tola, Bhusru (Khunti) 1984. 2012 04 Barudih, Tangerkel, Namsili (Khunti) and Gutidih (Ranchi) 1805. 2013 02 Banta and Kajibaru (Ranchi) 646. 2014 01 Jurdag (Karra, Khunti) 13

Total 17 840

Fig. 5.4 On Farm Training at village level

Fig. 5.5 NAIP workshop at village-Lupungdih, Khunti

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Media production for mass communication

Two short video films in Hindi entitled (i) semialata poudha ka bagan taiar karna avam vaigyanik vidhi se lakh ki kheti and (ii) ber poudha ka bagan taiar karna avam vaigyanik vidhi se lakh ki kheti were prepared for easy transfer of technologies among farmers and were released for transmission at different levels. Two video films on success stories in Hindi entitled (i) safalata ki kahani – Shri Prakash Sanga (Village-Mangubandh, Ranchi) and (ii) safalta ki kahani—Shri Joydev Mahato (Village-Putidih, West Bengal) in CD form were also prepared under the project. These films have been provided to the Transfer of Technology Division of the Institute for showing in regular training programmes. Besides, NGOs like R. K. Mission, Ranchi; Udyogni, Khunti and researcher of Annamalai University, Annamalai, Chennai are using these films for better understanding and dissemination of technology.

Leaflet/folder publication and distribution

Lac growers who were not able access the facility of visual media were taken care of by publishing three leaflet/folders & distributing these among them. A document on ITKs related to lac cultivation customs and beliefs was published for the benefit of lac growers. Following publications were published for this purpose.

Ghosal S and N Prasad. 2013. Raising of lac host (ber and F. semialata) plantation and modern technique of lac cultivation (Extension folder). IINRG, Ranchi.

Ghosal S, Prasad N and Pal G. 2013. Flemingia semialata ka bagan lagana wa lakh ki kheti (Extension folder in Hindi). IINRG, Ranchi.

Ghosal S and Prasad N. 2013. Indigenous Technical Knowledge, Custom, and Belief Prevailing in Lac Production System in Jharkhand (Extension folder). IINRG, Ranchi.

One-to-one contact

Scientists associated with the project interacted individually during on-farm training programme in different villages of the project areas. During interaction, problems of the farmers were addressed with latest scientific knowledge in lac cultivation. Thus they could know the technical know-how of all basic operations of the lac cultivation viz. pruning, inoculation, phunki (used up brood lac) removal, spraying, harvesting etc. They shared their experiences in terms of problems they faced and got their solution by the scientists.

Continuous motivation

The lac growers were continuously motivated by reminding them about the operations which required attention on urgent basis. Regular visits and on-farm trainings were conducted. All associated farmers were pursued periodically by telephone, field visit and on-farm training to maintain their interest in lac cultivation. Otherwise, it was observed, that they did not pay adequate attention to lac as compared to their main agricultural crop, for which they were acquainted with. This resulted into motivation of the farmers and ultimately they became engaged themselves in lac cultivation and thereby enhanced their income from lac.

(c) Promotion of Kusmi lac cultivation on ber

Traditionally lac growers used to do Rangeeni lac cultivation on ber trees available on their field or bunds following traditional methods. But lac yield level used to be less. Non availability of broodlac due to frequent mortality of lac crop used to be a regular phenomenon. Hence, there used to be break in continuous lac cultivation. Farmers were finding difficulty in purchasing broodlac at the time of inoculation when they faced scarcity of broodlac with them. The ups and downs in the production were due to low productivity and high mortality rate over the years. Farmers were unaware about scientific lac cultivation and other proper operations and lac cultivation was vulnerable to vagaries of weather conditions to a great extent.

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In the villages of project catchment area of Ranchi and Khunti districts, lac production before the commencement of the project was negligible for last four to five years. They were abandoning lac cultivation gradually. It was the time when project intervened to revive lac cultivation for enhancing lac production and livelihood of the farmers. The lac production data from 2005-2013 of Ranchi and Khunti districts are presented in Table 5.3.

Table 5.3 Lac production from 2005-06 to 20012-13 in Ranchi and Khunti district

Year Lac Production (in tons) Ranchi and Khunti

Lac Production (in tons) India

2005-06 2484 180002006-07 2900 232292007-08 2280 206402008-09 875 171752009-10 980 164952010-11 1230 90352011-12 4250 179002012-13 4250 19577

The lac production data shown in Table 5.3 above indicated that production in the year 2008-09 dipped to minimum level in Ranchi and Khunti districts. By the intervention of project activity farmers got motivated and started taking interest in lac cultivation again due to high yield and better return. Some of the farmers, who had left lac cultivation years ago, restarted lac cultivation after commencement of the project. They are now benefited and satisfied by re-starting lac cultivation with main agricultural crops.

Under the project, from the month June- July, 2009 till June-July, 2013 a total of 5160 kg broodlac was distributed among 994 lac growers in 48 villages of Ranchi & Khunti districts in the targeted project area of Jharkhand. Seven lac growing seasons were covered in this period and about 2861 lac host trees (Kusum & Ber) were inoculated. A total of 13621.7 kg broodlac was harvested in different harvesting seasons. The details in season wise and year wise production data with other details are given below (Table 5.4).

With the efforts put together for increasing lac production, there had been a quantum jump in the lac production scenario of the project area. In the beginning, a target of 30 percent increase in the lac production was proposed in the project proposal. Against the targeted level of 30 percent, in the project area, lac production increased by 333 percent compared to its base value (2009-10). If the corresponding figures of all India production are compared, then 18 percent increase in production level was achieved in 2012-13 as compared to base year (2009-10). Thus, effort of NAIP (lac value chain) proved to be highly effective in bringing a change in lac production scenario in the area. For achieving success in this venture, following measures were taken.

Providing inputs to the farmers at their door steps

Farmers were provided inputs to their door steps for shifting them from rangeeni strain to kusmi strain lac cultivation on ber (Fig. 5.6). This intervention revived lac in the catchment area of the project. Farmers re-started lac cultivation with kusmi strain on ber and found very good result in terms of low mortality & high yield. For promotion of kusmi strain on ber, they were provided all initial inputs i.e. quality broodlac, pesticide/fungicides and spraying machine (in groups).

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Fig. 5.6 Distribution of broodlac at farmers’ door steps

From the commencement of the project in the year 2009 till the last phase i.e in the month July 2013, 5160 kg broodlac was distributed in both the districts (Table 5.4).

Table 5.4 Broodlac distribution and yield

Sl. No.

WinterRanchi Khunti

2010 2011 2012 2013 2014 2010 2011 2012 2013 2014 Total

1.Broodlac

distributed (in kg)

382 203 300 500 440 600 00 750 400 475 4050

2. No. of villages 1 4 8 7 5 7 7 15 14 21 89

3. No. of farmers 32 25 53 99 59 60 32 258 95 88 801

4. No. of tree inoculated 128 163 261 166 584 234 226 523 278 503 3066

5. Broodlac production 558 1609 1840 1907 - 109 532 2300 220 - 9075

6. Yield ratio 1.46 7.92 6.13 3.81 - 0.18 - 3.06 0.55 -

Sl. No.

SummerRanchi Khunti

2010 2011 2012 2013 2014 2010 2011 2012 2013* 2014 Total

1.Broodlac

distributed (in kg)

85 94 150 26 - 305 156 100 24 -

2. No. of villages 1 5 6 4 - 3 8 5 4 -

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3. No. of farmers 31 39 21 06 - 29 42 20 05 -

4. No. of tree inoculated 49 43 25 09 - 65 98 48 10 -

5. Broodlac production 222 2503 358 90.7 - 279 895 21 178 - 4546.7

6. Yield ratio 2.61 2.38 3.48 - 0. 91 5.73 0.21 7.41 -

Making awareness of lac cultivation among farmers

The farmers were hard to convince for lac cultivation over main agricultural crops. Therefore, they were made aware of economic benefit from lac cultivation, through training, demonstration and exposure visits. In the beginning few farmers got associated with the project, but gradually the number increased to more than 900 (Table 5.5).

Table 5.5 Number of farmers involved in the project in two different districts

Ranchi KhuntiYear 2009 2010 2011 2012 2013 2009 2010 2011 2012 2013

No. of farmers 32 56 92 120 65 60 61 300 115 93No. of farmers (cumulative)

32 88 180 300 365 60 121 421 536 629

Summer crop on kusum

For maintaining continuous cycle of lac production, broodlac should be produced successfully round the year in both the seasons. Ber and F. semialata does not support well, summer season kusmi lac production. Therefore, for maintaining the crop cycle, some amount of broodlac was also provided for inoculation on kusum tree. This intervention proved to be very successful in spreading kusmi lac cultivation technique.

(d) Success story

Farmers associated with the project learned lac cultivation and contributed substantially in total production of the area (Table 5.6). They have been trained to produce broodlac required for them for each season by their own, thus they are managing supply chain effectively.

The ratio of output and input obtained from each season of lac cultivation during 2009-2013 from the targeted area of Ranchi and Khunti district under the project are presented in Fig. 5.7 & 5.8.

Table 5.6 Lac Production by beneficiaries farmers in project area

Sl. No. YearProduction (Kg)

Summer Winter1. 2009 - 5102. 2010 660 30343. 2011 3398 4041.84. 2012 581 21175. 2013 268.75 --

Total 4907.75 9702.8

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Fig. 5.7 Winter season lac yield performance of Khunti and Ranchi districts

Fig. 5.8 Summer season lac yield performance of Khunti and Ranchi districts

The variations in year wise output/input ratio obtained are due to the different climatic conditions in different crop seasons. Some farmers did not care the crop during peak operational period, because they were involved in main agricultural crop and it was very hard to shift them to lac cultivation. Now a days, the farmers involved even once in the programme, learned basics of lac cultivation and doing better of their own. In general, lac yield in summer season was higher than winter season. The primary cause behind the fact was biotic factors, which acted intensively in favour of lac mortality during winter season particularly in rainy and post rainy season. Average lac yield ratio (output/ input ratio) of Khunti and Ranchi districts were 3.01 and 3.43 respectively. Farmers of Ranchi district were more aware of lac cultivation; therefore, they remained more consistent in lac production and yield ratios were in the range 2.38 to 5.24 during

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summer lac production. Range for Khunti district for the same season was much higher i.e. 0.21 to 7.41. Average lac yield ratio of Ranchi district was always higher than that of Khunti district in winter season.

Lac yield ratio figures indicated that values went on increasing throughout the period (2009 to 2013) except a decrease in 2012, where summer season lac production suffered a setback due to poor quality of broodlac. Lac production in the project area has increased several fold during the period under study. Lac production of both the districts (Ranchi and Khunti) had declined to 875 tons at the start of the project i.e. 2008-09. The production has reached to 4250 tons during 2012-13. Intervention of NAIP has played a significant role in increasing lac production in project area.

(e) Technologies offered for Kusmi broodlac production on Ber (Ziziphus mauritiana)

• Pruning of more than five year old ber tree in February-March

• Inoculation of broodlac (i.e. lac seed) @ 20g per meter shoot length in June-July

• Removal of phunki (used up broodlac) 21 days after inoculation (DAI)

• Follow spraying schedules

• 1st spray endosulfan @ 0.05% and carbendazim 0.01% at 30 days after inoculation.

• 2nd spray of dichlorvos @ 0.03% and carbendazim 0.01% at 60 DAI

• 3rd spray of dichlorvos @ 0.03% and carbendazim 0.01% at 90 DAI if needed

5.1.2 Promotion of intensive lac cultivation on plantation basisThe farmers of the project area were doing lac cultivation since their ancestral time, but it was initially collection of naturally occurring lac on host trees available in field or forests. Later they shifted to lac cultivation on host available in their field or field bund. Scattered distribution of hosts is an important problem in existing lac cultivation system, for which theft of lac used to be common phenomena. Realizing the problems of farmers, a new concept “systematic lac cultivation on plantation basis” was introduced. This concept was conceived after identification of economically viable bushy lac host plant, Flemingia semialata, more commonly known as semialata. Not only plantation of F. semialata (Fig. 5.9), but also that of Ziziphus mauritiana (ber) was raised for easy management and monitoring of the lac crop.

Fig. 5.9 Lac crop on F. semialata

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(a) Reason for inclusion of ber and semialata

There are more than 400 lac host trees/plants reported, but all are not economically viable for lac cultivation. Kusum, palas, ber and F. semialata are traditionally important lac hosts. Kusum and palas take a long time (10-15 years) to grow and become ready for lac cultivation; therefore, hosts with relatively short gestation period i.e. ber and F. semialata were promoted for lac cultivation on plantation basis. F. Semialata is a bushy lac host and can be inoculated for lac cultivation, one year after transplanting, while ber trees, if taken proper care for raising in respect of soil fertility and water management can become ready for lac inoculation in 4-5 years. Besides, there is wide scope of taking inter-cultivation with vegetables in the field of F. semialata. Thus, F. semialata plants extends an added advantage to the farmers to cultivate lac wherever and whenever they like. Besides, it can host summer season lac cultivation under irrigated condition. Raising plantation in scientific method enables farmers to manage its canopy (specifically for ber) in suitable shape in one hand and keep a better watch to the plantation on other. Both are needed for increased profitability.

Initially farmers showed interest and planted seedlings of F. semialata and ber with all enthusiasms but most of the farmers did not care of their plantation in the first year. Therefore, they could not succeed in raising plantation.

Farmers faced heavy seedlings mortality due to indifference in raising plantation. Initially they had belief of sure income but later they became involved in their regular activities of main crops. They did not take care of their plantation; even they did not prepare their field for planting seedlings i.e. digging of pits, fencing, fertilization etc.

For establishing plantation under the project, progressive farmers form project area were selected with the help of NGO partner associated with the project. The selected farmers were trained for raising lac host plantation. Only those farmers were provided input for raising plantation who had prepared their field and arranged for fencing and irrigation. They were provided F. semialata and ber seedlings to raise plantation. The details of seedlings distribution are presented in Table 5.7. But even after rigorous exercise and continuous follow up, most of the farmers could not establish plantation for lac production. It was tried to find out reasons of such poor performance. It was found that full involvement of farmers in the activity was not there. After identification of this problem, some criteria were developed for the selection of farmers and found that the rate of success improved substantially (Table 5.8). The criteria were as follow:

• Fencing of the proposed plot.

• Arrangement of water source for irrigation.

• Digging up of pit for transplantation of seedlings.

Table 5.7 F. semialata and ber seedling distribution during 2009 to 2013 under NAIP sub-Project on “Lac Value Chain”

Sl. No. Year No. of ber seedlings

No. of semialata seedlings

No. of beneficiaries

No. of villages

1. 2009 1250 9000 07 032. 2010 150 1500 03 033. 2011 530 11350 14 134. 2012 730 7900 18 14

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5. 2013 3715 16100 41 30 Total 6375 45850 83 63

Table 5.8 Success of raising lac host plantation of F. semialata & ber

YearNo. of seedlings distributed No. of seedlings established

Ber F. semialata Ber F. semialata2009 1250 9000 78 (6%) 2000 (22%)2010 150 1500 22 (14%) 500 (33%)2011 530 11350 180 (33%) 2700 (23%)2012 730 7900 110 (15%) 4000 (50%)2013 3715 16100 3230 (86.94%) 11000 (68%)

After introduction of the said criteria the rate of success improved gradually and more number of successful plantation could be established.

Farmers were offered following technologies before transplanting seedlings in the field.

(b) Technologies offered for raising plantation

Raising ber plantation

• Maintaining a plant geometry of 4.5 m x 4.0 m.

• Digging up of pits 45 cm x 45 cm x 45 cm dimensions in the month of May/June at the advent of first shower.

• Application of Karanj cake of 500g or 10 Kg FYM along with 100g of N, 170g P2O5 and 80g K2O per plant.

• Making of rings around the seeding for capturing rain water.

• Polythene mulching for better establishment in summer.

Raising F. semialata plantation

• Maintaining a plant geometry: Paired row system to facilitate intercropping. 75 cm within paired row and 180 cm between two paired rows; plant to plant distance in rows kept 1.00 m.

• Digging up of pits 30 cm x 30 cm x 30 cm dimensions in the month of May/June at the advent of first shower (Fig. 5.10).

• Application of Karanj cake of 200g per plant.

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Fig. 5.10 Field preparation for transplantation of F. semialata seedlings

(c ) Lac cultivation on raised plantation

The plantation of ber was raised by Mr. Prakash Sanga of village Mangubandh, Block- Namkum, Ranchi during 2009 which became ready for lac cultivation in 2013 and he raised first lac crop during July 2013-Feb 2014 (Fig. 5.11). The farmer after establishing the said plantation successfully started raising seedlings of F. semialata and ber by their own and motivating other farmers to go for such plantation (Fig.5.12).

Fig. 5.11 Plantation of ber

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Fig. 5.12 F. semialata seedlings raised by farmer

Seven successful farmers started lac cultivation on raised F. semialata plantation (Fig. 5.13) and getting good return in terms of yield. Details of the successful plantations are presented in the Table 5.9.

Fig. 5.13 Plantation of F. semialata

Table 5.9 Details of F. semialata plantations raised

Sl. No. Name of the farmer Village No. of

seedlings Remark

1. Mr. Barnabas Nag Lupungdih 1700 Raised 3 crops successfully2. Mr. Anil Mahto Kudri 600 Raised 2 crops successfully3. Mr. Champa Toppo Hurua 1000 Raised 2 crops successfully4. Mr. Surender Nag Tangerkela 1700 Raised 2 crops successfully5. R. K. Mission Getalsud 1200 Raised 2 crops successfully6. Mr. Ramesh Kumhar Banta 1000 Raised 1 crop successfully7. Mr. Magan Singh Munda Kajibaru 400 Raised 1 crop successfully

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(d) Seed production

Few farmers collected seed from F. semialata plants and sold. They earned handsome return. Farmers who are unable to do lac cultivation, may go for seed production and earn some return. R. K. Mission, Getalsud; Mr. Champa Toppo, Hurua; Mr. Prakash Sanga, Mangubandh; and Mr. Surendra Nag, Tangarkela have started work in this direction.

(e) Success story

Most of the beneficiary farmers of the project started lac cultivation after a gap of three to four years with the intervention of project. Few of them did excellent in lac cultivation and became popular. Mr. Barnabas Nag (Lupungdih, Khunti), Mr. Surender Nag (Tangarkela, Rania), Mr. Anil Mahto (Kudri, Torpa), R. K. Mission (Getalsud, Ranchi), Mr. Prakash Sanga (Mangubandh), Mr. Jagan Nag (Barasalga, Khunti), Mr. Champa Toppo (Hurwa, Ranchi), Mr. Ramesh Chandra Kumhar (Banta, Silli) started making handsome income from lac cultivation on plantation basis. Many farmers have come forward and established lac hosts plantations for lac cultivation after observing success of their fellow farmers.

One ber plantation has just come in innoculable stage at Mangubandh, Ranchi. The farmers have expressed their deep sense of gratitude to the NAIP for extending relevant technologies and inputs for quick raising of lac host plantations. Mr. Barnabas Nag from Lupungdih village in Khunti district has trained farmers of near by Gibri village, where F. semialata plantation of more than 3500 plants has been established. Farmers of the village also got themselves engaged in lac cultivation.

5.1.3 Indigenous technological knowledge Farmers involved in lac cultivation have some indigenous knowledge which helps them in carrying out lac cultivation operations were compiled and listed below.

• Characteristics of good lac yielding kusum tree.

• Protection of plantation from grazing animals.

• Use of live posts for making fences.

• Novel lac cultivation methodology on kusum trees.

• Characteristics of a good lac yielding ber trees.

• Broodlac cutting instrument devised by the farmers.

• Snake moults strung on ber trees protects the lac crop from rats and squirrels.

A booklet was published in which the above indigenous technological knowledge, custom and belief in lac cultivation have been compiled.

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5.2 Processing and Value Addition

5.2.1 Primary processing of lac After harvesting from trees, lac is in the form of lac stick. Traditionally, lac is scraped from the sticks, then it is ready to sale in form of sticklac. The sticklac is raw material for lac industries. Lac growers sell sticklac immediately after scraping it, at low prices due to associated storage problems and in need of immediate cash. Proper storage of sticklac requires large space with adequate ventilation. Such facility is not available in lac grower’s houses. If sticklac is stored in bags, it forms lump which is difficult to crush during processing. Further lump formation leads to deterioration in quality of lac. The sticklac converted into seedlac can be stored like grains in bags or bins. During baseline survey, it was found that there is lack of primary processing units at village level. This was identified as main hurdle for lack of knowledge of farmers about processing of lac and lac products. No value addition is being done at farmer’s level.

Establishment of model small scale lac processing unit for training, demonstration and entrepreneurship developmentTo create awareness of lac processing at village level through learning by doing, the need was felt to establish small scale lac processing unit at institute. Keeping this in view a lecture cum demonstration of Small Scale Lac Processing Unit (Capacity – 100 kg/day) was included in the regular training activity of the institute under scientific lac cultivation and improved method of utilization. To fulfill the aim of promotion of primary lac processing at village level, two sets (motor and manually operated) of small scale lac processing units were installed at Institute Research Farm (IRF) of the institute (Fig. 5.14 and 5.15) comprising of Lac crusher, Lac washer, Lac grader and Lac winnower.

Fig. 5.14 Small Scale Lac Processing Unit Fig. 5.15 Lac Processing Unit Machines

Training on primary lac processing to rural entrepreneurs/lac grower

Generally, lac growers/rural entrepreneurs scrap the lac incrustation from lac stick using specially devised scraping knife before selling. Manual process of removing lac incrustation is tedious, labour intensive and time consuming. Lac growers generally sell scraped lac at low price as scraped lac contains about 25-30% impurities. To remove the impurity before selling and fetching higher price in market, training on process and machinery of primary lac processing to rural entrepreneurs/lac growers was imparted on these two model units installed at IRF, IINRG during the project duration.

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Training on primary lac processing under sub-project

Two nos. of Model lac processing units (both manual & power operated) of Capacity-100kg sticklac/day were installed in IRF, IINRG to impart training and demonstration to farmers/beneficiaries of the targeted Ranchi and Khunti districts under this project. A total nos. of 31 farmers/beneficiaries of these areas were trained for developing skill of primary lac processing in 2 batches (15 farmers and 16 farmers respectively), so that they can add value in their produce through primary processing of lac in these catchment areas.

Training on primary lac processing under institute regular training programme

The installed units were continuously used to impart training and demonstration to farmers/beneficiaries under regular training programme of the institute and entrepreneurship development (Fig. 5.16 and 5.17). A total number of about 3130 farmers/beneficiaries were imparted training on Small Scale Lac Processing Unit during 2011–2014 out of which 880 farmers were attended training in the year 2011, 971 number of farmers in 2012, 1172 number of farmers in 2013 and 107 number of farmers in the year 2014, respectively. The details of training imparted to farmers/beneficiaries for promotion of primary lac processing at village level under regular training programme of the institute are presented in Table 5.11.

Table 5.11 Year wise details of training imparted to farmers/beneficiaries on Small Scale Lac Processing Unit (100 kg/day)

Year No. of participants State

2011 880 Odisha, Jharkhand, Chhattisgarh and Maharastra 2012 971 Odisha, Jharkhand, Maharastra, Chhattisgarh, West Bengal

and Madhya Pradesh2013 1172 Jharkhand, Chhattisgarh and Karnataka2014 107 Andhra Pradesh and Jharkhand Total 3130

In similar context, training was also imparted to B. Sc. (Ag.) students of Agricultural University, Uttar Pradesh (331 Nos.), M. Sc. (Ag.) Students of Agricultural University, Chhattisgarh (15 Nos.), master trainer of West Bengal and Chhattisgarh (112 Nos.), subject matter specialist and progressive farmers of West Bengal (38 Nos.) and entrepreneurs under regular training programme of the institute during 2011-14.

Fig. 5.16 Demonstration at small scale lac processing unit Fig. 5.17 Training programme on lac processing

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The technology of Small Scale Lac Processing Unit (Capacity–100 kg/day) developed at IINRG, Ranchi was licensed to M/s National Enterprises, Hatia, Ranchi and M/s Small Industries Service Organization (SISO), Nagpur. About 50 units of Small Scale Lac Processing Unit have been sold by these firms in Chhattisgarh, Madhya Pradesh, Uttar Pradesh, Gujarat, Maharashtra, Jharkhand, Orissa, and Bihar. As a result of organizing frequent training programmes and demonstration on established unit under NAIP Sub Project on “Lac Value Chain” in the institute to visitors, further demand of unit increased and M/s. National Enterprises, Hatia, Ranchi was able to sell 25 more units during NAIP-Project period 2009-12 out of total 50 nos. sold by the firm since it started production 7 years back. Combined together, these units can process about 1500 tons of lac per year, which is about 10% of the total lac production in the country.

5.2.2 Study on yield, quality, economics and process of making shellacStudies were undertaken for determining yield, quality, economics and process of making shellac. For this, different shellac manufacturing units were surveyed for determining yield and quality of shellac samples of existing process and evaluated from ISO Certified Quality Evaluation Laboratory(QEL), IINRG, Ranchi to know the status of shellac manufacturing. In existing methods of shellac manufacturing, two methods are popular i.e. earthen oven method at cottage industry level and hot filtration method using steam heated press and sheeting rollers at industry level. Although earthen oven method require very less initial investment, but involves cumbersome process, which causes drudgery for workers. On the other hand second method requires heavy initial investment and large space, as costly equipment like boiler, steam heated press, sheeting roller etc. are needed. Therefore, study on alternate filtration of lac was also carried out for developing suitable compact small unit for cottage industry, which may be up scaled for commercial production of shellac.

Assessment of yield, economics and quality parameters of shellac made from existing process

Assessment of quality requirement of lac products was carried out by survey and discussion with lac processors and exporters. On the basis of survey of lac processing units, yield of shellac in existing process was found to be 80-83% by wt. of seedlac and processing cost for machine made shellac was Rs.10-15/kg and for hand made shellac Rs. 18-20/kg by wt. of shellac.

Seven lac processing industries in Jharkhand, MP and Chattisgarh were surveyed and five shellac samples from different lac industries of Shakti & Kathgora (Chattisgarh), Khunti & Bundu (Jharkhand) and Balrampur (W.B.), were collected and evaluated for determining quality of shellac. Important quality parameters of shellac thus observed are given below.

Quality: Flow-14-49 mm, Life-15-36 min, Impurities-1-2%)

5.2.3StudyonalternatefiltrationtechniqueforshellacmanufacturingTrial for hot filtration of seedlac was carried out in extruder used in plastic industry at a commercial unit of M/s Samriddhi Enterprise, Keshav Nagar, Kumartoli, Ranchi (Fig. 5.18). During trial excess fluidity of melted lac was observed. Problem of softening of lac was also encountered at hopper section (feeding point) of extruder which resulted in non feeding of seedlac with passage of time and further filtration was stopped. Problem may be due to reason that lac has softening temperature 40-500C and melting above 700C, whereas plastic has only melting temperature above 700C. The study suggested that improvement in design of barrel is needed for filtration of lac for making shellac using extruder. Quality of seedlac and lac filtered using extruder evaluated from QEL, IINRG, Ranchi and presented in Table 5.12.

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Fig. 5.18 Study on alternate filtration of manufacturing shellac

Table 5.12 Quality of seedlac and lac filtered using extruder evaluated from QEL, IINRG, Ranchi

Material Life (min) Flow (mm) Impurity (%) ColourRaw material (Seedlac) used in extruder

63 72 2.80 8

Filtered lac obtained from extruder 57 77 2.36 10 off shed

5.2.4 Study on quality requirement, economics and improvement in bleached lacStudies were carried out for determining quality requirement, economics and improvement in bleached lac making. Different bleached lac manufacturing units were surveyed and quality of bleached lac samples of existing process were evaluated from QEL, IINRG, Ranchi to know the status of bleached lac manufacturing. The quality requirement of bleached lac for domestic and export market were enquired through discussion with manufacturer and exporter and testing bleached lac samples.

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Assessment of quality requirement of bleached lac and evaluation of quality parameters of bleached lac produced using existing method

Assessment of quality requirement of bleached lac was carried out by studies, survey and discussion with lac processors and exporters. The yield of bleached lac was found to be 80-82% by wt. of seedlac and processing cost was Rs. 65/kg by wt. of bleached lac. Important quality parameters for domestic and export markets were wax content (below 0.5% for refined), low hot alcohol insolubility and acid value (80-85).

Five bleached lac samples from lac industries in Dhamtari & Shakti (Chattisgarh) and Khunti (Jharkhand) were collected and evaluated for determining existing quality parameters of bleached lac. Important parameters of bleached lac thus observed are given below.

(Wax-0.20-0.25%, Life-0-15 min, Impurities-0.24-1.28% , Colour Index ˂ 1)

Bleached lac manufacturing industries informed that bleached lac manufactured using, existing made has shelf life of only 6 month, if stored in cold storage condition. Industries expressed the need for improving shelf life of bleached lac. Considering the feedback received from the industries, study was conducted to find out the reasons for shorter shelf life of bleached lac. The study indicated that main reason for shorter life of bleached lac was mainly due to the presence of residual chlorine in the bleached lac.

To address this problem further studies were conducted to identify improved bleaching agent for making bleached lac with higher shelf life. Based on the study, improved bleaching agent i.e. combination of Hydrogen peroxide and Sodium hypo-chlorite was identified, which improved the quality of bleached lac and resulted in improvement in its shelf life.

Improvement in manufacturing process of bleached lac for improving its quality

To validate the results obtained from studies carried out in laboratory, up-scaling trial of bleached lac preparation on pilot plant scale with alternate bleaching agent (Hydrogen peroxide and Sodium hypo-chloride) was carried out in Pilot Plant of Product Demonstration Unit (PDU), IINRG, Ranchi with 5 kg batch. One control sample was also prepared as per commercial process for comparison. Evaluation of quality parameters of both type of samples (Fig. 5.19) from Quality Evaluation Laboratory, IINRG, Ranchi indicated improvement in quality using mixture of sodium hypo-chlorite and hydrogen peroxide as bleaching agent over sodium hypo-chlorite alone (Table 5.13 & Table 5.14).

Fig. 5.19 Bleached lac prepared using alternate bleaching agent

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Table 5.13 Quality parameters of commercial, control and test samples

Test Parameters Commercial Sample Control Sample Test

Sample 1Test

Sample 2Test

Sample 3

Flow in mm 7 16 35 15 30

Life in minutes 3 7 13 17 17

Colour 1.2 0.4

A portion insoluble

1.5 1.6 1.8

Impurity % 0.4 0.5 A.P.I 0.22 0.32 0.32

Moisture % 1.085 1.72 1.43 1.29 1.41

Wax % 0.25 0.58 A.P.I 0.38 0.45 0.50

Acid Value 82.6 85.4 A.P.I 82.6 78 76

Table 5.14 Quality parameters of bleached lac prepared using conventional and improved bleaching agent

Method of Making Bleached Lac

Life (min)

Flow (mm)

Moisture (%)

Hot Alcohol Insoluble (%) Colour Acid

Value

Seedlac + NaOCl + H2O2

Initial 17 30 1.41 0.32 1.8 76After 6 months 15 18 1.84 0.45 1.8 70

Seedlac + NaOCl (conventional)

Initial 7 16 1.72 0.5 0.4 85.4After 6 months Nil Nil 1.75 4.0 0.4 55

Cost/economic analysis of bleached lac manufacturing

Cost analysis of bleached lac preparation with improved bleaching agent was done and found that there was not much difference in processing cost in comparison to conventional method. There was marginal increase (10-15%) in bleaching cost compared to conventional bleaching. By establishing unit for manufacturing bleached lac of 50 Kg/day (a minimal feasible capacity), one can earn net monthly profit of Rs. 50,000 to 60,000.

Commercial trials of bleached lac manufacturing with improved process

To judge the feasibility of manufacturing bleached lac at commercial level using improved bleaching agent, first trial in batch of 60 kg seedlac was carried out at bleached lac manufacturing unit of M/s Tajna Shellac, Khunti consortium partner in this project (Fig. 5.20). The yield of bleached lac was 80%.

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Fig. 5.20 Photographs of commercial trial at M/s Tajna Shellac Pvt. Ltd., Khunti

Quality parameter evaluation of samples of 1st Commercial trial for the preparation of bleached lac using modified method of bleaching was conducted at M/s Tajna Shellac, Khunti after 3, 6, 9 & 12 month of storage at ambient condition are given below (Table 5.15).

Table 5.15 Quality parameters of bleached lac manufactured using improved bleaching agent in commercial trial

Method of Making Bleached Lac

Life (min)

Flow (mm)

Moisture (%)

Impurity (%) Colour Acid

Value

Seedlac + Hypo + H2O2 Initial 37 42 3.0 1.4 - 86.1 After 3 months 37 42 - 1.4 1.3 86.1 After 6 months 35 35 - 1.4 1.3 87.6 After 9 months 32 29 - 1.6 1.3 88.4 After 12 months 32 29 - 1.8 1.4 88.7

Second commercial trial of technology was also carried out at M/s Tajna Shellac Pvt. Ltd., Khunti successfully. One confirmatory trial was also done successfully at M/s Gupta Brothers (Shellac), Bundu for this technology.

5.2.5 Study on quality requirement, economics and improvement in yield of aleuritic acidStudies were carried out for determining quality requirement, economics and improvement in yield of aleuritic acid. For this aleuritic acid manufacturing units were surveyed and samples of aleuritic acid were collected for quality evaluation. Quality of aleuritic acid samples collected from industries were evaluated from QEL, IINRG, Ranchi to know the quality. The quality requirement of aleuritic acid for domestic and export market were enquired through discussion with manufacturer and exporter and testing of samples.

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Assessment of quality requirement of aleuritic acid and evaluation of quality parameters

Assessment of quality requirement of aleuritic acid was carried out by survey and discussion with lac processors and exporters. The yield of aleuritic acid was reported to be 12-14% by wt. of seedlac and processing cost was Rs. 150/kg by wt. of aleuritic acid. It is an export commodity and quality requirements in export market are melting point above 960C, purity-98% and it should be white in colour.

In beginning, two samples of aleuritic acid from industries were collected and evaluated. Melting point was found as 94˚C and 96oC & Purity-96%. Low yield of aleuritic acid was major concern expressed by the industry and desired that further work need to be carried out for improvement in yield. Considering the feedback received from the industries, research work was carried out.

Improvement in manufacturing process of aleuritic acid

Process of making aleuritic acid was improved (filtration and saponification) which increased yield from 12-14 to 18% and melting point (94-96˚C) as compared to method followed in the industry. The up-scaling trials of developed process was carried out in pilot-plant at IINRG, Ranchi and yield of minimum 18% were obtained.

Cost/economic analysis of aleuritic acid manufacturing

Cost-economic analysis for commercial production of 25 kg/day capacity aleuritic acid was calculated. The processing cost of aleuritic acid was estimated to be Rs. 300/kg. Aleuritic acid presently fetching above Rs. 2,000/kg in the market. By establishing aleuritic acid manufacturing unit of capacity 25 kg/day (single shift), a minimal feasible capacity, net monthly profit of Rs. 75,000/- can be earned.

Commercial trials of aleuritic acid manufacturing of improved yield

To validate the results of up scale trial carried out in pilot plant at IINRG, Ranchi, three commercial trials of aleuritic acid were carried out following improved process successfully with 25kg seedlac batch and 10 days hydrolysis at the industries of consortium partners of project (Fig. 5.21 & 5.22).

• M/s Tajna Shellac, Khunti- 01 nos.

• M/s Gupta Brothers, Bundu- 02 nos.

• Yield in these trials were above 18% by seedlac weight.

Fig. 5.21 Commercial trial of making aleuritic acid at M/s Tajna Shellac, Khunti

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Fig. 5.22 Commercial trial of making aleuritic acid at M/s Gupta Brothers (Shellac), Bundu

5.2.6 Packaging study for enhancing shelf life of shellac and bleached lac Packaging study was carried out for standardization of measures and packaging materials for enhancing shelf life of bleached lac and shellac. For the study freshly prepared samples of bleached lac and shellac were stored in 5 different packaging materials along with control (open condition) and evaluated at quarterly interval of 3 months from QEL, IINRG, Ranchi. Colour parameters (L, a, b) were also measured with Hunter Lab Colorimeter to see any change in colour of samples.

Packaging trials of bleached lac

Under storage study, 60 samples of freshly prepared bleached lac (Fig. 5.23) were packed in 5 different packaging materials (LDPE, HDPE, PP, Paper bag & Aluminum coated polythene) & stored in ambient and refrigerated condition (14 to 15oC). The initial moisture content, flow and life of samples before packaging were 5.5%, 55 mm and 10 min respectively.

After 3 months of storage of samples without any packaging material, flow and life was lowest in case of samples stored in ambient condition compared with samples stored in refrigerated condition (flow & life – Nil & 3 minute for ambient, 22mm & 6 minute for refrigerated respectively). Where as these parameters were highest in aluminum coated polythene (flow & life – 10 mm & 5 min for ambient, 35mm & 10 min for refrigerated respectively), which was mainly due to higher moisture retaining capacity in aluminum coated polythene bag (4.12 & 5.5 %) compared to 1.01 & 1.23% moisture in open condition without any packaging material after 3 month of storage.

After 6 months of storage of samples in ambient, there was no difference in flow & life ( 0 mm & 2 min.) of samples stored in different packaging materials and open condition. However, for samples stored in refrigerated condition flow and life was least in open condition without packaging (flow & life - Nil & 3 minute). Where as these parameters were highest in aluminum coated polythene (flow & life - 25 mm & 5 min).

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Fig. 5.23 Bleached packed in different packaging materials

From this study it has been found that packaging in aluminium coated polythene gives better keeping quality in comparison to other method due to higher moisture retaining capacity over period of time.

Packaging trials of shellac

Experiments were also carried out for storage study of shellac using different packaging materials (HDPE, LDPE, PP, Aluminium coated polythene, Paper bags) and storage at ambient as well as controlled condition of temperature/humidity in order to standardize the storage method for enhancing shelf-life of the products. Freshly prepared kusumi shellac samples (Fig. 5.24) were packed in different packaging materials viz. LDPE (200 & 400 gauge), HDPE (200 gauge), Polypropylene (200 gauge), Aluminium foil laminate and Paper bag and stored in ambient and refrigerated conditions for evaluation.

Fig. 5.24 Shellac packed in different packaging materials

Further study was made on different quality parameters i.e. Moisture content, Flow, Life, Impurity and Acid value were determined from QEL, IINRG Ranchi, on quartely basis. The colour parameters (L, a, b) were also studied using Hunter Lab Colourimeter. The results obtained till six month of storage indicated no appreciable effect of packaging materials on quality of shellac. Thus study suggested for use of cheapest material among above these for packaging of shellac.

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5.2.7 Development/ documentation of good manufacturing processes/practices of lac based products

Good Manufacturing Practices (GMP) for lac based products seedlac, shellac, bleached lac and aleuritic acid were prepared (Fig. 5.25). The GMP contains details related to principles of good manufacturing practices, personnel, documentation practices, premises, equipments, materials handling, packaging practices, quality control, sanitation, hygiene and waste disposal, shipping, recalls & returns, self inspection & quality audits, complain etc.

Fig. 5.25 GMP of lac based products

5.3 By-products Value Addition

5.3.1 Study on recovery and improving quality of by-product of lac industry lac dyeStudies were undertaken for estimating production potential, economics of recovery and process of manufacturing. For this different lac dye manufacturing units were surveyed and lac dye samples recovered from existing process were collected and evaluated from QEL, IINRG, Ranchi to know the quality.

Assessment of production potential of lac dye for possible use in dyeing and food industry

On review of survey data and information, it was found that the production potential for lac dye is very high as only few lac processing industry in India, manufacture good quality lac dye. Considering 20,000 tons annual production of sticklac in the country, there is potential of producing 50,000 kg lac dye (average yield-0.25% by wt. of sticklac). There is also good scope for the export of lac dye to other countries. Enormous potential exists for recovery of the dye as by-product of lac industry. Lac dye is non toxic. Use of proper chemicals and process in lac dye recovery with proper material of construction (M.O.C.) of plant, gives bright red lac dye of improved quality for dyeing purpose. It also meets the limit of lead, arsenic and heavy metal making it suitable for its further use in its purified form as food additive.

Evaluation of quality parameters like dye contents and presence of heavy metals.

Commercial samples of lac dye collected from M/s Tajna shellac, Khunti and M/s Gupta Brothers (shellac), Bundu were evaluated at QEL, IINRG, Ranchi. The evaluation report revealed that dye sample contained maximum 30% dye content. These samples were also evaluated at CFTRI, Mysore to determine presence of heavy metals, lead (Pb), arsenic (As) etc. for determining their suitability for conversion into pure lac dye for use as food additive. The evaluation findings are presented in Table 5.16, which are within safe permissible limit as food additive for colouring.

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Table 5.16 Evaluation data of lac dye samples

Sl. No. Particulars

ResultTest Method

1 2

1. Lead, mg/Kg 0.76 1.32 AOAC 18th Edn. 2005,999.11

2. Iron, mg/Kg 358 249 AOAC 18th Edn. 2005,985.35

3. Arsenic, mg/Kg Below detection limit of 0.02 AOAC 18th Edn. 2005,912.01

4. Nickel, mg/Kg 0.51 1.66 AOAC 18th Edn. 2005,975.34

Improvedprimary lacprocessing (lacwashing) technologyandrefinement inplant for enhancedrecovery of lac dye

Work on lac washing was carried out for improvement in recovery of lac dye with use of minimum quantity of water. Twelve washing trials were carried out in repeated batch washing (5-6 batches) with fixed quantity of water (5, 10, 15 litres) in each batch.

Dye samples were recovered separately for each batch washing trials. Results indicated that maximum recovery of lac dye (Fig. 5.26 & 27) was from first batch and wash water requirement was less (5-6 times by wt. of stick lac). However, in traditional continuous washing, water requirement was 10-12 litres per kg sticklac.

Fig. 5.26 Filtered cake of lac dye Fig. 5.27 Lac dye recovered from different lots

Improvement/refinementincommercialunitoflacdyeandcommercialproductionThe technology for recovery of lac dye of improved quality was introduced at M/s Gupta Brothers (Shellac), Bundu and industry was suggested to modify dye recovery unit. The industry agreed to the suggestion and carried out modification/ improvement in wash water collection unit, pipelines, filtration system, pumps etc. of lac dye plant (Fig. 5.28).

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Modification of wash water collection tank

Overhead tank for filtration

Installation of filter press

Modified wash water collection tank in use

Softener installed in the unit

Fig. 5.28 Modification /improvement in lac dye plant at M/s Gupta Brothers (shellac), Bundu

After modification/refinement firm started making lac dye using the modified lac dye plant and producing on an average 200 kg lac dye per year and getting price of Rs. 2,500/kg. Thus M/s Gupta Brothers (shellac), Bundu is earning Rs. 5 lakhs per year from sale of lac dye. The intervention improved dye quality and product was preferred in the market and sold easily. The technology of recovery of lac dye of improved quality is now adopted by M/s Gupta Brother’s (Shellac), Bundu.

5.3.2 Cost/economic analysis of lac dye productionCost-economic analysis for commercial production of 2 kg per day capacity lac dye plant was calculated. The processing cost of lac dye is Rs 900-1,000/kg. Whereas good quality lac dye fetches higher price above Rs. 2,500/kg in domestic market. By setting this unit of capacity 2 kg/day (single shift), a minimal feasible capacity, net monthly profit of Rs. 40,000/- can be earned from this by-product.

5.3.3 Packaging study for standardization of measures to enhance shelf life of lac dyeExperiments were carried out for storage study of lac dye using different packaging materials (HDPE, LDPE, PP, Aluminium coated polythene, Paper bags) and storage in ambient condition (Fig. 5.29). Freshly prepared lac dye was purchased and its initial quality parameters were measured. Lac dye samples were than packed in different packaging materials viz LDPE (200 & 400 gauge), HDPE (200 gauge), polypropylene (200 gauge), aluminium foil laminate and paper bag and stored in ambient conditions for evaluation.

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Fig. 5.29 Lac dye packed in different packaging materials

The quality parameters i.e. dye content and color were determined at 3 months interval for one year from Quality Evaluation Laboratory, IINRG, Ranchi. The results obtained indicated no appreciable difference in quality parameters for lac dye samples stored in different packaging material. Thus cheapest packaging material i.e. LDPE was recommended for storing lac dye.

5.3.4 Development of good manufacturing processes/practices Good Manufacturing Practices (GMP) for lac dye was prepared (Fig. 5.30). The GMP contains details related to principles of good manufacturing practices, personnel, documentation practices, premises, equipments, materials handling, packaging practices, quality control, Sanitation, hygiene and waste disposal, shipping, recalls & returns, self inspection & quality audits, complain etc.

Fig. 5.30 GMP of lac dye

5.4 Lac Handicraft To promote lac handicraft making at village level in the project BRIAT, Allahabad was associated as consortium partner. BRIAT, Allahabad trained the rural youth from project area on lac handicraft making and established four training-cum-production centres in these area. The aim of establishing training-cum-production centres (Fig. 5.31) and training rural youth as master trainers was to develop facility and manpower for training large number of rural youth in making lac handicraft and ultimately increasing their income through employment generation.

53


5.4.1 Establishment of lac handicraft making units for training and demonstration• 20 persons were trained to become as master trainers for making lac handicrafts by BRIAT, Allahabad.

They were later engaged in training beneficiaries at training-cum-production centre established at Khunti (in Khunti district) and Banaburu, Sodha and Kataribagan (in Ranchi district) and they trained 175 beneficiaries.

• 40 trained beneficiaries were engaged for making lac handicrafts (Fig. 5.32) at four established training-cum-production centers and they produced handicraft of value Rs. 4.86 lakhs during April, 2013 to August, 2013.

Fig. 5.31 Lac handicraft making at Training-cum-production centre

Fig. 5.32 Lac handicrafts made at Training-cum-production centre

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6. Innovations (NAIP interventions)Under this project six innovations were introduced through NAIP interventions. The details and impacts of these innovations are described below :

6.1 Kusmi Lac Cultivation on Ber (Ziziphus mauritiana)In general practice, rangeeni and kusmi strains of lac were inoculated on palas and kusum trees respectively. Whereas ber is common host for both the strains of lac insects. Although, kusmi strain can be reared on ber, but it is not in practice by farmers. Farmers traditionally rear rangeeni lac insect on ber. By the intervention of Institute’s technology, the farmers have started rearing kusmi strain on ber (Fig. 6.1) and getting very good result.

Farmers are now expanding lac cultivation on existing ber trees as well as by establishing ber plantation for lac cultivation.

Fig. 6.1 Kusmi lac on ber (Ziziphus mauritiana)

Impact of Innovation/technology

• Adopting the technology of high yielding lac insect (Kusmi) cultivation on ber and kusum trees, all the families (36 nos.) of Village – Mangubandh in Ranchi district have started lac cultivation and in the January – February, 2011, they harvested very good lac crop. Apart from inoculating their own lac host trees, they have sold more than 2500 kg of broodlac (lac seed) @ Rs. 250 per kg in Jharkhand and Chhattisgarh.

• About 795 lac growers of 43 villages started kusmi lac cultivation on ber.

• Many lac growers are earning even more than one lakh rupees per year from lac cultivation.

• Farmers of nearby villages have also started kusmi lac cultivation on ber. Earlier farmers used to cultivate rangeeni lac insect on ber, which is more prone to crop failure and less yield (Broodlac yield ratio- about 1:2). In several areas, lac growers have discontinued rangeeni lac cultivation on ber due to frequent crop failure. Kusmi lac is less prone to crop failure which is due to moisture stress, pest and diseases and crop yield is more (broodlac yield ratio- about 1:4).

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6.2 Establishment of F. semialata Plantation & Ber Plantation (Ziziphus mauritiana) for Lac Cultivation on Plantation BasisFlemingia semialata and ber are very promising lac host plant for kusmi lac cultivation on plantation basis (Fig. 6.2 & 6.3). On an average 4-5 times crop as input and output ratio is harvested. These hosts can be established on plantation basis for better management compared with traditional lac hosts i.e. kusum and palas.

Fig. 6.2 Plantation of ber Fig. 6.3 Plantation of F. semialata


The technology have been adopted by farmers and more than 50 Ha plantation of Flemingia semialata and ber have been raised in Ranchi & Khunti districts. Khunti district administration has sanctioned a project of Rs. 61.88 lakhs for promotion of lac after observing the success of NAIP Sub-project on Lac Value Chain.

6.3 Small Scale Lac Processing UnitA Small Scale Lac Processing Unit (100 kg sticklac/day) was established at Institute Research Farm, IINRG, as Model demonstration unit (Fig.6.4). The unit is being used for training and demonstration of farmers under this project and institute regular training programme for promotion of primary processing of lac at village level. The unit consists of four machines viz. Lac Crusher, Lac Washer, Lac Grader and Lac Winnower for different unit operations like crushing, washing, grading and winnowing respectively. These machines can be driven manually or with electric motor. The unit can be established in production catchment area for value addition at farmer’s or cottage industry level.

Fig.6.4 Small scale lac processing unit

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Due to impact of training programme and demonstration of unit to visitors, there was further demand of units. As a result M/s National Enterprises, Hatia, Ranchi and M/s SISO, Nagpur who has taken license for production and sale of unit, have sold 25 more units during NAIP-Project period 2009-13, out of total 50 sold by these firms since 2006. Combined together, these units can process about 1500 tons of lac per year, which is about 10% of the total lac production in the country.

Techno-economic feasibility of Innovation/technology

Lac grower sell stick lac immediately after scraping at throw away price due to problem associated in storage of sticklac. The proper storage of sticklac requires large space having proper ventilation. Such facility is not available in lac growers’ houses. If sticklac is stored in bags then it forms lump which is difficult to crush in lac processing. Further lump formation leads to deterioration in quality of lac. By setting small lac processing units ( Capacity-100 kg sticklac /day) for processing raw lac at village level (may be on cooperative basis, if not possible on individual basis), the lac farmers can supply the material directly to industry avoiding middlemen. The processed lac i.e. seedlac can be stored for longer period and gives more return due to value addition. With seedlac the lac growers can become more self-dependent for negotiating price of lac/seedlac with traders, financially stronger and also to make lac cultivation more remunerative. If processing unit remains functional for six months in a year, about 750 man-day/year employment can generated by setting such units. By setting up such units net profit of about Rs. 25,000 per month can be earned/generated. For establishing such lac processing unit about 0.2 hectare of land will be required for each unit. The seedlac has still a good market. The production potential for this product is high, as there is demand in overseas market also.

Basic requirements/inputs to start business with technology

Financial investment ( Capacity- 100 kg/day)

Plant and Machineries - Rs. 1.50 lakhs

Fixed capital (including civil ) - Rs. 6.50 lakhs

Working capital for 3 months - Rs. 8.00 lakhs

Total capital investment - Rs.14.50 lakhs

6.4 Recovery of Lac Dye of Improved QualityLac dye (laccaic acid), a by-product of lac industry, is generally lost in the effluent during washing of sticklac in primary processing of lac. In the process of lac dye recovery (Fig. 6.5, 6.6 & 6.7), sticklac wash water is acidified with mineral acid and the supernatant clear liquor is further processed to recover lac dye in Ca-salt form which on further acidification, crystallization, filtration, washing and drying yields bright red colour lac dye (Fig. 6.8). The yield of this dye is 0.17-0.30% (by wt. of sticklac). Use of proper chemicals and process with proper material of construction (M.O.C.) of plant, gives bright red lac dye of improved quality. The lac dye thus obtained can be used for dyeing of animal fibres like wool and silk. As lac dye is non-toxic and meets the limit of lead, arsenic and heavy metal, it is suitable for use in its purified form as food additive.

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Fig. 6.5 Decanted liquid Fig. 6.6 Ca-salt of lac dye Fig. 6.7 Crystallization unit

Fig. 6.8 Bright red colour lac dye


The technology for recovery of lac dye of improved quality was introduced to M/s Gupta Brothers (Shellac), Bundu. The farm has now adopted the technology. The intervention improved dye quality and product was preferred in the market and sold easily. After modification/refinement firm started making lac dye using the modified lac dye plant and producing on an average 200 kg lac dye per year and getting price of Rs. 2,500/kg. Thus M/s Gupta Brothers (shellac), Bundu is earning Rs. 5 lakhs per year from sale of lac dye.


Lac dye (laccaic acid), a by-product of lac industry, is generally lost in the effluent during washing of sticklac in primary processing of lac. In this, sticklac wash water is acidified with mineral acid and the supernatant clear liquor is further processed to recover lac dye in Ca-salt form which on further acidification, crystallization, filtration, washing and drying yields bright red colour lac dye. The yield of this dye is 0.17-0.30% (by wt. of stickdlac). The production potential for the product is very high as only few lac processing industry in India, manufacture good quality lac dye. Considering 20,000 Tons annual production of sticklac in the country, there is potential of producing 50,000 kg lac dye (average yield-0.25% by wt. of sticklac). There is also good scope for the export of lac dye to other countries. Enormous potential exists for recovery of the dye as by-product of lac industry.

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Since non-toxic, so use of proper chemical and process with proper material of construction (M.O.C.) of plant gives bright red lac dye of improved quality for dyeing purpose and also meeting the limit of lead, arsenic and heavy metal making it suitable for its further use in its purification for food additive. The processing cost of lac dye is Rs 800-900/kg. Whereas good quality lac dye fetches higher price above Rs. 2,000/kg in domestic market. By setting this unit of capacity 2 kg/day (single shift), net monthly profit of Rs. 40,000/- can be earned.






Total capital investment - Rs. 22.80 lakhs

6.5 Improved Bleaching Agent for Bleached Lac ManufactureThe process uses improved bleaching agent, which gives bleached lac of higher flow (fluidity) and life (heat polymerization time) compared to conventional bleaching agent sodium hypo-chloride. The alkaline solution of lac is bleached with improved bleaching agent, acid precipitated, washed and dried to get bleached lac of higher shelf life. Study of its quality parameters at different time intervals indicates that its life does not deteriorate as fast as for sample made from conventional bleaching agent. Sample stored even under ambient condition for six months shows very slight reduction in life compared to samples made from conventional bleaching agent, whose life became nil after six month in ambient storage. The chlorine content of bleached lac prepared using improved bleaching agent reduced to 0.4% as compared to 1.5% in conventional bleached lac, which in turn increases storage stability of bleached lac (more than 6 months).


The technology of improved bleaching agent was introduced to M/s Tajna Shellac, Khunti and commercial trials of this technology for better quality of bleached lac were carried out two times at M/s Tajna Shellac Pvt. Ltd., Khunti successfully. One confirmatory trial was also carried out at M/s Gupta Brother (Shellac), Bundu of this technology.


The process developed for bleaching lac solution uses improved bleaching agent which gives bleached lac of higher flow (fluidity) and life (heat polymerization time) compared to conventional bleaching agent sodium hypochloride alone. The alkline solution of lac is bleached with improved bleaching agent , acid precpitated, washed and dried to get bleached lac of higher storage stability. The production potential for the product is very high as bleached lac is one of the most important lac-based products for which there is constant demand in western markets. Nearly 50% of the world consumption of lac is in the form of bleached lac. Bleached lac is mostly prepared in fresh due to its poor keeping quality and entrepreneurs has to depends on current availability and price of raw material to meet their export demand which is a problem due to wide fluctuation in price of raw material(sticklac/seedlac).

The above method provides flexibility for entrepreneurs to prepare and store bleached lac when prices of raw material are low. Cost analysis of bleached lac preparation with improved bleaching agent reveals that there was marginal increase 10-15% (approx.) in bleaching cost compared to conventional bleaching (processing cost in conventional-Rs. 70/kg bleached lac). By setting this unit of capacity 50 kg/day (single

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shift) , net monthly profit of Rs. 50,000 to 60,000/- can be earned.







6.6 Manufacturing of Aleuritic Acid of Improved YieldAleuritic acid (9,10,16-Trihydroxyhexa-decanoic acid) is a major constituent acid of lac resin and is present in the lac resin to an extent of 35%. There is a continuous growing demand of aleuritic acid in the fields of perfumery and pharmaceuticals. It is obtained from seedlac by alkaline hydrolysis/sponification in which it is first obtained as sodium aleuritate, which is dewaxed and acidified to precipitate as technical grade of Aleuritic acid (Fig. 6.9). The method developed at Institute gives improved yield (16-18%).

Fig. 6.9 Aleuritic acid


The technology of preparation of aleuritic acid with improve yield was introduced to M/s Tajna Shellac, Khunti and M/s Gupta Brother (Shellac), Bundu. Commercial trials of this technology were done three times at M/s Tajna Shellac Pvt. Ltd., Khunti and M/s Gupta Brother (Shellac), Bundu successfully. Yields of more than 18% were obtained in these trails at both places.

Techno-economic Feasibility of Innovation/technology

Aleuritic acid (9,10,16-Trihydroxyhexadecanoic acid) is a major constituent acid of lac resin and is present in the lac resin to an extent of 35%. There is a continuous growing demand of aleuritic acid in the fields of perfumery and pharmaceuticals. It is an excellent starting material for the synthesis of fragrances such as civetone, exaltone, ambrettolide, isoambrettolide etc, which are used as fixative in perfumery industry and synthesis of glucose manoaleuritate (a non-toxic non-hemolytic water-soluble compound) in medicine as

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an isocaloric substitute for dietary tripalmitin. It may be used for preparing other useful compound like insect sex pheromones, plant growth regulator, stabilizers(metallic salt), insect repellants and nematicides. Most of the aleuritic acid produced in India is exported and fetch good export price. The product is thus of considerable commercial importance. The total production and export of aleuritic acid is showing growth rate every year. The production potential for the product is very high. There is a good scope for the export of this acid to other countries.

As it is value added product, most of the present production of this compound is exported. So, it is advisable to set up a unit for this value added product and by setting up such units of capacity 25 kg aleuritic acid/day, net profit of about Rs. 68,000 per month (yearly- 8.27 lakhs approx.) can be earned/generated. For establishing such unit about 500 sqm of land will be required. The aleuritic acid unit can also be installed near the existing seedlac lac unit and more profit can be earned.







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7. Process/ Product/Technology Developed (List partner-wise major Process/ Product/Technology developed and their outcome in quantifiable terms)

Sl. No.

(Process/Product/Technology Developed

Adoption/ Validation/ Commercialization, etc. Responsible Partner

1. Improved bleaching agent for bleached lac

Up- scaling trial on pilot plant at IINRG, Ranchi &

Industrial trials at M/s Tajna Shellac Pvt. Ltd., Khunti and M/s Gupta Brothers (Shellac), Bundu carried out successfully for validation of technology.

• IINRG, Ranchi;

• M/s Tajna Shellac Pvt. Ltd., Khunti;

• M/s Gupta Brothers (Shellac), Bundu

2. Process for manufacturing of aleuritic acid with improved yield

Up- scaling trial on pilot plant at IINRG, Ranchi &

Industrial trials at M/s Tajna Shellac Pvt. Ltd Khunti and M/s Gupta Brother (Shellac) Bundu Ranchi carried out successfully for validation of technology.

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8. Patents (Filed/Granted)Sl. No. Title of Patent Inventor(s)

(Name & Address)Filed/Published/

Granted (No./Date) Responsible

Partner- - - - -

9. Linkages and Collaborations Sl. No.

Linkages Developed (Name & Address of Organization) Date/Period From-To Responsible

Partner

1. R. K. Mission, Ranchi Jan. 2011 to March 2014

IINRG, Ranchi

2. PRADAN (NGO) , Ranchi Jan. 2011 to March 2014

3. Udyogini (NGO), Ranchi Jan. 2011 to March 2014

4. Nature Conservation Society (NGO), Ranchi Jan. 2011 to March 2014

5. Deputy Commissioner, Khunti, Jharkhand Sept. 2011 to March 2013

6. Dr. A. Sharada Devi, Dean of Home Science ANGRAU, Hyderabad (AP)

July 2010 to March 2014

7. Dr. Sarfaraz Ahmed Wani, Professor, SKUAT, Srinagar (J&K)

July 2010 to March 2014

10. Status on Environmental and Social Safeguard Framework Brief note of Environmental and Social SafeguardsEstablishment of lac host plantations, crop diversification, utilization of lac wash water for recovery of lac dye, and production of lac based value added products were some of the activities that created positive impact on the environment. Positive impacts included agro-biodiversity, conservation of soil and natural resources, increased availability of land. Use of chemicals, insecticides, pesticides and fertilizers might result in degradation of soil, air and water biological status. However, to mitigate, measures like integrated nutrient and pest management principles were scientifically and judicially adopted by the target groups through facilitation of the consortium partner.

Increased livelihood security of the tribal lac growers, diversified income and occupational patterns, employment generation and value addition were the positive impacts generated as a result of project activities. Effective dissemination and wide spread adoption of these interventions resulted in sustainable livelihood security among the targeted rural community, increase profit to farmers and entrepreneurs and more export earnings for the country. These interventions targeting the farming community might also result in the unequal access of the available inputs & knowledge. Also, promotion of advanced technologies generally might have some incremental cost & lack of availability or dependence on external resources. These negative impacts arising due to the developmental activities were carefully mitigated through effective impartial institutional mechanisms & community participation will be ensured across all levels of decision making.

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other Governmental Bodies and line departments working in the cluster region were sensitized through workshops. These mechanisms ensured augmented awareness among the line departments. Further more cluster level coordinator of the project were pursued with village and district level authorities to execute program successfully. Identification and selection of farmers for the cluster were based on the time tested protocols followed by State Government and other Non governmental organizations.

As the two of the selected clusters for this project face insurgency problems, some jitters were expected to occur. But confidence of the local community accrued from the past projects and support from district administration facilitated better execution of this project. Farmers, Panchayat Raj Institutions, research institutions, government and non-government institutions engaged in improving rural livelihoods were the key stakeholders for this project. Several rounds of discussions and brainstorming sessions with stakeholders and workshops were organized during the project implementation. After the launching also a stakeholders interaction meeting involving all the line departments were organized.

Table 1. Environmental safeguard: Activities, Issues, Impact and Mitigation Measures

Activities IssuesAnticipated Level

of Impacts Mitigation Measures

(Negative Impact)Positive NegativeCultivation of high yielding lac insect.

Use of pesticide for pest control. Ö (1) Pesticide (other than

those banned) were usedEstablishment of lac host plantation

Agro-biodiversity, afforestation, soil erosion control, efficient utilization of barren lands

Ö (4)

Primary processing at village level

Increased consumption of water and discharge of

lac wash water Ö (2)

Wash water was used for production of lac dye

Increased production of lac based value added products

More demand of raw lac encouraged more production of lac

Ö (2)

More use of water, chemicals etc. Ö (2) Waste water was treated

before disposalUtilization of lac wash water for recovery of lac dye

Reduce environmental pollution

Ö (4)

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Table 2. Social safeguard: Activities, Issues, Impact and Mitigation Measures

Activities IssuesAnticipated Level of

Impacts Mitigation Measures

(Negative Impact)Positive NegativeCultivation of high yielding lac insect

Increase in productivity and production of lac Ö (4)

More dependence on external resources i.e. broodlac (Lac seed ) Ö (2)

Emphasis was given for production of broodlac for generation of internal resources

Unequal access to inputs

Ö (2)

Institutional measures were employed to make inputs available particularly to small farmers through collective action

Establishment of lac host plantation

Efficient utilization of barren lands Ö (3)

Primary processing at village level

Employment generation at village level and increase in income.

Ö (4)

Increased production of lac based value added products

More consumption of raw lac and increase in export earning for the country

Ö (3)

Recovery of lac dye from wash water

More utilization of by-product and increase in export earning for the country

Ö (3)

11. Constraints, if any and Remedial Measures TakenSl. No. Constraints/problems Remedial Measures Taken

1. The project area in Ranchi & Khunti districts of Jharkhand is affected by naxal problems which created fear in implementing the project activities.

To carry out field activities in the project areas NGO NBJK, Khunti was associated as consortium partner in the project. The NGO had prior experience of working in these areas.

2. Majority of the farm families were poor tribal with less knowledge in scientific method of lac cultivation and resources. It was difficult to motivate the farmers/society for adoption of newer technologies.

Different awareness programmes i.e., in-campus & on-farm training programme on scientific method of lac cultivation, exposure visit to IINRG research farm were organized. Input support was extended to the farmers.

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3. Non-availability of quality broodlac (lac seed)

Broodlac production programme on their own host trees solved this problem.

4. Local tribes are poor and it is difficult for them to manage finance to start primary processing activities at villege level.

Continuous efforts were made to establish linkage between Financial Institution and developmental programmes of the Government.

12. Publications (As per format of citation in Indian Journal of Agricultural Sciences)

A. Research papers in peer reviewed journals

Sl. No.

Authors, Title of the Paper,

Name of Journal, Year, Vol. & Page No.NAAS

Ratings Responsible

Partner

1. Pal G, Prasad N, Ghosal S, Pandey S K & Kumar M. 2013. Socio-economic profile of lac growers in Ranchi & Khunti District of Jharkhand. The Journal of Rural & Agricultural Research.13 (2): 1-5.

2.0 IINRG, Ranchi.

2. Ghosal S. 2012. “Effect of weather and application of primary nutrients and liming of ber (Ziziphus mauritiana) in winter season (aghani) Kusmi lac production”. (in) Proceedings of the 99th Science Congress, Bhubaneswar 2012, section of Agriculture and Forestry Science. Pp. 76-77.

-

3. Ghosal S, Ramani R and Mishra Y D. 2011. Influence of thickness of branch, phunki scrapped weight, weighted living cell and Kusmi encrustation thickness on broodlac quantity. Ann. Entomol 29 (1): 71-75.

3.4

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B. Books/ Book chapters/ Abstracts/ Popular articles,/Folders/ Brochures, etc.

Sl. No.

Authors, Title of the Papers Name of Book/ Seminar/ Proceedings/Journal, Publisher, Year, Page No.

Responsible Partner

1. izdk'k lkaxk ,oa ,l- ?kks'kky] lQyrk dh dgkuh & Jh izdk'k lkaxk (xzke & ekWxwckWa/k] ukedqe] jkWph)

IINRG, Ranchi

2. ,l- ?kks'kky] fujatu izlkn ,oa eukst dqekj] lQyrk dh dgkuh & Jh t;nso egrks (xzke & iqrhMhg] >kynk] if'pe caxky)

3. lkSesu ?kks'kky] fujatu izlkn ,oa xksfoUn iky] ¶ysfefUt;k lsfe;kyrk ikS/kk dk cxku yxkuk o yk[k dh [ksrh

4. lkSesu ?kks'kky] fujatu izlkn ,oa xksfoUn iky] csj ikS/kk dk dk cxku yxkuk o yk[k dh [ksrh

5 Ghosal S, Prasad N & Kumar M. 2012. Report on production aspect of Lac Value Chain Project. IINRG News Letter July-Sept. 2012.

6. Pandey S K, Prasad N & Baboo B. 2012. Small Scale Lac Processing Unit for Seedlac (Capacity-100 kg Sticklac/day), Extension folder (English), IINRG, Ranchi.

7. Pandey S K, Prasad N & Baboo B. 2012.Small Scale Lac Processing Unit for Seedlac (Capacity-100 kg Sticklac/day), Extension folder (Hindi), IINRG, Ranchi.

8 Ghosal S. 2013. Raising of Lac hosts (ber & F. semialata ) and modern techniques of lac cultivation. IINRG, Ranchi.

9. Pandey S K, Srivastava S, Prasad KM. 2013. Recovery of Lac dye- A by-product of lac industry (Extension folder), IINRG, Ranchi, pp-4.

10 Ghosal S, Prasad N & Kumar M. 2013. Report on NAIP Project on A Value Chain of Lac and lac Based Products for Domestic and Export Markets. IINRG News Letter July-Sept. 2013.

11. Giri S K, Pandey S K, Prasad N & Baboo B. 2009. A value Chain of Lac and Lac based Products for Domestic and Export Markets (Extension folder). IINRG, Ranchi, pp-16.

12. Pandey S K, Srivastava S, Prasad N. 2012. Good Manufacturing Practices for Bleached Lac. NAIP Sub-Project on Lac Value Chain. IINRG, Ranchi, pp1-16

13. Pandey S K, Prasad N, Sharma S C and Kar A. 2013. Good Manufacturing Practices for Aleuritic Acid. NAIP Sub-Project on Lac Value Chain. IINRG, Ranchi, pp1-26

14. Pandey S K, Prasad N, Sharma SC and Kar A. 2013. Good Manufacturing Practices for Lac Dye. NAIP Sub-Project on Lac Value Chain. IINRG, Ranchi, pp1-25

15. Pandey S K, Prasad N, Sharma S C. and Kar A. 2014. Good Manufacturing Practices for Seedlac. NAIP Sub-Project on Lac Value Chain. IINRG, Ranchi, pp1-28

16. Pandey SK, Prasad N, Sharma SC and Kar A. 2014. Good Manufacturing Practices for Shellac. NAIP Sub-Project on Lac Value Chain, IINRG, Ranchi, pp1-29

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13. Media Products Developed/DisseminatedSl. No. CD, Bulletins, Brochures, etc. (Year wise) No. of

Copies Distribution Responsible Partner

1. Film on “Host plant raising and lac cultivation on F. semialata”

25 15 IINRG, Ranchi

2. Film on “Host plant raising and lac cultivation on ber”

25 15

3. A video clip prepared on success story of Mr. Joydeb Mahato - A lac grower

10 8

4. A video clip prepared on success story of Mr. Prakash Sanga - A lac grower

10 8

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

Organizer (Name and Address)

Details of Meetings/ Seminars/ Trainings, etc. Duration

No. of personnel training

Budget

TrainingonScientificMethodofLacCultivationatIINRG,RanchiIINRG, Ranchi Training on scientific cultivation

of lac(One week training) - 03 Nos.

Oct. 12-16, 2009;

Dec. 29, 2009 - Jan. 02, 2010.

&Jan. 10-16, 2011.

17

42

31

IINRG, Ranchi One week training at IINRG, Ranchi on Scientific Method of Lac Cultivation

Feb. 6-10, 2012 42

OnFarmTrainingonScientificMethodofLacCultivationIINRG, Ranchi On-farm training on scientific

cultivation of lac- 07 Nos. 1. Mangubandh, Ranchi2. Syankel & Digri, Khunti3. Lupungdih, Khunti4. Barka Silda, Khunti5. Barka Salga, Khunti6. Mangubandh, Ranchi7. Mangubandh, Ranchi

Jun. 28, 2009 Jun. 28, 2009 Mar. 04, 2010Mar. 05, 2010Oct. 07, 2010Oct. 28, 2010Dec. 02, 2010

36725557752862

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IINRG, Ranchi & Udyogini, Ranchi

One day on Farm training on Scientific Method of Lac Cultivation at Village – Rai, Khunti, Jharkhand

Sept. 16, 2011 70

IINRG, Ranchi & PRADAN, Khunti

One day on Farm training on Scientific Method of Lac Cultivation at Village – Rui Tola, Murhu, Jharkhand

Sept. 22, 2011 48

IINRG, Ranchi & NBJK, Khunti

One day on Farm training on Scientific Method of Lac Cultivation at Village – Bhursu, Murhu, Jharkhand

Nov. 21, 2011 80

IINRG, Ranchi On Farm Training on Scientific Method of Lac Cultivation

Jun. 20, 2012Jun. 22, 2012Jun. 29, 2012Aug. 01, 2012

44911827

Exposure Visit IINRG, Ranchi & PRADAN, Khunti

Exposure Visit for Lac Growers from Village - Rui Tola, Murhu and adjoining villages to IINRG, Ranchi Research Farm

Oct. 08, 2011 83

IINRG, Ranchi & Udyogini, Ranchi

Exposure Visit for Lac Growers from villages of Bundu, Ranchi to IINRG, Ranchi Research Farm

Jan. 10, 2012 45

IINRG, Ranchi & Udyogini, PRADAN and NBJK (Ranchi and Khunti)

Exposure Visit for Lac Growers from villages of Bundu, Ranchi to IINRG, Ranchi Research Farm

Feb. 13, 2012 250

Training on Primary Processing of LacIINRG, Ranchi Training on primary processing of

lac – 02 Nos.March 8-12, 2010

& Nov. 18-20, 2010.

15

16Training on Making Lac HandicraftBRIAT, Allahabad Training on value added lac based

products (as Master Trainers)Dec. 15-23, 2011 20

Meetings organizedIINRG, Ranchi Meeting on post NAIP

sustainability with NGO at NBJK, Khunti.

Jan. 22, 2013 06

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

Sl. No.

Details of Meetings/Seminars/Trainings/Radio talk, etc.

(Name &Address)

Duration(From-To)

Budget(Rs.)

Participant (Name & Address)

1. Flexible packaging atIndian Institute of Packaging, Hyderabad

November 16-20, 2010

- (Dr. S. K. Giri, Mr. R. L. Sharma and Mr B. K. Gupta)

2. 45th Annual Convention of ISAE and International Symposium on Water for Agriculture held at College of Agriculture, Nagpur

Jan. 17-19, 2011

- Er. S. K. Pandey, Scientist (Senior Scale) & CPI, IINRG, Ranchi

3. Attended NAIP Review Meeting held at GBPUAT, Pantnagar

Feb.18-19, 2011

- Dr. Niranjan Prasad, Principal Scientist & CPI, IINRG, Ranchi

4. Attended Review Meeting of NAIP Sub-Project in Jharkhand held at IINRG, Ranchi

June 29, 2011

- Dr. Niranjan Prasad, Principal Scientist & CPI, IINRG, Ranchi

5. Attended 99th Science Congress at KIIT, Bhubaneswar and presented a research paper on “Effect of weather and application of primary nutrients and liming of ber (Ziziphus mauritiana) in winter season (aghani) Kusmi lac production”.

Jan. 3-7, 2012

- Dr. S. Ghosal, Sr. Scientist & CPI, IINRG, Ranchi.

16. Foreign Trainings/Visits:

Sl. No.

Name,Designation,Address ofthe Person

Visit/Training/Seminar its Place, Organization and

Duration (From-To)

Dates of Seminar Delivered

and Report Submitted on

Return

Follow upAction

Total Cost (Rs)

1. Er. S.K. Pandey, Sci. (SS) & CCPI

School of Packaging, Michigan State Univ., East Lacing, MI, USA

Oct. 16, 2013 to Oct. 25, 2013.

Nov., 2013 Packaging study of bleached lac, shellac and lac dye were carried out under the project

8,05,056

2. Dr. S. Srivastava, PS & CCPI

70


17. Performance Indicators(As per the enclosed format in Appendix-1: Component-wise; and Sub-component-wise)

Sl. No. Indicator Total

Numbers1. No. of production technologies released and/or adopted 032. No. of processing technologies released and/or adopted 023. Number of technologies/products commercialized based on NAIP research 014. No. of new rural industries/enterprises established/ upgraded 025. No. of product groups for which quality grades developed and agreed -6. Total no. of private sector organizations (including NGOs) participating in

consortium 07

7. No. of farmers involved in consortia activities 9948. Total number of farmers’ group for marketing and processing -9. Number of patent/intellectual property protection applications filed based on

NAIP research -

10. Number of patents/intellectual property protections granted/published based on NAIP research

-

11. Number of scientists trained overseas in consortium-based subject areas 0212. Success stories 0213. Incremental employment generated (person days/year/HH) 994 HH14. Increase in income of participating households (Rs. per annum) > 5000

15. Publications (No.)NAAS rated journals 02Other journals -Book -Book chapter -Thesis -Popular articles (English) 02Popular article(s) in other language -Newspaper article (s) 05Seminar/Symposium/Conference/

Workshop presentation(s)

02

Seminar/Symposium/Conference/

Workshop proceedings

02

Technical bulletin(s) 00

71


Manual(s) 05CDs/Videos 04Folder/Leaflet/Handout(s) 10Report(s) 10

16. Additional accrued in value chain16.a Enhancement in product quality 0216.b Cost reduction 0016.c Export enhancement 0016.d Additional return to farmer, Rs. /year > 5000

18. Employment Generation (man-days/year)Sl. No. Type of Employment Generation Employment Generation up

to End of Sub-projectResponsible

Partner1. Employment generated from lac cultivation

on existing host4200 IINRG, Ranchi

2. Lac cultivation on plantation basis 5100 IINRG, Ranchi3. Lac handicraft making 13125 IINRG, Ranchi

Total 22425

72


19. Assets Generated(Details to be given on equipments and works undertaken in the sub-project, costing more than Rs. 10,000/- in each case)

(i) Equipment

Sl. No.

Name of the Equipment with Manufacturers Name, Model

and Sr. No.

Year of Purchase

Quantity (Nos.)

Total Cost (Rs.)

Responsible Partner

IINRG, Ranchi

1. Small Scale Lac Processing Unit 2009 02 1,45,808

IINRG, Ranchi

2. Water Chiller

(Advance Cooling Systems Pvt. Ltd./ WC-9000-134-T-CITC-AC-CMC)

2010 01 2,23,578

3. Environmental Chamber (Remi/ CHM-16S)

2010 01 2,06,196.75

4. Vacuum Packaging Machine (Winner Electronics/Vertical Model)

2010 01 5,34,375.00

5. Digital Camera 2010 01 17490.00

6. Notebook Computer with Accessories 2010 01 85651.00

7. Desktop Computer with Accessories 2010 01 76369.00

8. Inverter 2010 01 14,100.00

9. Furniture 2010 01 2,25,788.00

10. Extruder 2014 01 1,41,750.00

NBJK, Khunti

1. Office Table 2010 01 13,500.00

Nav Bharat Jagriti Kendra

(Consortium Partner)

2. Visitor’s Chair (Model 6063) 2010 01 14,040.00

3. Visitors Chair (Model 6064) 2010 01 10,800.00

4. Laptop (Model Vastro 540) 2010 01 34,500.00

5. Computer Sys

( HP DX 480)

2010 01 23,712.00

6. Digital Camera

(Cannon 1100 IS)

2010 01 11,180.00

73


(ii) Works

Sl. No.

Particulars of the Work, Name and Address of Agency Awarded

the Work

Year of Work Done

Quantity (Nos.)

Total Cost

(Rs.)

Responsible Partner

1. Nil NA NA NA NA

(iii) Revenue Generated (Details may be given on revenue generated in the sub-project viz., sale of seeds, farm produce,

products, patents, commercialization, training, etc.)

Sl. No. Source of Revenue Year Total amount (Rs.) Responsible Partner1. Nil NA NA NA

(iv) Livestock (Details of livestock procured/produced in the sub-project)

Sl. No.

Details of Livestock (Breed, etc.)

Year of Procurement/Production

Nos. Total Cost (Rs.)

Responsible Partner

1. NA NA NA NA NA

20. Awards and Recognitions

Sl. No.

Name, Designation, Address of the

Person

Award/ Recognition (with Date)

Institution/ Society Facilitating (Name &

Address)

Responsible Partner

1. Dr. Niranjan Prasad, Principal Scientist & CPI

Bioved Fellowship Award 2012 for work in the field of Lac Production Technology

Bioved Research Institute of Agriculture & Technology, Allahabad

IINRG, Ranchi

2. Shri Karmu Munda (beneficiary farmer of NAIP Sub - Project on “Lac Value Chain”)

Best farmer’s award

(by IINRG, Namkum, Ranchi during Kisan Mela-2012)

Indian Institute of Natural Resins and Gums, Namkum, Ranchi

3. Shri Anil Mahto (beneficiary farmer NAIP- “Lac Value Chain”)

Best farmer’s award

(by IINRG, Namkum, Ranchi during Kisan Mela-2013) Feb. 13, 2013

Indian Institute of Natural Resins and Gums, Namkum, Ranchi

74


21. Steps Undertaken for Post NAIP Sustainabilityl District Administration, Khunti has sanctioned a project of an amount Rs. 61.88 lakhs for promotion

of scientific lac cultivation and primary processing of lac.

l Initially full support in terms of input was given to the farmers to demonstrate selected Institute technologies. Gradually, support was withdrawn in phased manner. Due to benefit from the technology, farmers came forward to adopt even without any support and activity is likely to continue in future.

l For sustainability of project activities beyond project period, two private industries and six NGOs were associated as partner for large scale trial of selected institute technologies and their adoption.

l Capacity building programme was carried out in the project on entrepreneurship development of unemployed youths for establishment of small scale lac processing unit and lac handicraft making unit.

22. Possible Future Line of Work (Comments/suggestions of CPI regarding possible future line of work that may be taken up arising

out of this sub-project)

1. Large scale programme for high yielding kusmi lac cultivation on ber may be promoted for increasing lac production and income of lac growers

2. Promotion of lac cultivation on plantation basis may be undertaken on ber and F. semialata for intensive lac cultivation and better management of host trees.

3. Establishment of primary processing unit for lac may be promoted for value addition and employment generation at village level.

4. Promotion of recovery of by product – lac dye among lac processing industries for additional income and hygienic disposal of wash water effluent.

23. Personnel (Staff of Lead Centre & Partner-wise, their Name, Designation, Discipline and Duration)

From – To (DD/MM/YYYY)Research Management (CL)1. Dr. Bangali Baboo

Director, IINRG, Ranchi

Feb., 2009 to Jan., 2010

2. Dr. A. Bhattacharya

Acting Director, IINRG, Ranchi

Feb., 2009 to June, 2010

75


3. Dr. R. Ramani

Director,

IINRG, Namkum, Ranchi

Jun.14, 2010 to Mar. 31, 2014

Scientific(CPI, CCPI, others)1. Dr. Niranjan Prasad

PS & CPI, NAIP on “Lac Value Chain”

IINRG, Namkum, Ranchi-834010

Feb. 03, 2009 to Mar. 31, 2014

2. Dr. S. Srivastava

Co-Principal Investigator


Feb. 03, 2009 to Mar 31, 2014

3. Er. S. K. Pandey



Feb. 03, 2009 to Mar 31, 2014

4. Dr. S. Ghosal



Feb. 03, 2009 to Mar 31, 2014

5. Dr. S. C. Sharma



April 02, 2011 to Mar. 31, 2014

Contractual

1. Manoj Kumar (RA) Feb. 03, 2009 to Mar. 31, 2014

2. Shailendra Kumar Mishra (RA) May 01, 2009 to Nov. 26, 2009

3. Kunal Kumar Prasad (RA) Sep. 19, 2010 to Jan. 24, 2011

4. Mahfooz Alam (RA) April 07, 2011 to Oct. 19, 2012

5. Amit Kumar Kar (RA) July 10, 2013 to Mar. 31, 2014

6. Rakesh Kumar (OA) Nov. 16, 2009 to Dec. 31, 2012

7. Manoranjan Kumar Sinha (OA) July 10, 2013 to Mar. 31, 2014

76


24. Governance, Management, Implementation and CoordinationA. Composition of the various committees (CIC, CAC, CMU, etc.)

Sl. No. Committee NameChairman

(From-To)

Members

(From-To)1. CIC

Dr. Bangali Baboo - Chairman

Director, IINRG, RanchiFeb., 2009 to

Jan., 2010 -

Dr. A Bhattacharya - Chairman

Acting Director, IINRG, RanchiFeb., 2009 to June, 2010 -

Dr. R Ramani - Chairman

Director, IINRG, Ranchi June 14, 2010 to Mar. 31, 2014 -

Mr. R L Sharma - Member

M/s Tajna Shellac Pvt. Ltd P.O.Khunti, Dist: Khunti, Jharkhand

- Feb. 03, 2009 to Mar. 31, 2014

Mr. Binay Kumar Gupta - Member

Gupta Brothers (Shellac)

P.O. Bundu, Dist: Ranchi

- Feb. 03, 2009 to Mar. 31, 2014

Mr. Mohit Purty - Member

Nav Bharat Jagriti Kendra

Lobin Bagan, Dak Bugnlow Road P.O. Khunti, Dist: Khunti Jharkhand

- Feb. 03, 2009 to June 30, 2012

Er. S K Pandey - Member

Scientist(SS)

IINRG, Namkum

Ranchi, Jharkhand

- Feb. 03, 2009 to Mar. 31, 2014

Dr. Sanjay Srivastava - Member

Sr. Scientist

IINRG, Namkum, Ranchi

- Feb. 03, 2009 to Mar. 31, 2014

AdministrativeOfficer-Member

IINRG, RanchiFeb. 03, 2009 to Mar. 31, 2014

Finance&AccountsOfficer-Member

IINRG, RanchiFeb. 03, 2009 to Mar. 31, 2014

77


Dr. Niranjan Prasad - Member Secretary

PS and CPI, NAIP on “Lac Value Chain”, IINRG, Namkum

Ranchi

- Feb. 03, 2009 to Mar. 31, 2014

2. CACDr. NSL Srivastava - Chairman

Executive Director, TIT Group of Institutes, Anand Nagar, BHEL, Bhopal- 462021

Feb., 2009 to March, 2014

Mr. B Anand Babu - Member

Conservator of Forest, Aranya Bhawan, Station Road, Raipur, Chhattishgarh

Feb., 2009 to March, 2014

Mr. Joydeb Mahato - Member

Village-Putidih, P.O.-Illo, Dist. Purulia (W.B.) Mrs. Anupama Sinha - Member

Bariatu, RanchiFeb., 2009 to March, 2014

3. CMUDr. Bangali Baboo - Chairman

Director, IINRG, RanchiFeb., 2009 to

Jan., 2010 -

Dr. A Bhattacharya - Chairman

Acting Director, IINRG, RanchiFeb., 2009 to June, 2010 -

Dr. R Ramani - Chairman

Director

IINRG,Namkum

Ranchi

June 14, 2010 to Mar. 31, 2014 -

Mr. R L Sharma - Member

M/s Tajna Shellac Pvt. Ltd P.O. Khunti, Dist: Khunti Jharkhand

- Feb. 03, 2009 to Mar. 31, 2014

Mr. Binay Kumar Gupta - Member

Gupta Brothers (Shellac)

P.O. Bundu, Dist: Ranchi

- Feb. 03, 2009 to Mar. 31, 2014

Mr. Mohit Purty - Member

In charge Nav Bharat Jagriti Kendra

Lobin Bagan, Dak Bugnlow Road P.O. Khunti, Dist: Khunti Jharkhand- 835 210

- Feb. 03, 2009 to June 30, 2012

78


Er. S K Pandey - Member

Scientist(SS)

IINRG, Namkum

Ranchi, Jharkhand

- Feb. 03, 2009 to Mar. 31, 2014

Dr. Sanjay Srivastava - Member

PS, IINRG, Namkum, Ranchi-10- Feb. 03, 2009 to

Mar. 31, 2014

Dr. Niranjan Prasad - Member Secretary

PS and CPI, NAIP on “Lac Value Chain”,

IINRG, Namkum

Ranchi

- Feb. 03, 2009 to Mar. 31, 2014

B. List of meetings organized (CIC, CAC, CMU, etc.)

Sl. No. Details of the meeting Date Place & Address (Where meeting was organized)

1. CIC Jul. 07, 2009

Indian Institute of Natural Resins and Gums, Namkum, Ranchi - 834010 (Jharkhand)

Mar. 22, 2010

May 17, 2010

Oct. 06, 2010

May 02, 2011

Jul. 21, 2011

Oct. 06, 2012

2. CAC Dec. 29, 2009

Jan. 23, 2010

Feb. 08, 2011

Sept. 1-2, 2011

Dec. 19-20, 2012

Sept. 9-10, 2013

79


3. CMU Mar. 20, 2009

Indian Institute of Natural Resins and Gums, Namkum, Ranchi - 834010 (Jharkhand)

May 07, 2010

Aug. 12, 2011

Sept. 05, 2011

Oct. 14, 2011

Dec. 09, 2011

Jan. 06, 2012

Apr. 28, 2012

Apr. 04, 2013

Jun. 07, 2013

Nov. 12, 2013

Dec. 10, 2013

80


Part-III: Budget and its Utilization

STATEMENT OF EXPENDITURE

(Period from 30/04/2009 to 31/03/2014)

(Date of start) (Date of completion)

Sanction Letter No. – F.NO: 10(29)/Comp-2/2008-NAIP

Total Sub-project Cost – 227.413 lakh

Sanctioned/Revised Sub-project Cost (if applicable) – 193.71 lakh

Date of Commencement of Sub-project – 30/04/2009

Duration: From 30/04/2009 to 31/03/2014 (DD/MM/YYYY)

Funds Received in Each Year (IINRG, Ranchi)

I Year - 1.43220 lakh

II Year - 114.227 lakh

III Year - 35.43581 lakh

IV Year - NIL

V Year - 47.44260 lakh

VI Year - 10.00 lakh

Bank Interest Received on Fund (if any) - 1.89241 lakh

Total Amount Received - 210.48002 lakh

Total Expenditure - 89.96480 lakh

Expenditure Head-wise : IINRG, Ranchi

81


Sanc

tione

d H

eads

Fund Allocated (*)

Fund

s Rel

ease

dE

xpen

ditu

re In

curr

ed

Total Expenditure

Balance as on Date/

RefundRequirement of Additional

Funds

Remarks

1st Year

2nd Year

3rd Year

4th Year

5th Year

6th Year

1st Year

2nd Year

3rd Year

4th Year

5th

Year

6th Year

A. R

ecur

ring

C

ontin

genc

ies

(1) T

A3.

430.

150.

101.

40.

000.

850.

000.

000.

4328

60.

5048

20.

6393

60.

4441

20.

6567

92.

6779

5

(2) W

orks

hops

4.05

0.25

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0.94

680.

001.

250.

000.

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4468

00.

5410

80.

0640

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6775

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3946

12.

3739

9

(3) C

ontra

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l Se

rvic

es/R

A/S

RF

28.7

90.

432

2.16

8.47

20.

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624

0.00

0.00

3.34

078

3.99

977

7.01

305

5.93

949

5.85

357

26.1

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(4) O

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(1-4

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9266

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1794

313

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6814

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6314

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1258

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52

B. H

RD

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(5-6

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110

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96

82


Sanc

tione

d H

eads

Fund Allocated (*)

Fund

s Rel

ease

dE

xpen

ditu

re In

curr

ed

Total Expenditure

Balance as on Date/

RefundRequirement of Additional

Funds

Remarks

1st Year

2nd Year

3rd Year

4th Year

5th Year

6th Year

1st Year

2nd Year

3rd Year

4th Year

5th

Year

6th Year

C. N

on-R

ecur

ring

(7) E

quip

men

t23

.27

0.00

83.0

00.

000.

000.

0010

.000

000.

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4031

89.

8649

40.

000.

001.

4175

014

.685

62

(8) F

urni

ture

1.95

0.00

2.00

0.00

0.00

0.00

0.00

0.00

0.27

238

1.68

021

0.00

0.00

0.00

1.95

259

(9) W

orks

(new

re

nova

tion)

0.00

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000.

000.

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(10)

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mal

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, etc

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(7-1

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7767

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30.

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84.

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1

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nd T

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(A

+B+C

+D)

137.5

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219

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522

0.00

* In

stitu

tiona

l cha

rges

will

be

10%

of t

he re

curr

ing

cont

inge

ncie

s for

the

Lead

Con

sorti

um a

nd 5

% fo

r Con

sorti

a Pa

rtner

s.

Nam

e & S

igna

ture

of C

PI :

Dr. N

iranj

an P

rasa

d

Nam

e & S

ignat

ure o

f Com

peten

t Fin

ancia

l aut

horit

y: M

r. G.

C. J

oshi

Dat

e: J

une,

201

4 D

ate:

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e, 2

014

Sign

atur

e, Na

me a

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esign

ation

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onso

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r : D

r. R.

Ram

ani, D

irecto

r

Dat

e: J

une,

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4

83


Con

sort

ium

Par

tner

-wis

e St

atem

ent o

f Exp

endi

ture

Con

sort

ium

Pa

rtne

rFu

nds

Allo

cate

d

Fund

s Rel

ease

d, R

s. L

akh

Exp

endi

ture

Incu

rred

, Rs.

Lak

h

1st Year

2nd Year

3rd Year

4thYear

5th Year

6th Year

Total

1st Year

2nd Year

3rd Year

4th Year

5th Year

6th Year

Total

IIN

RG

, Ran

chi

137.

511.

4322

011

4.27

735

.435

810.

0047

.442

6010

.000

0020

8.58

761

0.55

12.4

1222

19.0

5293

17.4

9798

15.5

4866

24.9

0301

89.9

6480

M/s

Taj

na

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lac,

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nti

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000.

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7419

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40.

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01.

5383

6

M/s

Gup

ta

Brot

hers

(She

llac)

, B

undu

9.55

0.00

0.15

750

0.91

675

0.00

1.52

250

3.41

500

6.01

175

0.00

0.15

550

0.97

221

0.07

721

1.18

333

0.20

800

2.59

625

NB

JK, K

hunt

i11

.13

0.00

5.60

851

2.30

305

0.80

061

1.52

250

0.00

10.2

3467

0.00

4.32

652

2.84

380

1.88

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0.00

0.00

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bad

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000.

000.

000.

000.

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.64

11.6

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0.00

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nd T

otal

193.

711.

4322

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1.77

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39.3

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0.80

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50.8

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112.

5361

8

84


PART-IV: DECLARATION

This is to certify that the final report of the Sub-project has been submitted in full consultation with the consortium partners in accordance with the approved objectives and technical programme and the relevant records, note books; materials are available for the same.

Place: Ranchi

Date : June, 2014 Signature of Consortium Principal Investigator

Comments & Signature of Consortium Leader

Date : June, 2014

final report of naip sub project on · a final report of naip sub project on a value chain on lac...

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