SETTING UP A BIO-FERTILIZER PLANT

Meaning

Biofertilizer is most commonly referred to the use of soil microorganisms to increase the availability and uptake of mineral nutrients for plants.

Biofertilizers :are defined as biologically active products or microbial inoculants of bacteria, algae and fungi (separately or in combination), which may help biological nitrogen fixation for the benefit of plants.

The name itself is self explanatory. The fertilizers are used to improve the fertility of the land using biological wastes, hence the term biofertilizers, and biological wastes do not contain any chemicals which are detrimental to the living soil. They are extremely beneficial in enriching the soil with those micro-organisms, which produce organic nutrients for the soil and help combat diseases.

NEED

Use of synthetic fertilizers, herbicides, pesticides, and fungicides have polluted the agriculture land.

Removal of micronutrients without replenishing them.

Human health hazards and biodiversity.

Due to soil, air and water pollution, the beneficial microbial load in the soil has reduced.

STRENGTH• GOOD QUALITY AND NEAR TO THE MARKET.• HEALTH CARE FERTILIZERS.• STRONG SUPPLY CHAIN MANAGEMENT • PRICE, VALUE TO THE CUSTOMERS AND QUALITATIVE PRODUCTS.• NEW TECHNOLOGY INNOVATIVENESS IN PRODUCTION.

WEAKNESS• NEW IN THIS AREA.• FARMERS ARE NOT HABITUAL TO USE ORGANIC FERTILIZERS.• NO BRAND EQUITY AND IMAGE

OPPORTUNITY• LESS COMPITITIVE MARKET • EASY AVAILABILITY OF RAW MATTRIAL.• NEW MARKET• FUTURISTIC MOVE. • HEALTH CONCIOUS • GOVERNMENT SUBSIDIES

THREATS• ENVIRONMENTAL EFFECT IS VERY HIGH.• LACK OF SKILLED WORKERS IN THIS AREA.• FARMERS DEMAND IS TO GIVE QUICK RESULTS.

Major requirements

Land-It is required to set up laboratory and other facilities and office. Space may also be required for installing tube well / dug well and parking of vehicles.Preferably, the entire site should be fenced with barbed wire or compound wall with gates at suitable places. The boundary may be planted with thick and tall growing species like Asoka, to filter air and reduce dust.

Layout and buildings-The civil works comprises of factory building for laboratory, Carrier preparation and enrichment, sterilisation, Inoculation and quality control, Maturation of culture, Mixing and packing, storage/ staff etc,. The total covered area of about 3000 sq ft is required for the product manufacturing and other utilities. Rest of the area of land will be enough for future expansion

Plant and Machinery-Manufacture of biofertilisers needs a good number of laboratory equipments as well as other production facilities such as fermentors, culture medium tank, fermentor assembly, autoclaves, boiler, broth dispensers for sterlisation, deminralising plant, air compressor etc,.

Manufacturing process and Source of technology-generally comprises of media preparation room, media store room, inoculation room, growth room, culture transfer room, sterilization ,Mixing and packing, etc. The floor plan should be designed to promote maximum efficiency and minimum contamination. The design should facilitate maintenance of optimum temperature, humidity and ventilation. Inside air of the unit should be free from dust particles.

Infrastructural Facilities for raw material, carrier material and utilities-The raw material required for biofertilser production include ingredients for growth medium for the production of broth, carrier, packing materials like polythene packets. corrugated boxes, etc,.

Basic utilities Power-Normally a three phase electric supply is required for

these plants. Depending upon the position of power supply, stand by generator may be needed.

Water-A Biofertiliser production unit requires water mainly for steam generation for sterlisation of carrier, broth preparation and cleaning of equipments. Accordingly well/ bore well of designed size and according to the quality of water demineralisation equipments are to be installed. The average per day requirement of water will be about 2500 to 3000 liters

Compressed air-It will be required for various pneumatic operations as well as for controlled air supply to fermenters, sterlisation / cleaning operations etc,.

Vehicles-The vehicles are required for procurement of carrier material and distribution of biofertilisers as well as for office use . Accordingly one LCV and a jeep have been included in the project.

MANPOWERMARKETINGMANAGING DIRECTORMARKETING EXECUTIVE = 5SALES MANAGER = 1050 FIELD SUPERVISOR = 50

OPERATIONSCHIEF OPERATION OFFICERSUPERVISOR = 8OPERATION LABOR = 60

FINANCECHIEF FINANCIAL OFFICERHEAD ACCOUNTANT = 2ACCOUNTANT = 6

RESEARCH AND DEVELOPMENTSENIOR SCIENTIST = 3JUNIOR SCINTIST = 5

Estimated costs The project cost will depend upon the capacity of the unit and

technology adopted.

Project Outlay – Model Project on 200 TPA / Shift Bio-fertilizer Unit. (Rs.in lakh)Land and Building1. Cost of Land(on lease) : Rs. 0.00 2. Land Levelling : Rs. 1.00 3. Fencing & Compound Wall and Gates: Rs. 5.00 4. Civil structure :

Rs.30.005. Legal expenses : Rs.5

6. contingency reserve : Rs.5

Plant Machinery and Equipments

1.Essential equipments for strain : Rs.20.35

maintenance and quality control glassware

plastic ware etc.

2.Fermentation & bio mass up-scaling : Rs.65.00

equipments and machines

3.Product handling, packaging : Rs.32.50

equipments and machines and storage

equipments

Other expenses Capitalised

1.Interest during gestation/ : Rs.3.50

construction period and first year

expenses capitalised

2. Margin money for Working CapitaL : Rs.2.373

3. Preliminary and Pre-op.expenses : Rs.2.20

4. manpower : Rs.20

5. Working capital : Rs.5

6. preliminary expenses : Rs.3

Total cost(estimated) : Rs.200

Govt. scheme

The scheme provides credit linked and back-ended capital investment subsidy @ 25% of total financial outlay subject to the maximum of Rs.40 lakh per unit, whichever is less.

The subsidy for expansion/renovation of the existing units will be restricted to 25% in case of Bio-fertilizer units.

CONCLUSION

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