Basmati Rice Cluster Report
Basmati Rice Cluster Report
Basmati Rice Cluster Report
VISION-2025
Basmati Rice Cluster Feasibility and Transformation Study
I truly hope that the policies, strategies, and interventions suggested in this report will
facilitate the federal and provincial governments to chalk out and implement plans for
cluster-based transformation of the agriculture sector.
I am also grateful to Centre for Agriculture and Bioscience International (CABI) and
its Regional Director for Central and West Asia, Dr. Babar Ehsan Bajwa and CABI team
especially Mr. Yasar Saleem Khan for selecting me as commodity specialist for this
task and offering outstanding cooperation, support and advice during all the stages of
this project. However, the research team takes the responsibility of any shortcoming
left in the report.
Citation:
Saeed, Ikram., Ali Mubarik, Farooq Umar, and Yasin Aqsa. (2020) Basmati rice cluster
feasibility and transformation study. In Ali Mubarik (ed.). (2020) Cluster Development
Based Agriculture Transformation Plan Vision-2025. Project No.
131(434)PC/AGR/CDBAT-120/2018. Unpublished Report, Planning Commission of
Pakistan, Islamabad, Pakistan and Centre for Agriculture and Biosciences International
(CABI), Rawalpindi, Pakistan.
Despite significant improvement in yield during the 2000s, Pakistan has lost the
competitiveness edge in basmati as indicated by its plummeting shares in total basmati
export from 46% in 2006 to less than 10% in 2017, which was conveniently picked up
by its competitor India. Pakistani basmati exports also declined by 45% in absolute term
during the period. This declining competitiveness is due to number of factors that
favoured India than Pakistan during the period including stronger technological
innovations which gave higher productivity growth in basmati that have more elongated
kernel size without aroma, lower production costs due to high input subsidies,
aggressive marketing tactics which enabled to earn high prices to Indian basmati
without aroma and showcasing of cooked dishes like “Biriyani” instead of “Murgh Pulao”
etc.
In view of the above scenarios, the present project is developed to explore the
technological and economic opportunities for investment in the basmati rice value chain
in Pakistan with the goal of improving its competitiveness. Focus group consultation
meetings/discussions were arranged to gather field information from diversified
stakeholders engaged in basmati paddy production, marketing, and processing viz.,
farmers, commission agents, traders, processors, and development partners in public
and private sector. Based on the final basmati product processed, two clusters for
basmati rice are defined in this study: i) Katcha (polished) rice-Cluster-I supplying white
rice with its central district of Sheikhupura; and ii) Parboiled (Saila) rice-Cluster-II
supplying parboiled rice with central district of Hafizabad. While Super Basmati and
Basmati-386 are the major varieties cultivated in Cluster-1, Kainat basmati is the
dominant variety in Cluster-II each have relatively different management practices and
passes through different processing process.
Six interventions are suggested in the focal districts and feasibility of these
interventions is estimated. These are: i) gradual shifting to mechanical rice
transplanting which is needed for increasing plant population and long awaited
productivity enhancement issue of the area; ii) diffusion and adoption of high yielding
varieties in the area which is required to replace the varieties like basmati-386, Supra,
Supri, etc.; iii) introducing improved crop management practices as large gap between
average and progressive farmers’ yield and associated variations in crop management
practices can be noticed across farms; iv) shifting to rice combine harvesters which are
essentially needed to control harvest and post-harvest losses in milling and address
the problem of burning of rice straw; v) introduction of paddy drying at farm level in
The economic feasibility analysis shows that, from stakeholders’ perspectives, the total
gross revenue from the Basmati Up-gradation Plan in the focal points of both clusters
(i.e., Sheikhupura and Hafizabad) would be US$105.9 million during the 5th year of the
plan. From development project perspective, it will require an investment of US$73.8
million in a 5-years project both by the public and private sectors. The public sector
investments shall address the areas like strengthening of basmati rice research and
extension services, arranging farmer’s training programs towards adoption of improved
crop management practices, providing capacity building training to all value chain
stakeholders to efficiently manage the value chain, organizing Farmer’s Entrepreneur
Group (FEG) with collection centres, building cluster-based infrastructure,
strengthening international linkages, and offering concessional loans all of which will
cost to the government about 26% of the total investment which will be US$26.4 million.
The remaining 74% of the total investment of US$47.4 million will be brought by the
private sector which will be mainly required for mechanization of transplanting & drying,
extraction of bran oil and modernization of Saila process. We believe that private sector
can be attracted for these investments with the proposed incentives structure by the
government and highlighting the expected potential benefits of the interventions.
The additional operation cost (undiscounted) due to the improvement in the value chain
would be US$52.2 million and net cash flow after (undiscounted) deducting all
associated operational costs and investment at the focal points of both the clusters
would be US$68.1 million during the 5 th year of the project. The Internal Rate of Returns
(IRR) of the whole basmati rice Up-gradation Plan in the focal points of both clusters
was estimated at 28% thus clearly indicating an economically viable project. In addition
to economic returns, the Up-gradation Plan will add to the foreign exchange earning
worth of US$157 million during the last year of the Plan. These investments will also
generate thousands of skilled and unskilled jobs along the value chain nodes including
respective industrial zones, mostly in rural areas. It must be noted that the proposed
Upgradation Plan is only for the central points of each cluster, which covers only 40%
of the total basmati clusters and 30% of the whole basmati growing areas. The targeted
Plan will have tremendous spill over effects within and outside of each cluster. Thus,
the above impact is very conservatively estimated. The summary of cluster-level
information and economic impacts of basmati Up-gradation Plan of each cluster are
presented in the Summary Sheet given below.
The main pillars of the basmati rice Up-gradation Plan are: the capacity building of all
stakeholders in the value chain management, development of cluster-based
infrastructure, reforms in R&D system, mechanization and diversification of the value
chain and strengthening of international interaction and collaboration. Among these,
we give highest priority to the capacity building of stakeholders and reforms in basmati
R&D.
The name ‘basmati’ is traditionally associated with its geographical origin (Bligh, 2000). It is
generally accepted that good quality basmati rice is characterized by extra-long super fine
slender grains with chalky endosperm and a shape comparable with a Turkish dagger;
pleasant and exquisite aroma, sweet taste, dry, fluffy and soft texture when cooked, delicate
curvature, low amylose, medium-low gelatinization temperature, 1.5 to 2-fold lengthwise
elongation with least breadth-wise swelling on cooking and tenderness of cooked rice (Siddiq
et al., 1997). Because of all these attributes, basmati rice commands a premium price in the
world market (Bhattacharjee et al., 2002).
In Pakistan during 2016-17, basmati rice was cultivated on 1.45 million ha producing a total of
2.74 million tonnes of cleaned rice and giving 1.89 tonne/ha yield. During 2001-16, the area
under basmati rice experienced a negative growth in the country, while production and per ha
yield had a positive trend at annual growth rates of (-)0.31, 1.31 and 1.61 percent, respectively,
(Table 1).
Punjab Pakistan
Productio
Years Area Production Yield Area Yield
n
(000 Ha) (000 t) (Kg/Ha) (000 ha) (Kgs/ha)
(000 t)
2000-01 1114 1601 1438 1158 1701 1468
2001-02 1294 1914 1479 1332 1999 1501
2002-03 1317 2176 1652 1377 2304 1673
2003-04 1426 2309 1619 1521 2522 1659
2004-05 1467 2348 1601 1558 2555 1639
2005-06 1535 2642 1721 1659 2920 1761
2006-07 1474 2494 1691 1589 2736 1721
2007-08 1377 2453 1781 1467 2643 1801
2008-09 1548 2602 1680 1697 2901 1710
2009-10 1414 2475 1751 1543 2732 1770
2010-11 1334 2365 1773 1413 2445 1731
2011-12 1121 1889 1685 1241 2124 1711
2012-13 995 1758 1767 1057 1867 1766
2013-14 1193 2057 1725 1298 2268 1748
2014-15 1320 2337 1770 1424 2548 1789
2015-16 1254 2279 1817 1359 3466 2551
2016-17 1353 2524 1866 1454 2740 1885
Growth rate (%) (-) 0.54 0.6 1.14 -0.31 1.31 1.61
Source: Government of Pakistan, 2018a.
Over 92% of basmati rice production in the country comes from Punjab. In Punjab, the area
fluctuated between 0.95 million ha in 2012 to 1.55 million ha in 2008, while production varied
between 1.76 to 2.6 million tonnes during the period. Overall during 2000-2016, the basmati
area in Punjab declined at a rate of 0.54% per annum, while yield and production increased
at the respective rate of 1.14% and 0.6% per annum. Both area and production experienced
a serious dip from 2011 to 2013 which was subsequently recovered (Figure 1).
In Punjab, during 2016-17, basmati (aromatic and non-aromatic) varieties are cultivated nearly
on 77% of total rice area planted, while their share in total rice production is around 73%.
Remaining 23% area and 28% of the total production goes to course-grain varieties
(Government of Pakistan, 2018). More than 7 basmati varieties are grown in the province, of
which Super Basmati (aromatic) and Kainat (non-aromatic) are the two dominant varieties
occupying over 69.2% and 28.3% of total basmati area, respectively (Table 8). In the recently
conducted field survey, Super Basmati followed by Kainat and Basmati-386 (aromatic) are
found to be dominant varieties collectively planted at 95% of total basmati rice area during
2017 (Bashir et al., 2018).
Considerable changes in basmati varietal mix spread can be seen during 2010s. An overtime
substitution of Super Basmati1 with Kainat-1121/PS-22 has taken place in the rice-wheat
1
The line was evolved through hybridization of Basmati-320 and line 10486. Since its approval in 1996
for general cultivation, it gained popularity among rice growers for its longer grain, aroma, and better
cooking quality. The variety also gained attention of its quality among international buyers (Bashir et al.,
2018).
2
Indian Pusa-1121 variety, recognized in Pakistan as PK-1121 (or Kainat), was evolved through the
process of hybridization over a long breeding process in Indian Agricultural Research Institute (IARI).
The variety is known for its extraordinary kernel (grain) length, which can be as much as 8.2 millimeters
(0.32 inches) for a single grain, the longest ever known released rice cultivar in the world. It has very
high kernel elongation ratio ranging from 2 to 2.5, i.e. length of cooked to uncooked kernel. When
cooked, the rice does not turn sticky, possesses minimum breadth-wise expansion with intermediate
alkali-spreading value and amylose content. It was leased for commercial cultivation in kharif season
of 2003 (see Annexure-1 for its pedigree). By 2007, the variety was rapidly popularized among Indian
farming community, as Pusa-1121 is photo-sensitive, requires less water, matures early and yields 4.5-
5.0 tonnes per ha as compared to 2.5 tonnes per ha for traditional tall basmati.
Table 2: Trends (%) in area under different basmati varieties in rice-wheat belt of
Punjab
2010- 2011- 2012- 2013- 2014- 2015- 2016-
Varieties 11 12 13 14 15 16 17
--- (Percent area under different basmati varieties) ---
Super Basmati 93.53 92.95 90.65 83.17 78.02 71.12 69.25
Kainat-1121/PS-
2 2.34 0.60 3.10 14.55 19.59 27.33 28.28
Basmati-385 1.25 0.96 0.40 1.11 0.89 0.80 0.67
Basmati-2000 0.00 0.06 0.07 0.00 1.22 0.74 0.51
Basmati Karnal 0.00 1.93 0.00 0.35 0.28 0.00 0.00
Basmati-370 0.00 0.06 0.00 0.12 0.00 0.00 0.00
Basmati
Shaheen 0.00 0.06 0.00 0.00 0.00 0.00 0.00
Other Basmati 2.89 3.37 5.79 0.70 0.00 0.00 1.29
Source: Government of the Punjab (Crop Reporting Services Department), Lahore (2018c).
In Pakistan, the ‘Kainat’ variety was imported in around 2006 and officially released in 2013.
Because it is high yielding and fetch about similar or sometime even better farm gate prices
as Supper Basmati or Basmati 386, its adoption is rapid. The variety is non-aromatic but very
much suitable for parboiling processes. Therefore, the parboiling facilities have mushroomed
in the region. Currently parboiled plants are operating in the basmati growing region of ‘Kalar’
in Punjab. In parboiling process or preparing Saila rice, paddy is soaked in water for a certain
time period and afterward dried and then milled. In this way, the starch inside paddy grain is
gelatinized, and after removal of outer paddy layer, the rice grain appeared yellow in colour,
which can be darkened according to the requirement. In the process, however, the bran losses
its oil quality thus cannot be processed into bran oil suitable for human consumption but it may
be used for other industrial by-products. The parboiled rice grain is relatively harder than the
non-parboiled rice and upon cooking; there are little chances of grain burst. Any rice can be
milled with this process, basmati or non-basmati rice (Choudhary, 2016), but in India and
Pakistan, it is most popularly done with basmati long-grain non-aromatic rice like Kainat in
Pakistan and Pusa in India due to high consumers’ demand. Detailed parboiling processes
are explained in Annexure-2.
Parboiled rice is favoured by consumers and chefs who desire an extra fluffy and separately
cooked rice, and presently very popular amongst the commercial caterings to prepare salty
rice dishes as ‘Biryani’ as well as sweet rice dishes as ‘Zardah/Mutanjan’ at the occasion of
marriage parties and other festivals. The popular dishes of rice are “boiled rice”, “Zardah”,
“Pulao” and “Biryani” that are relished almost universally.
This shift started with the development and release of a series of ‘Pusa’ type varieties by
Indian researchers. Initially, Pusa-1121 was released in 2003 which shifted the yield frontier
from 3.0 t/ha to 3.6 t/ha. The gain was further strengthened with the release of Pusa-1509 in
2010 which further enhanced the farm-level yield to 4.25 t/ha. This not only reduced the market
price of basmati rice for traders but also improved the profit of the farmers, thus creating win-
win situation for both parties (Table 3). These benefits provide the quick drive for adoption of
these varieties.
As noted in Footnote 2, Pusa varieties are good for par-boiling, efficient par-boiling
technologies were developed in India. However, these developments with Pusa varieties
would have been meaningless if Indian traders would not have adopted pro-active commercial
strategy. The Pusa-varieties gave completely a new product to traders to sell. It has much
longer kernel (grain) length than traditional basmati varieties, but has little aroma especially
after parboiling. Indian traders through product promotion strategies, such as food stalls,
propaganda campaign, etc., convinced the Middle East consumers that aroma is not so
important especially when par-boiled rice is cooked which gives completely a new attractive
look to the dish. In addition, the catering industry of India introduced internationally a new
variety of dishes called ‘Biryani’ (instead of ‘Murgh Pulao’ from aromatic basmati varieties)
3
In Steaming Process, steam passes through paddy grains, and upon drying paddy husk is removed.
The rice grain inside remain white, however, its surface become harder and upon cooking, the grains
do not burst (Choudhary, 2016).
Some policy factors also favoured Indian traders which are: i) Availability of highly subsidized
inputs (i.e. fertilizers, pesticides, custom-hiring of sowing and harvesting machines) gave
market edge to Indian farmers and traders vis-à-vis Pakistan where inputs are relatively less
subsidized. ii) Although, India banned the export of non-basmati rice in April 2008 through
September 2011, but Indian traders continue exporting Pusa rice as basmati under the nose
of Indian customs. iii) Indian Government also withdrew Minimum Export Price (MEP)
regulation from basmati rice, which allows Indian traders to play around with the market as it
suits them.
International political environment also favoured Indian traders. Not affected by USA sanction
under the Food vs Oil Program, India could export food grains to Iran. On the other hand,
Pakistan’s trade was routed through the Bank of New York, which was suspended by the US-
Government. Hence, Pakistan was deprived of its niche Iranian rice market. In addition, Iranian
Government also offered other facilities to India4 during sanction period.
On the other hand, Pakistan could not respond quickly to the changing basmati environment
internationally. First of all, there was no counter strategy to nullify the Indian propaganda on
aroma and traders could not convince the Middle East consumer that aroma is in fact the most
important element in basmati rice dishes. Secondly, its research system could not develop
parallel to ‘Pusa’ varieties of its own which can compete with Indian varieties. Although some
seed companies brought the seed of Pusa varieties from India and was able to get it released
officially with the name of PK1121 (commonly known as Kianat) in 2013, but it was too late.
India by then moved to higher Pusa varieties and Pakistan remains behind in technological
front. On top of it, the Indian government support to farmers through input subsidies, especially
free electricity for tube wells, is generally higher than in Pakistan. Aslam (2016) reported that
49% untapped productivity gaps in Pakistan can be attributed to poor research (12%) and
weak agricultural advisory services (37%). In addition, the export of Pakistani basmati rice has
been impacted by leaf blight, bearish trade practices, and inefficient market conditions (ADB,
2018). The Chairman of REAP pointed out that Indian basmati industry is more organized in
approaching international market. Lack of support from the Pakistani government to establish
brand image is also a factor in losing the competitiveness.
In the current scenario, Pakistan is losing trade war in basmati rice with India, as is evident
from the export growth trends. It should be noted that in the drive to gain basmati share, India
has expanded the basmati market from US$1.1 billion in 2006 to US$4.58 billion in 2013
(Table 4). India not only has captured the additional expanded market but also encroached
upon Pakistani share thus the later not only lost its relative share to India but also could not
maintain its absolute level of export both in quantity as well as in value (Table 4).
4
Iran has decided to open a direct route with India to import basmati rice from the country
[http://www.business-standard.com/article/markets/basmati-rice-exports-to-iran-via-dubai-soar-
115111001536_1 .html].
While Indian export of basmati increased from 1.04 million tonnes in 2006 to 4.06 million
tonnes in 2017, Pakistani basmati export plummeted from 0.7 tonnes to 0.42 tonnes in the
corresponding period, which is about 45% decline in 11 years. The Pakistani share in export
of basmati quantities declines from over 42% in 2006 to less than 10% in 2017. Similar trends
can be seen in the foreign exchange earnings from basmati rice during the period.
Since 2008, Pakistan has lost its basmati share in all major Middle East basmati markets, as
well as UK, and USA markets (Table 5).
Table 5: Country level share of India in total basmati export market during 2008-2017
Saudi
Years UAE Yemen Iran Kuwait Qatar USA UK
Arabia
2008-09 86.6 71.7 44.6 38.2 89.1 18.3 73.9 67.7
2009-10 87.9 72.6 48.8 66.1 91.8 9.6 59.1 39.5
2010-11 89.4 70.2 53.3 75.5 94.5 12.6 73.9 52.6
2011-12 92.1 79.1 60.7 82.3 97.0 24.2 86.9 77.4
2012-13 91.9 65.3 77.6 96.2 97.8 75.6 81.7 82.9
2013-14 93.2 49.5 71.4 99.6 96.4 60.0 81.1 71.7
2014-15 95.8 71.8 82.5 99.8 97.8 87.5 81.8 79.7
2015-16 95.9 85.0 72.9 99.3 99.8 72.2 84.7 88.5
2016-17 96.6 80.8 79.6 99.4 98.6 86.3 85.8 100.0
Overall, Pakistan has lost basmati share in international market from almost 46% in 2006 to
less than 10% in 2017. The decline started more rapidly in 2010 when India consolidated its
impact of innovation by releasing Pusa-1509 variety (Figure 2).
Total Pakistani rice export has been fluctuating between 3.4-4.2 million tonnes during 2017
(Table 6), but the proportion of basmati rice to non-basmati rice in total rice export quantities
has declined from 31% to 12% during the period. Similarly, the total value of Pakistani rice
export had touched to US$2 billion, but the share of basmati in the value of total basmati rice
export has declined from US$953 million to US$525 million, i.e., from 46% to 26% of the total
export in the corresponding period. In total, the export of rice from Pakistan is confronting with
a seriously crisis situation during 2010s (Table 2). This continued discouraging position led to
piling up of the carry-over stocks and falling domestic basmati prices within the country. The
government had to provide financial support to farmers and traders costing billions of Rupees
to partially compensate the losses during 2016.
Source: Quality review Committee (QRC) & Trade Development Authority of Pakistan (TDAP)
Table 7: Top basmati rice importing countries from Pakistan during 2017-2018
Average price
Quantities (000 tonne) Values (000 US$) (US$/ton)
Non- Non- Non-
Basmat Basmat Basmat Basmat Basmat Basmat
Country i i Total i i Total i i
UAE 74.86 109.68 184.538 89.4 42.3 131.6 1194 385
UK 66.93 2.81 69.733 64.3 2.3 66.6 961 834
Belgium 46.59 5.48 52.068 49.6 4.3 53.9 1064 794
Oman 32.80 38.39 71.198 37.8 26.9 64.6 1178 699
Saudi Arabia 28.04 56.70 84.744 31.2 35.2 66.4 1113 621
Italy 27.57 6.70 34.268 28.2 4.9 33.1 1024 733
Source: Quality review Committee (QRC) & Trade Development Authority of Pakistan (TDAP)
The above macro-level analysis suggests that Pakistan is fast losing its basmati
competitiveness in its international markets. To remain competitive, Pakistan must put the
whole value chain of basmati in order. The Planning Commission of Pakistan initiated this
study to identify various constraints, suggest appropriate interventions and evaluate their
feasibility at various segments of the value chain. As situation may be different in various
basmati clusters, the analysis will be conducted at basmati cluster levels. Based on this
analysis, an upgradation plan for each cluster will be suggested to improve the
competitiveness of basmati rice.
ii. To characterize each cluster and conduct a diagnosis and SWOT of the basmati rice
value chain in each cluster
iii. To identify technological, institutional, infrastructure and policy gaps in each cluster
iv. Assess the potential of basmati rice production in each basmati rice producing cluster
vii. Make suggestions and prepare an upgradation plan to improve the competitiveness of
the basmati rice sector in Pakistan.
Following generic and current updated parameters and indicators were used in collecting the data:
The author used the data set generated to identify and characterize the basmati rice clusters,
conduct SWOT analysis, describe the value chain, identify gaps and opportunities, suggest
interventions, and set values for various parameters used in feasibility analysis. The
investments required for various interventions and associated costs were quantified, and
expected benefits of each intervention were also estimated. The Net Present Value (NPV) and
Internal Rate of Return (IRR) of the whole package of interventions to upgrade the identified
clusters were worked out. Basmati Rice Cluster Transformation Plan is also formulated which
identified the useful signals in each cluster for updating and scaling up the whole value chain
of basmati rice on sustainable ground. The Basmati Upgradation Plan is initially designed for
the focal point of each basmati cluster. However, we believe that the Plan will generate forward
and backward spill over effects to the surrounding districts and regions of the focal point.
Mainly these spills over effects will open up the additional income and employment
opportunities through boosting productivity of land, labour and capital resources across the
value chain and benefit all stakeholders including farmers, commission agents, processors,
service providers, traders, consumers, etc.
In Pakistan traditional DSR is reported on limited areas across southern part of Punjab and
still warrants a big challenge for both research and extension wings of the agriculture
department for its standardization, popularization and adaptation. The author of this report
observed that Rice Research Institute (RRI), Kala Shah Kaku (KSK) has also introduced the
DSR technology in different parts of the Punjab. But, the diffusion process is very slow due to
number of reasons, especially lack of expertise on the part of farmers, unsuitability of
hard/clayey soil type zones (mostly in ‘Kalar’ tract) and the danger of dense weed infestation.
Therefore, DSR technology got less reception in the Kalar tract. However, visiting and talking
with the people in number of villages of Narang Mandi, Muridke, Malikay, Kamoke,
Eimanabad, Wazirabad, Daska, Nowshera Virkan, Ali Pur Chatta areas of Union Councils, we
In the stakeholders’ discussions, they pointed out that some potential companies in basmati
rice processing can improve its value chain. For example, Matco Foods Limited, which is
Karachi based leading basmati rice exporting company for over 50 years across 60 countries
in the world, is in the process of expanding its operations into new rice products, such as rice
glucose, and rice protein at its own plant through seeking and adopting the Chinese
technology. Similarly, rice bran oil, which is considered most healthy edible oil and already
being produced in large quantities in China, India, and Vietnam, is also being marketed in
Pakistan although economic viability of its local production is not yet clear. In this report, the
feasibility of bran oil extraction will be explored.
Controlling weeds with just through chemical gives the weeds a chance to adapt to that
chemical. Integrated weed management practices in rice includes proper land preparation,
water management, hand hoeing, crop rotation, and herbicides as a last resort. In Pakistan,
where rice seedlings are transplanted into puddled soil, the competition at the initial stage
while crop establishment is in progress is minimal than in the DSR fields.
Conclusions: In the basmati rice clusters, the most commonly weed management operations
in vogue are land preparations through puddling method, where good water management
In view to overcome the shortcomings of R&D funds, Pakistan always look for and explore the
local as well as international R&D partners. For example, since independence, Pakistan has
been member of Consultative Group of International Agricultural Research (CGIAR),
especially International Rice Research Institute (IRRI), Philippines. The technical assistance
from IRRI in the areas of breeding through germplasm sharing and capacity building had been
an integral part of the rice research system in the country. The development in the rice
production up to this point is an evidence of IRRI technical support to Pakistan during the last
50 years or so.
In a relatively recent development, Pakistan has entered a new partnership agreement with
Chinese government; name the ‘China Pakistan Economic Corridor’ (CPEC). It has multiple
areas of mutual cooperation in terms of financial, capital, technical, capacity building,
communication, infrastructural networking, etc. Chinese companies have already been
engaged in development of hybrid paddy and wheat seeds in Pakistan. The Chinese
researchers of Sinochem Group Agriculture Division and Yuan Longping High-Tech
Agriculture Co. are already engaged, in partnership, with Pakistan’s public and private
research institutions (e.g., Guard Agriculture Research Services Pvt. Ltd.), and running pilot
projects at 200 sites to develop hybrid rice varieties.
The Pakistani and Chinese governments have jointly identified a couple of areas for
cooperation in agriculture. China has promised to build agriculture demonstration centres
across Pakistan and supply seeds and machinery to Pakistani farmers. So far infrastructure
projects were a priority in CPEC, but recent government has given priority to include
agriculture related projects in CPEC like building farm-to-market road networks that will
connect with storage, packaging and processing units. Unlike other infrastructure projects
which are mostly taken up by the private sector, the agriculture infrastructure development
projects in CPEC is waiting for the long-term state funding. Some of the reservations were
also reported in the literature about the implications of CPEC agreement, for example:
The author of this report learned from the traders and processors of basmati rice that Pakistani
rice and its by-products are in high demand, and enjoying the status of niche market in
exporting of brown rice amongst the quality cautious consumers across the European Union
countries as well as in Middle East-Gulf and America.
ii) Saila (Pucca) rice (Cluster- II) - This cluster consists of Hafizabad and Nankana Sahib
districts of Punjab with Hafizabad as its focal point. The total area of the cluster is 204
thousand ha supplying a total production of 407 thousand tonnes, which is about 14%
of the total basmati rice area and production in the country. About 75% percent of the
production in this cluster is comprised of PK-1121 variety, which is mainly processed
for parboiled/Saila (or Pucca) rice. The focal point of the cluster is Sheikhupura district
that contributes 104.4 thousand ha and 213.3 thousand tonnes of Pucca rice, which is
more than one half of the total cluster area and production. The focal point of the cluster
has not only highest acreage under basmati rice cultivation but also highest yield
among the two districts of the cluster (Table 8).
Table 8: Area, production, and yield of major basmati rice growing districts of Punjab
during 2016-17
Rice occupies about 35% of the total annual cropped area in both clusters; however, it is a
major crop during the Kharif season as it occupies about 90% of the total cropped area in the
season in both clusters. The basmati to non-basmati ratio in the total rice area is 70:30 percent.
Fodder occupies another 7-8% of the total kharif cropped area (Government of the Punjab,
2016a).
The Kalar tract of Pak-Punjab situated in between two rivers including Ravi and Chenab called
doaba belt. These districts are operating under the public advisory services of adaptive and
general extension departments. However, the role of private extension advisory services,
especially of pesticide companies to provide plant protection coverage, in both the cluster is
on the rise. The knowledge and approach of the public sector extension service is confined to
the farm-level and very limited to address the issues of the farming and allied community which
is under paradigm shift to meet the global challenges of agrarian economy. The
comprehensive comparison between Cluster-I and II are presented in Table 9. The key
aspects covered in characterization are: varieties planted, crop husbandry, R&D
infrastructure, export, supply chain, certification of international standards, socioeconomic
networking, marketing practices, socioeconomic networking, etc. of Cluster-I and Cluster-II
Varietal Dev. Inputs supplies Rice harvesting/ Upgrading paddy Rice grading,
Research systems, especially threshing/combine drying system branding/packaging,
seed, fertilizer, oldness
Crop Mgmt. pesticide, and Paddy quality – Technology used
Research credit proper drying in rice milling Rice marketing
(maintaining outlets (traders,
Farm machinery Agri. services proper moisture Types of various rice commission agents,
development providers on crop content) products (brown super stores, etc.)
(planting/spray/ management rice, single- polished
harvest/thresh/Dryi practices at farm Paddy marketing rice, double-polished Rice catering outlets
ng Technology level outlets (beoparies, rice, silky rice, (vendors, restaurants,
Research commission agents, parboiled Saila) rice marriage halls, food
Plant density rice mills) and steamed rice streets, others, etc.)
Agricultural technology
advisory services supplier Rice grading,
packaging
Policy incentive
for technology
adoption
Recently released basmati varieties, Kissan, Chenab and Punjab, by RRI, Kala Shah Kaku
are not getting diffused among the rice growers due to the lack of the traits they expect, i.e.,
something additional to the traits in super basmati variety. Moreover, Pakistani breeders are
still emphasizing on developing aromatic basmati varieties unlike Indian's emphasizing on
non-aromatic high yielding with elongated kernel size rice varieties like Pusa series (Kainat
There are many emerging and unresolved issues that need to be resolved through research t
keep basmati competitive in national and international markets, such as: a) Further
improvement in basmati varieties to meet international demand (e.g., improved version of PK-
1121 competitive to Indian Pusa series); b) Discover safe technology to maintain the quality
of rice after parboiling (e.g., to control Saila rancid in storage); e) Promotion and training of
Integrated Pest Management (IPM) techniques or use of organic pesticides, especially to
control weeds; e) to promote mechanization of production processes; f) diversification of
basmati value chain. .
Recently the National Rural Support Program (NRSP) has launched a unique development
project in Saila rice zone (Cluster-II) of Punjab to mobilize farmers through establishing
community-based organizations for the purpose of setting community-based marketing,
processing and trading facilities. In this process, the resources are pooled for accomplishing
the above-mentioned activities in order to gain maximum profit share by the farmers. These
community organizations are also linked with provincial agricultural research and extension
services for advisory services. These organizations can be used as catalyst in improving the
whole value chain of rice basmati clusters.
Several internationally accredited quality certification laboratories, like PCSIR under Ministry
of Science and Technology, NIBGE under the aegis of Pakistan Atomic Energy Commission,
Grain Testing Lab. at Karachi, PARC under Ministry of Food Security and Research have
been established in the country.
Fauji Fertilizers Co. (FFC), Engro Fertilizers Limited (EFL), Ali Akbar Group (AAG), Jafar
Brothers Limited, Fatima Fertilizer Company, Syngenta, Bayer Crop Science are the main
crop input (chemicals and seed) suppliers and all of these have well established dealership
and distributor network system across the Punjab especially in basmati rice belt. Seed is
mostly supplied by the Punjab Seed Corporation Pvt. Ltd., & Seed Council, and on small scale
quality basmati rice seed is also supplied by the RRI, KSK as a breeder seed, truthful labeling
seed and foundation seed for popularization as well as growers’ feedback. Seasonal, short
term interest free loans are also disbursed by the scheduled banks for purchased inputs
including seed and fertilizer. Commonly, farmers are using below average and imbalance
fertilizer input levels, therefore, it impacts negatively, equally on output productivity and quality,
except few progressive growers. Input and output quality monitoring system is not well
established in Pakistan and its situation is better in Punjab than other provinces. The public
institutions performance and Standard Operating Procedures (SoPs) are same in both
clusters.
In 'Kalar' tract, mostly granular as well as liquid pesticides are applied to protect the pest
attacks at different stages of paddy crop growth. For example, the granular pesticides were
used to control rice leaf folder, stem borers, grasshoppers (i.e., green and red), and liquid
pesticides spraying to control green leafhoppers, aphids and Jassid on rice crop. On average,
farmers are spending to control all pests including weeds ranged from Rs.4500 to Rs.5500
per acre (Inayatullah et al., 1986; Field Survey Information, August-October, 2018). Serious
lapses observed in public agriculture sector, especially plant protection department, because
the pesticide companies are aggressively selling their products to maximize their profits. It is
very common problem noticed on the farmers’ fields pertaining to non-judicious use of micro
and macro nutrients, pest control measures and insufficient pest management strategies.
Since, farmers' practice like reckless use of pesticide due to lack of pest scouting awareness
& non-declaration of minimum resistance limits (MRL) - defence against residual effects of
pesticides on the living organisms, as well as, lack of government prudent monitoring system
to check the quality of inputs and outputs at right time, form and location. As per author’s field
observations, farmers had adopted the behaviour of overusing of pesticides even without
monitoring of pest load; farmers are used to apply pesticide as a precautionary measure to
avoid severe pest losses on fine basmati paddy crop, especially the productivity of super
basmati crop. It is general opinion that the allied departments like Plant Protection and
49 KNOWLEDGE FOR LIFE
Agricultural Extension are not pro-actively addressing these issues as compared to the
pesticide private companies may be due to their business opportunities by selling their
products. The crop husbandry practices are not much different across the basmati clusters
except, plant protection, weed control and frequency of irrigations. The Cluster-II area of
Kainat variety belt is relatively drier and exhibits separate flora and fauna. It requires more
care of frequent irrigations to snub weeds germination as well as paddy plant establishment.
Some more weedicide application performed than Cluster-I paddy crops.
The strategic solutions may be opted by the government to resolve above mentioned issues
by creating awareness, tax rebates/ interest free loan provisions on imported farm machinery
like rice transplanter, rice combine harvesters and dryers. Since, these farm
machinery/equipment and technology require lumpy investment to procure as well as
launching of skill development programs in line acquaintance about the intervention of
technology in order to earn maximum benefits at all nodes of value addition players through
satisfying the needs of the ultimate stakeholders/producers.
5.7. Harvesting
The traditional way of manual harvesting and threshing has totally vanished. Presently, 80%
of the farmers are harvesting and threshing the basmati paddy crop mechanically by
employing wheat combine harvesters (using both for wheat and rice crops) with rental charges
of Rs.2500 -3000 per acre (takes 30-40 minutes). More than 80 percent farmers are using this
machine in both basmati rice clusters. The paddy straw harvested with wheat combine is not
much useful, especially for feeding to the animals, and the field is left with longer stubbles.
Recently, upgraded rice combine harvester (Kubota) has been introduced, designed by the
Korean/Chinese technology for paddy harvesting and threshing. Its rental charges are
Rs.4500-5000 per acre (takes 1.2 hour). Presently, Kubota combines are covering about 15-
20 percent harvested area of paddy crop. The paddy straw harvested with Kubota machine
has many advantages like: relative green paddy can be used for animal feeding; short stubbles
in the field enables easy ploughing for next crop; saving more than 60% harvest losses thus
giving 6-7 maunds higher production per acre compared to paddy harvesting by wheat
combine harvester; avoiding health effects of smog due to rice straw burning in cold winter
season in metropolitan cities of rice belt and Lahore. It suggests alternates to straw burning
and support allied agro-industrial.
The traders, wholesalers–sheller owners buy the paddy directly from the farmers. The
commission agents often charge 1-7 percent of the total value of paddy received from the
growers. In addition, they deduct one-kilogram paddy per 40-kg on account of 'Palidhari' as a
labour charges for loading/unloading and weighing services, etc. of paddy. The growers who
do not take loan from the 'Arthi' pay commission or Arhat @ 1-2 percent of the value of produce
sold, which increases from 3 to 7 percent, if some money is borrowed from the Arthi. On
average, the Paddy growers/Arthi/Sheller Owners/Wholesaler/Retailers purchased paddy of
different basmati varieties during the season as: Super Fine (banned): Rs.900-1050; Supri
(Banned): Rs.1100-1300; Basmati-386: Rs.1100-1300, Super basmati: Rs.1500-2000; The
basmati rice wholesale prices of major varieties recorded during survey period in September-
October, 2018 are as follows: Basmati-386: Rs.2100-2300, Super Basmati: Rs.3600-4000.
Supply chain of basmati paddy exhibited numerous inbuilt constraints throughout its flow from
the farmers' field to the rice processing mills including high moisture content prone to aflatoxin,
farmers’ exploitation by commission agents lead to offering low paddy rates, mixing of inferior
basmati rice varieties of Basmati-386, Supri, etc. in Super basmati especially by Sheller mill
owners as well as basmati traders.
The strategic post-harvest solutions need to be followed by taking care of efficient harvest and
quick disposal of quality products of paddy and its by-products including Katcha and Saila rice
commodities by using marketing intelligence and interconnected structure of regional and
inter-regional nodes of markets. Since, farm machinery like rice combine harvester may be
employed to save harvest losses and additional contribution by saving rice straw that would
generate higher value additional towards the kitty of all stakeholders involved. The farmers
will gain relatively better share out in the form of marketing margins by less harvest losses
plus additional wheat straw for the animals besides reduction in the cost of production.
The prices of paddy and its main products, especially rice are low at the commencement of
the season, increasing gradually as the supply shrinks against demand as well as on aging of
Katcha rice, but aging parameter is not counted in case of 'Saila'. The price of PK-1121
(Kainat) used in Saila was Rs.1700-2300 per 40 kg during early season of crop harvest. While
the wholesale price of its parboiled was Rs.5000-5700 per 40 kg during early October, 2018.
The price of Saila is normally more by Rs.250-300 per 40 Kg than 'Katcha rice'.
The exact grading is not determined for the paddy and rice products except purity of variety,
moisture content, head rice and broken categories of rice. The supply chain limitations of
paddy of ‘Kainat’ (PK-1121) are similar as explained in Cluster-I, but inbuilt bottlenecks of its
processed products (Parboiled/ steamed) include rancid of stored grain---aging lead to
rejection by the consumers, resultantly reducing its demand and price.
Processing through passing the phases of drying, storing and milling to recover quality
products of Katcha and Saila rice each have distinct channels to pass through in value addition
phases. In the process, the importance of efficient technology of mechanical dryers as well as
rice sheller mounted with upgraded Saila rice making plants are necessary to yield quality
products to meet consumers’ demand and as fetch good price.
REAP representative said that the process for quality finished rice starts from paddy
procurement. The paddy is procured and dried and then kept under silos for effective storages.
It is then cleaned, husked, polished, graded and then packed for exports. The value-addition
of rice ranges from 100 percent to 140 percent. The paddy of basmati is procured at $450/
metric tonne while it is exported at around $1000 PMT. Parboiled and steamed is exported at
around $1200 PMT. (Web portal information, December, 2018).
Several brand names in export of rice have been stablished brand in packing of 1, 2, 5 and 10
kg. However, majority of companies are trading as non-branded product in bulk lots. The
branded products are earning better reputation as well as higher price than the non-branded
products.
The major constraints being faced among the rice exporters that hinder free trading are
complex procedural formalities including rules and regulation especially for food safety
measures varied for different importing countries, and import/export duty charges, etc. To
overcome these constraints, Standard Operating Procedures (SOPs) be designed for
assurance of quality control mechanism acceptable globally.
On top of all, like the Indians, there is an urgent need of adopting the aggressive promotional
campaign of Pakistani brands especially in Saila of Kainat for rapid reception amongst the end
users through different means like launching international food contests in food street galas,
rice catering outlets-vendors, restaurants, marriage halls, food streets and others. This type
of efforts will definitely promote the basmati rice products’ marketing domestically as well as
globally to fetch value addition for the kitties of all stakeholders starting from farmer to
consumers.
Both of the basmati rice clusters have their unique strengths, weaknesses, opportunities and
threats, the details are illustrated in Table 11. The salient features of these clusters are
suitable ecological mainly due to enabling sun light, temperature, natural precipitation, sweet
ground water, irrigation network through canals and tube wells, soil types, farmers’ expertise
gained from past generations, physical location of the crop area near to roads, markets,
processing mills, etc. Some major threats came up in the SWOT analysis are: i) rice straw
burning leading to environmental pollution triggers smog problem during winter, ii) lodging in
Super Basmati in Cluster-I due to imbalance use of nutrients and pest attacks, iii) overuse of
pesticide lead to added costs and residual effects, iv) stagnant or even declining total factor
productivity due to lack of organic matter as well as other micronutrients, v) problem of
aflatoxin manifested due to green crop harvests, vi) declining export trend of Pak. basmati rice
due to change in consumers’ demand, un-competitiveness due to low productivity; changing
consumers’ taste preferences and convenience of catering service providers, vii) lack of
sufficient R&D funds as well as laxity in the release quality basmati varieties/seeds superior
than Super basmati, viii) inefficient processing of rice sheller mills as well as for preparing
Saila rice, etc.
The Pucca-Rice Cluster-II production also faces tough competition with India in international
market. For the last two decades India has been ahead of Pakistan in releasing better yielding
non-aromatic basmati rice. The latest comparison shows that the Pusa varieties like Basmati-
1509 yields about 26% higher at average farmers’ field than Pakistani PK-1121 (Kainat)
variety. Overall, India has developed better parboiling technologies, while in Pakistan the
efficiency of the technology is mixed. According to farmers, the PK-1121 is also gradually
becoming vulnerable to many diseases.
The gradual shifting from manual to mechanized paddy harvesting in the rice-wheat area of
Punjab dates back to the introduction of Basmati-385 when it had significantly higher yield
compared to Basmati-370. The shortage of harvesting labour emerged as a major problem.
The introduction of wheat combine-harvesters for paddy harvesting rescued the farmers,
despite paddy and straw losses at harvesting and increased percentage of broken rice at
milling. Secondly, the farmers have to either burn paddy straw and left-over stubbles in the
field or utilize disc plows for preparing their fields for wheat plantation. The burning of rice in
the field also created smog problem causing pulmonary diseases. The introduction of wheat
straw chopper has provided another alternate. Despite these disadvantages, the shifting to
mechanical harvesting was fast.
Recently, however, with the increasing concerns on the environmental impact of agriculture
production, especially with smog, and high cost of the existing wheat combined harvester used
in basmati, in terms of high broken percentage, changing basmati rice harvesting and
threshing method has become essential as well as a challenge for basmati stakeholders and
policy makers.
Rice seed or the paddy kernel is covered with two layers: bran (the inner layer) and husk (the
outer layer) (Figure 8). Paddy becomes rice only when the two layers are removed properly
through milling. During milling, first brown rice is extracted by removing the husk from paddy,
leaving the bran layer intact around the kernel --- this process is called “husking”. In the second
step, the bran layer is removed by polishing machines that rub the gains together under
pressure --- this process is called “milling”. The output is a polished white kernel or fine rice,
which is ready for cooking (Patil, 2011; TDAP 2010). In general, the term rice milling implies
both husking and milling.
Pakistan has a great challenge to indigenize this technology; otherwise, the country will further
loose its competitiveness with India in basmati value chain. Bran oil extracting machinery is
costly for Pakistan as India is one of the leading countries in rice bran oil technology. Its’ per
litter cost is close to sunflower oil. Thus, currently bran oil extraction can be commercially
viable if it fetches as high price as sunflower oil. However, by indigenizing the technology, the
63 KNOWLEDGE FOR LIFE
cost can be decreased significantly (for costs details of bran oil, See Annexure-6). Rice bran
oil can also be blended with other oils in many countries including India (The Express Tribune,
20th August 2014) https://tribune.com.pk/story/750936/innovative-concepts-setting-up-
pakistans-first-rice-bran-oil-plant/
Realizing several advantages of parboiled rice, India has mastered not only in its processing
but also in marketing. As noted earlier, India used this product not only to expand basmati rice
market, but also to encroach on Pakistani basmati share. Pakistan came late in the par-boiled
rice technology and feel threat to further loose basmati market unless it gets mastery in
parboiling technology and marketing of parboiled rice. The efficiency of processing paddy into
Saila in terms of the quality of the produce and ratio of broken rice is low compared to India -
-- converging into higher milling costs. In addition to the yield gap between Indian and
Pakistani in non-aromatic varieties, the gap in the efficiency in parboiling cost must also be
closed.
The BLB, Paddy blast, stem borer, etc. are the major threat for Basmati rice. At present, some
mildly susceptible BLB resistant varieties are available. As per demand of REAP (Rice
exporters Association of Pakistan), PS-2 fine extra-long grain rice without significant aroma
has been approved in the recent Punjab Seed Council meeting held in 2018 with a new name
of PK-1121. Rice exporters did not wait for release of new variety and brought Indian extra-
long grain varieties to meet the demand for extra-long-grain. Recently Kainat-1509 and Kainat-
1401 brought from India are at adaptability stage at the farmer’s fields (Bashir et al., 2018).
These efforts in developing and adapting new basmati varieties, both aromatic and non-
aromatic, are commendable. Although, generally, it is claimed that the new varieties are higher
yielding as compared with Super Basmati. However, these varieties could not get popularity
among the farmer as Super Basmati is still the major basmati variety cultivated in Kallar tract.
Although, PK-1121 has been recently officially approved, but it has been already adopted by
majority of farmers in Pucca-Basmati Cluster-II. However, we believe that if new available
approved varieties are properly pushed through a campaign, the average yield in Cluster-I can
be increased by 10%, while 20% in Cluster-II. Higher anticipated potential in Cluster-II is
because of the higher gap between the experiment and average yield of Kainat type long-
grain (non-aromatic) varieties.
Recently, few progressive farmers imported Chinese rice transplanters and have successfully
used it for rice transplanting in on a large area in Hafizabad district. They have established
success stories and some service providers have also now involved in the diffusion of
mechanical transplanting package in basmati rice farming communities.
The mechanical transplanting, as reported by few farming communities who have adopted this
technology, can save more than 82 percent labour and increase plant population by nearly 18
percent compared to manual transplanting (Bashir et al., 2018). It can be anticipated that
application of other inputs according to plant population shall certainly contribute in increasing
paddy yield in the area. Hence, it can be easily assumed that mechanical transplanting can
increase existing yield by at least 15%.
Farmers are cultivating rice since decades, however, when new technologies like varieties,
chemicals, management practices, etc. are introduced, their knowledge about latest
development in production technologies need to be upgraded on regular basis for sustained
productivity growth along with conserving agricultural resource (Ali and Byerlee, 1991).
According to the extension workers in each cluster, the farming community is already being
educated on the updated knowledge about day-to-day developments in crop farming through
electronic and print media along with demonstrating various technologies through
workshops/seminars/demonstration plots/farmers’ field days of the departments of agricultural
extension, agricultural advisory services, etc. However, results are not very effective, as it is
mostly supply driven (Ali et al., 2018). If advisory service is made more target and result
oriented, this can significantly improve the farm management practices and harness yield
potential. However, acknowledging the slow institutional change, we assume that only 5%
increase in yield is possible through improved management practices.
The introduction of combine rice i harvesters (called Kabota) by some progressive has created
a great opportunity to address these issues. At present, this intervention is at infancy stage.
To diffuse this technology at a faster rate so that the entire paddy area can be served with
Kabota within five years span;, however, it will require certain incentives. But once adopted, it
can save at least 15% of the harvesting losses. This will not only result in saving farmers’ loss
of paddy due to shattering and rice straw in the field, but also address environmental issues
plus easy land preparation for the cultivation of following wheat crop.
In rice shellers, paddy is normally sun dried before husking. The problems of using sun-drying
floor are: i) needs more space, while land is becoming limited; ii) fully depends upon weather
condition, therefore, the frequency of hot-sunny days is low during wet and cold seasons; iii)
causes a higher loss due to animal and other disturbances; and, iv) results in low quality of
grain due to sudden rains, dust and other foreign materials contamination (Nugraha et al.,
2007; Swastika and Sutrisno, 2010).
However, new opportunities have emerged with the invention of solar drier. The use of
mechanical drying systems offers so many advantages over sun-drying like maintenance of
paddy quality, safe drying during rains and at night, increased capacity, easy control of drying
parameters and the potential for saving on labour cost. The solar drying can be provided to
Basmati Farmers Entrepreneur Groups (FEGs) at union council level, so that when paddy
comes from the field, it can be dried before it is delivered to traders or rice sheller owners.
This can not only improve the quality of rice, reduce post-harvest losses but also minimize
farmers’ exploitation due to arbitrary hand-felt method of moisture measurement by traders.
There is considerable scope for improving farmers’ returns by introducing paddy solar dryers
to farmers as they have to face price cut from 9 to 13 Rs./kg (which can be saved) if fungal
Studies conducted in Thailand and Cambodia showed that the cost of drying in both countries
is equivalent to 4% of total paddy production cost. All the dryers that were successfully
commercialized in Vietnam have drying cost <5% of the paddy value. Case studies in other
Asian countries indicate that mechanical dryers with cost higher than 5% of the paddy value
cannot be introduced successfully (Rice Knowledge Bank, IRRI, Philippines). In feasibility
study carried out in Indonesia by Swastika (2012) revealed that the use of mechanical dryers
proved to be highly profitable compared to sun-drying at the floor. Paddy drying at farm level
using mobile paddy dryers is becoming gradually popular in India.
We assume here that the farmers will receive 20% higher paddy price after solar drying. Seven
percent of this premium will be due to the reduction in moisture content from an average of
25% to 18%, while 10% premium will go due to improvement in quality such as reduction in
aflatoxin and broken percentage. With these assumptions, farmers will receive additional
revenue of US$21.6 million in Cluster-I and 19.0 million in Cluster-II.
5
[http://www.knowledgebank.irri.org/step-by-step-production/postharvest/drying/economic-aspects-f-drying]
Rice bran oil expelling relies on high quality rice bran oil expellers and its state-of-the-art
technology is available with India – though expensive. During oil extraction, rice bran is put
into the feeder of expeller. As the screw worm transports rice bran forward, the space becomes
smaller and smaller, thus squeezing rice bran oil out. The extracted bran oil seeps out though
a small opening in the bottom of the squeezing barrel, where rice bran oil cake cannot pass
through, thus, separating rice bran oil from oil cake. At present, two imported brands namely
Seasons Rice Bran Oil and King Bran Oil are marketed in Pakistan. Keeping in view the
interest of certain class of consumers, there are chances of popularizing it on the lines of
Canolive and Corn Oil in Pakistan.
Our estimates show that sufficient quantities of raw material, i.e. rice bran, is available in the
area and at least two such units can be installed in Cluster-I. These plants can produce over
447 tonnes of rice bran oil to arrest the target of about 900 tonnes of rice bran product. If
properly popularized, these supplies of bran oil can be domestically consumed which can give
a big relief to the edible oil import in the country and save huge foreign exchange. Some of
these supplies can also be exported which can earn foreign exchange earnings. However, for
this proper financial and technical support to the private sector would be needed. One
technical issue is that the bran must be used in oil extraction within few hours after it is
produced during rice milling, otherwise oil quality in it gets deteriorates. However, there are
several technologies available to preserve the bran for several weeks with simple technologies
like heating and using chemicals.
These changes in market and technology have created significant potential for all stakeholders
along the basmati value chain for increasing the proportion of Saila rice and upgrading the
Saila processing technologies. Our consultation with stakeholders suggests that currently
about 60% of Kainat produce in Cluster-II is utilized in Saila processing, which can be
increased to at least 80% to utilize almost all the Kainat production in the cluster. It means the
focal point of Cluster-II (just district Hafiz Abad) has the potential of producing additional of
over 64 thousand tonnes of Saila.
The continued increasing demand for Saila in the Middle East and within the country suggests
that additional supply can be absorbed in the national and international market. The
upgradation of Saila processing technology shall reduce Saila rice manufacturing cost, which
is currently expensive compared to katcha rice. Moreover, incentives in establishing Saila
manufacturing plants shall help the private sector to not only meet the national and
international demands but also to compete with India in the Moiddle East. Raising the
proportion of Saila rice to 80% in Cluster-II will generate additional revenue to the processor
to the tune of US$9.68 million assuming it fetches higher price of US$148 per tonne compared
to the katcha rice.
Firstly, there shall be clear long-term vision of the government about the basmati sector which
clearly sets policies and targets with respect to the type of basmati rice and its byproducts
including Saila, brown rice, rice bran oil, etc., the country should go in the future. The status
of the sector vis-à-vis industry must be clarified.
Thirdly, the R&D system shall be reformed to make it more responsive to resolve the issue
along the whole value chain. The private sector shall be encouraged to get engaged in varietal
development, especially in basmati hybrid where any innovation can be protected. The public
sector research institute shall move towards those issues which currently private sector is not
addressing, like developing efficient high-yielding Saila varieties that can compete with India
in productivity and quality, develop SOPs for efficient management practices to improve
productivity and sustainability, and provide cheap machinery models and SOPs for bran oil
manufacturing, efficient SOPs for Saila manufacturing, etc. The approval of varietal
development shall be made transparent and efficient. The system will be made financially and
administratively autonomous from the bureaucratic control and snags.
Fourthly, support shall be provided to organize Farmers Entrepreneur Groups (FEG) which
shall become the focal points for basmati upgradation Plan. The groups will become a key in
ensuring quality to millers and traders thus induce quality and price-based contract farming
with commission agents, traders and processors.
Fifthly, the public sector especially Ministry of Commerce will work with the private sector, like
REAP, in analysing the changing market demand trends in basmati rice and its quality
requirements in national and international markets and disseminate these to various
stakeholders like traders, mill owners, and FEGs.
Finally, any upgradation plan for basmati rice would require huge operational costs in terms
of additional inputs, machinery, technical skills, etc. that has to be borne by the stakeholders
themselves and usually not accounted in development plan. In the proposed upgradation plan,
financial system will be made to supply the loans to meet additional operating costs to farmers,
traders, processors, and other stakeholders along the value chain.
Basic infrastructure like shed for collection point, room for storage and drying will be
built by the government although land will be provided by the FEGs.
Management of the collection center will be through a hired manager by the FEGs
through consensus but initially paid by the government.
All incentives and capacity building training would be channeled through FEGs.
The FEGs will also be given priority on specialized loans for the purpose of promoting
mechanization of the rice value chain.
The groups will be encouraged to start quality- and fixed price-based contract with rice
mills and traders. The main responsibility of FEGs would be to ensure quality.
From the total R&D funds, special funds will be confined to enhance research
collaboration between international universities and rice related research
organizations, like International Rice Research Institute (IRRI), Australian
Collaboration for International Research (ACIAR), etc. for sharing advanced
germplasm/nurseries and collaborative research on strategic basmati rice issues.
Unfreezing and redirecting the cess funds for creating its Research Endowment Funds
for financing rice research activities in Pakistan. Some of the funds will go to FEGs to
conduct the group level activities, like seed and seedling production, training of
farmers, etc.
The Commodity Board on basmati rice will be given more autonomy to decide and
monitor the research conducted in Rice Research Institute Kala Shah Kaku, NIBGE,
etc.
The extension wing of Agriculture Department will be made more responsive to the
needs of the farmers, traders and processors. New dedicated and professionally
sound staff will be hired to implement the Plan. They will set up demonstration and
conduct training as per demand of the FEGs and trade and processors associations.
The quality and outcome of the training and advisory services will be monitored by the
stakeholders.
Detailed and practical modules will be developed for the capacity building of farmers
for good agriculture practices like: i) testing the latest released basmati rice varieties
and other management practices on their own farm; ii) mechanical rice transplanting
for achieving recommended plant population; iii) periodic use of laser land levelers for
saving water and better pegging of better nursery plants during mechanical
transplanting; v) proper decomposition of Farm Yard Manure; vi) use of balanced
Collaboration with local and international rice related organizations and universities
will be improved. International and local consultants will be engaged in conducting
trainings of the extension staff and researchers on strategic issues like bran oil
production, research on bacterial leaf, maintaining the quality of basmati rice during
production, drying, and processing, etc.
FEGs will select progressive farmers within the group for producing certified seed of
latest approved varieties under the direct supervision of scientists at Kala Shah Kaku,
NIAB, NIBGE and PARC as well as member farmers within the FEGs.
The FEGs will be linked with the service providers of mechanical rice transplanting in
the area for supplying certified nurseries of latest released varieties to other farmers
in the rice belt of Punjab.
Providing financial support to FEGs in engaging certified seed production and the
service providers of mechanical rice transplanting in the area. Financial incentives will
also be provided to the scientists extending their supervisory services in producing
certified seed.
Provision of nursery of certified seed at subsidized rate during project period in order
to achieve early spread of modern basmati rice varieties on farmers’ fields.
FEG member farmers will be trained for certified seed production and nursery raising.
The skills of farmers and other stakeholders in the value chain will be continuously
updated on new emerging methods of cultivation. Incentives will be provided to FEGs
establish demonstration plots by the selected members of farmers in the group under
the guidance of experts of Agriculture Department and Universities on the issues the
group consider to be important. However, the FEGs will be made aware of the new
cultivation methods and their anticipated impact on yield and costs, such as DSR,
mechanical transplanting, optimum use of fertilizer, proper decomposition of manure
and its use, etc.
The key staff of Extension Wings of Agriculture Department will be trained on the DSR
and mechanical rice transplanting for achieving recommended plant population,
efficient decomposition and use of farm yard manure, application of balanced dozes of
fertilizers; and application of recommended doses of plant protection chemicals. This
staff will train the selected members of FEGs on these issues as per their demand.
As noted earlier, the mechanical rice harvesters can significantly reduce the harvesting
losses and mitigate environmental pollution. Providing financial support to the
Based on the recommendation, various types of dryers (e.g. mobile dryers, solar
bubble dryers, solar dryers etc.) already used in various countries in Asia will be
introduced in the focal point of both the clusters.
A total of 290 driers in Cluster-I and 235 driers in Cluster-II would be sponsored in the
cluster focal points of each cluster costing US$12.9 million and US$10.4 million in
respective cluster. These driers would preferably be provided to the FEGs where return
would be proportionately shared according to the investment made by the members of
the group. Each farmer will be charged for the services rendered to him/her.
Installation of Rice Bran Oil Extraction unit is an intervention not being picked by the private
sector in Pakistan despite considerable quantities of rice bran is produced/available in the
Cluster-I. Moreover, India is successfully producing rice bran oil and exporting to the world; so
why not Pakistan? Following strategies are proposed here to install rice bran oil mills and
promote its use in the country:
The government will provide interest free loans on four-year maturity basis to install
two rice bran oil mills,
The import of all machinery used in bran oil production will be duty free.
The bran oil will be promoted among consumers through media campaign.
Keeping in view the rising prospects of marketing of parboiled basmati rice in domestic and
international front, there is a strong felt need to upgrade existing parboiled paddy preparation
technology in the Cluster-II where varieties suitable for parboiling are already grown.
The production increasing intervention of Kainat in Cluster-II will provide increased raw
material for Saila making.
As parboiled paddy production requires only three operations, i.e. soaking, steaming
and drying, the paddy drying intervention above will be dovetailed with Saila making.
The mobile paddy dryers will be introduced for Saila paddy manufacturing afterwards.
Interest free loans on four year-terms will be offered to set up the new Saila plant in
Cluster-II.
Special incentives will be provided to export Saila to Middle East to enable the traders
to compete with India.
A Market Research Cell will be established at REAP that will continuously analyse
the international trends in basmati rice markets in major basmati importing countries,
including total quantities imported, quality, prices, domestic production and prices of
basmati in Pakistan and India, technological development in the basmati sector
(production, processing, trade, etc.) in both India and Pakistan. The cell will also
forecast the market situation for short and long-run. These trends will be regularly
and timely communicated to the traders, research station, FEGs and advisory will be
issued for necessary action to all stakeholders along the value chain.
Study tours will be organized to explore new potential market and devise strategies
to explore these markets.
Organize rice cooked dishes gala amongst international buyers of basmati rice.
Some international exhibition in the rice-wheat belt of Pakistan for the basmati rice
importers of the world with due arrangements for field visits and visits of the rice
processing mills for the trust building on quality.
6. (a) Oil Extraction from Rice Bran - Katcha Chawal Cluster-I and
In this section, these suggested interventions along with their underlying assumptions are
explained. Their impacts on productivity enhancement, gross revenues, increase in costs, net
returns, and investment requires are estimated. Then Internal Rate of Return (IRR) and Net
Present Value (NPV) of the whole package of intervention are quantified. We also explained
these parameters for the Key Product Intervention, which is bran oil in this case, at the end of
this section.
At present during 2016-17, basmati rice mainly aromatic is produced on 158.23 thousand ha
which supply nearly 290 thousand tonnes of basmati paddy in the focal district, Sheikhupura
of Cluster-I. The annual yield growth is estimated (based on recent past 17 years) to the extent
of 1.14 percent. It is worth noting that price of paddy as well as clean rice in the Cluster-I was
calculated as weighted price (i.e., based on the weightage allotted to super basmati equal to
70 percent and basmati-386 equal to 30 percent). Without any intervention, assuming the
existing growth rate in yield, the expected production shall reach to the level of 306.76
thousand tonnes worth valuing to the tune of US$115.77 million at the farm gate prices (i.e.,
@ 377.38 USD/t) during the 5th year of the project as benchmark level. The expected
production of clean rice from the basmati paddy would yield 199.40 thousand tonnes (@ 65%
79 KNOWLEDGE FOR LIFE
recovery rate of clean rice from paddy) valuing worth 172.43 million USD at wholesale level
(i.e., price @ 864.76 USD/t) on 5th year of the project life (Table 10).
Table 10: Benchmark Status of the Katcha Chawal Cluster-I in Sheikhupura District
Sr.
Items Inputs Year-2 Year-3 Year-4 Year-5
#
1. Area under cultivation in focal point (ha) 158,230
2. Total production in the focal point area 289,840
(tonnes)
3. Baseline yield (tonnes/ha) 1.83 1.87 1.90 1.92 1.94
4. Annual yield growth without intervention (%) 1.14%
5. Annual expected production (tonnes) 296,472 299,864 303,294 306,764
6. Farm gate price of basmati paddy (US$/t) 377.38
7. Total value of basmati paddy (Million US$) 111.88 113.16 114.46 115.77
8. Existing clean rice-paddy ratio (%) 65.0%
9. Annual expected production of clean rice 192,707 194,911 197,141 199,397
(tonnes)
10. Price of clean rice at wholesale level (US$/t) 864.76
11. Annual expected value of rice (Million US$) 166.65 168.55 170.48 172.43
The benchmark information about focal district, Hafizabad, in Cluster-II exhibits 104.41
thousand ha of land under basmati rice cultivation that produced 213.30 thousand tonnes of
clean rice (i.e., yield @ 2.04 t/ha) during 2016-17 year. The annual yield growth is estimated
as 1.14 percent (based on recent past 17 years). The expected production level of paddy will
reach to the level of 225.755 thousand tonnes worth valuing to the tune of 96.21 million USD
at the farm gate prices (i.e., price @426.19 USD/t) on arresting 5th year of the project without
any intervention. The expected production of clean rice from basmati paddy will recover to the
tune of 158.028 thousand tonnes (i.e., @ 70% recovery rate of clean rice) that become by
valuing worth 150.50 million USD at wholesale level (i.e., price @ 925.38 USD/t) by arresting
on 5th year of the project life (Table 11).
Table 11: Benchmark Status of the Pucca Chawal Cluster-II in Hafizabad District
Sr.
Items Inputs Year-2 Year-3 Year-4 Year-5
#
1. Area under cultivation in focal point (ha) 104,410
2. Total production in the focal point area 213,300
(tonnes)
3. Baseline yield (tonnes/ha) 2.04 2.09 2.11 2.14 2.16
4. Annual yield growth without intervention 1.14%
(%)
5. Annual expected paddy production 218,181 220,677 223,201 225,755
(tonnes)
6. Farm gate price of basmati paddy
(US$/t) 426.19
In the feasibility analysis, it is assumed that the introduction of mechanical transplanter would
increase the per ha yield by 15 percent on the adopters’ farm at the end of 5th year of project
span and onwards. The gradual increase in yield of 3.75 percent of incremental rate per
annum is fixed starting from 2nd year through 5th year. In five years starting from 2nd year,
quarter of the total rice area will be planted by mechanical transplanters which would be
phased out with the incremental rate of 6.25 percent annually. As a result of adoption of
mechanized transplanting intervention, an additional production of 115.04 thousand tonnes of
The intervention of introducing mechanical transplanters is also suggested in this cluster due
to same nature of issue, such as, low plant population density per ha, unavailability of labour
at the time of transplanting, etc. In the feasibility analysis of Table 14b for Cluster-II, similar
extent of yield increases and adoption rate is assumed as in Cluster-I. As a result of adoption
of mechanized transplanting intervention, an additional production of 84.66 thousand tonnes
of PK-1121 (Kainat) paddy (added Yield @ 0.32 t/ha) would be of expected value US$3.61
million at farm gate prices on the 5th year of the project (Table 13).
The modern high-yielding varieties like Kissan basmati, Chenab, Punjab and Basmati-515 are
already approved but not adopted by the farmers. The varietal degeneration process of Super
Basmati (the Queen of basmati rice varieties) is reported to be quite high resulting in shrinking
and deforming the size of kernel, losing uniformity and stability in plant height and yield. Rice
researchers/bio-technologists of public (RRI, KSK, Muridke) and private institutions (Guard
Agricultural Research & Services Pvt. Ltd, Raiwind Rd., Lahore) are diligently engaged to
release, very soon, the promising varieties superior to super basmati, especially hybrid. In the
light of above discussion and assumptions, the feasibility study was carried out in Kalar tract
with the special interest to boost productivity of basmati rice through promoting “improved high
yielding basmati rice varieties” as an intervention in the focal district, Sheikhupura.
It is assumed here that the intervention would add 7 percent per annum productivity gain on
maturity of project (i.e., on and after 5 th year of project life) with 1.8 percent annual incremental
rate from 2nd year to arrest 5th year of project life span. The seven percent gain in productivity
would yield 0.14 tonne/ha of basmati paddy in 5th year. It was assumed that 50 percent area
of the focal district would be covered in the intervention with the incremental rate of 12.5
percent per annum effective from 2 nd year through to 5th year of the project span.
Table 14: Yearly Returns from Diffusion of HYV in Katcha Chawal Cluster-I
Sr. # Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
1. Area replaced by modern basmati 50% 12.5% 12.5% 25.0% 37.5% 50.0%
HYV (%)
2. Increase in yield due to HYVs (t/ha) 0.03 0.07 0.10 0.14
3. Yield increase due to basmati HYV 7% 1.8% 1.75% 3.50% 5.25% 7.00%
(%)
4. Additional prod. due to diffusion of 649 2624 5971 10737
HYVs (tonnes)
Under the prevalent situation of emerging global and national trend of enhancing consumers’
demand for Saila rice, the present feasibility study is prepared to boost Kainat production by
exploiting the upcoming HYV potential.
It is assumed that improved high yielding varieties of Kainat series will bring 20 percent
productivity gain on maturity of project i.e., on 5 th year of project life with an annual incremental
rate of 5 percent contribution staring from the 2nd year up to 5th year (i.e., 0.43 tonnes/ha). To
achieve 20 percent productivity gain in 5 years of project life on account of diffusion of HYV,
60 percent paddy area of the focal district will be covered in four phases with 15 percent per
annum increment staring from the 2nd year of the project. As a result, an additional production
of paddy will be fetched to the tune of 27.091 thousand tonnes (i.e., an additional yield @ 0.43
t/ha) valuing worth US$11.55 million on the 5th year of the project. The intervening production
and its revenue results of 2nd through 4th year may be viewed from Table 15.
Table 15: Yearly Returns from Diffusion of HYV in Pucca Chawal Cluster-II
Sr. # Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
1. Area replaced by modern basmati
HYV (%) 60% 15.0% 15.00% 30.00% 45.00% 60.00%
2. Increase in yield due to HYVs 0.10 0.21 0.32 0.43
(t/ha)
3. Yield increase due to basmati HYV 20% 5.00% 10.00% 15.00% 20.00%
(%) 5.0%
4. Additional prod. due to diffusion of 1636 6620 15066 27091
HYVs (tonnes)
5. Value of add. paddy due to HYVs 0.70 2.82 6.42 11.55
(Mill US$)
The advisory services will be provided by specially hired and trained extension worker for this
purpose. About 106 additional professional extension workers in Cluster-I would be required
to render these services in the focal targeted sites of each cluster. Thus, additional production
of paddy to the tune of 21.473 thousand tonnes would be expected worth US$ 8.10 million at
farm gate prices on the 5th year of the project. The interim additional production and its
additional revenue results of 2nd year through 5th year may be viewed from the Table 16.
Table 16: Yearly Returns from Yield Improvement by Better Crop Management in
Katcha Chawal Cluster-I
Sr. # Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
1. Yield improvement by better crop 7% 1.75% 1.75% 3.50% 5.25% 7.00%
mgmt. (%)
2. Yield increase by better crop mgmt. 0.03 0.07 0.10 0.14
(t/ha)
3. Additional paddy production by 5188 10495 15923 21473
enhanced yield (tonnes)
4. Value of addition paddy due to yield 1.96 3.96 6.01 8.10
improvement (Million US$)
Here 70 additional dedicated professionals will be hired and trained to conduct the advisory
services. This will add into the productivity by 0.22 t/ha of Kainat basmati rice at the end of 5th
year of project life. Thus, an additional production of 22.8 thousand tonnes of paddy would be
expected amounting to US$ 9.62 million at farm gate prices on the 5th year of the project. The
year to year gain in additional production and its additional revenues effective from 2nd year
through to 5th year of the project due to employing improved management practices may be
viewed from the Table 17.
Table 17: Yearly Returns from Yield Improvement by Better Crop Management in
Pucca Chawal Cluster-II
Sr. # Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
1. Yield improvement by better crop 10% 2.50% 2.50% 5.00% 7.50% 10.00%
mgmt. (%)
2. Yield increase by better crop mgmt. 0.05 0.11 0.16 0.22
(tonne/ha)
3. Add. paddy prod. by enhanced yield 5455 11034 16740 22575
(tonnes)
4. Value of additional paddy (Million 2.32 4.70 7.13 9.62
US$)
Based on the information gathered from the service providers of wheat and rice harvesting
machines, on average, 500 ha could be harvested by the Kubota type rice combine harvesters.
The service charge for the Kubota machine is assumed to be 33% higher than that in wheat
combined harvester.
It is assumed that 13 percent post-harvest losses during wheat combine harvesting shall be
reduced to 5 percent at farm level after introducing Kubota rice combine harvester, making
net-effect of 8 percent phased out into four years with an annual increment rate of 2 percent
starting from 2nd year through 5th year of the project. We also assume that rice combine
harvester will be fully adopted in each cluster area in the project period (phased out with 20
percent per annum incremental rate on the completion of 5 year’s span of the project). Two
pronged benefits on adoption of rice combine harvester will be in the form of saving paddy
straw worth 7.53 million USD, and additional paddy of 22.43 thousand tonnes (i.e., worth of
8.46 million USD) making the total revenue of US$ 16 million towards 5th year of the project.
The annual details are portrayed in Table 21 pertaining of economic and feasibility analysis.
Table 18: Yearly Returns from Diffusion of Rice Combine Harvesters in Katcha Chawal
Cluster-I
Sr. Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
# mental
1. Current losses by harvesting rice
13%
with wheat combine harvesters (%)
2. Losses by rice harvesting with
5% 8% 2.00% 4.00% 6.00% 8.00%
Kubota rice combine harvesters (%)
3. % rice area currently harvested by
20%
using combine harvesting method
Similar assumptions are applicable as in Cluster-I made in terms of saving in harvest losses
an adoption speed of the machine. The value of paddy straw saved would be worth US$ 4.97
million, and saving of harvest losses would be worth of US$18.17 thousand tonnes worth of
US$ 7.74 million fetching total benefit as 12.71 million USD during the 5th year of the project
(Table 19).
Table 19: Yearly Returns from Diffusion of Rice Combine Harvesters in Pucca Chawal
Cluster-I
Sr. # Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
1. Current losses by harvesting rice with
13%
wheat combine harvesters (%)
2. Losses by rice harvesting with Kubota
5% 8% 2.00% 4.00% 6.00% 8.00%
rice combine harvesters (%)
3. % rice area currently harvested by
20%
using combine harvesting method
4. % rice area shifted to Kubota rice
100% 80% 20.00% 40.00% 60.00% 80.00%
combine harvesting (%)
5. Additional paddy achieved by reducing 903 3846 9350 18169
harvesting losses at the farm level
(tonnes)
6. Value of additional paddy achieved 0.38 1.64 3.98 7.74
(Mill. $)
7. Value of paddy straw got @ $60/ha
1.24 2.49 3.73 4.97
(Mill. $) 60
8. Total benefit to farming community by
shifting to Kubota rice harvesting 1.62 4.13 7.71 12.71
(Million $)
Currently, about 20 percent basmati paddy already dried through mechanical driers and the
target is drying of 90 percent paddy by employing mechanical dryer making annual adoption
rate of 18 percent per annum from 2nd year through 5th year of the project. In total 290 dryers
would be needed to remaining 70 percent paddy in the focal district. These driers will be
supplied to FEGs on subsidized rate. In this way, 261.04 thousand tonnes of paddy shall be
dried by 5th year considering 9.3 conversion factor. In the drying process of paddy, and an
additional value added in the farm gate price (460 US$/t) of basmati paddy was by 83 US$/t
that finally arrived at 543 US$/tonne. As a result of introduction of mechanical dryer in the
area, the expected additional value of paddy from improved quality would be 1.79, 6.81, 10.89
and 15.57 million USD from 2nd year though 5th year of the project (Table 20).
Table 20: Yearly Returns from Introducing Dryers in Katcha Chawal Cluster-I
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Percent of product currently dried 20%
Target %age of practicing paddy 90% 18% 18% 35% 53% 70%
drying
Conversion factor of paddy drying 10 to
(W to D) 9.3 7%
Similar assumption regarding current output being dried through mechanical drier and
conversion factor, and additional price to be fetched after drying are made here as in Cluster-
I. Additional 235 dryers (with the capacity of 1000 tonnes of paddy drying during the paddy
crop season) would be required in four phases to dry additional paddy of the targeted focal
district. As a result, additional dried paddy would be 196.64 thousand tonnes on the 5th year
of the project that would be phased out into four-year span of the project starting from the 2nd
year through to 5th year. As a result of drying, new higher price 520 USD/tonne will be realized
due to improvement in quality of paddy with a drying premium of price of 94 USD/tonne at
farm gate prices. Hence, the value-added paddy shall fetch additional value to the tune of
1.49, 5.76, 9.52 and 14.25 million USD from 2nd year through to 5th year, respectively.
Table 21: Yearly Returns from Introducing Dryers in Pucca Chawal Cluster-II of
Hafizabad District
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
% of product currently dried 20%
Target %age of practicing paddy 90% 18% 18% 35% 53% 70%
drying
Conversion factor of paddy drying (W 10 to
to D) 9.3 1.25
36,893 79,502 131,371 196,638
Dried paddy production (tonnes)
It is assumed that currently there is no bran oil extracted from the rice bran in Cluster-I of the
targeted focal district. It is suggested from the 2nd year onwards, the rice bran oil will be
assumed to extract oil from 20 percent paddy with an annual increment rate reaching 80
percent on the 5th year of the project. Since, the recovery rate of rice bran from the basmati
paddy is 1.5 percent (Bashir et al., 2018), the rice bran production would be collected from the
total production (i.e., existing production without intervention as well as additional production
gained by employing all the interventions). At the rate of 1.5% of bran production from the
paddy milled, it was estimated that the rice bran amounting to 4,475 tonnes shall be available
from the available paddy in the 5th year of the project. Total number of bran oil extraction
machines required would be 3. It is assumed that each unit will collect rice bran from 10 rice
mills each will install bran palletization machine which will make pallets of bran and thus
stabilize the quality of oil content in it. It is assumed that rice bran contains 20 percent oil
contents, resultantly; the enhanced production of bran oil would be extracted to the tune of
895 tonnes in the 5th year of the project (Sagar and Ashraf, 1986). The intervention of bran oil
extraction would be contributing to the extent of US$ 0.52 million (sold at US$1630/ t) in the
5th year as a gain from bran oil. The other details in this respect may be seen in Table 22.
Table 22: Yearly Returns from Rice Bran Oil Extraction in Katcha Chawal Cluster-I
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Current %age of bran converted to
bran oil 0%
Target %age of bran conversion into 80.0% 20.00% 20.0% 40.0% 60.0% 80.0%
bran oil
Qty. of rice bran produced for oil 1.5% 3,651 3,850 4,122 4,475
extraction
Conversion rate of oil from rice bran 10%
Quantity of rice bran oil produced
(tonnes) 369 391 417 447
Expected value of bran oil @ 1629.60
US$1630/t (Million US$) 0.43 0.46 0.49 0.52
Parboiled rice is favoured by consumers and chefs who desire extra fluffy and separate
cooked rice. The 'Saila' of this variety is very popular amongst locals and overseas traders
and consumers. The Pakistani commercial cooks ('Pakwans') are totally using basmati rice
'Saila' and steamed products for preparing Biryani and sweet dishes ('Zardah/Muttangan') due
to number of good reasons especially, Saila yields better performance after cooking, as said
by the consumers and 'Pakwans' the quantity of serving plates increased than that of non-
Saila ('Kaccha Chawal') product, good show casing of 'Pakwans', no breakage of cooked rice
grains as well as convenience of 'Pakwans'.
With the increasing demand of Saila in the Middle Eastern countries and within country,
absorption of additional supply of Saila generated through this intervention will not be an issue.
However, it may reduce the market for Katcha rice.
During field visit, it was observed that currently 50 percent of Kainat basmati variety is used
for making Saila rice. In order to achieve the targeted level (i.e., 80 percent of Saila making),
an additional 30 percent Kainat paddy need to be brought under Saila making OR it would be
30 percent with annual increments as 7.50 percent staring from 2nd year through to 5th year of
the project. After intervention, total expected production of Saila rice of Kainat would be 63.432
thousand tonnes in the 5th year of the project. The wholesale price premium of Saila rice is
148.15 US$/t higher than Katcha Kainat rice, making additional 5.56 million USD on 5th year
of the project life. For other years, please see the Table 23 below.
Table 23: Yearly Returns from Making Saila Rice in Pucca Chawal Cluster-II
Incre-
Items Inputs Year-1 Year-2 Year-3 Year-4 Year-5
mental
Current status of making Saila rice 50.0%
from Kainat basmati (%)
Target percentage of preparing Saila 80.0%
rice from Kainat basmati (%)
Net-increase in Saila rice conversion 30.0% 7.50% 15.00% 22.50% 30.00%
(%) 7.50%
Enhanced production of Saila 11,901 25,646 42,378 63,432
basmati rice (tonnes)
Premium price of Saila rice compared 148.15
to Katcha Chawal ($/t)
Expected additional value from
increased Saila basmati rice
production (Million US$) 1.04 2.25 3.71 5.56
The yearly benefits stream from the six introduced interventions in focal point of Sheikhupura
district in Cluster-I are summarized in Table 27. It can be observed that the total benefits from
the six introduced interventions shall be worth of US$ 48.59 million by the 5th project year.
Table 24: Yearly Expected Gross Returns from Katcha Chawal Interventions in Cluster-I
(Million US$)
The yearly benefits stream from the six introduced interventions in focal Hafizabad district of
Cluster-II is summarized in Table 25. It can be seen that the total benefits from the introduced
interventions are worth of US$ 57.29 million by the 5th project year.
Table 25: Yearly Expected Gross Returns from Pucca Chawal Interventions in Cluster-II
(Million US$)
As mentioned earlier that in five years starting from 2 nd year, total 15 percent area will be
covered by using mechanical transplanter with annual incremental rate as 3.75 percent. As a
result of adoption of mechanized transplanting intervention, an area of 23, 735 ha shall be
mechanically transplanted by the 5th year of the project. As mechanical transplanting is 40%
expensive than manual transplanting (however, by mechanical transplanting the plant
population per ha will increases), it will result an additional cost to the farming community to
the extent of USD 0.40 million by 5th year of the project (Table 26).
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Percent area covered by mechanical 15% 3.75% 3.75% 7.50% 11.25% 15.00%
transplant
Area brought under mechanical 5,934 11,867 17,801 23,735
transplant(ha)
74.07
Manual transplanting cost (US$/Ha)
Rise in cost by shifting from manual to 40.0%
mechanical transplanting (US$/Ha)
Expected additional cost due to shifting
from manual to mech. transplanting
(Million US$) 0.102 0.203 0.305 0.406
The intervention of introducing mechanical transplanter is also suggested in this cluster due
to same nature of issue as well as opportunity to overcome the problem of low plant population
per ha, non-availability of labour during transplanting period, etc. In the cost analysis of Table
21b for Cluster-II, in five years starting from 2nd year, a total of 25 percent area shall be covered
by using mechanical transplanters with annual increments as 6.25 percent. As a result of
adoption of mechanized transplanting intervention, an area of 26,103 ha shall be mechanically
transplanted by the 5th year of the project. Since mechanical transplanting is 40% expensive
than manual transplanting, therefore, the additional cost to the farming community due to
shifting to mechanical transplanting shall be 0.74 million US$ by 5th year of the project (Other
details are presented in Table 27).
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Percent area covered by mechanical
transplant 25% 6.25% 6.25% 12.50% 18.75% 25.00%
Area brought under mechanical 6,526 13,051 19,577 26,103
transplant(ha)
Manual transplanting cost (US$/Ha) 74.07
Rise in cost by shifting from manual to 40.0%
mechanical transplanting (US$/Ha)
Expected additional cost due to shifting
from manual to mech. transplanting
(Million US$) 0.185 0.370 0.555 0.741
The diffusion of latest released high yielding varieties (HYVs) require purchasing of new seed,
which is relatively expensive than the home retained seed of previous crop season. Moreover,
it is also assumed that the farmers shall continue purchasing new seed for the additional
plantation under new varieties. Therefore, additional expenses are involved on the part of
farming community. Assuming that with the efforts of provincial Department of Agricultural
Extension and other Agricultural Advisory Services of private sector, farmers are convinced to
adopt new varieties, hence some additional expenses need to be incurred by the farming
community in order to buy the seed of newly released varieties. It is estimated that the farming
community has to spend nearly 0.66 million USD towards 5 th year of the project. For further
details, please see Table 28 below.
Table 28: Yearly Costs for Diffusion of HYV in Katcha Chawal Cluster-I of Sheikhupura
District
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Area covered under basmati HYV (%) 50% 12.50% 12.50% 25.00% 37.50% 50.00%
Area planted under new HYV (ha) 19,779 39,558 59,336 79,115
Cost of raising nursery of new 16.67
HYV(USD/ha)
Increase in cost/ha due to new 25.00
HYV(USD/ha) 8.33
Table 29: Yearly Costs for Diffusion of HYV in Pucca Chawal Cluster-II
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Area covered under basmati HYV (%) 50.0% 12.50% 12.50% 25.00% 37.50% 50.00%
Additional area planted under new HYV 13,051 26,103 39,154 52,205
(ha)
Cost of raising nursery of new 16.67
HYV(USD/ha)
Increase in cost/ha due to new 25.00
HYV(USD/ha) 8.33
Additional cost due to shifting to HYV 0.11 0.22 0.33 0.44
(Million USD)
As a result of improved management practices, the cost on seed (both because of the increase
in quality and improvement in quality), nursery management practices, fertilizer consumption
especially its balanced use, and labour harvesting practices will increase. We assume that all
this will add 7% of the total cost in Cluster-I and 13% of the total cost in Cluster-II. The
difference is because in cluster-I, improved management practices will involve not much of
additional inputs, rather improved skills and knowledge through rendering additional advisory
services of Agricultural Extension professionals, while in cluster-II, in addition of skills and
knowledge additional inputs would be required. The detailed cost structure under traditional
transplanting and improved practices is shown in Annexure-10.
For achieving 5 percent yield increase through improved management practices, the farmers
have to incur additional expenses worth US$ 13.29 million by the 5th year of the project (Table
30).
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Paddy production cost at farm level
(US$/ha) 1152.0
Increase in cost due to adoption of 7% 1.82% 1.82% 3.65% 5.47% 7.29%
better crop management practices (%)
Total increase in cost due to improved 3.32 6.657 9.97 13.29
crop management practices (Million
US$)
The recurring cost incurred on providing improved management practice is assumed to the
extent of 13 percent with an annual increment of 3.26 percent that was phased out in four
years w.e.f. 2nd year through to 5th year respectively. Thus, total cost was computed to be
18.84 million USD on arresting of 5 th year of the project life (Table 31).
Table 31: Yearly Costs for Yield Improvement by Better Crop Management in Pucca
Chawal Cluster-II
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Paddy production cost at farm level
(US$/ha) 1383
Increase in cost due to adoption of better 13% 3.26%
crop management practices (%) 3.26% 6.52% 9.78% 13.05%
Total increase in cost due to improved crop
management practices (Million US$) 4.711 9.422 14.133 18.843
Reducing the harvest and post-harvest losses is a big challenge virtually in all crops produced
in Pakistan including rice. The gravity of this challenge is relatively more in perishable fruits
and vegetable crops. In case of basmati rice, any mistake taken place at harvesting and/or
post-harvest handling results not only a loss in the quality of the product produced, but also
increases the proportion of by-products (particularly broken rice) produced during processing.
Till recent past, the harvesting of paddy was done by using wheat combine harvesters, which
not only results in loss of valuable rice straw (mainly burnt by the farmers in the field), leaving
big stubbles in the field and grain shattering in the field. Therefore, to get rid of huge by-
product, the farmers started burning the straw, which caused environmental pollution and
chest diseases by inhaling smog in those days. Moreover, the ratio of broken rice produced
during milling was also higher. Therefore, the need for introduction of some machine which
harvest the paddy crop from the height close to the soil and preserves rice straw rather than
resorting to its burning.
96 KNOWLEDGE FOR LIFE
9.9.4.1. Katcha Chawal Cluster-I
In recent past, Kubota rice combine harvesters were introduced in the area by the private
sector itself. This intervention has proved its worth in terms of controlling grain shattering in
the field during harvesting and preserving rice straw which could be either fed to the animals
or sold to the paper industry. The rental price of these combine harvesters are 33 percent
higher than the conventional wheat combine harvesters, but the farming community warmly
welcome this machine as well as evidence of fast adoption. In Table 35 below, the stream of
costs associated with the use of Kubota rice combine harvesters is presented. It has been
estimated that farming community has bear additional expenses amounting 2.32 million USD
by shifting paddy harvesting of 126.58 thousand ha to Kubota rice combine harvesters by 5 th
year of the project. The other details are presented in Table 32.
Table 32: Yearly Costs About the Diffusion of Rice Combine Harvesters in Katcha
Chawal Cluster-I
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Paddy harvesting cost by using
wheat combine harvesters 55.56
(US$/Ha)
Percent increase in cost by
shifting to Kubota rice combine 33.0% 8.25% 8.25% 16.50% 24.75% 33.00%
harvesters (%)
Percent increase in area towards
Kubota rice combine harvesters 100% 20.00% 20.00% 40.00% 60.00% 80.00%
(%)
Area harvested with Kubota rice
combine harvesters (Ha) 31,646 63,292 94,938 126,584
Additional cost due to shifting to
Kubota combine rice harvesters
(Million US$) 0.580 1.160 1.741 2.321
Turning to cluster-II, it has been estimated that farming community has bear additional
expenses amounting 1.53 million USD by shifting paddy harvesting of 83.53 thousand ha to
Kubota rice combine harvesters by 5 th year of the project as depicted in Table 33.
Table 33: Yearly Costs of Diffusion of Rice Combine Harvester in Pucca Chawal Cluster-II
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Paddy harvesting cost by using wheat
55.56
combine harvesters (US$/Ha)
Percent increase in cost by shifting to
33.0% 8.25% 8.25% 16.50% 24.75% 33.00%
Kubota rice combine harvesters (%)
Mycotoxins are naturally occurring toxins produced by certain molds and can be found in
crops. Warm humid conditions accelerate their growth. One such mycotoxin is aflatoxin which
damages DNA and increases incidence of liver cancer. High levels of aflatoxins have been
reported in rice from India. Toxin reviews is a medical journal which published an article
regarding aflatoxin in rice around the world. As per the article published in 2006, India has
amongst the highest levels of incidence among rice producing countries. A survey covering
12 states showed that 16 percent samples exceeded the Indian permissible limits of 30 hg/kg,
61.5 percent of the samples reported aflatoxin level above 5 hg/kg. On the other hand, EU
allows maximum level of 4 hg/kg of rice https://www.brecorder.com/2019/01/15/465958/fungi-
toxins-and-basmati-exports/
Relative to Pakistan, India has a technologically advanced agriculture sector, more prone to
using pesticides and fungicides manufactured domestically. Pakistan has not developed
chemical pesticide market which has to be imported hence being too expensive to use. Thus,
Pakistan has a comparative advantage in employing more organic farming which is why
tricylazole limits are not a problem for basmati exports from Pakistan. However, improper
storage and sun-drying of paddy increases the incidence of aflatoxins in rice. While the private
sector has been fast in setting up driers in their units, therefore, this problem is addressed to
a large extent. On the other hand, there is news that in the rice sector, the aflatoxin levels will
be further revised by the European commission. Between the permissible limits of tricylazole
and aflatoxins, Pakistan can increase basmati exports to EU further. However, government
initiatives may be required to increase mechanical drying of paddies. Since warm humid
conditions are required to decrease aflatoxin levels, antiquated methods of drying may hamper
Pakistan’s exports of basmati rice https://www.brecorder. com/2019/01/15/465958/fungi-
toxins-and-basmati-exports/
As discussed in previous section that the intention is practicing universal paddy drying in the
area (i.e. 90%) or making it mandatory in the cluster area, which is currently operating at 20
percent level. Though the farming community has to face a nearly 25% quantitative loss by
practicing paddy drying before taking it to the market, however, it is also assumed that market
is responsive in terms of offering better prices to farmers brining dry paddy in the market. At
present, what so ever the sun-drying of paddy is practiced, it is mainly done by domestic labour
or permanently hired farm labour, whose opportunity cost falls around 40.38 USD per tonne.
Considering the introduction of paddy driers in parboiled rice cluster-II of Hafizabad District,
the same target of making it mandatory in the cluster area is also fixed, which is currently
operating at 20 percent level. In this cluster, what so ever the sun-drying of paddy is practiced,
it is also mainly done by domestic labour or permanently hired farm labour, whose opportunity
cost falls around 10.71 USD per tonne. It is estimated that by 5th year of the project, more than
181 thousand tonnes of paddy shall be dried, costing to the farming community as 7.99 million
US$ (See the details in Table 35).
Rice bran is one of the abundant by products produced in the rice milling industry to yield
familiar white rice. Research conducted during the last two decades has shown that rice bran
is a unique complex of naturally occurring antioxidant compounds. In recent years, rice bran
has been reckoned as a potential source of edible oil in its natural form (Moldnhauer et al.,
2003; Iqbal et al., 2005; Chatha et al., 2006; Sagar and Ashraf, 1986). Young-Hee et al. (2002)
reported that rice bran contains 15-20 percent of oil, depending upon degree of milling, variety
and other agro-climatic factors. Rice bran oil, its natural state, contains several constituents of
potential significance in diet and health. It also contains high valued protein, fat and dietary
fiber. In addition to phytonutrients, vitamins and mineral and medicinally important anti-
oxidants, γ-oryzanol (natural mixture of ferulic esters) rice bran has reckoned as potential
source of edible oil (Iqbal et al., 2005).
At present, virtually no rice bran oil extraction activity is going on in the targeted clusters. Our
target is to utilize all the rice bran produced in the cluster for extracting rice bran oil, before
utilizing it for other purposes. It has been estimated that from 2 nd through 5th year, 3.65, 3.91,
4.17 and 4.47 thousand tonnes of rice bran shall be available in the cluster for making rice
bran oil out of it. Based on the discussions made to various experts during the field visit, it
came out that almost 250 US$ per tonne is the bran oil extraction cost, therefore, the stream
of costs associated with bran oil extraction in the cluster shall be 0.143, 0.46, 0.49 and 0.52
million USD from 2nd through 5th year of the project (See other details in Table 36).
Table 36: Yearly Cost of Rice Bran Oil Extraction in Katcha Chawal Cluster-I
Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
Current % of bran used to extract bran
oil 0.0%
Rice bran to be used to extract bran oil 20.00% 20.0% 40.0% 60.0% 80.0%
(%) 80.0%
Bran production to be used in bran oil
(tonnes) 1.5% 3,694 3,911 4,170 4,475
Quantity of bran oil produced (tonnes) @20% 369 391 417 447
Cost of bran oil extraction @ 249.57 $/t
(MUS$) 249.57 0.43 0.46 0.49 0.52
Parboiled or Saila rice is the rice that has been partially boiled in the husk. The three basic
steps of parboiling are soaking, steaming and drying. These steps also make rice easier to
process by hand, boost its nutritional profile and change its texture. About 50% of the world
paddy production is parboiled. The parboiling treatment is practiced in many parts of the world
such as India, Bangladesh, Pakistan, Myanmar, Malaysia, Nepal, Sri Lanka, Guinea, South
Africa, Italy, Spain, Nigeria, Thailand, Switzerland, USA and France (Wikipedia).
It is assumed that the present level of conversion of 50 percent of the Kainat basmati varieties
into Saila-parboiled rice shall be enhanced to 80 percent of Saila making. The Saila rice is
fetching relatively higher price in the domestic and international markets. However, in Saila
rice, some degree of aroma present in basmati varieties is lost. The cost of preparation of
Saila rice product from Kainat paddy is estimated nearly 51.3 USD per ton. Total cost incurred
for making Saila rice of Kainat was estimated to the tune of 0.11, 0.252, 0.416 and 0.623
million USD starting from 2nd year through to 5th year respectively (Table 37).
Table 37: Yearly Cost of Making Saila Rice in Pucca Chawal Cluster-II
Sr. # Incre-
Items Inputs Year-2 Year-3 Year-4 Year-5
mental
1. Cost of preparing paddy for Saila 51.28
rice purpose (US$/ton)
2. Total cost of paddy production for
Saila rice purpose (Million US$) 0.117 0.252 0.416 0.623
Table 38: Yearly Expected Costs incurred Against the Introduced Interventions in
Katcha Chawal Cluster-I (Million US$)
Table 39 summarizes the yearly costs stream from the six introduced interventions in focal
Hafizabad district. It can observe that the total costs related with the introduced interventions
shall cost US$ 7.004 million in 2nd year to US$ 30.165 million by 5th project year – implying an
increase of more than four times towards the end of the project period.
Table 39: Additional operational costs due to Interventions in Cluster-II (Million US$)
Table 40: Yearly Expected Costs against the Introduced Interventions in Katcha Chawal
Cluster-I (Million US$)
Table 41: Yearly Expected Costs against the Introduced Interventions in Pucca
Chawal Cluster-II (Million US$)
Table 42: Yearly Stream of Public Investments Needed for the Development of Katcha
Chawal Cluster-I (Million US$)
Table 43: Yearly Stream of Public Investments Needed for the Development of Pucca
Chawal Cluster-II (Million US$)
Table 44: Net-Present Value and Internal Rate of Returns of Costs and Investments
Incurred in Katcha Chawal Cluster-I
In Table 45, the discounted value of stream of investments incurred under project approach
and the net-benefits achieved by the farming and non-farm business community are estimated
on yearly basis. It revealed that the Internal Rate of Returns (IRR) for the basmati rice cluster
development in Hafizabad District is 32.8 percent --- clearly indicating an economically more
viable project than that of Katcha Chawal Cluster-I.
Table 45: Net-Present Value and Internal Rate of Returns of Costs and Investments
Incurred in Pucca Chawal Cluster-II
Reddy C.S. (2009). Mycotoxin Contamination of Rice. Rice Knowledge Management Portal
(RKMP) Directorate of Rice Research, Rajendranagar, Hyderabad 500030.
Reddy, S.V. and Waliyar, F. (2012). Properties of aflatoxin and it producing. International
Crops Research Institute for the Semi-Arid Tropics (ICRISAT). [Online] Available at:
http://www.icrisat.org/aflatoxin/ aflatoxin.asp [last accessed 1 May 2014].
Rehman, A., Inayatullah, C. and Ashraf, M. (1986). White –Backed Plant –Hopper: A Major
Pest of Paddy. Progressive Farming. 6(1), January/February: 63-64.
Saeed, M. (2006). Brown Rice Export from Pakistan to EU Declines. The World Trade Review
[http://www.worldtradereview.com/news.asp?pType=N&iType=A&iID=144&siD=20&n
ID=30453].
Siddique, M. (1986). Agricultural Credit - Problems and Policies. Progressive Farming. 6(1),
January/February: 99-101.
Sagar, M. A. and Ashraf, M. (1986). Potential Uses of Major Rice Milling By-Products.
Progressive Farming. 6(1), January/February: 96-98.
Sagar, M. A.M Avesi, G. M. and Akram, M. (1985). ‘Basmati-370’--- A High Quality Rice.
Progressive Farming. (2), March/April: 10-12.
Sagar, M. A., Ahad, A. and Ashraf, M. (1986). Significance of Harvesting and Threshing in
Improving Paddy Yield. Progressive Farming. 6(1), January/February: 84-86.
Samson, B. and Duff, B. (1973). Patterns and magnitudes of grain losses in paddy production.
Proceedings of IRRI Saturday Seminar. July 1973. International Rice Research
Institute (IRRI). Los Baños, Philippines.
Schroeder HW, Hein HJR (1967). Aflatoxins: Production of the Toxins in Vitro in Relation to
Temperature. Applied Microbiology, 15(2): 441–5.
Rice Bran
Rice Bran consists of 8 to 10 percent of rough rice exhibiting about 20 percent oil contents in
it. In most of South-east Asian countries, the bran material is not fully exploited due to number
of known and unknown reasons, especially in Pakistan. So, these needs to be explored on
war footings. Since, the present study has proved its economic significance in Pakistan that is
not less than the contribution made by maintaining the rice crop plant population density at
par with the recommended levels. In Japan, a major proportion of edible oil comes from this
source. Burma, Thailand, India, Nepal, and republic of Korea also manufacture edible oil from
rice bran to some extent. Some agencies have attempted to explore the possibilities of its uses
through extracting quality edible oil in Pakistan. But the bottleneck of moisture contents
appearance in the rice bran triggers to rancid the oil quality due to up surging in the rates of
free fatty acid (FFA) as per hour reaction of lipolysis enzymes. Some studies have determined
that rice bran contains 2.5 percent FFA, so it is necessary to save the oil from decaying if
treated the rice bran immediately after separation with some suitable chemicals to check
hydrolysis. The rice bran contains high value edible material with 15 percent protein, 20
percent B vitamin, and very rich in other vitamin ingredients like thiamine, riboflavin, and
pyridoxine to the tune of 2.26, 0.25 and 2.5 mg /100 gm., respectively. Bran oil has safe and
valuable multiple uses viz., balanced animal feed preparation, vegetable cooking oils (contains
12-17 % lipids).
On other hand, the oil from parboiled rice is low in acid values (i.e., low contents of FFA). This
special characteristic of oil extracted from parboiled rice bran seems to be subjected to
treatment by steam which prevents lipase from decomposing the bran oil into free fatty acids.
This area needs further probing for developing the understanding about the feasibility of oil
extraction from parboiled paddy rice.
Rice Polish
Rice polish is usually considered the fraction of milled rice grain which is obtained by milling it
for another pause after removing the bran. Its value on average basis is 4 percent but varies
on milling depending on degree of hardness of rice kernel. Similar to rice bran, it is rich in
nutrients viz., thiamine, riboflavin and pyridoxine to the extent of 1.84, 0.18 and 2.0 mg. per
100 gm., respectively. Oil and protein contents presence in rice polish bearing low protein and
high protein rice grains are varied from 12.8 -13.7 percent and 13.1-18.8 percent, respectively
(i.e., on dry weight basis). The lipid content ranges are from 9 to 15 percent. It is primary
ingredient for stock feed but sometimes it is used in baby food and health food.
Rice germ
A) RICE: means milled rice includes cargo rice, white rice, glutinous rice and boiled rice (e.g.,
whole grain, head rice, big broken, broken or small broken):
1) Cargo Rice: (BROWN RICE, HUSKED RICE) means rice obtained from paddy of which
only the husk has been removed. This includes whole grain, head rice, big broken, broken,
and small broken;
2) Plain or White Rice: means rice obtained from paddy which has been husked and milled
while by removing its bran layers. This includes its whole grain, head rice, big broken, broken,
and small broken; and
3) Parboiled Rice: may be husked or milled rice processed from paddy or husked rice that
has been soaked in water and subjected to a heat treatment so that the starch is fully
gelatinized, followed by a drying process.
1) Extra Long Grain: Exhibits, head rice/whole grain measuring the average grain length of
6.90 mm or more depending upon type of variety;
2) Long Grain: Contains, head rice/whole grain measuring the average grain length of more
than 6.0 mm but not more than 6.90 mm, and again depends upon variety;
3) Medium Grain: Reveals, head rice/whole grain measuring the average grain length of
more than 5.0 mm but not more than 5.9 mm; and
4) Short Grain: Shows, the head rice/whole grain with the average grain length of 5.00 mm
or less.
C) YELLOW KERNEL: means the kernel of which 25% or more of the surface area has turned
yellow in color.
D) CHALKY KERNEL: means the kernel of which 50% or more of the surface area is white
like the color of chalk.
F) BROKEN RICE: Broken of size ¾ length of grain and above shall count as head rice.
The above definitions as well as classifications are standardized in the business circle of rice/
Paddy products’ transaction in domestic and international trading. The same concepts have
been discussed for interpretation in the present project report.
The rice bran is a by-product of the rice milling process. The conversion of paddy into brown
rice as well as well as white rice produces this by-product. Bran is the outer shell of our daily
rice grain and is often removed during processing and used as animal feed and others.
According to the American Heart Association, rice bran oil is the healthiest edible oil in the
world. Rice bran oil may be the largest underutilized agricultural commodity in the world. The
production and processing of rice bran oil are similar to many other vegetable oils. The cost
per liter is close to sunflower oil, but relatively healthier. The production of rice bran oil is
economically viable. Pakistan is also one of the largest exporters of rice in the world, but does
not produce any bran oil like other countries. India is currently the largest producer of rice oil.
Every year about 3-4 million tonnes are produced worldwide, mainly in Asian countries like
Japan, Thailand and China. Increasing home cooking oil production is a good option. Pakistan
currently produces 6.7 million tonnes of rice annually and can reduce its import edible oil bill
by around $ 510 million, using the potential of producing rice bran oil. Pakistan can gradually
improve the efficiency of rice bran oil technology. At present, domestic rice bran oil
consumption is very low, so an aggressive marketing campaign is required to launch the
product on the domestic market.
Objective:
The objective of this feasibility study is to estimate feasibility of the Rice bran oil on small
scale processing plant for the future investors so that by following functions in the value
chain can be incorporated:
The process
Rice bran oil processing plant /oil leaching plant /oil solvent extraction machine process is
given below:
1. The material (for pre-treatment) is sent to rotary extraction by the scraper conveyor.
The material will be extracted by the solvent or mix oil. After this step, we will get meal
and mix oil.
3. After the mix oil from the rotary extraction enters into 1st evaporator and 2nd
evaporator, most of the solvent in the mix oil is separated.
4. The mix oil from 2nd evaporator goes to stripping tower and almost all the solvent is
separated. From the stripping tower, we can get crude oil and solvent. The solvent is
sent to condenser and is recycled to rotary extraction.
Process Flow chart of Rice Bran Oil extraction
Craft features:
Introduction:
(1) The solvent extract equipment adopts stainless steel fixed grid tray, frequency
conversion speed regulation, extract equipment storage tank feeding level is automatic
control, high extracting efficiency, low energy consumption; Extracting condenser,
steam degassing condenser, stripping condenser, evaporative condenser, the final
condenser is aluminium alloy tube-type condenser, the condensation effect is fast.
(2) Wet meal dissolution using DTC toast-desolventizing, dissolution, drying in one
machine. The production of finished meal powder is small, good colour, toast-
desolventizing level is self-automatic control.
(3) Adopts film evaporation process, evaporation temperature is low, crude oil quality is
good, energy saving, secondary steam from toaster and waste heat can be utilized,
as the first evaporator heat source.
(4) Steam-lift crude oil and steam mixed oil heat exchange, save energy.
(5) The tail gas recovery uses the water bath type tail gas recovery device, the tail gas
recovery two times utilization, reduces the solvent consumption.
Pre-Operative Expenses:
Expenses incurred prior to commencement of commercial production are covered under this
head that total US$ 7632. Pre-operative expenses include establishment cost, rent, taxes,
traveling expenses and other miscellaneous expenses. It has been assumed that the funds
from various sources shall be available, as required. Based on the project implementation
Pre-Operative Expenses
Sr. No. Particular (for 1 year) Amount (US$)
Based on a processing capacity of 10 tonnes per day considering and 90 days of working per
year, the annual raw material consumption of the pack house is 900 tonnes. The cost of bran
based on its average selling price as determined through interview with randomly selected
farmers and converting it into US$ (with conversion rate of one US$=135) is $170/tonne.
Adding US$20 per tonne transportation cost from the field to processing unit, the raw material
cost for pack house would be US$190.
Required land is 6,000 sq. ft. which has been considered on lease @ US$200 per annum for
first three years and @ US$232 for the fifth year and subsequently @5% increase every year.
The unit cost of electricity has been considered @ PKR.20.70/ unit assuming that the entire
power requirement is met from the grid. A power supply of 2.2 Kw is deemed appropriate. The
expense on water supply, treatment and distribution has been suitably considered, based on
the tariff by water and sanitation agency (WASA) for per month consumption of water tariff of
@ 92.82 PKR/thousand gallons. Water requirements are approximately 100 gallons per day.
NPV =47,004
IRR =40%
Project Viability:
The Internal Rate of Return of the project is estimated at …..%, which is significantly higher
than the bank return rate of 16%.Hence, the project is deemed financially viable. The NPV of
the project is positive (US$ ….) at a discount factor of 16% during the first 5 years of operation
considered. This implies that the project generates sufficient funds to cover all its cost,
including loan repayments and interest payments during the period. This also indicates that
the project is financially viable over the long term.
Note: Extracting 1 tonne of raw rice bran will produce 20% of oil.
Per day efficiency @10 hrs work every day (ha) 1.8
Working days in a year 25
Area transplanted in a season (ha) 46
Revenue (US$)
15 0.1 0.2
Increase in per ha yield (%) % 0.07 4 2 0.29
Total increase in production for the whole 6.4 9.8 13.2
season (tonnes) 3.20 7 2 4
Price of paddy (US$/tonne) 377 377 377 377
244 370 499
Increase in revenue due to improved yield (US$) 1207 2 5 7
Direct variable costs
Cost of manual transplanting (US$/ha) 226 226 226 226
Cost of mechanical transplanting (US$/ha) 171 171 171 171
Saving in cost (US$/ha) 56 56 56 56
252 252 252
Total saving in cost during the season (US$) 2528 8 8 8
14. 14.
Cost of training support by the government 14.8 8 8 14.8
Maintenance (2% of the machinery cost) 120 120 120 120
Depreciation 550 550 550 550
Increase management cost of paddy field due to
improved plant population (0.05% of the initial 262 262 262
cost) 2622 2 2 2
Total variable cost 779 779 779 779
166 292 421
Gross profit 428 3 6 7
Indirect fixed cost
-
600
Machinery 0
-
600
Total 0 0 0 0 0
-
600
Grand total cost 0 779 779 779 779