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Improved Postharvest Technologies

for reducing
postharvest
losses
Presentation
Title Goes
Hereand
increasing
of farmers
presentation
subtitle. incomes form
their rice harvests.
Martin Gummert
Postharvest Section, GQNPC, IRRI
Post Production Workgroup,
Irrigated Rice Research Consortium, IRRC

Contents
Introduction
Postharvest problems and options for better
postharvest management
o Harvesting
o Drying
o Storage
o Milling
o Market information
Lessons learned
Key issues

Problems faced by Asian rice farmers?


Farmers income has been eroded
Farmers are price takers and sell
most at harvest because:
indebtness
poor storage
lack of market knowledge
Rural labor shortage
Little chance to add value

Options to increase rice farmers


incomes
1. Increase crop yields and
reduce production costs
2. Reduce losses especially
in post harvest
3. Reduce cost of
postharvest operations
4. Find higher value
markets
5. Diversify into other crops

Postharvest losses add up

Grain loss
Loss in quality
Farmers dont add value to their rice

Grain value

Combined losses
Weight: 10-20%
Value: 25-50%

IRRIs Postharvest Projects

Postharvest Unit of GQNPC in Los Baos


o

Postproduction Workgroup of IRRC (SDC funded)


o
o
o

Research on principles (hermetic storage), coordination

Phase IV: 2009-2012


Indonesia, Lao PDR, Myanmar, Philippines, Vietnam
Focus on out-scaling postharvest technologies

Reduction of postharvest losses and increasing farmers


incomes (ADB funded)
o
o
o
o

Follow-up of ADB/JFPR funded project 2005-2008


Implementation: 2009-2013
Cambodia, Vietnam and the Philippines
Out-scaling PH technologies verified in the ADB/JFPR project

Postproduction Partnerships 2007

PPD

NAFRI
VIAEP

MRPTA
CARDI
SME

HUAF

NLU
SIAEP
BLSC

BPTP

IRRC Members
ADB-IFPR Partners
Postharvest trainees

SSFFMP / BPTP
ABC

ICAPRD

BPTP

Approach for improving postharvest

Training

Understanding Quality

Harvesting

Machine Harvesting

Drying

Machine Drying

Policy

Storage

Hermetic Storage

Milling

Rice mill
improvement

Postharvest Value Chain


Farmers: reduce losses / cost; more participation in the value chain > increased income
Commercial sector: reduce losses / increase quality > increased profit
Policy: food security, poverty reduction, health

Marketing

Marketing
Assistance

Harvesting Problems
Physical losses (2-5%)
o Shattering in field
o Over drying
o Transporting
Quality losses
o Grain Discoloration
o Fungal infestation
Migration leads to labor shortage
in rural areas
o High harvesting cost
(Cambodia up to 75$/ha)

Stripper harvesting
Reduce harvesting cost
Reduce losses
Failed in the Philippines, Vietnam, Myanmar, Thailand

1994-1996 Initial testing of IRRI


prototype in Indonesia
Manufacturing in Surabaja

Promotion through
ATIAMI in South
Sulawesi (Sulsel)
1997-2001
In 2005 local production in Sulsel
3 Manufacturers
Chandue: 210 units in 2005

Mechanized harvesting, Cambodia

Manual harvesting
o US$ 75/ha
o Delays
Mini combine
o 1ha/day
o US$ 4,000
o Loss 1-3%
o Cost: US$ 35/ha
Benefit for farmers
o Lower cost
o Timely harvest
o Better quality
o Less losses

Mechanizing Harvesting
Lessons learned
o In areas with labor shortage highly beneficial
o Introduction takes time (4-10 years)
o Some organizations have difficulties to source
technologies abroad (Lao, Myanmar)
Key issues
o Often too little involvement of private sector in
government driven development programs
o Support to manufacturers, after sales services
o Financing
o Do not re-invent the wheel

Drying Problems
Double cropping systems:
o One harvest in the wet
season
o Sun drying often not
feasible
Discoloration,
fungal infestation
Sprouted grain
10-30% reduction in
head rice yield
Traditional drying systems
Over drying in field (1-4%)

Farm level dryers

Vietnamese farm level


dryer (UAF-IRRI-GTZ)
o 1t capacity
o Cost: < $ 150
o 1.000 + sales by 1997
Testing by ATIAMI and
CREMNET failed
o Philippines, Myanmar,
Bangladesh,
Cambodia
o 1kW electric motor
o Investment
o Benefit?

Vietnamese Flat bed dryer

Continuous increase of capacity


o 1t in 70ties
o 4t in mid 80ties
o 8t in late 90ties
o Reversible air-flow in 2002
Status 2007
o 6,000 dryers in Mekong Delta
Farmers benefit
o Safe drying
o Low cost (<5% of paddy value)
o Option for sale of wet paddy
Technology transfer through IRRC
o Myanmar, Cambodia, Lao (2005..)
o Optimization in Indonesia (2006)

Drying Systems Transfer

Users

Source country (Vietnam)

Proven commercial options


Technology evaluation

Target countries (LAO, MMR, CAM)

Current problems / needs

Need assessments

2007: 40 dryers
installed in Myanmar

User training

Demo,
Promotion,
Training

Manufacturers

IRRI / NARES facilitated technology transfer process


Scientific Principles
Tech. assistance

Dryer components made by


manufacturers in

Technology
Participants start local production

Production
know-how

Drying systems training


at NLU, Vietnam
Manufacturing
Testing
System integration

Manufacturing
potential
Lao

Cambodia
Farmer processing center

Rice hull furnace,


NLU, Vietnam

Features
o
o
o
o

Automatic feeding and ash


removal
Clean burning, Low emissions
No fly ash
Saves ~ 10l kerosene/t
(CO2 neutral)

Results
o Low cost (< US$ 3,000 for
dryer, blower, and furnace)
o Saves labor
o Long term monitoring
underway
o Can produce carbonized rice
husk

Commercial furnaces in Vietnam


o Tray Ninh
o Farmers at Cat Tien District
o Nhon Hinh Cooperative
o Hau Thanh Dong Cooperative

Lessons learned

Mechanical dryers have better performance than sun drying


o 10-30% more head rice in mechanical dryers compared to
sun drying (Indonesia, Ramchandra, 2007)
o Sun drying cheapest option
Manufacturers modify on users request
-> negative effect on performance
Successful introduction where research institutions stayed
involved and adapted dryers to users needs
Size and complexity:
o Simple, locally produced dryers get adopted
o Small dryers economically not attractive -> trend towards
bigger dryers -> commercial and contract drying for farmers
o Farmers benefit from better quality, eliminated weather risk,
safe storage (benefits are not very visible)

Dryers, key issues


Local production (local
workshops will copy)
Adaptation (up scaling)
Performance testing
Financing (users)

Storage Problems
Weight loss (3-5%)
Respiration
Consumed by pests
Quality (10-15%)
Spoilage by pests
Yellowing
Head rice
Cooking quality
Farmers seeds
Loss of Germination after a
few months

Hermetic sealed storage systems

5 t Volcani cube

Special plastic - low oxygen


permeability
Respiration of grains and insect
activity reduce oxygen quickly
Plastic prevents moisture
adsorption

O2 concentration, %

Principle

50 kg Super bag

18

Claypot
PVC drum lrg
PVC drum sml

12

0
0

20

40
60
Storage time, days

80

Life insects after 8 months


initial
hermetic
control

60
Insects / kg

Effective
control over
time
No
pesticides
needed

80

40

20

0
Source: Bac Lieu Seed Center, 2006

Tai Nguyen

Mot Bui Do

Jasmin 85

Variety

OM 2717

Germination after 8 months


100

Germination (%)

80
60
40
20
0
initial
hermetic

Tai Nguyen

Mot Bui Do

Jasmin 85

OM 2717

Variety

control

Source: Bac Lieu Seed Center, 2006

Higher returns in milling


100.0

8 months of
storage
4 varieties
Hermetic: IRRI
super bags
Control: Woven
PVC bags
Conducted in
2005

initial

Head Rice Yield (%)

hermetic

80.0

control

60.0
40.0
20.0
0.0
Tai Nguyen

Mot Bui Do

Jasmin 85

OM 2717

Variety
Source: Bac Lieu Seed Center, 2006

Other crops: Maize


Myanmar: 5 months of storage with an initial MC of 17% w.b
Hermetic super bag

Conventional bag
Source: IRRI-MAS research, Plant Protection Division, Myanmar, 17 May 2005

Hermetic bag made in Indonesia


(Kantong Semar)
25

Supplier:
Agri Business
Club Jakarta

20
Oxygen, %

Cheaper,
minimum order
10,000 pieces

Super bag
Kantong Semar

15

10

Slightly better
performance

0
0

14

21

No. of days

Source: IRRI, 2005

28

35

Farmers benefit, Battambang, Cambodia

Farmers use 80-90% own


seeds
Germination drops quickly
Traditional seed storage:
3 bags @ 70kg
Hermetic storage:
o Germination above 90%
o Seed rate reduced by 1/3
o Additional sale of 70 kg =
US$ 9
o Investment: US$ 2.00

Key issues, hermetic storage


Private sector started to buy hermetic systems
o INO: Seed producers in Java, PT Effem South
Sulawesi
o PHI: Bayer International, local hybrid rice seed
producers
So far no product champion for farmers bags
No dissemination channels to farmers
(minimum order 5,000-6,000 bags)
How to ensure that users get training?

Rice milling (in %)


Theoretical
Yield

Indonesia

Philippines

Cambodia

Husk

20

26

24

24

Brown rice

80

74

75

76

Bran

10

11

11

Milled rice

70

63

63

65

Head rice

55

46

38

40

Broken kernels

15

17

27

25

Source: IRRI

Rice Mill Improvement


Objectives
o Baseline on milling
industry
o Improved quality
o Reduced losses
o Increased incomes
Target groups
o Village rice mills
o Commercial mills
in selected
countries

Farmers processing center, Cambodia


Benefit of drying (higher
quality) realized after
milling (sale of higher
quality milled rice)
Dryer and mill used by
farmers groups
o Less over-milling
o Bran stays with group
o Sale of under-milled
rice to health conscious
markets

Lessons learned and key issues


Lessons learned
o Millers can deliver extension and input to farmers
if they realize the importance of good quality raw
materials (MRPTR, Myanmar)
o Organizing farmers groups is beyond our mandate
o Financing schemes for investment are essential
Key issues
o Networking with millers / millers associations
o Partnerships needed for financing schemes,
assistance to groups

ADB / JFPR Postharvest Project

Village market information systems


Village market

Market info boards

Info Board
Manager

Decision making:
Provincial market

Village Market, Kabupaten Subang - 2004

3,200

Rice price, Rp

3,000

Capital market

2,800
2,600
2,400
Grade 1

2,200

Grade 2

2,000

Grade 3

1,800
3

7
Month

Extension Service
ADB/JFPR 9036: Cambodia and Vietnam
Irrigated Rice Research Consortium

10

11

Where to sell?
When to sell?
What quality to
produce?

Lessons learned, key issues


Lessons learned
o Farmers need to understand the value of market
info, then they make decision on sales
increasingly based on market information
o Official information often has to be approved
delays
o Farmers participation important
Key issues
o How to institutionalize MIS?
o How to finance it?

Grain Quality Test Kit

Moisturecontent

Better understanding of grain quality


Better decision making in post harvest
management
Affordable, for farmer intermediaries and
processors

Millingdegree

Headrice,brokens

Cracks,Insects

Dimensions

Temperature

Weight

Volume

Lessons learned and key issues


Lessons learned
o Demand for low-cost moisture meter and quality
kit increases (weekly inquiries)
o Local production of MM in Philippines
o Privatization of quality kit difficult because of
economics of scale, capital requirements for batch
purchase
Key issues
o Support to manufacturers, commercialization

Capacity building from IRRI


1. Hands-on
training
2. Training
materials
o
o
o
o

Fact sheets
Reference
manuals
Videos
Included in
RKB

3. E-learning
courses

English
Khmer
(Vietnamese)
Open e-learning prototype

Summary: Key lessons learned

Capacity building most important component for Myanmar, Lao and Cambodia
Farmers benefit from reducing losses, better quality and the ability to sell later
Users need to understand the benefits before they adopt -> extension is
essential but weak in some countries
Locally produced technologies have higher potential for adaptation to local
conditions and therefore sustainable adoption is more likely
Adapt commercially available technologies to local conditions
A technology champion is essential for successful introduction
Involvement of the private sector at an early stage is essential for
commercialization
Most successful were technologies were researchers stayed involved in the
commercialization process and helped manufacturers to make the
modifications users wanted (linear TOT process chain in some countries)
Systems approach: Non technical issues need to be addressed (in
partnership with suitable public and private organizations or projects)
o Training of users, marketing of PH technologies
o Industrial extension for local production and adaptation
o Financing (investment, working capital)
o Advise to policy level

Key questions

How to ensure more participation of farmers and the industry in


technology selection, adaptation and impact assessments?
How to ensure more and earlier private sector participation
o Suppliers: Manufacturers, traders
o Partners: e.g. millers who provide extension
o Financing institutions
Linking of organizations with postharvest mandate
What is the role of the government in postharvest development?
o Supply of equipment through government programs? Or..
o ..generating favorable frame conditions for the local industry to
develop?
o How can we advise the policy level accordingly?
How to ensure sufficient allocation of resources?

Major Partners
Agribusiness Club Jakarta, Indonesia
BLSC, Vietnam
BPRE, Philippines
BPTBs in Sumbar, Sulsel, Jatim, Sumut, Indonesia
CARDI, Cambodia
CRMA, Cambodia
DISIMP, Indonesia
Grainpro Inc., Philippines
Hue UAF, Vietnam
ICAPRD, Indonesia
ICRR, Indonesia
MAS-PPD, Myanmar
NAFC, Philippines
MMRPTA, Myanmar
NAFRI, Lao PDR
NFA, Philippines
NLU, Vietnam
PDA Battambang and Prey Veng, Cambodia
PhilRice, Philippines
ProRice, Lao PDR
PRPC, Philippines
SIAEP, Vietnam
SSFFMP, Indonesia
UPLB, Philippines
VIAEP, Vietnam

Thank You

Thank You

Benefits of PH technologies
Operation

Potential benefit for farmers

Benefits for commercial


sector

Mechanized
harvesting

Reduction of harvesting cost


Physical loss reduction 2-5%
Better quality (no delays)

Income (machine owners,


manufacturers)
Better quality (rice mills)

Mechanized
drying

Insurance (weather risk), increased


value of paddy, safe storage

Income (s.a.)
Better quality (millers)
Safe storage

Reduced seed rate, more grain to


Hermetic
storage, seeds sell, better crop establishment

Safe storage, higher germination,


no pesticide needed

Less losses to pests and humidity,


Hermetic
storage, grains no deterioration

Higher head rice recovery (~10%)

Rice mill
improvement

More returns from village mills


0 Interest conflict with millers

Market
information

Higher incomes from: market


oriented production, storage,
production of better quality

Higher incomes from better


quality (markets?)

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