1 AGRICULTURAL MACHINERY AND MECHANIZATION 1. Engr. Prof. Dr. Muhammad Iqbal 2. Engr. Dr. Muhammad Azam Khan, Chairman and Associate Professor 3. Engr. Dr. Khawja Altaf Hussain (Associate Professor) Department of Farm Machinery, Faculty of Agricultural Engineering & Technology University of Agriculture, Faisalabad Pakistan (Revised 2021) 2 Table of Contents Chapter Title Page 1 Farm Mechanization in Pakistan: An Overview 3 2 Sources of farm power 22 3 Engine & working principles 24 4 Basic terminology used for an engine 34 5 Internal combustion engine system 37 6 Fuel & fuel system 47 7 Engine cooling and lubrication systems 57 8 Tractor power transmission system 66 9 Land development machinery 74 10 Farm tractor 82 11 Estimating farm power & machinery costs 99 12 Tillage implements 103 13 Secondary tillage 118 14 Sowing machinery 125 15 Interculture tools and implements 136 16 Plant protection equipment 142 17 Harvesting & threshing equipment 171 References 179 Farm Machinery & Equipment – Practical Manual 184 3 CHAPTER-1 FARM MECHANIZATION IN PAKISTAN: AN OVERVIEW Dr. Muhammad Iqbal, Dr. Muhammad Azam Khan and Dr. Kh Altaf Hussain Abstract Pakistan Agriculture has reached to a stage, leading towards industrial agriculture, man- machine relationship is strengthening and output rate improving year wise. The indigenous manufacturing and skill training are increasing to attain standardized production. Trend towards export to earn foreign exchange has led to competitive market behavior. The farm machinery manufacturing industries are source of becoming pivotal for industrial farming system. Multiplier effect of industries is spreading fast and rural unemployment/ disguised employment is reducing. Non-traditional crop farming is on the rise and copping intensity has improved. High efficiency irrigation system, no till/zero –till machine use is on the rise, improved crop varieties and better animal breeds are introduced, resulting in higher average yields. The farming systems are transforming into industrialized agriculture. Time is near when agriculture as an industry will become dream of every young Pakistani to become a part. 1. Historical Background The historical background of agricultural machinery use in Pakistan was traced back to the report of the Royal Commission on Agriculture in which the Commission recognized the need to replace the oxen with the tractor, but stressed the need for a proper search on different aspects of farm mechanization (Commission on Agriculture in India, 1928). As a result of the Commission's recommendations, the Agricultural Engineering Workshop of the Department of Agriculture in Faisalabad, founded in 1914 has been strengthened to undertake research and development of agricultural implements. In 1945 the Famine Commission of Inquiry stressed the need to minimize the pressure of animals on the land using farm tractors for farm operations (Woodhead, 1945).In 1951 the Pakistan Agricultural Enquiry Committee recognized the opportunity to use machinery for the rapid development of new lands and cultivating riverine tracts (PAEC, 1953). The Food and Agriculture Commission also realized the need to introduce farm mechanization in Pakistan (PFAC, 1960). In Revelle report it was commented that suitable agricultural machinery and tools be designed and manufactured for small landholders (ANONYMOUS, 1964). It was also suggested the development of small horsepower tractor. The five-year development plans have subsequently provided funding of the expansion of the development work of the area with heavy machinery and the creation of a network of agricultural laboratories in the province (Chancellor, 1970).Agriculture machinery Organization (AMO) has been established at the Agriculture Department, Government of West Pakistan to continue the work already underway with the "Power Farming", Research Station Agriculture Faisalabad with a mandate to develop the land and to increase water supply with the help of machines. Bulldozers and power plants drilling have been added to the system to complement 4 the efforts that are under taken by the Thal Development Authority which later merged into the Agricultural Engineering in 1970. 2. Tractor Manufacturing / Assembling in Pakistan Millat Tractors Limited (MTL) was established in 1964 and started marketing Massey Ferguson (MF) Tractor in Pakistan. An assembly plant was established in 1967 to assemble tractors imported semi - knocked down (SKD) condition. Al - Ghazi Tractors Limited (AGTL), established in 1983, installed its plant in Dera Ghazi Khan, Punjab, Pakistan and started producing New Holland tractors and generators in collaboration with the Fiat New Holland. In 1991, Al- Futtaim Group of Dubai, took over management of Al- Ghazi Tractors, with the acquisition of 50 % of its shares. Production of tractors under the government program approved disposal started in 1981 and five companies were licensed to produce tractors. The producers of Belarus, Ford and IMT tractors left the business and now only two manufacturers are actively involved in the local production of tractors. M / s Millat Tractors Ltd. Lahore and M / s Al-Ghazi Tractors Ltd. Dera Ghazi Khan are producing 10 models of tractors in the range from 50 to 85 hp (Table 2.1). Both companies have production / assembly plants and distribution networks and after-sales service around the Punjab and Pakistan. M / s Millat Tractors Ltd. is producing around 45,000 units per year, while M / s Al-Ghazi Tractors Ltd., has an installed capacity of over 30,000 tractors a single shift basis. In addition to these two main manufacturers of tractors, few other manufacturers are also manufacturing and marketing of locally assembled and imported tractors on a limited scale. Two models of tractors have been presented in Figure 2.1. Table 2.1 Makes and models of tractors in Pakistan S. Tractor Model Rated speed Max Power Lower link lift No Company (RPM) (hp) capacity (kg) 1 Millat MF-240 2250 50 1415 2 Tractors MF-260 2250 60 1415 3 Limited MF-350 2250 50 2145 4 (MTL) MF-360 2250 60 2145 5 MF-375 2000 75 2145 6 MF-385 2200 85 2145 7 MF-385 (4WD) 2200 85 2145 8 Al - Ghazi FIAT-480 2160 55 1540 9 Tractors FIAT-480 (S) 2160 55 1450 10 Limited FIAT-640 2160 65 1650 (AGTL) Source: MILLAT TRACTORS LIMITED, Millat Group. www.millattractor.millatgroup.net Al-GHAZI TRECTORS LIMITED, www.alghazitractors.com/ 5 Al Ghazi Tractor FIAT 640 Millat Tractor MF 375 Figure 2.1 Two models of tractor in Pakistan 3. Farm Mechanization in Pakistan Agricultural mechanization, an important input in modern agriculture, improves the productivity of both land and labor in addition to increasing cropping intensity and help support early establishment of crops, cultural practices, crops along-with reduction of post-harvest losses. It considerably saves fodder and feed through a reduction of number of draft animals. Thus, a transition from subsistence to commercial agriculture can be achieved through the dissemination of modern, efficient, cost-effective mechanization technologies to farming systems. The efficient use of scarce agricultural resources coupled with an accelerated agricultural mechanization therefore, is of utmost importance. Agricultural mechanization has been selective in Pakistan and only those operations have been mechanized for which there had been shortage of labor or power at peak farming operation timings. The effects of mechanization had always been overall positive. Farm mechanization not only increased the income and labor productivity at farm, but also generated off-Farm Employment in manufacturing, supply / maintenance of agricultural machinery, provision of other inputs and post-harvest operations of agriculture produce. The most popular forms of mechanization in Pakistan have been; bulldozers, drilling rigs, tube-wells, grain threshers, sprayers, tractors, cultivators and trailers. Out of all the tractor owners, 95% have cultivators, 20% have MB plows, 15% have disc plows, 5 % have Chisel plows, 5 % have rotary tillers, 10% have disc harrows, 10% have Ridgers, and 22 % have seed drills / planters (Figure 3.1). 6 120 100 100 95 80 58 60 60 40 34 20 22 Tractors owners with owners Tractors 15 20 10 10 respective implements (%) implements respective 5 5 5 1 1 1 0 Type of equipment / implement Figure 3.1.Percent tractor owners having various agricultural machinery Source: GOP. 2004. Pakistan Agricultural Machinery Census, Gulberg III, Lahore, Punjab The horse power for availability per acre in Punjab has been found to be 0.74, which is much lower than India (1.01), China (1.57) and Japan (2.83). This low farm power input led to crop losses of 15-20% in cereals and 40 to 45% of fruits and vegetables, which can be reduced to a minimum by increasing the availability of power for timely execution of farm operations. ANONYMOUS (2006) reported that organizations that deal with the issues related to agricultural mechanization in Pakistan are: Ministry of Food Security and Research; Research and development institutions, especially Agricultural and Biological Engineering Institute (ABEI), NARC, Islamabad under the Pakistan Agricultural Research Council (PARC) at the federal level, Agricultural Mechanization Research Institute (AMRI), Multan under the Punjab government, Agricultural Mechanization Research (AMRC), Tandojam under Government of Sindh, Center for Agricultural Industries, Mian Channun under Punjab government and the Agricultural program Light Engineering (ALEP), Mardan in Khyber Pakhtunkhwa Government ; agricultural machinery