SOLAR SPINNING OF 6000 MILLION KG LINT COTTON IN FARMS

Cotton is grown in the farms. So it is quite natural that it should be processed in the farms. With the advent of small 10 KW solar power plants costing Rs 6 lakhs, millions of such 10 kw solar power plants should be installed in farms for water pumping mainly. But water pumping is not required daily and for all 12 months. So intermittently solar power will be surplus. This surplus power can be ideally utilized for further processing of cotton. India produces 600 crores of kg of lint cotton annually. Almost 40 % of lint cotton is exported in the form of bales. Lakhs of bales are exported draining of our wealth out of country. I am sure that entire production of 6000 million kg lint cotton can be converted in to yarn in farms by using 30 lakhs of solar power plants of 10KW only. Entire scheme is as under.

(1) COTTON GINNING

The modern double roller ginning machine costing Rs 125000/-works on 5 hp electric motor and gives output of 80kg of lint cotton and 100kg of cottonseed per hour. So in 6 solar hours, it can produce 480kg of lint cotton. So any farmer having 10 KW solar power plant in his farm will install ginning machine and he will run it on surplus solar power when water pumping is not required. So all neighbouring farmers will prefer to gin their Kapas cotton and sell lint cotton and cottonseeds in stead of selling their kapas as selling lint cotton and cottonseeds separately will fetch them some more income. So ginning activity will be fully decentralized in to farms. The biggest benefit of decentralization of ginning activity will be that it will save power consumed in ginning factories and also save transport of cotton. And all profits of ginning factories will be automatically distributed among farmers.

(2) BLOW ROOM PROCESSING

But what to do with loose lint cotton produced in the farm. It is more difficult to transport. So textile spinning activity must start in the farms. It is observed that present blow room machinery has been designed in England to process hard pressed cotton bales imported from India. Nobody applies the mind that now bale binding is not at all necessary. Loose cotton spinning can be done with more ease and cloth becomes 20% more durable if loose cotton is spun directly. So present day complicated blow room machinery can be simplified such that 20 hp power required in blow room will reduce to 10hp, space requirement will reduce to half and also cost will reduce to half. The best quality second hand blow room is almost 50 ft long x 15 ft wide, it employs about 6 electric motors of total 20 hp and costing Rs 8 lakhs. Same capacity simplified blow room for loose lint cotton will cost Rs 4 to 5 lakhs and utilize about 4 electric motors of total 10 hp. Such simplified blow room will be most appropriate to run in the farm by 10 KW solar power plant. Such blow room will clean cotton, removes all dirts and will make blankets of pure cotton roughly 38" wide 1" thick and wrapped and wound in 18" dia of cylinder. Processing capacity will be about 800 kg in 6 solar hours. Such a cotton in the form of blanket cylinders can be transported from one farm to another farm by three wheeler rickshaw where further process of carding will be done.

(3) CARDING MACHINE

Present carding machines available in the market can be directly run by solar power in the farms. It works on 3 hp motor. Carding machine converts cotton blankets in to long rope after passing through thousands of needle pokes arranged on revolving drum to further remove dirt if any and to make cotton fibers loose and parallel to some extent. Such long ropes are filled in cylindrical card cans roughly 1 mt height and half mt dia. About 100 such card cans are required with one carding machine. Second hand carding machine costs Rs 3 to 4 lakhs and occupies 25 ft x 10 ft area. It processes about 100kg in 6 solar hours.

(4) DRAWING MACHINE

This machine costs only Rs 1.5 lakhs and occupies 10ft x 25 ft area. This machine is driven by 5hp + 2 hp electric motors.The function of this machine is to draw cotton rope almost 8 times longer. But 8 ropes are drawn together at a time. So length and diameter of rope remains the same. But fibres of cotton become parallel to length which is required for spinning of cotton. In fact 2 lines of 8 ropes are drawn in the machine. So 16 ropes at a time. So 16 card cans are being emptied at a time, but on delivery side, other 16 card cans are filled up again after drawing. Processing capacity of this machine is 350kg in 6 solar hours.

(5) SPEED FRAME OR INTER MACHINE

This machine occupies 60 ft x 8 ft area and it is driven by 7.5 hp electric motor. Initial partial spinning is done on this machine from thick rope to thin say 5mm dia string like ropes and it is wound on big bobbins say 4" dia x 15 " long. So all card cans are emptied now. Capacity of machine is 120kg in 6 solar hours. Product wound on big bobbins is called roving or puni in Hindi

(6) RING FRAME

This is final spinning machine converting roving in to yarn. It costs about Rs 3 lakhs. But 10 hp and 3 hp motors can drive this machine.It is out of capacity of our solar power plants in the farms. So it is essential to make it smaller. It is 60 ft long having 440 spindles. Its 60 ft length is really connected 5 times 12 ft each with 88 spindles. So remove one part of 88 spindles. So length will be 48 ft with 352 spindles.Then it will be driven by 7.5 hp motor + 2 hp motor. Then it will be driven by solar power plant of 10 kw capacity. The yarn produced on this machine on small bobbins goes for cone winding machine. This modified ring frame will produce 16 kg of yarn in 6 solar hours.

(7) CONE WINDING MACHINE

Spinning on ring frame is done on small bobbins.It is not possible to sell such small bobbins. So cone winding machine has been developed. It occupies 60 ft x 8 ft area and it is driven by 3hp+3hp+1hp motors. 120 cones of about 1.5 kg are wound in this machine at a time. With 4 persons working on this, output will be about 170kg in 6 solar hours. This is salable commodity in the international market. There are huge markets doing speculation on these cotton cones throughout the world. These cones go to weaving of cloths.

HOW TO EQUALIZE PRODUCTION CAPACITY?

We have observed that there is wide variation in production capacity of each machine. So let us calculate how many machines are required to get 1000 kg of yarn per day.

(1) Cotton ginning machine capacity 480kg daily x 3 machines
(2) Blow room processing 800kg. x 2 machines
(3) Carding machine 100kg.x 10 machines
(4) Draw frame 350kg x 3 machines
(5) Speed frame 120kg.x 8 machines
(6) Ring frame 16kg x 63 machines
(7) Cone winding machine 170 kg x 6 machines

Totally 95 machines.

Each farmer having 10 KW solar power plant at his farm will install only one particular machine of textile spinning mill. So 95 machines will be installed at different 95 solar power plants in 95 different farms, preferably of same village or nearby village. For any machine, preceding machine's final product will become raw material and and its final product will go as raw material to succeeding machine. i.e. say for (4) draw frame,raw material will be the final product of (3) carding machine. Draw frame's final product will go to (5) speed frame. Final salable product will be at cone winding machine. So there will be transport from one farm to another farm. But collectively entire cluster of 95 machines in 95 farms will work as one spinning mill. It is equivalent to spinning mill of 4000 spindles. But centralized spinning mills work round the clock for all 12 months, while this cluster can work only for 6 hours a day and also roughly 200 days when solar power plants are not fully occupied with water pumping activity. Due to this limitation, many more machines are involved.

We can safely assume that textile spinning activity will work for 200 days in a year. So 1000kg yarn per day x 200 days = 200000kg of yarn. Ginning to yarn will add value of Rs 100 per kg of yarn. So total income of a cluster of 95 machines will be 2 crores, which will be distributed among 95 machines more or less equal but with some difference with capital investment etc as per norms prevailing in textile industry. So each solar plant owner will get Rs 2 lakhs and about 10 lakhs will go for transport, administration, marketing, accounting, maintenance etc. It should be noted that with each machine one worker will be required. So wages of workers will be 200 days x Rs 250 per day = Rs 50000/-. So in every village, 100 people will get employment with income of Rs50000/- in 200 days. So total income of wages to 100 workers will be Rs 50000 per worker x 100 workers = 5000000/- i.e.50 lakhs. These workers will be landless people who work in the farm and suffer starvation if no work or no rain in the farm.

We have seen that such cluster of 95 machines scattered in different 95 farms of same village will process 1000kg per day x 200 days = 2 lakh kg. Now to process entire production of India i.e 500 crores of kg of cotton, only 25000 such clusters will be required, each cluster with 95 textile machines and 95 solar power plants of 10 kw each.

By processing 600 crores of kg of lint cotton in to yarn, total rural economic benefit will reach to 600 crores kg x Rs100 per kg = Rs 60000 crores. This is actual amount reaching to villages which will be automatically distributed in villages.

Please note that in this scheme, all existing spinning machinery is assumed at present second hand rates. It is extremely cheaper. Please note that in this scheme, entire processing of cotton Kapas to yarn is processed in farms by solar power. No power is to be used from grid lines. Please note that in this scheme, weaving is not considered. In fact weaving by solar becomes still easier as power loom hardly requires one hp motor.

This is real way to provide jobs and employment to vast majority of people. This is the real way of rural development and real way of peace and happiness.

Spinning in every home and weaving in every village was a normal scene in happy and peaceful India for many centuries. But with the inception of big textile mills before about 150 years, English Government encouraged big textile mills with the molafide intention of exploiting entire India and created hurdles against home scale textile industry. So this important home scale village industry was broken resulting in to poverty and unemployment. During the freedom struggle, Gandhiji tried his best for 40 years to revive this home industry in the name of Khadi and spinning in millions of homes was started. But after independence, our Government made the situation the worst by encouraging heavily centralized textile mills. As a result entire textile industry is centralized in 700 big textile mills in 3 big textile centres I e. Ahmedabad, coimbatore and Mumbai and millions and millions of people working in their homes lost their independent jobs. This is the situation created by so called our democratic Government. As a result, after 60 years of independence, spinning in every home and weaving in every village is considered as a ideological and nonsense impracticable imagination. But if we scrutinize hard facts in favour of decentralization, spinning in every home and weaving in every village by utilizing modern technology of tiny scale machines operated on solar electricity can be made pleasant reality and normal scene throughout the country. These hard facts are so much convincing that nobody can deny it.

1. Cotton is cultivated in almost in 80 % villages. Or it can be cultivated easily. So raw material is ready in every village.
2. If spinning and weaving is done in every village, baling of cotton is no more required. So heavy expense of baling cotton is saved.
   
3. If spinning is done in every village, transport expense of cotton bales from all over India to 3 or 4 textile centers can be saved.
4. In a big textile mills, almost half of the complicated machinery costing crores of Rupees is for breaking the bales and to make the cotton loose and to make the fibres parallel from the pressed cotton. If spinning is decentralized to every village, this entire expense is saved and better results can be achieved with simple and smaller machines for spinning loose ginned cotton.
5. Scientist have proved that cloth made from the loose cotton is 15 to 20 % more durable than the cloth made from the bales. This means that spinning and weaving in every village will give more durable cloth than present mill cloth.
6. The centralized mills require to procure cotton from half million villages and again to provide cloth to same half million villages. This entire system is full of injustice, exploitation, profiteering and betrayal to the entire nation. If spinning and weaving is decentralized to every village, this entire exploitative unjust system will break down.
7. Spinning and weaving require very less energy. So much less that it can be done simply by human power. Average woman can drive Amber Charkha of 8 spindles which requires only 80W. Millions of hand looms still work to weave the cloth which requires only 100W. Human power capacity is maximum 80 to 100 W. This much small power can be easily produced by photovoltaic solar cells. 
   

All the above points are self explanatory and even layman can understand it. So all the above points are heavily in favour of decentralization of entire textile industry again in crores of homes in half million villages. We should remember that making cloth is simple thing. We are studying in the history that Dhaka's MULMUL a very fine cloth was famous throughout the world. It was simply hand spun and hand woven on the equipments costing only 50 rupees at that time. It was just art and practice which made very fine cloth. Machinery has nothing to do with it. In fact complicated machinery makes simple thing also complicated. Now we believe that good quality cloth can not be made without big complicated machines. This is absolutely wrong concept. This also applies to solar cells. Thin film technology of making solar cells is not complicated at all. It is just like screen printing technology. In a few hundred rupees, screen printing can be done. Similarly solar cell making should be possible. Once the technology of making solar cells is known to Indian women, huge economic revolution can be made. I am sure that making a solar cell will be left hand job for any Indian woman - no matter she may be illiterate - who can make delicious roti, chapatti, papad, dosa, uthappam, parotha, thepla, puri etc. So SWADHARM of PV experts is to disseminate technology of making solar cells to common masses. The SWADHARMA of textile engineers and machinery manufacturers is to develop small simple and cheap machines for spinning and weaving the cloth. If this is done, then really India can be the modern and strongest and prosperous country with homogeneous development without poverty, unemployment and without exploitation and will inspire the rest of the world how to live peacefully without war and without exploiting other nations. This will be biggest tribute to Gandhiji.

Paddy is the biggest crop of India. Rice is the staple food for 75% people of India. Paddy crop is about 200 million tonnes. It will generate 150 million tonnes of rice and 50 million tonnes of rice husk. To remove the rice husk from the paddy and to get the rice is really very simple technology. Previously people used to do by hand pounding. Then simple rice hullers were developed. Hand operated rice hullers also were developed. Any rice milling technology expert still can develop hand operated simple rice huller of 100kg per hour capacity. If human power is utilized, lakhs of people can get employment in preparing rice from paddy at local level i.e. in farms and villages itself. This is surest way of removing exploitation of big rice mills. But now a days there is aversion of utilizing human power. It is considered as drudgery. In fact it should be considered enjoyment to make your own rice from your own rice for your own consumption. This is true Swadeshi work. But if human power is not desired, mechanical power can be used to drive the rice the rice huller for hulling the rice locally. Aim should be that paddy must be processed into rice just in the farm or at least in the village. In no circumstances paddy should go out of village to big rice mills. In processing paddy into rice at the farm level, hurdle is of power only. Electricity is not available in every farm. Diesel engine will become very costly for processing paddy into rice. Now a days small rice hullers are not available. So there is acute need for development of small rice hullers, say 250kg to 500kg processing capacity per hour. It may require 5 to 10HP mechanical power. This much power can be produced at every farm by burning rice husk as fuel in the small boiler thus producing steam and running the 5 to 10 HP steam engine . Roughly 30% rice husk will be consumed in running the rice huller and 70% rice husk will remain surplus. If rice huller has a capacity of 500kg of paddy per hour, then 125 kg rice husk will be produced per hour. Out of this quantity, roughly 40kg of rice husk will be used in the boiler per hour to run the steam engine to drive the rice huller. So steam engine operated rice hullers will be highly viable for farmers, because farmers will be able to sell rice at higher prices than selling the paddy at very low price. One rice huller of 500kg capacity, working 8 hours in a day will process 4000kg of paddy i.e. 4 tonnes in a day. If working season id for 150 days, total processing in a season will be 6000 tonnes. So for processing entire crop of 200milion tonnes, roughly 3 lakh rice hullers will be required. In a present system of big rice mills, they exploit the farmers heavily. They give very low price of paddy to farmers. If total exploitation of centralized rice industry is Rs.5 per kg of paddy, total amount for India becomes 200 million tonnes x 1000 kg x Rs.5 = 1 million x million = 100000 crores . This is a huge money drained from farmers to rice mill owners and rice traders. To stop this exploitation, 3 lakh rice hullers must be developed and installed into villages. The cost of the rice huller may be around Rs.50000/-. Small boilers also can be manufactured in villages by blacksmiths and technicians. So complete power independent rice huller consisting of rice huller , steam engine and boiler will cost roughly 1.5 to 2 lakhs. This will be excellent family enterprise where all near by farmers can get their paddy processed into rice on custom milling basis so that no sales purchase activity will be there and farmers will be the owners of the rice. So they can sell their rice at the better prices. This way entire rice milling business must be fully decentralized into village scale rice hullers and present giant capacity rice mills must die their natural death.

Before the emergence of big rice mils, entire population used to eat unpolished rice everywhere. But big rice millers started polishing of rice for bad profit motive. Because they were knowing that by polishing process outer nutritious elements of rice kernels are removed. So nutrition has also gone and some weight has also gone. So polishing makes double disadvantage. Only for marketing purpose white attractive appearance of rice kernels was created. Now a days it has become wide spread and entire rice production is invariably polished and people have forgotten the beauty of unpolished rice. If this entire rice milling industry is decentralized at village scale, then again there is need to popularize to eat unpolished rice. Ethical traders of rice should make special efforts to popularize unpolished rice in cities. This is subject of mass awareness. The health department of governments also should help to create such awareness. But recent day governments are sold out to multinational companies and centralize big industries. So we can not expect anything from them. So enthusiastic village workers should take up this work of establishing rice hullers in villages and selling unpolished rice into cities by inculcating to the people that real rice is unpolished rice and polished rice is stuff less product. It is our misfortune that entire rice mill industry has been heavily centralized into a few hundred giant rice mills. Crores of our common people have to become victim of exploitation of big rice mills owners. This is the challenge for engineers, technicians and village workers to get rid our entire mass from such pitiful exploitation in the matter of basic food of rice. This is not a very big task. If engineers and technicians start working with full confidence for establishing rice hullers, only within 5 years miracles can be achieved. Technology of rice huller is not complicated at all. Those who jump into business of making tiny rice hullers and disseminating it into villages will earn fortunes.

India produces 200 million tonnes of paddy. One tonne paddy gives 700 kg of rice and 300 kg of rice husk. Rice husk has heating value (calorific value) of 3000 kcal per kg. So it is excellent fuel. So we can burn rice husk and produce steam and generate power from it. For villages 10 KW power plant based on steam engine is quite appropriate which can process 4000 kg. of paddy into unpolished rice in 8 hours and it will also generate rice husk of 1200 kg. as fuel. In processing 4000 kg. of paddy, about 700 kg.(60%) of rice husk will be consumed and 500 kg. (40%) of rice husk will remain surplus which can be utilized to run the 10 kw power plant for generating electricity which can provide lights to 200 homes at night for 3 CFL lamps of 11 W each. So to process entire production of paddy into rice, we require 4 lakhs 10 kw power plants which will remove entire exploitation of big rice mills worth of Rs. 100000 crores. It means that 4 Lakhs tiny power plants of 10 kw will increase rural wealth by Rs. 100000 crores simply by rice milling in villages. Moreover this will electrify 80 million homes of all the rice producing villages of India with green electricity and this will also provide employment to 20 lakhs people.

At present, electricity is not given in villages. 10 crores of homes have no electric connection at all. Rural population is suffering heavy injustice in this matter. By making excuse of non availability of electricity into villages, Government is advancing the scheme of giant nuclear power plants which are most dangerous for the safety of people, most hazardous, most polluting and most expensive also. Government is simply favouring dangerous multinational American companies and corporations allowing them to exploit entire India by snatching away small farmers' land and leaving them at the mercy of merciless people. Even after spending billions and billions of rupees on nuclear power plants, production capacity of nuclear power plants has not gone beyond 4000 MW. Investment in nuclear energy per mw is said to be Rs. 30 crores and production cost per KWH is also about Rs. 15/-.

As against this, 4 lakhs of tiny power plants of 10 kw based on rice husk will make total installed capacity of 4000 MW and will invest only 2 crorers per MW i.e. less than 10% investment in nuclear power plant. So there will be very cheap, innocent and renewable green energy in all the rural homes of India.

But government is acting as if it is enemy of people. Government does not promote tiny rural power plants based on rice husk and other agro waste and always thinks in terms of giant power plants of nuclear energy or coal energy which are not only hazardous and polluting but also heavily expensive.

At present, entire paddy processing into rice is made through a few thousand big rice mills which use electricity produce in thermal power plants & nuclear power plants. Consumption of electricity in all rice mills may be about 4000 MW. i.e. we can safely assume that entire electricity produced in nuclear power plants goes for big rice mills. This is complete wastage and extravagency. Heaps of rice husk are dumped as waste and scare electricity is consumed in rice processing.

But Solution is very simple by developing 4 lakhs rice husk operated tiny power plants of 10 kw capacity. Thus we can save grid electricity of 4000 MW and stop installing further nuclear power plants and become self reliant in rice processing and providing electricity to 8 million homes also.

So rural people should think in constructive direction to set up tiny 10 KW power plants based on rice husk in all the villages in lakhs of numbers by peoples own initiative. This way rural people can produce their own power in villages and process paddy into rice in all the villages and we can become free from exploitation of big rice mills and increase the wealth of villages worth Rs. 100000 crores. This type of constructive activity will force the Government to think in right direction in favour of the villages and against the exploitative multinational companies.

Here I have thought about rice milling only but tiny steam power plants are useful and blessing in jaggery making, oil milling, cotton ginning, spinning and weaving of cloths, in water lifting for irrigation etc. etc. I have estimated that more than 1 crore such tiny steam power plants can work in India which will increase rural wealth of Rs. five lakh crores.

(1 crore = 10 million, 1 lakh = 100000 = 0.1 million) 

Thermal power plants is the main source of energy and electricity in India and almost all countries of the world. Most of the giant thermal power plants have capacity of 500MW to 1000 MW. Investment in such giant thermal power plants is Rs 100 million per MW including transmission lines and distribution lines. ( 60 rupees = 1 US$, MW=1000KW). So 1000MW thermal power plant costs Rs 100 million/MW x 1000MW =Rs 100 billion.

Now let us think about tiny thermal power plants. Mostly 10 HP power plant will be people's friendly as it will satisfy most of the basic needs of the people such as oil milling, rice hulling, cotton ginning, yarn spinning, cloth weaving, sugarcane crushing, grain grinding, water pumping, village lighting etc. This will be equivalent of 10 KW electric power which when converted to mechanical power will be 10 HP. This 10 HP thermal power plant without generator will cost Rs 270000/- . Let us compare this with giant power plant. One MW i.e. 1000KW cost Rs 100 million. So 10KW costs Rs 1 million. But in practice it costs Rs 270000/-. It is only 27% cost of giant power plants.
But this cost of Rs 270000/- can be drastically reduced. Tiny thermal power plant consists of steam engine and suitable boiler which generates steam, and alternator if electricity is required. But we have observed that in most of the cases, no electricity is required as direct mechanical power of steam engine can be more efficiently used by running the machines by belts. So power plant means only steam engine and boiler. Now main cost in power plant is boiler. At least 2/3 cost is boiler and 1/3 cost is steam engine. So 10 hp steam engine costs Rs 90000/- and Boiler costs Rs 180000/-.

Now when steam engines will be mass produced in thousands, its cost will reduce to Rs 50000/-. And when boilers will be produced in villages by technicians even without any mass production, its cost will also reduce to Rs 50000/- from Rs 180000/-!  So 10 HP steam power plant will cost only Rs 100000/- which is only 10% cost of giant thermal power plant compared on equal capacity. It means that 100 steam power plants of 10 HP ( equivalent to one MW)  will cost only 100 plants x Rs100000 = Rs 10 million i.e. only 10% of 100 million investment in giant thermal power plant per MW.

But how cost of the boiler will reduce from Rs 180000/- to Rs 50000/- only? It is sure that it will reduce to Rs 50000 only. Water tube boiler used in power generation is nothing but series of tubes welded in parallel with header pipes closed at both ends and housed entire assembly in enclosed fabricated structure well insulated. This can be easily done by village blacksmiths and welders and technicians. Just we have to teach them and train them how to do it. We have to explain them construction of boiler and system of hydraulic pressure testing it. This can be done in one week training for technicians already running fabrication shops in villages. Then they will make their own boilers which will be far more safer than presently available giant boilers.

Is this really possible? Yes. This is really practicable, economical and blessing to common masses. 20 million boilers can be fabricated in villages by village welders and technicians. They are really possessing enough skill to produce boilers in villages. India is the country of inherent skill. It is not found in other countries. This skill is artificially and legally suppressed by Indian Boiler Regulation Act by imposing hundreds of restrictions against manufacturing of boilers in the name of public safety. So special vested interest class of boiler manufacturers have come up who produce and sell boilers at 5 to 10 times its real cost. And small boilers are not produced saying that cost becomes exorbitant and hence not viable. So only giant technology of boiler prevails and hence only giant thermal power plants.

So Indian Boiler Act is the biggest impediment against rural industrialization, against creating millions of self enterprises, against removal of poverty and against creating wealth and prosperity in villages. The biggest paradox is that our Prime Minister shri Narendrabhai Modi is totally against Boiler Act and he understands that Boiler Act comes in to our way of real homogeneous development of our country and he wants to abolish Boiler Act. Please listen his famous speech on 5-1-2014 in which he has bitterly criticized provisions of Boiler Act. His speech is available on youtube
( http://www.youtube.com/watch?v=decVCdTIBU4). In spite of this, Boiler Act is not abolished.

All the arguments in favour of Boiler Act are thrust upon us in the name of safety of people. All these arguments can be simply nullified by testing the boilers produced by villagers at four times the working pressure of boiler, while Boiler Act provides to test at double the working pressure. So all boilers produced by villagers will be double stronger and double safer than IBR certified boilers. So arguments put forward in the name of safety becomes null and void.

So if Boiler Act is abolished or at least it is exempted for small boilers below 30 sq mt heating surface, then small water tube boilers will be manufactured by village technicians and its technology will spread everywhere and cost of boiler will be only material cost plus labour of technicians just to maintain their families. No profit, no overhead cost will be counted in the cost of boiler. Boiler for 10 hp steam engine will weigh about 500kg and its cost to customer will be only Rs 50000/-. Then there will be real rural industrial revolution bringing happiness to every family. Boiler is the main source of producing prosperity. All the prosperity which we see in the world is generated through boilers. Boiler generates steam and steam generates power everywhere in the world. So Gandhiji has also asserted that "We must learn how to use steam and electricity appropriately". So once we spread the technology of boiler to our villages, millions of boilers will be produced in villages. Then all basic need industries will be fully decentralized including power industry. 20 to 30 million tiny thermal power plants and tiny solar thermal power plants will generate all the energy - almost half million MW in decentralized way - running all the industries in villages. Poverty and unemployment will become matter of past only in 10 to 15 years. Then India will become the strongest country of the world, happiest country of the world  and India will become inspiring Guru of entire world. Then Gandhiji's cherished dream of Swadeshi prosperous villages will be materialized. Then only way to Gram Swaraj will be clear and heaven will descend on this earth.
So only one injustice is to be removed. Rules made for elephants should not be applied to ants. Rules made for giant boilers can not apply to tiny boilers. So small boilers must be exempted as our Prime minister Narendrabhai desires. Then heaven will descend on villages. Government need not worry for them. They will electrify themselves. Government should give them due budget allocation village to village. Per capita budget of central and state governments is Rs 28000/-. Give them 50% with restrictions against its misuse and you will see miracle.

Date 24-11-2015

Honorable shri Narendrabhai,

When you were at Gandhinagar as CM, I used to write many letters which you read and appreciated also.

But this letter is the most important of all.

So if you want to make our villages overflowing with prosperity, if you want to provide independent self business to crores of people, if you want to increase electricity generation up to 5 times i. e. 10 lakh MW only by solar, if you want to double the agricultural production, if you wan to abolish poverty and unemployment for ever from India, if you desire to gain and retain your popularity and serve as Prime Minister for next 20 years, if you like to become world leader, then kindly read my following suggestions. Whatever I am suggesting below is really panacea of present situation to solve all problems at a stretch.

1. Enforce the banks immediately to provide loans up to 6 lakhs at reduced rates of interest to purchase 10 kw solar power plant to 8 crores wives of small farmers having land of 4 hectares or less.
2. No need to give single rupee subsidy to farmers. So no any expense of subsidy to Government.
3. 10 kw solar power plant shall generate 20000 KWHs annually. Please enforce electricity companies to purchase all such surplus electricity which farmer will not consume at Rs 6/- per KWH compulsorily. Then each farmer's wife will have income of Rs 120000/- annually.
4. All this surplus electricity will go to grid. Electricity Company will make 50% payment to Banks to pay installments of loan and remaining 50% will be credited to the bank account of farmer's wife. From this income, she will purchase cows and will increase milk production. So animal husbandry will be greatly promoted.
5. Wives of farmers must get loan at their homes, no bureaucracy, no harassment, no forms to be filled up, no any fee, no any deposit to be paid. Please impose tight responsibility on banks and electricity companies.
6. Please abolish all taxes including income tax, VAT, sales tax on solar panels and raw materials consumed in making solar panels. Please abolish custom duty in import of solar cells. Then production of solar panels must increase 50 to 100 times in one year only. Kindly declare all possible incentives for solar panels manufacturing.
7. Kindly ensure that no any bureaucracy may harass to farmers under the excuse of non agriculture use when they establish and run cottage and small industries by solar power in their farms as not even 1% land is used in such industries without affecting agricultural production at all. Kindly declare by newspaper advertisements that up to 2% use of land in industries, no any non agriculture rule is violated as agricultural production is not affected at all.
8. This much is enough. If this much is done, all villages will become paradise in a few years and poverty, starvation, unemployment, mal nutrition will disappear very fast. Small farms of India will flourish with various kinds of industries. Cooking oil, rice, jaggery, cloth etc will be produced in farms by solar power at cottage and tiny scales only. Two crores of pumps will work with solar power only. So agricultural production will be doubled. No grid connection necessary to them.
9. Installed capacity of farmers only will be 8 lakh MW. So no power cut in cities at all. For any industry, power connection will be available in 24 hours only. Electricity will be surplus everywhere. Where to dispose will be problem. No any new giant power house will be needed. Delhi, Mumbai etc will get electricity from millions of farms.
10. Cities and towns also will become heavenly. Urban population will reduce to 75% as 25% living in slums will go to villages. So automatically slums will disappear. Governments will not need any budget for the schemes to expand water supply, drainage, electricity, roads, housing etc in cities.
11. 600 crores kg of lint cotton (350 lakh bales) will be ginned in farms by solar power, will be spinned in farms by solar power and will be weaved in farms by 75 lakh solar powered looms. No any bale binding. No any export of single bale. Once solar power is available in farms, appropriate machinery to spin the cotton and weave the cloth will be developed by people in no time. No any Government effort will be required. Industrial development will be unimaginable.
12. Injustice to women will be reduced to negligible extent. It will be splendid fact that 8 crores of solar power plants will be owned by women. So purpose of women empowerment will be served fully. Entire world will be astonished to look this scene. India will become world Guru. All the countries of the world will come to you to get your advice and to follow you. Europe and USA also will follow you and will discard their exploitative policies.
13. To achieve this objective, Banks have to make finance of 8 crores solar plants x 6 lakh rupees each = 48 lakh crones to farmers' wives. Out of this huge amount, not a single rupee will be bad debt. So NPA will be really zero. In the history of banks, this will be the safest and the most secured loan. FDI is not necessary at all.
14. If you implement my suggestions, then you will get blessings from 125 crores hearts so much that you will be elected up to next 20 years without any further effort of election propaganda.
15. To explain this scheme of 8 crores solar power plants in farms, I have written 56 page booklet in Gujarati KHETRE KHETRE SOLAR POWER which I am sending herewith. Also my Hindi book GAVON KA NAVSARJAN is enclosed herewith. I hope your responsible officer will read it and appraise you.

DANGERS OF CENTRALIZED POWER PLANTS

Solar power has come as a blessing to the humanity, not only to provide energy to all but to save humanity from the evils of industrial revolution. The biggest evil of industrial revolution in last two centuries is the concentration and centralization of wealth and resources and also huge political powers in the handful of people. So huge factories, mass production, big industrial and financial corporations, large cities, huge network of transport, huge scale mining, giant thermal power houses, giant cement factories, dangerous nuclear power plants, huge dams, huge skyscrapers etc are emerged in the world in the name of development which in fact exploit billions of people, throwing them into starvation and poverty. The net result of the industrial revolution has not increased happiness on the planet but it has increased starvation, poverty, disparity, diseases, hospitals, mafiaism, crimes and offenses, terrorism, wars, unrest, suicides, greed in the human minds, consumerism etc and so humanity has lost the way of peace and happiness.

DISADVANTAGES OF MW SIZE SOLAR POWER PLANTS

KW size solar power plants have certain inherent advantages against MW size solar power plants.

(1) MW size solar power plants cannot exist without grid connection. They utilize some energy of grid. They cannot be established off grid. While KW size solar power plants can be established off grid. They do not require any electricity for their operation. So MW size solar power plants are not really independent.
(2) MW size solar power plants require large area of land. Almost 5 acres per MW. For 10 MW solar power plant, 50 acres of land will be required. 100 MW solar power plant will occupy 500 acres of land. This much large space is rarely available. So huge expense of land is involved with every MW size solar power plant. So MW size power plants are not suitable where land is scare or costly. But KW size power plants can be installed very easily in every farm, on roof of homes, shops and factories. 5 KW solar power plant will require 30 sq mt (i.e.6mt x 5 mt) area only. This much space is available everywhere. No special land is required and hence no expense of land for KW size solar power plants.
(3) MW size solar power plants have to feed their energy in to grid at very high voltage say 11000V for one MW and 66000V for 6MW or bigger. So they have to incur huge expenses of heavy step up transformers and sub stations to create and control high voltages. KW size solar power plants can easily create voltage up to 440V by simple inverter. Mostly its generated power is for consumption. But if it is to be fed to grid lines, then also it can be fed at 440V. So no any additional expense.
(4) MW size solar power plants are generally installed near grid lines to minimize expenses to feed power to grid. No such limitation to KW size solar power plants. It can be installed at any place.

In fact any effort to produce solar energy at MW size and to feed into the grid is tantamount to transporting the sunshine from one place to another place. Naturally this will be absolute foolishness. If MW size solar power plants are installed everywhere in the world, no any favourable change will come to the world in favour of peace and happiness. All the evils of industrial civilization will remain intact by way of MW size solar power plants. This is the worst misuse of solar energy.

WHAT IS 10 KW SOLAR POWER PLANT?

It is extremely simple. So much simple that difficult to believe.
It is fully automatic. No operator required.
It occupies only 60 sq mt area. say 12 mt x 5 mt. It is 68th part of one acre land.
40 solar panels of 250 W each with inverter controller make 10 kw solar power plant.
It can be installed in one day only.
Once installed, it goes on working for 25 years.
So free electricity for 25 years.
10 KW solar power plant costs only Rs 6 lakhs.
If deposited 6 lakhs in a bank, you get only Rs 48000/-
But solar power plant produces at least 18000 KWH power in a year.
Only power selling fetches Rs 120000/-.
So 20% return on investment.
So it is economically viable.
But if you utilize solar power for water pumping, benefit will be far more.
If you utilize solar power for running industry, benefit will be far more.
So 8 crores farmers should install 10 kw solar power plant.
Then 8 lakh MW power will be produced in farms in rural areas.
Then abundant power in cities. No power cut at all anywhere.
This is the real way of freedom and happiness.
Look video of 3 hp submersible pump running on 3 kw solar panels in my factory.
https://youtu.be/zj3Z_XFn9Io

1 KW TO 10 KW SOLAR POWER PLANTS IS THE PENECIA FOR ALL EVILS

Solar energy has come as a blessing to solve all these problems and to rectify the major defects in the structure of the society created by industrial revolution. Solar energy is inherently decentralized way of energy production. Sunshine is equally distributed everywhere. So solar power should be generated at the point of consumption and so it must be produced in few KW only. So wherever energy is required, it should be produced there and consumed there. So all the industries related to agriculture can be naturally decentralized at farm scale level. Energy will be required to pump the water in the farm. So 1 KW to 5 KW power will be enough for pumping. It can be produced in the farm itself by solar panels. Energy may be required for agro processing such as flour milling, rice hulling, sugarcane crushing, grain thrashing, cotton ginning, cotton spinning, cloth weaving, wood working, oil milling etc etc. Each of such processes may require 2 to 10 KW power at the most. It can be produced by solar panels. Just use sunshine and get solar power automatically without any manpower. Transmission lines and grid lines will be used to feed excess power in farms which will go to cities and towns.

HUGE SCOPE OF 1KW TO 10 KW SOLAR POWER PLANTS

So looking to above favourable inherent benefits of KW size solar power plants, there exists huge scope for producing local power at every farm for every purpose right for water pumping to any process industry of agricultural produce, at every industry, in every village in every country. It is the real way of happiness through localization.

There exists huge scope of 80 million solar power plants of 10 KW capacity only in the farms of India. I will describe this scope in detail.

There are 9 crore (90 million) farmers in India. Out of them 5 crore farmers are marginal farmers having land 1 hectare or less. So these 5 crore farmers comprising 25 crore population are the poorest farmers and they cannot sustain only on agriculture without some additional income from other sources. Gandhiji also has asserted that poor farmers of India cannot sustain their life without additional income from some home industry. He suggested spinning and weaving activity in every home. But textile industry has been heavily centralized by faulty government policy and it will take many years to decentralize it again in rural homes. But generating solar power in every farm, no matter it may be very small farm, is the easiest way to provide some additional income to really needy farmers. So 10 KW solar power plant is the panacea of this problem. It will drive out poverty and unemployment from India very quickly. 10 KW solar power plant consists of (a) 40 numbers of solar panels of 250 Watt capacity each, size 1 mt x 1.5 mt (b) Supporting structure of fabricated steel for 40 panels i.e. 10 mt x 6 mt (c) Inverter controller to convert low voltage DC power of solar panels to high voltage AC power by which electric motor can be run. So this is the simplest solar power plant which can be commissioned within 2 days only. It is completely automatic not requiring any manpower.

India is blessed with maximum sunshine in the world. We can safely assume 280 clear sky sunny days. Atleast 7 hours energy generation is sure to get. So total annual energy generation will be 280 days x 7 hours x 10 KW =19600 KWH. If electricity companies purchase this power at Rs 6 per KWH, total income to farmer from 10 KW solar power plant will be Rs 117600/-. Complete solar power plant of 10 KW is now available at Rs 6 lakhs. Government must abolish VAT and any other tax. So income of 117600, say 115000 by investing Rs 6 lakhs means 20% return on investment. It means that 10 KW solar power plant has become economically viable and every farmer can afford to install it. Government need not give any subsidy to anybody for installing solar power plants. But government should impress upon all the banks to give finance of Rs 5 lakhs to each and every marginal farmer's wife to establish 10 KW solar power plants. So owners of all solar power plants will be women everywhere. Electricity company must purchase all power generated in farms and they can make 50% payment directly to banks towards instalments to pay debt and interests and remaining 50% to women owners of solar power plants. So NPA will be ZERO. Only this much encouragement will bring huge revolution in our country.Women ownership of solar power plants will greatly empower women to remove social injustice and bring up women's status equal to men.

10 KW solar power plant will occupy only 60 sq mt land, which is just 1/68 acre. It is only 0.6 guntha. 100 guntha becomes 1 hectre. So such a small piece of land remains in every farm rejected by a farmer for any reason. So utilizing only 60 sq mt in 1 hectre is absolutely negligible and it will not affect agricultural production in any way. On the contrary agricultural production will increase because of available power in every farm for water pumping and also because of income of power generation in the farm as farmers' wives will utilize that income in animal husbandry, natural manures and to improve land conditions and agricultural production.

10 KW solar power plant can be installed only in 4 days. If equipments are available, it is not impossible to install 1 crore such solar power plants annually. So in 5 years time, 5 crore solar power plants will come up. This means total installed capacity will be 5 crores x 10 KW = 5 lakh MW. Present installed capacity of all types of power plants is 2 lakh MW. So there will be surplus power everywhere. Power cut in cities will be matter of past. No pending application for power connection. It will be immediately available. So real industrial progress will start after power becomes surplus.

But so far we have considered only marginal farmers. There are 2 crores of farmers in somewhat better conditions having land 1 hectare to 3 hectare. They also can install 10 KW solar power plants in their farms. Moreover there are still 2 crores farmers having land more than 3 hectares. These are comparatively richer farmers. They can afford to install 10 KW solar power plant without any bank facility. So again 2 crores of such solar power plants will come up. So on the whole 9 crores of farmers can install roughly 9 crores of solar power plants of 10 KW ideally. But let us assume that practically 8 crores of farmers power plants of 10 KW will come up. So 8 lakh MW capacity of farmers only. Again urban people, factory owners, institutes having large buildings, hospitals, colleges etc will install roof top power plants which may account for one lakh MW. Adding the present capacity of 2 lakh MW, it will be 11 lakh MW. Then India will be a glorious country inspiring all other countries of the world how to solve power problem and how to bring happiness to common masses.

So no land acquisition required. No eviction of people from their homes. No coal mining necessary. No uranium to be imported. No nuclear power plants required. Not to supplicate western countries for giving power technology. Only 10 KW Solar power plants will make a miracle.

But what about equipments? Present capacity of manufacturing solar cells and solar panels is just nominal. For establishing 1 crore solar power plants of 10 Kw each, we require manufacturing capacity of solar cells and solar panels of 1 lakh MW. But present capacity is only 2000 MW. It must be increased 50 times higher. So government must give incentives to solar cell manufacturers and solar panel manufacturers. At least income tax must be abolished for manufacturers of solar cells and solar panels. Then thousands of new unit will come into manufacturing and capacity of 1 lakh MW will be reached in 1 or 2 years. After we have installed 8 crores of 10 Kw solar power plants, entire India’s production of solar cells and solar panels will be exported for other countries. There also roughly 24 lakh MW power in the form of 24 crores of 10 KW solar power plants is required to create peace and happiness throughout the world. To achieve this target, government should ban new MW size power plants whether solar or thermal or nuclear. Present MW size power plants may continue for power requirement at night until that requirement is met by wind turbines and tiny biomass power plants in farms and villages. 

HEAVEN OF HAPPINESS WILL DESCEND ON INDIA

If this happens, evils such as terrorism, wars, world level exploitation, poverty, starvation, unemployment, urbanization etc will disappear. it will be greatest tribute to Gandhiji. Then heaven of happiness will descend on India. Picture will be more or less as under:-

1. Electricity generation 5 times in 10 years.
2. Entire generation in small farms through tiny solar power plants.
3. Electricity will flow in reverse direction - from farms to cities.
4. Agricultural based industries such as textile, sugar, jaggery, cooking oil, rice will be decentralized in small farms.
5. Poverty and unemployment will be matter of past.
6. Villages will have high rise multi storeyed buildings.
7. Prosperity will overflow in villages.
8. 25% population of cities will be reduced as they will shift to villages.
9. So slums will be abolished automatically.
10. Land prices in cities will fall down to 25% only.
11. Land prices in villages will increase by 4 times.
12. No billionaire, No MNCs, No share market, No petroleum import.
13. No coal mining, no pollution, no eviction of farmers, no nuclear power plants, no slavery.
14. Entire world will be astonished with this revolution.
15. India will become World Guru.
16. Victory victory victory for Gandhiji's vision.

Primary aim of any rural technology training institute should be to create home scale industries related to primary needs of the people and thereby to create wealth and self-employment in villages and to abolish the exploitation of big industries. So we should prepare rural technicians capable of establishing their own home scale industry in the village. As industry must be related to the primary needs of the people, it will create rural alternative of big industries such as oil mills, sugar factories, textile mills, rice mills, cement factories, power houses etc. Generally these six organized exploiting industries related to the basic needs of the people must be decentralized because of our efforts of creating technicians for rural industries. Most of the people create a doubt that we cannot attack big industries and we cannot compete with this well established big industries. This is completely false notion. We can easily compete all these big industries simply because home scale and village scale industries enjoy many inherent benefits which big industries do not have. So any home scale or village scale industry related to primary needs of the people is inherently more viable than big industries. I have already tried and proved in 85 countries that tiny oil mill is far more viable than big oil mill because tiny oil mill enjoys more than 20 inherent benefits which big oil mill does not have. So big oil mill can never compete tiny oil mill. I have listed out all such inherent benefits in a separate article 'BENEFITS OF TINY OIL MILLS'. Similar inherent benefits are available for tiny rice hullers against big rice mills, tiny jaggery units against big sugar factories, to home scale spinning and weaving activities against big textile mills, to local farm scale power house against big thermal power plants, to tiny cement units of 20 bags per day against huge cement plant of 4000 tons per day etc etc. We must remember that big oil mills, big rice mills, big textile mills, big sugar factories, big thermal power plants, big cement factories can exist only due to government support and many hidden subsidies. In a free competition without any support from government, all these big industries cannot compete to tiny home scale and village scale industries.

If we have this faith in our heart, we should train rural youths to start their own tiny rice hullers, tiny oil mills, tiny jaggery units, tiny textile units etc.

I established 500 tiny oil mills unfortunately without any training institute in villages. All are working most successfully. Edible oil worth Rs.300 crore is produced annually from this oil mills. Big oil mills cannot compete my tiny oil mills. So we can go on establishing tiny oil mills upto 3 lakh units in India. As big oil mills cannot compete to tiny oil mills, they have to die their natural death. So our duty becomes to train maximum number of people who can establish tiny oil mills in their village. Similarly we should train maximum number of people in shortest possible time to establish tiny rice hullers in their village. Similarly we should train maximum number of people in shortest possible time to establish ginning machine in his village to gin the cotton. Similarly for spinning and weaving.

So our primary objective must be to train the youth so that he can establish his own business. So diploma or certificate must be avoided because once diploma or certificate will be given, student will be tempted to become a slave with a salary of some exploitative business which is simply dangerous to our aim. Once the trainee establishes his own home scale industry, it will be his success and it will be our success. No any other certificate or diploma.

So courses should be as short as possible. Not a single day more than necessary. For most of such industries 1 month course will be quite enough. It can be shortened to 2 week course also.

As Gandhiji has advised no any training or educational institute should build expensive buildings. Directors and founders of such institutes should understand beauty in simplicity. Please remember that India is burning by the flames of big industries. Before it burns to ashes we have to save India by extinguishing the fire of big industries. So we have no time and we must act as fast as possible. So we should create maximum possible technicians by shortest possible courses. Every course must be for one specific industry only. We should not have long course of 1 year teaching many things at a time. It will be wastage of time and energy because trained person will not establish 10 types of industries. So it is absurd to teach agriculture, animal husbandry, repairing of electric motor, fabrication and welding and making pickles in 1 course. If your institute trains 50 persons with 1 year course, then you create only 50 home industrial units. But if you run short term courses of 2 weeks only then you create 50 persons in each course x 24 courses in a year = 1200 home industrial units. Every training institute should consider local requirement with respect to local crops. In a paddy area course of rice huller must be predominant. Where sugarcane is main crop, jaggery production must be taught. In a cotton area, ginning, spinning and weaving must be emphasized. 

1. The ensuing energy revolution throughout the world will drive out most of the evils created by industrial revolution of the last century.i.e. poverty, unemployment, hunger, disparity, urbanization, polution, terrorism, war, centralization etc will be reduced to the minimum.
2. Days of MW power have gone. Present century is for KW power. Energy revolution is poised to decentralization of not only energy production but also of all the industrial activity in the world.
3. Power plants up to10 kw generated by steam, solar, wind biogas  or any other source is human, cheap, simple viable, manageable and beneficial to the humanity. Bigger than 10 kw is inhuman, costly, complicated, unmanageable and harmful to the society as it gives rise to the exploitation and other evils.
4. It is possible to devise all industrial activity of the world with 10 kw power or less.
5. It is possible to create the world without grid power lines.
6. If grid exists after 2 decades, electricity will flow in reverse direction i.e. from rural areas to big cities.
7. Steam power is coming back very fast and all the agricultural processing such as oil milling, sugarcane crushing, cotton ginning, rice milling, wood working will be shifted on steam power.
8. Solar thermal power plants of 10 kw or below will be millions in one or two decades.
9. Once the technology of making  Photo voltaic solar cells is known, it will be left hand job for every Indian skillful woman to manufacture it at home no matter she may be illiterate. Then real home scale industries for every primary needs will blossom.
10. Transport will be reduced to minimum at the end of 21 century.