What is GHANI ?

GHANI is a machine being used in India since last 4000 years to extract oil from sesame at very low temperature. It was driven by bullocks. The historians have found out that even in 2000 BC, mortar and pestle of GHANI were made of stone and granite and such GHANIs were used in India for extraction of oil from sesame. Later on it was made of wood.

Half million GHANIs were in operation throughout India even upto 1955. But with the advent of oil expeller technology and big oil mills promoted by Government's foolish policy, almost all GHANIs could not sustain and had to close down. But still some GHANIs are running which are now made of iron and steel and it is driven by 2 HP motor.

TINYTECH KAMDHENU GHANI machine is the most scientific and most modern piece of technology. When I perfected its design after 2 years efforts, my heart was filled up with deep complacency that I have done very nice work. Entire GHANI is a compact machine accommodated on 600mm x 600mm base frame. 2 HP electric motor drives vertical mortar revolving at 16 RPM through reduction gear box. Pestle and mortar are so much robust that practically there is no maintenance. Pressure increasing device is through heavy spring and screw. Shipping dimensions are 30" x 36" x 48" (750mm x 900mm x 1200mm). Ghani occupies only one sq mt area. Electric motor is hanging on vertical support of Ghani. So it does not require additional space. V belt cover is provided for V belt from motor to bottom gear box. No foundations required. For easy movement in the room, 4 castor wheels are provided. Ghani has crushing capacity of 10 kg oilseeds per batch. First batch takes one hour and then batch crushing is completed in 45 minutes. Oil cake is almost 12 to 14mm thick and is excellent cattle feed. 2 hours pouring in water is recommended before feeding cake to cattles. This ghani is ideally suitable to extract cold presses pure natural fresh cooking oil from sesame, sunflower, copre, groundnut, mustard, castoroil, mahuda, saflower etc. Ghani is not suitable for low content oilseeds such as cottonseed, neemseed, soyabean etc. Total weight of the Ghani is 300kg. Ghani is very sturdy and wooden packing is not nessary for transport.

What is SANI ?

SANI is the most nutritious and most delicious sweet product made of sesame and jaggery. SANI is made in GHANI machine. Though SANI is made of sesame and jaggery, it is not only mixture of sesame and jaggery. It is far more than that. Sesame is crushed into the GHANI and when oil is liberated from the cells of the sesame seeds and actual flow of oil is seen, jaggery is added and then it is thoroughly mixed with oily sesame in the GHANI machine. Then pasty crystalline sweet product called SANI becomes ready. It gives very good desirable flavour. So SANI is composed of sesame, its oil and jaggery. Though it is not cooked on fire, it is just like cooked product. Freshly prepared SANI is very much tasty and delicious and extremely nutritious. It is so much marvelous product that Europe and America have still not found any product equivalent to SANI in taste, in nutrition and its qualities.

How to prepare SANI ?

6 kg. of sesame seeds are crushed in to GHANI. It is very gradual process of grinding the seeds. After about 8 to 10 minutes, water upto 8% of the weight of sesame is sprinkled. i.e. about 500 ml. of water is added in to the sesame being crushed. Then after 4 to 5 minutes oil will be liberated from the sesame seeds and soon it will start flowing from the top of the cone where pestle is touching to the edge of the cone. When such clear flow of oil is seen, 4 kg. of jaggery is added in to the GHANI. Then GHANI is allowed to run for about 5 to 7 minutes until sesame and jaggery are thoroughly mixed. Then 10 kg. of SANI will be ready. Then it is taken out. Total cycle time will be about 25 minutes. Thus 200 kg. of SANI can be prepared in 8 to 10 hours. This SANI making business is highly profitable in all cities and towns. Daily profit of Rs 4000/- is normal profit in SANI if you can sell 100kg SANI. Total investment in machinery is not more than Rs 80000/- which can be earned back in 20 days only. You can come personally here in our office to see production and sale of SANI during winter. What you can not believe, you will see in reality.

Advantages of SANI

1. SANI is the most nutritious product for children, to youth persons and also to old people.
2. SANI is sweet, tasty and delicious product. So everybody can enjoy eating of SANI.
3. SANI is best and quick remedy for removing malnutrition from poor people.
4. SANI is blessing to the refugee camps as one GHANI can make SANI for 2000 people in 10 hours without cooking.
5. SANI can improve the health of the society and can make the body stronger.
6. SANI is the blessing to the poor people because it is the cheapest sweet. One person can eat 100 grams.
7. SANI eating by pregnant women will deliver healthy child.
8. SANI eating can improve the eye sight.
9. Regular eating of SANI in winter season will make the person free of disease.
10. If SANI is fed regularly to children or young persons suffering from malnutrition, all diseases arising from malnutrition will disappear and people will become healthy and expense of medicines and hospitals will be no more.

EXTRACTIONOF OIL FROM GHANI

Extraction of oil from Ghani is more art and less science. it requires good practice to master the art. For a technician of Ghani, it is very easy game to extract oil. But if you don't know anything, you will require practice. Adding water, at what time and how much is crucial factor for successful operation. Ghani machine is perfect in everything. But if you do not know art of extraction, it will not extract oil at all. So if oil is not coming out, it is not falt of Ghani machine, but it is fault and ignorance of operator of Ghani. When I first time made ghani, it did not give oil at all even after running many hours. Then we consulted one expert technician and he extracted 4 litres of oil only in 15 minutes in the same Ghani. Then I understood that machine has no fault but operator has fault. 

What is GHANI ?

GHANI is a sturdy rotary machine being used in India since centuries to extract pure , natural, fresh cooking oil from sesame, groundnut, coconut, sunflower, mustard etc as a cold pressed machine. It extracts oil at very low temperature below 50 degree C. So Ghani oil is the best quality oil. It is driven by 2 hp 3 phase motor or 3 hp single phase motor. It has crushing capacity of 10 kg per batch of 40 minutes. So it can crush 120 kg oil seeds per day. Ghani occupies only 1 sq mt space. So it is ideally suitable as home industry and women can also run it. Ghani has 4 castor wheels at the bottom for easy movement anywhere in the home or shop. There is a bright scope of establishing half million Ghanis in cities , towns and villages for providing fresh cooking oil.

TINYTECH KAMDHENU GHANI machine is the most scientific and most modern piece of technology.  When  I perfected its design after 2 years efforts, my heart was filled up with deep complacency that I have done very nice work. Entire GHANI is a compact machine accommodated on 600mm x 600mm base frame. 2 HP electric motor drives vertical mortar revolving at 16 RPM through reduction gear box. Pestle and mortar are so much robust that practically there is no maintenance. Pressure increasing device is through heavy spring and screw. V belt guard is provided for V belt from motor to bottom gear box.

Ghani is not suitable for low content oilseeds such as cottonseed, neemseed, soyabean etc. Total weight of the Ghani is 300kg.

What is SANI ?

SANI is the most nutritious and most delicious sweet product made of sesame and jaggery. SANI sweet is prepared in GHANI machine. Though SANI is made of sesame and jaggery, it is not only mixture of sesame and jaggery. It is far more than that. 6 kg of sesame is crushed into the GHANI for 8 minutes. Then about 6% water is added. After revolving for further 3 minutes, about 1 kg of sesame oil will be seen flowing from the top to bottom of the pestle. Then 4 kg jaggery is added. It will take further 3 minutes to get jaggery thoroughly mixed to make 10 kg of homogeneous paste called SANI sweet. Then Ghani is stopped and Sani is taken out which takes further 3 minutes. So total cycle time  is 8 + 3 + 3 + 3 = 17 minutes. So in one hour, 30 kg of Sani can be prepared. Though it is not cooked on fire, it is just like cooked product. Freshly prepared SANI is very much tasty and delicious and extremely nutritious. It is so much marvelous product that Europe and America have still not found any product equivalent to SANI in taste, in nutrition and its qualities.

This SANI making business is highly profitable in all cities and towns of India. Daily profit of Rs 4000/- is normal profit in SANI making if you can sell 100kg SANI. Total investment in machinery is not more than Rs 65000/- which can be earned back in 20 days only. Any person can come personally here in our office in winter time to see production and sale of SANI sweet. What you can not believe, you will see in reality.

Advantages of SANI sweet

(1)SANI is the most nutritious product for children, to youth persons and also to old age people.
(2) SANI is sweet, tasty and delicious product. So everybody can enjoy eating of SANI.
(3) SANI is best and quick remedy for removing malnutrition from poor people.
(4) SANI is blessing to the refugee camps as one GHANI can make SANI for 2000 people in 10 hours without cooking.
(5) SANI can improve the health of the society and can make the body stronger.
(6) SANI is the blessing to the poor people because it is the cheapest sweet. One person can eat 100 grams.
(7) SANI eating by pregnant women will deliver healthy child.
(8) SANI eating can improve the eye sight.
(9) Regular eating of SANI in winter season will make the person free of disease.
(10) If SANI is fed regularly to children or young persons suffering from malnutrition, all diseases arising from malnutrition will disappear and people will become healthy and expense of medicines and hospitals will be no more.

EXTRACTION OF OIL FROM GHANI

Extraction of oil from Ghani is more art and less science. it requires good practice to master the art. For a technician of Ghani, it is very easy game to extract oil. But if you don't know anything, you will require practice. Adding water, at what time and how much is crucial factor for successful operation. Ghani machine is perfect in everything. But if you do not know art of extraction, it will not extract oil at all. So if oil is not coming out, it is not fault of Ghani machine, but it is fault and ignorance of operator of Ghani. When I first time made ghani, it did not give oil at all even after running many hours. Then we consulted one expert technician and he extracted 4 litres of oil only in 30 minutes in the same Ghani. Then I understood that machine has no fault but operator has fault.

COST  OF THE GHANI = Rs.60000/- + 5% tax.

GHANI – WOODEN OR STEEL ?

I am receiving many inquiries of wooden ghani. I am really surprised why people are asking wooden ghani. It seems that there is a wide spread misunderstanding about wooden ghani. There is no doubt that wooden ghani is inconvenient compared to steel ghani.  Wooden ghani is full of problems of maintenance as mortar and pestle are worn out frequently and to be changed with lot of expense. 18’’ diameter wood for mortar is available rarely or with great difficulty. Cast iron mortar is life long with no maintenance at all. Steel pestle is also life long with no maintenance. So there are lot of benefits of steel ghani compared to wooden ghani.

So I wonder why people are asking wooden ghani. Before 30 years, when I developed steel ghani, I came across the argument that oil quality is better in wooden ghani. I searched and studied all the literature available throughout the world related to oil extraction and I found that this argument is completely baseless. It is just like superstition that wooden ghani gives better quality oil. It is not so at all. I personally feel that steel ghani gives better oil than wooden ghani because wood will absorb some quantity of oil and wood may be of inferior quality also. It is not so with steel. So I established that steel ghani gives better oil than wooden ghani. So in this age of industrialization where iron and steel are widely available , costly scarce wood should not be used for making ghani. It is just foolishness.

V K DESAI
(75 years engineer promoting people's own power)

AADHUNIK GLOBAL ENERGY

C/o TINYTECH PLANTS
Tagore Road, RAJKOT - 360002, INDIA
 91 92 27 60 65 70 ( MOBILE)
tinytech@tinytehindia.com
www.tinytechindia.com

Process in brief is as under

1. Palm fruits bunches are sterilized traditionally by feeding in drums with water and by burning palm waste underneath so that steam produced will sterilize all palm fruits. This system has been upgraded by scientific steam pressurized sterilizer.
2. Sterilized palm fruits bunches are emptied into a big hopper of palm fruit stripper and fed to stripper machine where palm fruits will be separated out by jumping the bunches and falling down and will be collected at bottom conveyor. About two tonnes of palm bunches will be processed and fruits will be separated and empties will come out from the discharge chute at the opposite end which will be excellent fuel for boiler after drying under the sun.
3. This palm fruits will be fed to the digester kettle with steam jacket at the bottom. Feeding is automatic by palm fruits conveyor of 6 mt long which will feed palm fruits to Digester kettle which is mounted on the expeller and is driven by chain and sprockets from palm expeller shaft.
4. In digester kettle, palm fruits will be vigourously cooked and then will be fed to Palm oil expeller just by gravity where crude palm oil will be extracted. Palm oil will be collected in the bottom tank and mixture of whole palm nuts and fibers will be discharged from the side of expeller.
5. Palm nuts will be separated in a very simple machine Nut Fiber Separator. It is inclined cylinder of wire netting screen from which fibers will pass through and nuts will be collected at lower end of cylinder. Cylinder will revolve by 1 HP motor. Fibers will be again excellent fuel for boiler. Palm nuts can be sold out in the market.
6. One steam engine of 20 hp will drive oil expeller and digester kettle. Another steam engine of 10 HP will drive palm fruits stripper. Third steam engine of 20 HP will drive generator for electricity for use for lighting, water pumping, for nut fiber separator etc etc. Capacity of the generator is far bigger than required. All the 3 steam engines will get the steam from one common boiler of 1 ton per hour capacity.
7. You will not require outside electricity or diesel. So you will be completely independent from power problem. So you can run your mill round the clock and get full production without stop. Let prices of diesel and electricity increase 100 times, you are not affected at all.
8. Factory shed requirement is 60 ft x 40 ft X 24 ft height. (18 mt x 12 mt x 7.5 mt )
9. Power requirement NIL, NIL, NIL,
10. Total cost of the plant is US$36500/- FOB cost. Electricity operated plant cost US$22000/-. If you can sterilize palm bunches traditionally in asphalt drums etc, Total plant cost will further reduce to US$ 19000/- 

Ask for proforma invoice with individual prices of all equipments with desired destination port.

STEAM OPERATED OR ELECTRICITY OPERATED PALM OIL MILL?

If you have confusion about steam operated or electric operated palm oil mill, I should give you some guidance.

1. You will observe that steam operated palm oil mill is very costly. US$40000/-. But electric operated mill is far cheaper. Only US$24000/-. So if electricity is easily available, electricity operated palm oil mill will be more convenient in working.
2. In case of steam operated mill, you have to continuously operate boiler and arrange for enough fuel like palm fibre etc. If fuel is wet, it will give trouble in working. Two persons are continuously required to feed fuel to boiler. For steam engine operation also 2 more operators are required to attend steam engines. So 4 persons extra salary will be paid.
3. But if electricity is not available or if its supply is erratic, then you may prefer your own independent steam power. If electricity is not round the clock, say only 6 hours or 8 hours, then you will suffer production loss. In case of steam, you can work round the clock once you have trained your workers to run boiler and steam engine.
4. In case of steam, you require 800 lit of water per hour, which you do not require in electricity.
5. If water quality is bad, say hard water coming from deep underground, then boiler life will reduce and water softening will be continuously required which comes with the boiler. But care is required because single boiler is costing US$14000/-. If water quality is good ( soft water) i.e. river water or surface water, then no problem of water quality.

From the above points, you can decide whether steam operated or electricity operated mill should be purchased.

PALM WASTE ENERGY REVOLUTION

PRODUCE YOUR OWN POWER FROM PALM WASTE

Highly suitable for rural electrification by green power Tiny palm oil mill generates a lot of fuel in the process it self - about 23% empty palm bunches, 15% fibers and 6% palm nut shells, totally 44% fuel. If you process 30 tonnes of bunches per day, palm waste is generated up to 12 tonnes which is very much valuable fuel. If you use steam power for running tiny palm oil mill, you will hardly consume 2 tonnes fuel per day. Thus you will have large surplus fuel almost 10 tonnes for generating extra power for rural electrification. If you want to run power house of 50 hp engine, 30KVA alternator and boiler, it will consume 2.5 tonnes palm waste in 24 hours. So you can run 4 such power houses round the clock from surplus fuel generated from your tiny palm oil mill. One such power house can give lights to 500 families for 6 hours at night and you can use power house for running industry such as maize milling, rice milling, water pumping etc for 18 hours. So one tiny palm oil mill will electrify 2000 homes (About 10000 population) and will make available green power for running 4 different industries in villages. This much power production will be from free of cost fuel. So tiny palm oil mill is really revolutionary blessing to the people and its waste is key factor for freedom and happiness of rural people.

This is PALM WASTE ENENRGY REVOLUTION.

LIMITATIONS OF TINY PALM OIL MILL

1. We have no much experience of palm fruits, as in India, it is rarely available.
2. We visited sophisticated huge palm oil mill in Malaysia which is too expensive and beyond the reach of most of the people.
3. So I thought to develop very simple tiny palm oil mill for small investment for small farmers.
4. I collected the literature and research books of palm fruit oil mill machinery and its process science from Malaysia and studied in depth. Then I developed various machines for tiny palm oil mill and tested it only once in my factory by bringing palm fruits from thousands of km away.
5. My observation is that oil expeller worked very nicely. But oil is mixed with sludge which is very difficult to separate.
6. Palm fruit stripper was developed later on. So we have never tested it. But I am sure that it works very nicely. Similarly atmospheric pressure sterilizer also has been developed subsequently But there is no doubt that it will work successfully.
7. Nut fiber separator works very nicely.
8. We had no any experience of oil clarifier. So we could not work on it. It is a matter of experience to add water 150% of oil quantity or more, allow to settle for many hours and separate the layer and decant the oil. It is heavily polluting process.
9. Our palm nut cracker is simply breaker machine and it can not control over breaking or under breaking.
10. We have not developed kernel shell separator as is available in big palm oil mill. You have to do it traditionally or by human labour.
11. We tried our best to filter the red palm oil in our filter press in hot condition. It was winter season and immediately oil was becoming too thick to pass through pipe line even though we provided steam jacket to pipe line. It was too difficult process. But we got very excellent high quality of red palm oil of pleasing appearance.
12. We have not developed any sludge separator which is found in big palm oil mills. So that small quantity of oil in the sludge will not be recovered.
13. We have developed steam engines for independent power. Big palm oil mills produce their own power by big boiler and steam turbine. Similarly you can produce your own power for running your palm oil mill and also for selling the power in the market by using surplus palm waste.
14. You should send here good technician for one week for training for steam engine and other machines. We will fully train him how to assemble steam engine, how to operate it, what to look after etc. But we should clarify that there is no palm fruits here and our people have never seen it. So our technicians are not useful to operate tiny palm oil mills.
15. Once we brought 2 tones of palm fruits from 2000km away and tested our expeller. We had no sterilizer. So we cooked palm fruits in our cooking kettle of expeller. It worked very nicely. But general practice is to sterilize palm bunches before stripping off.

So if you are interested in our TINY PALM OIL MILL, it should be purchased with above limitations. Certainly you can not expect same performance as big palm oil mill. Preferably, you should visit here and get convinced about steam powered tiny palm oil mill which will be excellent. Once you install one palm oil mill, there will be huge demand for it and also steam power plants to generate electricity for rural electrification as every tiny palm oil mill will have surplus fuel for running 3 steam power plants. So think over and take decision.

Please go through my article APPEAL TO AFRICAN ELITES before doing anything.

Mahatma Gandhiji had said that, if we desire the equitable structure of society free from any kind of exploitation, it is essential that the means of production must be in the hands of common people who should manage, control and also own such means of production. This is possible only if technology of production is decentralized at very small scale level-almost at home scale level. One of the most striking virtues of such decentralized home scale or village scale technology is that it creates self reliant and self supporting society completely protected itself from the external economic forces.

This contention has been vividly proved by us in case of edible oil industry by establishing 700 tiny oil mills in villages of India and 1100 tiny oil mills in 86 African, Asian and Latin American Countries. Although big oil mills and tiny oil mills use the same modern expeller technology for oil expression, socio-economic results of both kind of mills vastly differ from each other and it can be seen from the following comparison that operation of edible oil industry through tiny expeller units at village level is very much favourable and greatly beneficial to the society.

Big oil mill means a mill having crushing capacity of 25 to 100 tonnes/day or still bigger, while tiny oil mill will have crushing capacity of one tonne per shift or less. The following differences between big oil mills and tiny oil mills are noteworthy.

1. Tiny oil mills in villages of India work on job work basis. Mill owner has not to purchase oilseeds or he has not to sell any product. He simply crushes the oilseed on behalf of villagers and earns only job work charges. So there is no element of trading and marketing in this activity. Villagers go with their oilseeds and get it crushed in the tiny oil mills. So economic activity of tiny oil mill is completely different from that of big oil mill. In African and other countries also, when number of tiny oil mills will go on increasing up to saturation level, the work will go on shifting on job work basis
2.  Production in tiny oil mills is for consumption and not for marketing. People come with their own oilseeds to get it crushed for oil for their own use and not for selling. So speculation becomes impossible in tiny oil mill because  marketing does not come into picture. But in big oil mills, speculation is practiced on mass scale level.
3. Nowadays adulteration is wide spread evil in big mills. It is completely eliminated in tiny oil mills because crushing is carried out in the presence of customers.
4. Hoarding and profiteering is inseparable part of the activity of big oil mills. Tiny oil mill is free from this evil because tiny oil miller has not to purchase or sell anything.
5. Transport charges are mostly eliminated in tiny oil mills. Big mills located in towns & cities fetch the oilseed from 50 to 200 kilometers far or sometimes even more. Diesel & other transport expenses worth millions of Rupees are wasted in transporting oilseeds to big mills and again oil to remote villages. This is wastage of the national energy. Tiny oil mill mostly saves this expense.
6. Customers of tiny oil mills use the same oil tins for refilling the oil every time and same tins last for many years. Big mills use new oil tins every time, which customers have to sell at throw away prices. Thus tiny oil mill completely saves the cost of metal oil tins of 15 kg. And prevents national wastage. In many countries, oil is packed into transparent plastic bottles which cost heavily. Packing expense is sometimes 20%. This must be avoided. I have seen In Malawi that people have already started to use their own containers and save packing expense completely. This tendency will go on increasing everywhere. This is not possible in big oil mills.
7. Tiny oil mill provides fresh and pure edible oil to villagers and customers. More over, it makes available protein rich precious oilcake as excellent cattle feed. So, it increases milk production considerably. Thus tiny oil mill considerably contributes for improving nutritional and economic standards of rural people. In case of big oil mill, it takes away oilseed to cities from where oil cake is exported and never comes back to villages. So it results into drain of not only wealth but also nutritious cattle feed.
8. Big oil mills exploit farmers through complicated system of purchasing oilseeds through commission agents and traders. They make injustice to farmers in weighing of their oilseeds, in deducting trash elements and in fixation of seed ratio, on the basis of which payment is made. This entire injustice is automatically removed in tiny oil mills because of absence of selling purchasing activity.
9. Big oil mill is owned by one person or one family employing 50 to 100 persons working for the owner. But in case of tiny oil mill, owner himself is a worker as a self employed person. Thus tiny oil mill brings equality in society, while big oil mill creates disparity in the society.
10. Big oil mill has very big production capacity having turnover of millions of Rupees. So its power of exploitation is very big. Malpractice and mismanagement and profits run into big figures. Tiny oil mill being tiny in nature can not exploit people.
11. Big oil mills have to keep large warehouses to store lot of oilseeds. So they require huge working capital and they have to pay heavy bank interest on borrowed capital. All these eventually fall on society in the form of increased rates of edible oil. Tiny oil mill is completely free from this evil. It has not to store oilseed or oil for custom milling activity.
12. Big oil mills have to devise their marketing strategy through distributors, dealers, commission agents, advertisements etc. Tiny oil mill has not to pay any commission to anybody. In village, all villagers are customers. In city, neighbours and neighbouring area are the customers. So all customers are known to oil miller. So no any evil can enter into relations of oil miller with his customers.
13. Big oil mills may face labour problems, strikes, agitation etc. They have to employ labour consultants, tax consultants, advocates, accountants etc. Tiny oil mill has no such expense at all.
14. Big oil mill can not function without centralized bureaucratic infra structures of public utility services such as banks, telephones, communication, transport etc. Cheques of hundreds of thousands of Rupees are to be cleared everyday to maintain enough cash flow. Hundreds of telephones are connected everyday. All these evils do not come into picture in tiny oil mills running on custom milling.
15. Government taxation such as sales tax, purchase tax is eliminated in tiny oil mill. This benefit goes to really needy people.
16. Big mill has to ensure at least one month's oilseeds supply before starting the mill e.g. for 25 tonnes/day capacity mill, about 600 to 700 tonnes of oilseeds must be available before starting the mill. Tiny oil mill can be started and stopped very frequently even to crush 100 kg. Of oilseeds at any moment.
17. Big oil mill has to employ 40 to 50 workers. The miller has to forecast the continuous availability of raw materials for some months and accordingly, he will plan to appoint the workers or assign the labour contract for fixed period. Then he can't close his mill. Tiny oil mill can be started or stopped very frequently even twice in a day and no advance planning is required.
18. Big oil mills require huge quantity of oilseeds everyday. So they can't procure and collect oilseeds from large number of persons having very small quantity from scattered sources. It becomes uneconomical to them. They run the mill until enough quantity is smoothly available from agents, dealers of oilseeds in bigger quantity. When this is not possible, they close down the mill. So crushing season for big mill lasts for 6 to 7 months in a year. While tiny oil mill can run for 10 to 11 months in a year, because it is suitable to crush even 100 kg. of oilseed. Thus tiny oil mill becomes useful to large number of people having very small quantity of oilseeds. So capacity utilization of tiny oil mill is far better than that of big oil mill.
19. Investment in tiny oil mill calculated on per tonne of utilized installed capacity is far less than big oil mill. 25 tonne capacity oil mill has capacity utilization only 50% as it runs only for 6 months. So investment per tonne of utilized capacity becomes double. But Tiny oil mill of one tonne per shift has capacity utilization 80 to 90%. So investment per tonne of utilized capacity is half of big oil mill.
20. In actual practice, tiny oil miller in India incurs the expense of Rs. 500/-(US$12/-) for crushing one tonne of oilseed which includes power, labour, rent, depreciation, interest etc. Big miller considers the expense of Rs.1000/- per tonne of crushing, while giant oil miller having 100 tonnes or more capacity considers expenses of Rs. 2000/- per tonne including overheads. So it is quite clear that economy of big scale does not hold true here. In fact, tiny mill's overhead expenses are the least. As the size of the mill grows, overhead expense per tonne also increases.
21. Big oil mill has to stop the production temporarily in the situation of 'Disparity' which occurs under speculative forces. 'Disparity' means the adverse economic situation where running the oil mill becomes unprofitable because the market value of oil + oilcake becomes lower than market price of oilseed + oil mill expense. Tiny oil mill running on custom milling is free from this evil and it goes on working even under disparity condition.
22. Over and above this picture, some benefits are far more valuable which can not be measured in terms of money. One of the most striking benefit is that tiny oil mill creates technological awareness into illiterate villagers. Wherever, tiny oil mill is established, it becomes the subject of interest for entire village. Students and boys go to mill and observe its function to satisfy their curiosity. Whenever expeller or filter press is opened, boys gather together to understand the mystery of oil mill. Some boys grasp the technology immediately and it becomes the subject matter of discussion with their class mates. People begin to understand the technology of oil mill. A great confidence is created among villagers that villagers also can run industries. Economics of oil mill no more remains secret and people begin to understand yield of oil and oil cake, expenses incurred by miller and his income and profit. People begin to think for other process industries also. In this way, gate is opened for creative thinking among villagers and know how is automatically disseminated without any cost.

Looking to the above points, it will be clear that even though technology in big mill and tiny oil mill is the same including expeller, filter press, boiler, decorticator etc., there is a vast difference in socio economic effects of both the kinds of mills due to only size of the production capacity. It is clear that, on the whole, big oil mill is a blood sucking exploitative industry detrimental to the society, while tiny oil mill is a self reliant healthy rural cottage industry, nourishing the society. It is really blessing to common masses. At present a few thousands big oil mills situated in cities and towns of India crush major crop of oilseeds and exploit the entire India. But if 200000 of tiny oil mills are established in villages and cities, economic benefit of at least 50000 millions of Rupees can reach to villagers and common people and employment to 200000 of families can be provided in villages.

In view of the above ideology, I developed tiny oil mills and now 1800 tiny oil mills are working in 85 countries of the world most satisfactorily beyond my imagination and expectation. It is a humble experiment of decentralization. Only in Saurashtra, about 100000 tonnes of groundnut and other oilseeds are crushed into these tiny mills producing 2 million tins of oil (1 tin = 15 kg) and 40000 tonnes of oilcake. Total value of the product goes up to 2600 million of Rupees (US$ 60 million) out of which nothing goes to cities. Total benefit of about 260 million of Rupees is automatically distributed among half million families living in 1000 villages. This entire activity remains completely free from profiteering, hoarding, speculation, transport charges, government's taxations, middleman's' profit etc. This is the result of a small experiment of only 600 tiny oil mills. But if 200000 tiny oil mills are established throughout the India, its results will be tremendously significant. If tiny oil mill is encouraged wholeheartedly, it can really change the scene of edible oil industry in India.
In Africa and other countries, 1100 tiny oil mills are working as self employment enterprises. Transport cost in Africa is 10 times higher that in India. So tiny oil mills in Africa are highly profitable because there is complete absence of competition of such mills in rural areas. But these mills provide pure and fresh edible oil to the people. Particularly in Zimbabwe, 80 tiny oil mills have created their very high impression due to the efforts of ITDG and are working with their own brand names and providing pure, natural cooking oil to the people through Super Markets. To less extent, similar will be the situation in totally 86 Countries including Madagascar, Ghana, Malawi, Tanzania, Zambia , Uganda, Ivory Coast, Burkina Faso etc.

Cooking oil is the primary requirement of the people. All middle class families consume roughly 1 tin (15kg) of oil per head annually. So family of 4 persons will require 60 kg of oil annually. A village of 3000 population will need 3000 x 15kg = 45000kg of oil. Or 3000 tins. Each tin of 15 kg. In lower middle class and poor people, consumption will be less, say 8 to 10 kg per head per year. But cooking oil requirement for a village of 3000 in a poor states may be roughly 2000 tins annually. So total oil requirement for entire India is about 120 crore x 12 kg per head = 1440 crore kg = 1.44 crore tonnes. OR roughly we can say 1.5 crore tonnes = 15 million tonnes. If we consider rate of Rs.100 per kg, then edible oil business is Rs. 1.5 crore tonnes x 1000 kg x Rs. 100= Rs.150000 crores .= Rs.1500 billion.

So this is the huge trade. Entire oil seeds crushing activity is handled by big and medium scale oil millers. They exploit entire India. They adulterate inferior quality oil or cheaper oil in to super quality oil and make huge money. 120 crores of people are totally helpless and is at the mercy of big oil millers. In this situation multinational companies are trying to grab entire cooking oil market and to drive out small and medium scale oil millers and they want to heavily exploit entire India by profiteering, speculation, adulteration and playing with the rates of oil seeds and oil. They advocate refined oil and issue advertisements for benefits of refined oils.

Wherever there is a centralized giant production, they always resort to falsehood and untruth about quality of their product. Moreover wherever there is centralized giant production of any food item, quality and freshness is not possible to maintain. But they always claim best quality oil. THE FACT IS THAT REFINED OIIL CAUSES CANCER. Wherever oil is heated up to 220 degree C, internal structure of oil is destroyed and oil becomes harmful to human body. Two Indian scientists made experiments of refined oil on rats and they found that entire batch of 100 rats eating refined oil died of cancer in 30 months of time, while another batch of 100 rats eating fresh natural cooking oil remained completely healthy. Nothing happened to even one rat. This is eye opening experiment for the effect of refined oil. So it is proved that refined oil causes cancer. Still multinational companies and Indian big companies hide this fact and try to promote their refined oil in the market by befooling the people.

So health point of view, only natural oil must be preferred. No any chemical should be used in oil. Oil ghani can give best quality natural oil because it expels the oil gently and gradually at minimum temperature say 50 degree C. The lower is the temperature, better is the quality of oil. This is scientific truth. So cold pressed oil is always preferred. But big multinational companies hide the facts of science and fabricate false benefits of their refined oil and they aggressively try to promote their oil. In fact Government should ban on such detrimental activity and playing with the health of the people. But big companies can always manage with big government authority by huge corruption or otherwise by political pressure etc. So ultimate victims are people.

Total oil seed production of India is 26 million tonnes. Major oil seed crop is groundnut, rapeseed, mustard, sesame, sunflower, linseed, coconut etc. All these oil seeds are high price oil seeds giving best quality oil. The highest quality oil is from sesame. But entire production of sesame is almost 100% exported and Indian people can not get best quality sesame oil. Similarly most popular and precious oil is the groundnut oil. Groundnut production in India is 8 million tonnes. It is not sufficient for our own people. But groundnut kernels are exported as a HPS groundnut and so our people can not get enough groundnut oil. So only exporters are reaping the fruits by exporting sesame and groundnut. So edible oil is always short supply commodity. So government imports hopeless quality palm oil from Malaysia and thrust upon the poor people of India. They have no other way except to eat hopeless, inferior, unhealthy palm oil. So importers of palm oil earn crores of rupees. The adverse effect of cheap unhealthy palm oil is that it is abundantly used for adulteration in to good quality oil such as groundnut oil, mustard oil, rapeseed oil, sunflower oil, linseed oil etc. So it has become almost impossible to get really pure oil in the market. See the tragedy of India. Even though we are producer of best quality oil seeds in the world, our people have to eat dirty, imported, unhealthy palm oil.

This problem has arised from giant centralized production of oil through big oil mills and refineries. Before independence there were half million oil ghanis in villages and towns everywhere. People used to go to ghani owner with their oil seed to crush the seed on custom milling basis. This way entire India used to eat fresh, pure natural oil produced locally. There was no marketing game. So no profiteering, holding, adulteration, speculation etc. This situation can be brought back again by establishing 3 lakh modern tiny oil mills in villages wherever oil seeds are grown. Tiny oil mill consists of tiny oil expeller, cooking kettle, filter press to filter the oil and it runs with 10HP motor or diesel engine or steam engine. It can produce 5000 to 6000 tins of oil in a crushing season which will be quite adequate for 2 villages. It will provide fresh and pure natural oil to villages and also to towns.

Gandhiji has asserted that precondition of happy society is that means of production of all the primary needs of the people must be in the hands of common masses. Oil is primary need of the people. So machine to produce oil must be in the hands of people at village level. So centralized oil millers have no place in real Indian economy. Entire oil milling business can be and must be decentralized into villages through 3 lakh tiny modern oil mills and 2 lakh ghanis.

I am trying to decentralize this oil milling industry since last 30 years. I have developed all machines for tiny oil mill and I am manufacturing it and exporting it since last 30 years. My experience is encouraging. Only in Saurashtra region, my 500 tiny oil mills are working most successfully and most satisfactorily. Mostly this activity runs on custom milling which drives out all the evils of marketing from this business. Each oil mill on and average crushes 300 tonnes of groundnut in a crushing season of 200 days and produces 6000 tins of oil( 1 tin contains 15 kg). So totally 500 oil mills produce 3 million tins of oil i.e. 48 million liters of pure natural and fresh edible oil. Roughly half million families get their oil from their oil seeds on custom milling basis by paying only job work charges to the oil miller say 100 rupees per tin of 15kg.

Moreover I have exported my tiny oil mills in many countries. At present about 900 tiny oil mills are successfully and profitably running in 85 countries. I have also proved in 85 countries that “smaller is more viable” as against the dictum taught by uneconomists in universities and management schools that ” bigger is more viable”. At world level there is a huge scope of one million tiny oil mills over and above the scope in India for 3 lakh tiny oil mills.
Benefits of this activity has been separately described in detail in the next chapter. 

I have observed that most of the machinery manufactures are hard workers, intelligent and honest in their business.  But they tend to make bigger and bigger machines so that they get bigger profit.  They do not think or they do not know that bigger machines  have bigger exploitative capacity and highly centralized textile mills invariably  create huge disparity  in the society throwing crores of jobless people into starvation  and making handful of people multi billionaire. So bigger machines are evils invariably. But there is a trend among machinery manufactures to take a pride in making bigger and bigger machines. So consequences of bigger machines are essentially poverty, unemployment and starvation in the society. So bigger machines is the technology for mass exploitation and technology for death. So bigger machine is never innocent machine.  

So machinery manufacturers whose heart is burning for poor people and common masses should think very seriously the consequences of use of such machines on the society whether it is a technology for life or technology for exploitation and death . If it is technology for exploitation and death, then machinery manufacturers also will be responsible for creating evils of poverty, unemployment, starvation etc due to the use of their machines. So every honest manufacturer should refrain from making big machines which create mass exploitation and starvation in society.

In fact they have better option for making smaller and smaller machines which can provide employment to millions of people and bring equality in society. But question arises to the machinery manufacturer that from smaller simpler machines they get  less profit. Here I have to intervene specially. I am a machinery manufacturer and I have a good experience of making small machines.  I want to inculcate to machinery manufacturers that though you get a small profit in small machine, but on the whole you get a large profit by selling hundreds and thousands of such small machines. My this statement holds good everywhere and in all circumstances. So machinery manufacturer should not have any fear in his mind that by manufacturing smaller machines you will get less profit. In fact by making smaller machines you will get more profit.

Now my special appeal to textile machinery manufacturers.
Why do you manufacture 500 spindle ring frame?
Why not 50 spindles ring frame? Or why not 20 spindle ring frame?
You must know that only multi millionaire people can make huge spinning mills where your 500 spindles ring frames will be used. They will exploit the entire society. Entire population will be jobless and poor and go to starvation. Only a few people will be billionaires. But if you manufacture 50 spindle machine or 20 spindle machine, crores of women will run it in their homes and will get self  employment and will live happily. So this  is pious task. Even if you get less profit, then also it is worth doing. But I am sure that you will not get less profit. Suppose you manufacture 10 ring frames in a year each of 500 spindles. But if you go for smaller machine say 50 spindles, then you will be able to make 200 such machines in the same period. So your profit out of 200 machines will be higher than your profit from 10 big ring frames of 500 spindles. Smaller machines are blessing to the society and to you also. So my appeal is that you should develop and  manufacture very small machines which a blessing to the society. This is true for every type of machinery. Those who make blow rooms should make smallest possible by eliminating conveyors, elevators etc. Please remove the complications and make it simple. Complicated machinery make simple thing also complicated. Why 38 “ width of a blanket in a blow room? Why not only 8 or 9”? I think it should be possible to design efficient blow room running on 1 Hp motor which can be powered by solar panel.So please think very seriously about this. If tiny blow room of 1 HP is developed, then roughly 3 to 4 lakhs of blow rooms can be sold in India. So there is a huge scope for tiny blow rooms.

Why very big carding machine? It can be made very small. Try to make it smallest. Perhaps carding and blow room can be combined in to one machine. India requires simple machinery cheap machinery so that textile activity can spread into millions of cotton growing farms. No transport of cotton at all. No baling of cotton and no bale breaking.Ginning and spinning will be combined at one place. No transport at all.

So think very seriously. All machines must run on solar panels. No machine should be bigger than half HP or 1HP motor at the most. So new tiny solar operated spinning mills should emerge which will produce yarn in farm itself. At least one million such farm size ginning cum  spinning mills are required in India it self. Then India will be really strong country and happy country.

So crux of the problem lies with textile machinery manufacturers. They have the highest brain power to bring any type of revolution. Revolution in technology will bring revolution in economy also. Present day evils of centralized economy such as urbanization, disparity, unemployment, poverty  will disappear very quickly as soon as textile machinery manufacturers determine to manufacture very small machines working in homes and farms. It is  the technology for life, technology for happiness.  Present big scale machines is  technology for  mass exploitation and technology for death. So please realize the difference. Please understand the importance of smaller home scale and farm scale textile machinery. Please use your brain to develop it. I am sure you can earn crores of rupees and thus you can create benefit of billions of rupees for poor rural people and you will get blessing from hundred crores of people.

Just recently we have established small spinning mill of 2200 spindles in a remote village in Bhavnagar District. It is just same machinery as conventional spinning mill i.e. Blow room, card, draw frame, speed frame, 5 ring frames of 440 spindles and cone winding machine. We have connected cotton ginning with it to produce lint cotton. I am sure it will be highly profitable. We have purchased old running machinery from Ahmadabad and shifting it to a village. I have decided not to earn a single rupee from this activity. During this process, I am pondering over further decentralization of spinning machinery. I am not at all expert in this field but I have deep rooted faith in my heart that everything must be decentralized upto village scale and home scale. So I am narrating my ideas and you can give me your opinion whether it is foolish or it has some sense.

1. Blow room has 6 to 7 motors. I do not know what is process in it, but I felt that if we reduce the effective width of the blow room machines to 25%, then motor HP should also be 25%. So if motor is of 1 HP or less, then PV panel can work to generate that much power easily. Total load of blow room is say 20 HP and then it becomes 5 HP with 5 to 6 different motors of 1 HP or less, then all these motors can be operated by solar panels. Fast production and high production is not the criteria in village economy. So if production capacity is reduced by 20 times i.e 5% only then it will be best suited to village size blow room. Conveying and elevating can be totally removed and human labour can be replaced. Effective width should not be more than 6 to 8 inch. Please do not bring question of viability for such a small unit. I have proved in 85 countries practically that my tiny oil mills are far more viable than giant oil complexes. So I am sure that blow rooms, once produced in hundreds of pieces will be far cheaper. I am master of making the machines very cheap. You kindly advise me technical feasibility.
2. Carding machine also can be reduced in width say 25% or 6 to 8 inch width and diameter can also be reduced 25% or 50% so that 3 HP motor becomes 0.5 HP motor in tiny card. Please give me your views whether this is possible or not.
3. I have seen draw frame with 2 parallel lines in which 8 ropes are going together to make one rope but 8 times longer. Some how this machine should also be operated by half to one HP motor to process 4 ropes only and we have to repeat this process twice or thrice with the same machine of one HP or less.
4. I have seen the speed frames of 96 and 132 spindles which can be reduced to 16 spindles simply by cutting the length so that it may be driven by 1 HP motor. I understand that head, gears etc will cost more but it can be simplified with simpler and cheaper gears as we see in Amber Charkha.
5. Ring frame in conventional form of 440 or more spindles is not required at all. One expert textile engineer with 35 years of experience in big textile mills told me that spinning quality of Amber Charkha will be same as big ring frames in textile mills. Amber Charkha consumes less power per kg of yarn compared to big textile spinning ring frames.
6. Cone winding also can be split up from 120 to only 10 to 12 cones and motor size will also be reduced to 200 Watt instead of 3 HP.
7. In this way I have thought out a concept of entire spinning mill run by many motors with total load of 10 HP but all motors will be smaller than 1 HP. All motors will be DC motors and there will be totally solar power. So energy bill will be zero. If this is technically feasible, then I have a full courage to make it economically viable. I have no knowledge of textile technology at all. But still I feel that there must be some way to utilize modern textile technology into villages with solar power. If this solar powered spinning mill becomes equivalent to 100 spindles production of big textile mill, then it will become viable in villages and it will be owned by farmers and mostly yarn will be produced in farms itself not bringing the cotton in village. 

I have observed that when technology is disseminated upto grass root level, then most sophisticated machines can also be produced at throw away price by common people. This has become reality in Rajkot in case of Lister and Peter diesel engines which are produced in abundance even by illiterate people maintaining very high accuracy. So I am confident that decentralization of spinning technology must be possible.

India produces 500 crore kg. (3 crores bales) of lint cotton annually. Just by spinning this cotton in every home and weaving the yarn in every village, poverty and unemployment can be removed immediately. This can be practically done by using modern scientific machinery and by competing to present centralized textile industry. I will explain how. MODERN HOME SPINNING UNIT will consist of Amber Charkha 10 spindle cost Rs 11000/Energy unit of 12V, 100W PV panel, Battery 12V x 40Ah capacity, 12V, 50W DC motor ( suitable wiper motor of car or truck) and digital display of battery charging level duly converted in to hours and minutes woman can spin on it without discharging battery less than 50%. Cost Rs 14000/Total cost Rs 25000/-. Woman will spin the cotton by hand on this Amber Charkha for 3 hours from 7am to 10am and one more hour in the evening. She will switch over to automatic spinning for 8 hours from 10am to 6pm. in 12 hours of spinning, she will produce 60 hanks of yarn of 40 count. 40 hanks of 40 count will weigh one kg. So 60 hanks = 1.5 kg cotton yarn. As per the present KVIC rates, she will earn Rs 60 hanks x Rs 3 per hank = Rs 180. So monthly income may be Rs 180 x 25 days = Rs 4500/-. Annual income will be for 10 months = Rs 45000/-. So her family will sustain. Annual income of Rs 45000/- is against investment of Rs 25000/-. So return on investment is 180% annually. So highly viable as per present norms of economics. Total annual production of yarn per home will be 300 days x 1.5 kg per day = 450kg.

PILOT PROJECT To prove this, pilot project of 100 home spinning units should be established. Duly trained women should be given Amber Chakhas at their home and daily and monthly yarn production should be recorded for all 100 homes. Once we realize that annual production goes up to 450kg of yarn, we can conclude that this is really practical solution of poverty and unemployment of our country. Pilot project will cost Rs 25 lakhs in machinery only. Some Khadi institutes and NGOs can run such several pilot projects in different parts of India.

MY SCHEME TO RESHAPE TEXTILE INDUSTRY

1. Present textile industry can continue as it is.
2. There are about 2000 small spinning mills from 3000 to 8000 spindles in coimbatore and tamilnadu and 400 such mills in Ahmedabad. Many of them have spare capacity up to roving stage. So continuing their spinning mill, they can produce and sell roving for Amber Charkhas. Their income will increase by producing extra roving for Amber Chakhas. 
3. Lakhs of Amber Charkhas can work on rovings brought from small spinning mills. Many owners of such small spinning mills are humanitarian and may sell their rovings at favourable rates for poor women.
4. When lakhs of such Amber Charkhas will be working, many intelligent women will think and manage to put 2 or more Amber Charkhas in their homes to get more income.
5. Power consumption per kg yarn in Amber Charkha is quite less than in centralized ring frames of 500 to 1000 spindles. So it will happen that yarn spun on Amber Charkhas working on sun energy will become competitive to the yarn spun in spinning mills.
6. Quality of yarn spun on Amber Charkhas is completely equal to spinning mill yarn.
7. So demand of solar powered Amber Charkhas will increase to more than one crore units.
8. To supply rovings to Amber Charkhas, new roving mills will come in to existence. Second hand modern roving mill machinery still usable to next 40 years costs only 25 lakhs which can provide rovings to 25000 Amber Charkhas of 10 spindle. Such rovings mills will be established in villages with cotton ginning facility so that they will use loose cotton directly from gin. So no bale binding, no transport, rovings will be available in villages.
9. Roving mills will require 30% capital, only 20% construction space, only 30% power connection and hence will easily compete to spinning mills. Ultimate result will be either to close down spinning mills or to use the mill up to roving stage only. So all spinning mills will be converted to rovings mills.
10. So entire spinning activity will be decentralized in to solar powered Amber Charkhas and centralized roving mills. (11) At present about 10 million cotton bales are exported. This export will be stopped automatically due to production of rovings and yarn in villages. Entire production of 500 crores kg of lint cotton will be spun in to yarn and entire value addition benefit will go to poor rural women.
11. Manufacturing units for Amber Charkhas should be encouraged in private small scale sector at Rajkot, Ahmedabad, Coimbatore, Ludhiana, Delhi and elsewhere so that Amber Chakhas are available at reasonable cost to poor people everywhere.

HAND LOOMS

1. Hand looms should be converted to Hand Cum Solar Looms. 200W DC motor will drive hand loom very easily. Present Udyog Bharti peddle loom gives 16 mt cloth in 8 hours. Hand loom worker gets Rs 10 per mt cloth. About 300W solar panel will drive hand loom. Man can work 4 hours with human power and 8 hours on solar power. So he will earn Rs 240 for 24 mt cloth in 12 hours. Monthly income will be Rs 240 x 25 days = Rs 6000 and annual income will be Rs 60000/-.Peddle loom costs Rs 32000/-. Peddle cum solar powered loom may cost Rs 35000/-. Solar Energy unit may cost Rs 25000/-. So total investment will be Rs 60000/-. So investment is earned back in one year. So this is viable scheme.

SELF EMPLOYMENT & RURAL PROSPERITY

1. Spinning activity through Amber charkhas will provide direct employment to one crore women in their homes. This is direct additional employment. Present textile spinning mills will continue to work as roving mills and their employment will continue. Weaving by solar looms will provide self employment to 50 lakh workers in their homes. This will affect present power loom industry. But mostly all power loom workers will prefer to go to their native place and run solar loom in their homes and live peaceful village life. So it will be desirable change. Indirect employment in manufacturing equipments, trading of yarns and cloths, providing facility and goods to spinners and weavers families will be about one crore who will handle the turnover of Rs 75000/- which will be spent on goods and services required by spinners and weavers families.
2. One crore women will get Rs 45000 crores as their income and 50 lakhs hand loom workers will get Rs 30000 crores as their income. So rural prosperity will increase up to Rs 75000 crores. This will be huge amount and huge change in their condition compared to starving position at present. If this much is done, Gandhiji, s ATMA will rejoice. (16) When India produces 4000 crore mt cloth from 500 crore kg of lint cotton by using solar energy in spinning and weaving and giving self employment to 2.5 crores of people in their homes, it will be glaring and guiding example to entire world how to be happy with modern science. then there will be no scope for exploitation, war, big companies, terrorism etc. India will show the way to peace and happiness on the entire planet.

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.