Sisal - Potential For Employment Generation India has a vast resource for different natural fibers viz., jute, sisal, banana, coir etc., which are abundantly available in many parts. Presently, the production of natural fibres in India is more than 400 million tonnes. Sisal is a leaf fibre derived from the plant Agave sisalana. In India, it has been planted in rows on the bunds, as a soil conservation and field protection plant. It is also seen along the road side plantations on highways. The leaves of sisal plants yield about 4% of the dried fibre by weight. Sisal fibre is hard and is valued for traditional uses like ropes, twines, cordage, anchors, handicrafts etc. because of its Sisal (Agave sisalna) high specific strength. It is gaining momentum for its utility in various engineering applications. Sisal fibre can replace the existing natural fibres like jute in the applications like cloth, composites etc, which can have direct use in various sectors. Sisal is a xerophyte and can survive in most parts of arid and semi-arid climates. Input costs for sisal cultivation are least for its survival, regeneration and maintenance on sustainable basis, which makes its production cost-effective. Enough thrust is given to the research and development on the sisal technologies world wide, due to which its demand is constantly growing. In view of the growing demand of the sisal fibre in India, it is encouraged for cultivation for fibre extraction and its subsequent utilization. Origin of sisal Sisal was introduced in India by Portuguese around 1825 AD. It was mainly planted on the bunds or along the cattle proof trench-cum-mound structures for the basic purpose of either soil conservation or protection of the forested/ cultivated lands against predatory animals or both. In India the plant can be found mainly in the states of Orissa, Madhya Pradesh, Chhattisgarh, Andhra Pradesh, Bihar, Jharkhand, Maharashtra, Karnataka and Tamil Nadu. It is called as Ketki and Ram Baan in Hindi. A high yielding sisal hybrid named ‘Leela’ was released in 1985 for all the sisal growing tracts throughout India by the Central Research Institute for Jute and Allied Fibres (CRIJAF), Barrackpore, West Bengal. Worldwide, there are more than 275 agaves present in different continents. Other agaves apart from sisal, found prevalently in India include Agave vera-cruz (Elephant Aloe, Grey Aloe, Railway Aloe), Agave cantala (Maguey, Cantala/ Cantula, Bombay Aloe), Agave fourcryodes (Henequen, Mexican Sisal), Agave augustifolia (Dwarf

Aloe), Agave Americana (Century plant, American Aloe) and Agave mexicana. Each of these species yields fibre of varying nature and properties. Propagation mechanism Sisal is a monocarpic perennial plant, which produces a terminal tight rosette of narrow tapering spine after 6-9 years before it poles (flowers) and subsequently dies. Bulbils form on elongated flowering inflorescence and when become full-sized and generally fall on ground. On an average, a sisal plant generates 500-600 bulbils. These bulbils are collected and grown in nurseries. Sisal also produces suckers, which can also be used for propagation. Suckers begin to emerge from the second year of planting can be dug out and removed for raising in a nursery. Nursery raising Sisal bulbils are raised in nursery beds with a spacing of 25cm x 25cm. Bulbils may be preferred over suckers for planting. Bulbils or suckers can be collected about 6-8 months prior to the plantation. The growth of bulbils is Sisal plant with inflorescence improved by mulching sisal nurseries with grass, paper or polythene. Sisal nursery needs irrigation facility throughout and weeding in nursery beds as per requirement is also necessary. The nursery incubation periods is about 8 months depending upon the growth and vigour of the bulbils/suckers. The area of nursery to main plantation field may be approximately 1:10. Before plantation, the roots should be trimmed slightly and withered leaves should be pulled off. Avoid the plants with damaged bole, which may pose the risk of rots. The size of bulbils or suckers for raising plantation should be 40-50 cm in length and weigh about 600-1000g at the time of planting. The reliable quality sisal plantation materials (bulbils/ suckers/ plants) in India can be obtained on prior request from the Sisal Research Station of CRIJAF, Bamra (Near Sambalpur), Orissa. Climate suitability The sisal plant is drought resistant and very tolerant of a variety of soils and climates, hence could flourish even in arid and semi-arid regions to sub-humid tracts covering major parts of India. Sisal plant prefers well-drained and aerated soils because they are extremely sensitive to water logging and intolerant to marshy lands. Sisal can thrive in prolonged drought conditions and can survive at a low annual rainfall of 40-300cm also. Sisal can withstand temperatures up to 42-480C. Land preparation The commercial sisal plantations in rows with a specified plant-to-plant distance need preferably good land preparation like any other plantation crops. The land clearance, removal of boulders and stubbles, ploughing of the land and digging out pits are the basic needs of such plantations. The soil conservation contour bunds or field bunds can be utilized for sisal plantations with the excavated soil serving as support. The excavated soil along the cattle proof trenches can also serve as support to sisal plants. Arrangement of lines should be kept across the soil slopes and as parallel to

contours as possible for effective soil and water conservation and better survival of sisal plants. Sisal spacing and plantation The right time for sisal planting is 20-30 days ahead of the rainy season. Sisal plantation can be done either in single row or in double row. A spacing of 2m x 1m corresponding to 5000 plants/ ha in a single row system is convenient and economical. The grown up bulbils can be planted in the main field @5000 plants/ ha with a double row system (1m x 2mx 1m), where spacing of plant to plant is 1m and row to row is 2m. The most suitable spacing suggested is 2.5m + (1m x 1m) and 3.0m + (1m x 0.8m) give about 5700 and 6250 plants/ ha respectively. The depth of plantation may be kept at 6-8cm and enough care should be taken to ensure that the base of the spike is not buried in to the soil to avoid the risk of rotting. Irrigation to the transplanted sisal saplings is essential if a severe and prolonged drought follows immediately after transplantation. It should be kept in mind that about 2-3% of the sisal plants may be spared for gap filling in the event of initial mortality. Intercropping Intercropping can be done safely in the initial two years of the establishment of sisal plantations. Rainfed crops like fodders, horse gram (kulthi) castor (erandi), jowar, bajra etc. can be raised as intercrops. Where ever irrigation water is available, crops like beans, soybean, moong, urad, groundnut etc. can be raised in the rabi season. The width of intercropping in subsequent seasons depends on the growth of the sisal plants and their lateral spread. It is not advisable to raise water intensive crops like paddy, sugarcane etc. which may cause drainage problems. Fertilisers and manuring Under normal conditions, sisal does not require commercial fertilizers. However, application of fertilizers is definitely a boost to the sisal plant growth, vigour and ultimately the fibre yield, where as the deficiency of plant nutrients show the symptoms as in the case of any other plantation crops. Sisal responds very well to nitrogen, phosphorus and potassium. In general, application of 60-100 kg nitrogen, 30-35 kg phosphorus and 60-100 kg potassium per ha per year is recommended. Irrigation and drainage Sisal plantations require moderate irrigations in the first year immediately after plantation for proper establishment if the season faces severe drought or the rains are interspersed with prolonged dry periods. Once established, sisal plantations do not require irrigation. However, irrigation as per requirement in the winter and summer is beneficial for the growth of the plants and irrigation fetches healthy leaves of higher quantity proportionately. Sisal plantations cannot tolerate waterlogging and hence require proper drainage during continuous heavy rains and floods. Hence the sisal plantations are done on the upper side of the bunds and tentative provision should be made for drainage of the entire field.

Weed control Removal of weeds and abnoxious plants especially during the initial stage of plant growth is advised as weeds compete for survival with sisal. Excessive weed competition leads to pale sisal due to nutrient deficiency. Hand weeding may be done as per the intensity of weed infestation and growth. Harvesting of sisal leaves The plant generally grows up to 100 leaves, indicating its time of harvest. Leaves are generally ready for harvest after 21/2 -3 years from planting. A sisal leaf is considered to be mature for harvest when it attains a length of about 1.0m and forms an angle of about 60° with the main spike or when the colour of the terminal spine changes to ashy brown. A typical plant produces 200-250 commercially usable leaves in its life-time and each leaf contains about 1,000-1,200 fibres. The plant matures fully in 4-8 years after planting. The sisal plant yields productive fibre- bearing leaves for about 8-10 years in its life span of 10-12 years. Sisal leaves are cut by using an ordinary straight knife with a wooden handle. It is better to nip the terminal spines before cutting the leaves. Harvesting should be initiated always from the lower most whorls to the upper side and at least 20-25 leaves are spared after the first cut and about 15-20 leaves at each subsequent cut. Where growth of sisal is unsatisfactory, more number of leaves is left after each cut. Each leaf is cut at a point about 3 cm from the bole through the upper part of its bulbous base, or just below the neck. Depending upon the growth, vigour and maturity of the leaves, 2-3 cuttings per year may be undertaken. Care should be taken to avoid over cutting of the younger plants. After cutting, the spike at the tip of the leaf is removed and leaves are made into bundles for transportation to the decortication site. This must be carried out as soon as possible since the cut leaves soon deteriorate if left exposed to the sun and decortication will become difficult. Sisal plantations in India yield about 2.5 tonnes dry fibre per hectare per year. It fetches yearly a net profit of Rs 45,000/- per ha. The fibre is usually obtained from sisal leaves by decortication in a machine called raspador. The lustrous strands, usually creamy white, average from 80 to 120 cm in length and 0.2 to 0.4 mm in diameter. Production and consumption In 2007, sisal occupied 6th place among fibre plants. World’s largest producer of sisal are Brazil (1,99,000 tonnes), Kenya (40,000 tonnes), Tanzania( 28,000 tonnes) and Madagascar (20,000 tonnes). Smaller quantities of sisal fibre are also produced in South Africa, Mozambique, Haiti, Angola, Uganda, Malawi, Venezuela, Jamaica, Puerto Rico, France, Java, Cuba and India. Experts opine that the current worldwide demand for sisal fibre is about one million tonne. Currently, high prices offered for the crop at the global market, which the sisal fibre now fetches between 650-900 US$/ tonne up from 150 US$/ tonne in the 1990s. India needs about 25,000 tonnes sisal fibre to the tune of annually for internal consumption, while the production is less that 5,000 tonnes. In India, sisal fibre was priced at Rs. 9000-10000 per tonne in 1988-89, which rose to Rs. 27000 per tonne in

1996-97, showing a phenomenal rise of 170% in its price. Now sisal fibre is priced at about Rs. 35000 per tonne, indicating the decadal growth in price of about 30%. The advantages of sisal cultivation are listed below:

� Sisal can be cultivated in the dryland and arid regions in India. The marginal lands can safely be brought under sisal cultivation.

� It can be grown on undulated lands/ multi-directional slopes. � It may be cultivated on almost all types of soils except deep clayey

waterlogged soils and saline soils. � Inputs and managerial requirements are less than those of other field crops.

There are no chances of crop failure due to drought. � Sisal is very less prone to pests and diseases. � It is least affected by weeds. � Being xerophyte with widespread root system, it checks soil erosion, making it

a soil conservation plant and a utility plant for watershed management. � Sisal is easy to grow and maintain with minimum pre and post harvest losses. � Commercial fertilizer inputs under normal conditions are not necessary

although their application results in higher yields and early harvesting. � Series of sisal plants act as effective vegetative barrier/ fence to protect the

crops lands and forests from predatory animals and intruders. It is widely planted along the cattle proof trenches.

� Sisal can be harvested throughout the year. It provides employment opportunities in off-seasons in remote tribal/ forest areas which generates income.

Extraction of sisal fibre Sun drying of sisal fibre Raspador machine Sisal fibre is traditionally extracted by retting, a biodegradation process involving microbial decomposition of sisal leaves, which separates the fibre from pith. The fibres are washed and processed further. This process takes 15-21 days for a single cycle of extraction and degrades the quality of fibre. The retting process is water intensive, unhygienic and not eco-friendly. The other methods available for the extraction of fibre are chemical treatment and mechanical extraction. The mechanical extraction is done with the help of Raspador machine.

Processed sisal fibre Properties of sisal fibre Sisal fibre consists of 66-72% cellulose, 12% hemicellulose and 10–14% lignin. The superior engineering properties (diameter 50–200 micro meter; microfibril angle 10–220, Ultimate Tensile strength of 468–640 Mpa; Modulus of 9.40–15.80 Gpa and elongation of 3–7%) makes it as an excellent material for manufacturing high strength textile and reinforcement in composites for various applications. Applications of Sisal fibre The leaves of sisal yield a strong fibre, which is traditionally used for making ropes, cordage and twines. It is also being used to manufacture coarse fabrics, rugs, carpets, handicrafts, mats, fishing nets etc. The sisal pulp left after fiber extraction (which is about 95%) is used for making paper / paperboards, hecogenin (a cortico steroid), wax, biogas etc. Sisal based handicrafts

Sisal mats have some unique characteristics, apart from being made from a cactus. Sisal will expand or contract depending on the climatic conditions. Sisal mats are not to be recommended for areas that may receive wet spills or has constant exposure to rain, snow or water in general. There are best used in indoor applications or in enclosed or screened porches. Sisal mats

Spin offs It is discernible that there is a huge quantity of sisal waste (95% of the leaves by weight) can be effectively utilized for composting, vermi-composting and extracting other valuable products. The pilot scale demonstrations show that it is a valuable feedstock for biogas plants to cater to the local and rural energy requirements. One tonne of sisal pulp can generate 54.3 m3 of biogas by the methanogenesis. Sisal leaves are known to contain wax (0.38%) and hecogenin (0.10%). These expected spin offs in the form of secondary / allied activities which are labour intensive and have applications in rural and small-scale industrial sectors.

Engineering applications Due to superior mechanical properties and recyclable nature, sisal fiber can be used as potential input material for making composites for application in buildings, automobiles, railways, geo-textiles, packaging industries etc. Sisal fibre reinforced composite building materials like; wood substitute products, panels, doors, corrugated roofing sheets and instant houses suitable for disaster (floods / tsunami / earth quake) prone areas would be made which attract prospective entrepreneurs and stake holders due to its durability and cost effectiveness. Asbestos fibres being carcinogenic, sisal fibre cement corrugated roofing sheets, which are eco-friendly, can be an effective alternative. Employment generation Since sisal is a xerophyte, its establishment in major parts in India is not a constraint and its cultivation involves least water and crop management during its survival period of about 10 years. They can be raised along the bunds, hedges, forest and wastelands for soil conservation. Once established, an assured production of about 2.5 tonnes/hectare/year is possible for 6-8 years. Presently sisal plantations and their allied activities is an unorganized sector localized mostly in rural and tribal areas. The sisal fibre is an input material for various rural applications involving cordage and ropes, mats, handicrafts and other utility items, which can augment the employment opportunities for income generation in rural sector. The sisal fibre and its allied activities like cultivation; fibre extraction, processing and making value added products are proven sources of employment opportunity and income generation. The present experience indicates that trained artisans and women are able to sustain with the income generation through the sisal related activities. The engineering applications of sisal fibre like buildings, automotives, railways etc. are the prospective areas where it can generate employment potential. Easy to raise on wastelands in a wide range of agro-climates, sustained fibre yield for a considerable long duration, versatility of the fibre as a potential input material for various applications makes it a viable option for employment generation and rural development.

S. No. Spin-off Application Potential 1 Manures Agriculture Variable 2 Vermicompost Agriculture/ Horticulture Variable 3 Hecogenin Pharmaceuticals 1.00 Kg/tonne 4 Wax Industrial 3.75 Kg/tonne 5 Biogas Rural energy 54.3 m3/tonne 6 Electricity Rural energy 1.0 MW from 4500 ha

Acknowledgement The guidance and support provided by AMPRI Bhopal, CSIR New Delhi and Madhya Pradesh Council of Science and technology is gratefully acknowledged.

Dr. (Ms) Mohini Saxena

Ex- Scientist-F and Group Leader Building Materials Development Group Advanced Materials and Processes Research Institute (AMPRI) (Formerly Regional Research Laboratory) CSIR HabibGanj Naka, Bhopal, India-462064

Email: mohinisaxena@yahoo.com

Dr. Ashokan, Scientist, AMPRI, Bhopal,

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