Report ON
ENGRO DAIRY FARM, NARA , SINDH, PAKISTAN
Group Leader: Muhammad
Mithal Panhwar
Group Members: Muhammad Daud
Raza Muhammad
Muhammad Ishaque
ACKNOWLEDGEMENT
Respected Rizwan Hussain Bukhari,
Farm
Manager (Engro
Dairy Farm Nara)
Taluka Salehpat District Sukkur.
Thank you for taking the time to meet
with our group and other representatives of the Sukkur Ibians on last week
visit at Engro Dairy Farm Nara. We enjoyed meeting with you and your team
members. I’m glad we had the opportunity to discuss our concerns and whole
process of your Dairy Farm.
We especially appreciate your
commitment to serve the community by investing in educational and health
sectors.
Our whole group would like to
appreciate your support and
co-operation greatly. On behalf of all our members, I want to thank you
for taking the time out of your busy schedule to have us a visit at your Dairy
Farm.
Sincerely,
Muhammad Mithal Panhwar
EDP-II, Sukkur IBA.
Date: December 30, 2013.
Table of Contents
Being
major player in national economy livestock sector has been selected as an
economy engine for poverty alleviation from Pakistan. According to economic
survey of Pakistan 2012-13, its contribution to agriculture value added is
approximately 55.4 % and to national GDP is 11.9 %. Livestock is raised by more
than 8.5 million small and landless families in the rural areas and 35-40
million rural populations are dependent on this.
In Pakistan
livestock includes cattle, buffalo, sheep, goat, camels, horses, asses and
mules. Milk, meat, wool, hair, bones, fat, blood eggs, hides and skins are the
main livestock products among which milk and meat are taken as major products.
Besides this, these animals are used for draught purposes.
In 1980s, dairy sector in Pakistan
moved towards commercial side and development of rural commercial dairy
farms started. A typical rural dairy farm running on commercial basis consisted
of about 30 animals of which 70% were females, including some cows.
Approximately 40% of these adult females were in milk during most of the year.
Fodder crops provided 50% and straws about 35% of the feed requirements and
concentrates made the rest of it. More than 90% of the milk produced at the
farm was sold.
With growing demand for milk in
urban areas rural commercial dairy farming moved toward pre-urban areas. In pre-urban areas there are large and small dairy
herds consisting of 20-50 animals with nearly 90% of adult females
in production. Male calves are disposed off within first two weeks of birth.
These animals are fed chopped green fodder and wheat straw and concentrate mixture with target to sell almost total
milk produced.
Due to enhanced rate of urbanization
over the last 2 to 3 decades, large pre-urban commercial dairy farming is going
towards urban commercial farming. Targets of these farms are to get maximum
milk production with economical and quality feeding and good management.
Animals on these farms are fed good quality green fodder or silage along with
concentrate mixture. Dairy animals maintained at these farms are considered elite animals, hence their yields
per lactation are considerably higher than those of animals maintained under other
production systems. Milk produced on these farms is either sold out in
processed/fresh form through outlets or departmental stores or supplied to
dairy companies.
Technological advances have changed dairy farming from the
old-fashioned, messy and labor-intensive system of hand milking into a bucket
while sitting on a stool. Today's types of dairy farms are spotlessly clean,
efficient and often highly computerized businesses.
During last ten years major changes has
been occurred in dairy sector of Pakistan and due to these change this sector
is on the way to become an industry. A large number of modern dairy farms have
been established in different areas. Most of these dairy farms have exotic
animals and number of these animals is in hundreds and even in thousands. Dairy
farms with more than 3000 animals also exist and with 5000 animals are in plan.
Such farms have adopted most modern manage mental and feeding practices and
well trained man power. Milk produced on these farms is either sold out in
processed/fresh form through outlets or departmental stores etc. or supplied to
dairy companies.
Technological advances have changed dairy farming from
the old- fashioned, messy and labor-intensive system
of hand milking into a bucket while sitting on a stool. Today's
types of dairy farms are spotlessly clean, efficient and often highly
computerized businesses.
Global Milk Production
There are around 250 million cows producing milk
across the world. The European Union is the largest milk producer and has about
23 million dairy cows. This compares with 10 million in North America and over
6 million in Australia and New Zealand. Milk production is also on the increase
in South-East Asia, including countries not traditionally noted for their milk
consumption, such as China, which now has over 12 million cows producing milk.
Higher Milk Yield
Over the last fifty years, dairy farming has become
more intensive to increase the amount of milk produced by each cow. The
Holstein-Friesian, the type of dairy cow most common in the UK, Europe and the
USA has been bred to produce very high yields of milk. Around 22 liters per day
is typical in the UK. The average yield in the US is even higher at over 30 liters
per day. Milk production per cow has more than doubled in the past 40 years. If
they were producing just enough to feed their calves, as nature intended, this
would be about 3 or 4 liters a day.
TRADITIONAL MILKING and MODERN MILKING TECHNOLOGY
Modern dairy production is diverse
with systems ranging from cows housed indoors year-round to cows maintained on
pasture nearly year-round. Expansion to larger herd sizes has allowed producers
to increase the efficiency of production and capitalize on economies of scale,
but it has resulted in environmental challenges with larger numbers of cattle
and more manure concentrated in smaller areas.
Engro Dairy farm is a type of diversification industry by
Engro Corporation. It was initially started at Sukkur near Dawoo Stop to test
the animals’ survival with 100 Australian breeds. This test was very
successful, then it was thought to start dairy farm nearby Sukkur, but
unfortunately the land Engro was trying to purchase, was high-priced therefore they
shifted to Nara. It is not only reason of shifting but there are few other
causes which are as under:
·
The land area needed was not available
in surroundings.
·
Nara is sandy Area and Sukkur is not a
sandy region so it gets long time to absorb water.
·
Except 4 to 6 days whole the year air
blows at Nara.
Traditionally dairy farming is done without using any
standards and technology. From feeding cow to milking, everything is done
manually in traditional farming. In Engro standards are being followed in
rearing, feeding and milking like feed mixing area, milking parlor and chiller
etc…
On
May 24, 2008, Engro Foods Limited (EFL), the dynamic food industry venture of
Engro, performed the ground-breaking ceremony of Engro Dairy Farm in Nara
District Sukkur, Syed Khursheed Ahmed Shah, Federal Minister for Labor,
Manpower and Overseas Pakistan performed the ground-breaking and unveiled the
plaque of the dairy farm which will be setup near Salehpat in district Sukkur.
The
project execution phase-I was completed in October 2008 with the arrival of
imported animals. They purchased 220
Acres of Land, getting on lease about 350
Acres. On 220 Acres Engro established Dairy Farm and 350 Acres are used for
Cultivation of Crops, after processing used as feed for animals.
By
setting this type of large scale commercial dairy farms, Pakistan can not only
erase domestic supply deficit but also able to fulfill a significant part of
the vacuum in the international market.
“Jersey and Jersey Holstein animals are the
preferred breeds. Initially Engro Dairy Farm has imported 1500 non pregnant heifers.
After
thorough evaluation in Sindh & Punjab, the Nara Canal area was selected by
Engro Foods due to its excellent water and agricultural land availability and
suitable weather. The company will launch a comprehensive vaccination program
with provision of clean water and balanced nutrition to have disease free,
healthy and happy animals at all times.
Engro Dairy Farm is situated in the area of Nara Taluka
Salehpat District Sukkur. Its location is 80km from Sukkur City. Engro is farm
with the largest number of animals in Pakistan. More than 4300 animals, (Australian Breeds named, JERSEY and HOLSTEIN FRIESIAN)
are surviving at this farm. It is most high-tech milking Parlor in Pakistan.
Engro dairy farm Nara is certified from different
perspectives by different standards.
These certifications are;
ISO 9001,
for Quality Management System.
ISO14001,
for Environment management System.
ISO18001, for Occupational Health and Safety
Management System.
ISO22000, for Food Safety Management System.
It is also certified by Global Gas and
Halal being a Muslim country so the products must be assured to be Halal before
eating).
Engro
Foods will place experienced expatriates in key positions to ensure a smooth
startup of the operations, however, local staff will be attached with
experienced expatriates for on-the-job training for which a base team is
already in place. The Engro Dairy Farm is expected to open new opportunities
for the locals and provide great learning in livestock management for enhancing
yield.
GEA FARM TECHNOLOGY (used at Engro Dairy
Farm Nara)
The GT2 Parabone combines the best of herringbone and parallel stalls in
an economical parlor solution. Compact 30-inch stall spacing and
parallel-stall-style udder access provides efficient milking from the side or
between the rear legs. In this
Technology 60 cows can be milked within 06 minutes.
DELAVAL TECHNOLOGY
This technology is used in milking
parlor named as Dela Wall, it is half of the size of GEA Tech and used
especially to milk pregnant, injured and ill cows, it is also used to milk the
first milk of cow. It can milk 32 cows at a time and one cow in 5 minutes.
By setting
up Engro dairy Farm at Nara, Engro Corporation has benefiting its unit of Engro
Foods Sukkur, this Dairy Farm is facilitating
to ensure a more reliable or cost-effective supply
of inputs.
Complete
Process of Engro dairy farm Nara contains following steps:
Food
Making
Food for Animals made by Engro is kept hygienic and
frequently digestive. Following processes are involved in food making.
Fodder Selection:
Fodder should contain adequate amount of fermentable
carbohydrates and more than 65% moisture in fodder selected for silage making.
Commonly used fodder for silage making are maize, millet, oat, and sorghum
grass and they all are used at Engro throughout the year. Most of the time
maize is used for silage making as maize silage is considered the best silage
throughout the world.
Harvesting and Chopping of Fodder:
As the Engro has its’ own leased
land of about 350 Acres, so they produce good crops, also purchase maize from
open market after testing it from all perspectives. Grab test is used to measure the
moisture concentration in fodder. Use maize chopper for harvesting and chopping
of fodder.
Mixing
Additives:
Different feed additives may be mixed to stimulate or inhibit the microbial activities in silage. These additives may include:
Different feed additives may be mixed to stimulate or inhibit the microbial activities in silage. These additives may include:
Inorganic
chemical - Calcium carbonate, magnesium carbonate,
ammonium sulphate, sodium sulphate, zinc sulphate, copper sulphate, ferrous
sulphate, manganese sulphate, sodium chloride, sodium nitrite, calcium
phosphate, calcium silicate and phosphoric acid.
Organic
chemicals - Acetic acid, citric acid, benzoic
acid, formic acid, lactic acid, prop ionic acid, formaldehyde, ethyl alcohol,
propylene, glycol, gentian violet, lactate, sodium gluconate, ethyl acetate,
ethyl butyrate, ethyl demine, dihedral iodine and urea etc.
Feed
stuffs - Used as silage additives are wheat
bran, crushed maize, starch, dextrose, molasses, whey and yeast etc.
Fermentation
products and microorganism - A few enzymes, extract
of fungi and several species of microorganism like Lactobacillus acidophilus,
Turolopsis species, Bacillus subtitles etc.
Baling
of Silage
After
chopping and adding additives silo is filled. Inside silo chopped fodder is
compressed with silage baler, silage baler makes bale in well compacted form.
so that it is packed tightly and there is no air left. If air left anaerobic
condition will not be created.
Time
of silage readiness:
After a period of 40-45 days the silage is ready for feeding to the livestock.
After a period of 40-45 days the silage is ready for feeding to the livestock.
This whole process makes silage good for animals and also
makes it 60% digestive than the ordinary
feed.
Cow’s
preparedness Milk
A dairy cow needs to
give birth to a calf in order to produce milk. At Engro Dairy Farm a calf
reaches at Estrus at
6-9 months’ age. The ‘dry’ period is similar to an
adult going on maternity leave, where the cow will rest and prepare for the
birth of her calf. It is the period of lactation when cow’s milk is prepared in
cows tits. A cow gives birth to a calf after 09 to 10 months.
Milking Process
The milking process on Engro consisted of following steps
Ø Extracting milk
from animals
Ø Chilling Milk
and sending to tank
Ø Transporting
the milk to a storage tank
Ø Storing the
milk until it is picked up for processing.
There is good cooperation between cows and operators, the
cows automatically come to parlor at the time of milking, we saw that the door
was opened and cows came themselves and stand in comfort top. The workers came
firstly to clean tits with tissue, cluster the cow, then it started milk
extraction and after milking pyodine was used on each animal’s tits.
Along with milk extraction, extracted milk went to the
chillers to be cooled and stored to the tanks. The milk is stored until and
unless it is transferred to processing. Engro Dairy Farm itself has storage
capacity of 70,000 liter on the plant.
Logistics
Engro dairy delivers its milk to processing industry by
trucks with tanks especially made for milk logistics.
DuPont is
safety standard applied at Human and Animal at any Farm or Plant. DuPont PSM
involves the integration of three broad dimensions:
Facilities
to
manufacture and handle hazardous materials
Technology
of
the process
Personnel
who operate, maintain, and
support the process.
Engro
dairy Farm at Nara has achieved 3.6 rating in DuPont out of 5, and achieving >=2 is a standard.
Permanent Employees: 33
Third Party Contractual: 145
NO. and KIND OF ANIMALS AT ENGRO DAIRY FARM NARA
There are many breeds of cows in Australia but the
main dairy cattle breeds are Holstein Friesian, Jersey and Aussie Red, all of
which have different shapes and colours.
Two breeds , 1) JERSEY 2)
HOLSTEIN are available at Engro Dairy Farm Nara.
JERSEY
Origin
Jersey Cows originally came from the island of Jersey (in the English Channel between England and France). They were bought to Australia in 1829.
Looks like
These cows are fairly small, and fawn in color, with black tips on their muzzles, ears, feet and tail.
Interesting facts
Jersey Cows originally came from the island of Jersey (in the English Channel between England and France). They were bought to Australia in 1829.
Looks like
These cows are fairly small, and fawn in color, with black tips on their muzzles, ears, feet and tail.
Interesting facts
·
A Jersey
cow’s milk is ideal for making butter because it is so creamy
·
Jerseys
are the smallest of all dairy cows and can weigh up to 500kg.
·
Jersey’s
are the second most common breed in Australia.
HOLSTEIN
Origin
Holstein cows originally came from the Netherlands, but many breeding animals now come from North America.
Holstein cows originally came from the Netherlands, but many breeding animals now come from North America.
Looks like
These cows are mainly black and white.
These cows are mainly black and white.
Interesting facts
·
Holstein
cows are the most popular in the world.
·
Of
Australia’s 1.7 million dairy cows there are 1.4 million Holstein cows.
·
Holsteins
can be found in every Australian state, Victoria has the most.
·
Holstein
cows produce large quantities of milk; some cows produce 10,000 litres in a
year; that’s equal to 5000 x 2 litre milk cartons every year or 14 x 2 litre
cartons every day.
Holsteins are one of the biggest dairy animals;
cows can stand over 150cm tall and weigh over 600kgs while bulls stand over
180cms tall and weigh over 1000kg (about the same as a small car).
Note: Average Life of these Breeds is about 06-08
years.
Per Day average Milk production of per
Animal: Approx:
26 Liters
Per Day Average Milk production of Whole
Farm: Approx: 35000-43000
Liters
At
dairy farm all safety measures has been implemented in all units. By doing this
Engro dairy Farm at Nara has achieved 3.6 rating in DuPont out of 5, and achieving >=2 is a standard.
Engro
dairy farm has received ISO 18001 for health and safety because of its efforts
regarding steps taken towards animal and human protection.
Animals:
To make animals secure and safe in Engro, different barns and yards are made
for different nature of cows like they divided cows into pregnant cows at
initial stage and final stage, Estrus
or standing heat and calves. And to prevent diseases they timely diagnose
animals, seven doctors are also hired for that purpose. If any human (Visitor
or Worker) comes from outer atmosphere to Engro they are showered with a
substance, so they can prevent cows as well as humans.
Animal’s
survival: Most dairy cows are housed during the
winter and bad weather. The cows can move freely, socialize and eat and drink
when they want in sheds which are made by Engro that have natural light.
Normal
Diet: At Engro each cow is provided balanced
diet. Each dairy cow eats between 25 and 50 kilograms of feed each day. A dairy cow drinks around 60 litres of water per day.
Some cows may need up to drink 100 litres, or more, depending on how much milk
they produce.
Confined spaces:
Such as silos, water tanks, milk vats and manure pits may contain unsafe
atmospheres, which can cause poisoning or suffocation. To entre those places
different safety procedures are essential to apply and wear different type of
clothing and shoes.
Electricity: Everyone in the farm is made aware of
dangers include faulty switches, cords, and machinery or overhead power lines.
Workplace Health: The Occupational Health program at
Engro includes industrial hygiene and occupational medicine aspects, focusing
primarily on reducing health risks of employees. Two doctors are also hired.
They monitor their employees regularly in comparison with the risks they are
exposed to, taking all necessary steps to reduce these exposures.
Heights:
For climbing stairs special instruction is written on every step of stair to
avoid any major injury or accident.
Machinery:
Each and everyone in the Engro farm is informed about all machineries involve
risk. The operators are also trained to run machineries accordingly.
Vehicles:
To avoid major accidents drivers and riders are directed to move their vehicles
with velocity of 15km/hour. Vehicles are also passed through chemical substance
at entrance to avoid diseases. Separate walking tracks are also made to evade
industrial accident.
Weather:
Hazards include sunburn, heat stroke, dehydration and hypothermia. To prevent
animals from such hazards special barns are made with fans. For workers it is
allowed to leave the work on the spot and no one can force worker to continue
process even CEO.
Apart from that every
worker is instructed to wear tight cloths. Engro’s risk management & emergency
preparedness is qualitative, emergency assembly halls are made to be gathered
on emergency assembly halls to set plans of solving emergency and everyone is
assigned task to steer clear of mismanagement and chaos.
Initial Investment at Dairy farm was Rs. 40.00 Millions, according to their
officials now re-investment is double than initial investment.
·
Disinfectant shower is good for Animal Health.
·
Walking
track at farm was not constructed properly.
·
Only one person of Engineering Department covers
All other departments; Civil, Mechanical and Electrical.
·
Waste bales of fodder were placed at open air, not
disposed off properly.
This is an excellent example of Entrepreneurship,
because Engro taken risk, initiated 100 animals little farm at Sukkur. After
that they take a high risk by investing huge amount in Engro Dairy Farm
Nara.
·
Disinfectant shower should be applied at exit time
also, because it is good for human Health as well.
·
At the time
of fire at night, there should be a exit track of radium lights inside the
Power plant, ware house and all buildings.
·
Organizational structure should be re-organized at
Dairy Farm.
·
A proper disposal unit for manure and waste bales
should be designed at Farm.
·
Increase greenery at Farm House.
Syed
Rizwan H. Bukhari (Farm Manager EDF.)
Mr. Amjad
Farooque Bhatti (Eng. Deptt: EDF.)
Mr. Ahmed
Hassan Usmani (Farm Accountant at EDF.)
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