SYNOPSYS ON

MULCHING PAPER LYING MACHINE

INTRODUCTION
Mulching (Agriculture Film) is the practice of covering the soil around plants to improve
the growing conditions for the crop. Historically natural mulches such as straw, compost, hay
and wood chippings have been used but over the last 40 years paper and plastics have been tried.
Because of its poor wet strength and price, paper has been found less effective and more costly
than plastic.

The result is that plastic mulch film is the primary choice for agricultural application.
Plastic mulch film is widely used on high value crops, such as Tomatoes, Melons, Cucumbers,
Squash, Peppers and Strawberries increasingly on lower value crops such as Corn and Ginger.
For arable soils, the most effective conservation practices for reducing water loss through surface
evaporation are those that provide some degree of surface cover for the soil. A cover can be best
provided by mulches or by tillage practices that leave plant residues on the soil surface.

Mulch is any material placed on a soil surface for the purpose of reducing evaporation,
retaining moisture, reducing soil erosion, suppressing weed growth and providing plant nutrients
as the material decomposes. Mulches act as barriers to movement of moisture out of the soil.
They can be either organic (e.g. straw, wood chips, peat) or man-made (e.g. transparent or
opaque plastic). Besides keeping the moisture in the soil, mulches can also enhance soil
temperature; reduce the spread of soil borne diseases; reduce weed growth; reduce soil erosion);
and provide nutrients and organic matter. Moreover, mulches support infiltration of runoff and
irrigation water as the mulches protect the soil surface from the impact of raindrops preventing
soil crusting.
 PROBLEM DEFINITION

• In old days mulch paper and drip line is lapped over the bed with the help of manpower.

• This process is more time consuming and required huge human effort.

• Accuracy is less due to manual operation.

PRESENT THEORY AND PRACTICES

Mulching area should preferably be equivalent to the canopy of the plant. Then
required size of mulch film is cut from the main roll. Clean the required area by
removing the stones, pebbles, weeds etc. Till the soil well and apply a little quantity of
water before mulching .Required length of film for one row of crop is taken. Round holes
are made at the center of the film using a punch or a bigger diameter pipe and a hammer
or a heated pipe end could be used. One end of the mulch film (along width) is anchored
in the soil and the film is unrolled along the length of the row of planting. Till the soil
well and apply the required quantity of fertilizer before mulching. Mulch film is then
inserted (4-6”) into the soil on all sides to keep it intact. Seeds are sown directly through
the holes made on the mulch film. In case of transplanted crops, the seedlings could be
planted directly into the hole.
 OBJECTIVE OF PROJECT

The major objectives of project are:

1. To develop a machine which reduce cycle time of laying mulch film.

2. To reduce human effort.
3. To increase the production rate.
4. To minimize miss-operation.
5. To reduce no of worker.
6. To minimize the production time.
7. To develop a machine this can make work simple
 LITERATURE REVIEW

1) Title-AGRIPAP
Author-Jukka Ahokas , University of Helsinki

Plastic films are used increasingly in vegetable, berry and fruit production for the
prevention of weed growth, control of temperature and moisture of the soil as well as for the
prevention of raindrop- and wind-induced erosion. Globally over 80 000 km2 of arable land is
covered every year by plastic mulch films. By using plastic mulch films farmers are capable of
improving both the amount and the quality of yields and of decreasing the use of pesticides,
fertilizers and irrigation water. Plastic mulch films are made predominantly from polyethylene,
that is not biodegradable. Therefore the mulch films should be removed from the soil after each
cultivation period. The removal work is laborious and often leaves some plastic mulch film
fragments in the soil. Unfortunately, there is no viable use for used polyethylene mulch films,
which are typically contaminated by soil and plant residues, but the removed mulch films have to
be disposed in landfills. Biodegradable mulch films, which after use can be tilled into soil where
they biodegrade, exist on the market. Their use is still relatively limited (the market share is
estimated to be less than 10 %) due to the price which is 2-3 times higher than that of
polyethylene mulch films. Biodegradable mulch films are used particularly in countries where
labour and land filling costs are high.

2)Title -The Effect of Natural Mulches on Crop Performance, Weed Suppression and
Biochemical Constituents

Author: manuscript

The oat straw, flax straw mat, and wool mat mulches evaluated in this study effectively
suppressed weed populations below economic threshold levels. Crop growth and yield in the flax
straw and wool mat mulches were significantly greater or comparable to yield from hand-weeded
plots over two growing seasons. Similar yield responses and weed suppression were noted in
wool-mulched plots compared with hand-weeded plots in strawberry field production Though
initial purchasing and implementation costs may be higher than on-farm sources of grain straw,
flax and wool mulches offer farmers an environmentally sustainable alternative to hand-weeding,
synthetic mulches, and herbicides. Enhanced crop performance, effective weed suppression, and
enhanced bioactive constituents in this case extracts support the use of natural mulches as weed
management alternatives to manual labor and herbicides.

3) Title – International journal of science technology management and research .

Author – Mr. S.D.Ratnakar

First working model of mulch laying machine was developed by Leslie.E.Bailey in October 22,
1921. The mechanism was horse pulled and had a rotary drum arrangement to lay the paper. In
mid 1930s the mulching paper laying machine was used while being powered and pulled by
horses. Prior to the invention of the mechanism shown the fig 2. The mulching paper was laid by
simply unrolling the winded paper roll through manual labor. This technique was both time
consuming as well as tedious and not efficient. The use of horses was very much effective than
the manual process and hence preferred on large scale [1].
Herman John Herfort invented improvements in machines for laying mulch paper upon the
ground for protecting plants and various growths. The paper is laid upon the ground in a manner
whereby the paper will be prevented from blowing away. Another important

object of the invention is to provide a machine for laying mulch paper upon the ground in an
even and neat appearing manner. These and numerous other important objects and advantages of
the invention will become more apparent after considering the practical usefulness of the
invention. In a machine of the character described comprising a wheeled frame, a spool mounted
upon the same for supporting a roll of mulch paper, furrow diggers at the forward end of the
frame, means for depressing the edge portions of the paper into said furrows [2].

4) Title – Practicle manual on plastic mulching

First working model of mulch laying machine was developed by Leslie.E.Bailey in October 22,
1921. The mechanism was horse pulled and had a rotary drum arrangement to lay the paper. In
mid 1930s the mulching paper laying machine was used while being powered and pulled by
horses. Prior to the invention of the mechanism shown the fig 2. The mulching paper was laid by
simply unrolling the winded paper roll through manual labor. This technique was both time
consuming as well as tedious and not efficient. The use of horses was very much effective than
the manual process and hence preferred on large scale [1].
Herman John Herfort invented improvements in machines for laying mulch paper upon the
ground for protecting plants and various growths. The paper is laid upon the ground in a manner
whereby the paper will be prevented from blowing away. Another important

5 )Title -Potential alternatives to herbicides

Author- nick Mc Carthy .Claire Mc Carthy.

Mowing On sites where erosion is a problem, mowing may be an option between tree rows but it
does little to reduce the competition for moisture and nutrients. According to Davies (1987),
mowing of grass is positively detrimental to tree growth. He also found that in some un-mown
grass swards the weeds often die back thereby creating a self-mulching effect in winter that gives
the trees a good start the following season. Mowing does reduce fuel build-up, cover for rodents
and makes the plantation more accessible for other management activities (Atchison and Ricke
1996), but it is primarily cosmetic. Weed plant species compete with each another as well as with
newly-planted trees. Mowing can change the natural balance between weed species in favour of
detrimental perennial grasses, which are resistant to cutting. However, Willoughby and
McDonald (1999) found that maintaining a 1 m wide weed-free strip around trees, combined
with mowing the inter-row to minimize weed seeding, was a costeffective method of weed
control. In their study on vegetation control for the establishment of ash (Fraxinus excelsior),
Culleton et al. (1995) found that leaving an un-mown strip of grass between lines of ash was
beneficial. They speculated that the trees, while profiting from the weed-free zone around them,
were sheltered from the wind by the grass. The conclusion is that mowing on its own is
ineffective but combining it with another weed control method could have potential.
 METHODOLOGY
This study/project would be consisting of following chronological step of working:

1. Literature study.
2. Project identification
3. Project literature study
4. Field work
5. Design stage
6. System drawing
7. Material procurement
8. Manufacturing stage
9. Fabrication of assembly
10. Trials and troubleshooting.
11. Testing
12. Conclusion
13. Report and project presentation
 WORKING PRINCIPLE

Fig.(22) Conceptual dia. of mulch paper laying machine.

Above fig.(20) shows the conceptual diagram of automatic mulch paper laying
machine. It consist of main frame which supports the other components. Other components
mounted on the main frame which are drip roller, drip line director roller, mulch paper roller,
paper pressing roller and joining arrangement to tractor. When machine is pulled forward drip
line and mulch paper start to unwound as both are anchored at other end. Drip line guided below
the paper by drip line director and at the same mulch paper is placed over the bed by paper
pressing rollers.
The working of this machine is very simple just like pulling the machine in a
straight line in the farm. This machine is having very simple operation and no skilled operator is
required and it makes the work simple and efforts less. Now a days the farmer lay the mulch
paper by hand and this will not maintain the uniformity and no proper distance maintain
between the mulch films.
 PLASTIC MULCH FILM
Basic Properties of Mulch Film
a.) Air proof so as not to permit any moisture vapour to escape.
b.) Thermal proof for preservation of temperature and prevention of evaporation
c.) Durable at least for one crop season

Importance of parameters of the plastic film

a) Thickness:
Normally the thickness of the film does not affect the mulching effect except when it is
used for solarisation. But some of the recent references do indicate the impact of film thickness
on crop yield. Since it is sold by weight it is advantageous to use as thin a film as possible but at
the same time due consideration should be given for the longevity of the film. The early mulch
film used were of 60-75 micron (240-300 gauge) thickness, and today it is possible to have 15
micron thick film due to advent of film extrusion technology. These films are mechanically
weak, as shown by their easy tearing when pulled tension.
b) Width:
This depends upon the inter row spacing. Normally a one to one and half meter width
film can be easily adopted to different conditions.

c) Perforations:
The perforations may be advantageous under some situations and disadvantageous for
some other situation. The capillary movement of water and fertilizer distribution will be better
and more uniform under unperforated condition. But for prevention of water stagnation around
the plants, perforation is better. But it has got the disadvantages of encouraging weed growth.

Advantages of Plastic Mulching

1. It is completely impermeable to water.
2. It prevents the direct evaporation of moisture form the soil and thus limits the water
losses and conserves moisture.
3. By evaporation suppression, it prevents the rise of water containing salts.
 4. Mulch can facilitate fertilizer placement and reduce the loss of plant nutrient through
leaching.
5. Mulches can also provide a barrier to soil pathogens
6. Opaque mulches prevent germination of annual weeds from receiving light
7. Reflective mulches will repel certain insects
8. Mulches maintain a warm temperature even during nighttime which enables seeds to
germinate quickly and for young plants to rapidly establish a strong root growth system.
9. Synthetic mulches play a major role in soil solarisation process.
10. Mulches develop a microclimatic underside of the sheet, which is higher in carbon-di-
oxide due to the higher level of microbial activity.
11. Under mulch, the soil structure is maintained during cropping period
12. early germination almost 2-3 days.
13. Better nodulation in crops like Groundnut.
14. Water erosion is completely averted since soil is completely covered form bearing action
of rain drops. When compared to organic mulches, it serves for a longer period.
15. Moisture conservation
a. Plastic film with its moisture barrier properties does not allow the soil moisture to
escape Water that evaporates from the soil surface under mulch film, condenses
on the lower surface of the film and falls back as droplets.
b. Thus moisture is preserved for several days and increases the period between two
irrigations.
c. The irrigation water or rainfall either moves into the soil thru holes on the mulch
around the plant area or through the un-mulched area.
16. Weed control
a. Black plastic film does not allow the sunlight to pass through on to the soil
b. Photosynthesis does not take place in the absence of sunlight below black film
hence, it arrests weed growth.

Limitations
1. They are costly to use in commercial production when compared to organic mulches.
2. Probability of ‘burning’ or ‘scorching’ of the young pants due to high temperature of
black film.
3. Difficulty in application of top dressed fertilizer
4. Reptile movement and rodent activities are experienced in some places.
5. More runoff
6. Environmental pollution
7. Difficult in machinery movement
8. Cannot be used for more than one season using thin mulches
9. Weed penetration with thin films
10. Toxic to livestock

AREAS OF APPLICATION

Mulching is mainly employed for,

1. Moisture conservation in rainfall areas.

 2. Reduction of irrigation frequency and water saving in irrigated areas.

3. Soil temperature moderation in greenhouse cultivation.

4. Soil solarization for control of soil borne diseases.

5. Reduce the rain impact, prevent soil erosion and maintain soil structure.

6. In places where high value crops only to be cultivated.

ADVANTAGES

Advantages of mulch paper laying machine are:

1. Easy in operation.
2. Low cost.
3. Simple construction.
4. Adaptable.
5. Less operation and maintenance cost.
6. Performance.
7. Easy to setup
8. Light weight.
9. Easy maintenance.
10. No skill operator required.
 COMPARISON

Sr. Parameters Conventional Mulch paper

No. method laying machine
(Manual)

1. Time required to laying the Very high Comparatively very

mulch paper less

2. Number of labors required More (around 8-10) Less (around 2-3)

3. Accuracy of operation Relatively less High

(depends on labor
skill)

4. Initial cost Negligible High

5. Operation cost High Very low

PROJECT PLAN

Ghantt chart
 CONCLUSION
Plasticulture is crucial to Indian agriculture in view of the changing
technological scenario for boosting crop yields and productivity. Introduction of linear low
density polyethylene (LLDPE) as a mulch film has brought a revolution in agricultural water
management. It is actually a boon to dryland farmers. This is one of the fastest growing
plasticultural applications in the world. The cost of LLDPE film is also lesser than one third of
LDPE mulch film. Moreover for mulch activity lower thickness (15 to 20 microns) are highly
suitable. However due to ever increasing cost of raw materials the films are costlier now. Hence
Government should take all possible measures to produce the film in a mass scale and make it
available to the farmers at a reasonable price. Subsidy may also be given through banks to
encourage the farmer to adoption soil mulching. Low cost machines may be developed for
spreading and rolling down the film in the field. PFDC’s may be geared up for large scale
demonstration in farmer’s field to give a wide publicity.
REFERENCES
[1]. New York Standards and Specifications for Erosion and Sediment management 2005
Mulching.
[2]. M. Ashrafuzzaman, M. Abdul hamid, M. R. Ismail, and S. M. Sahidullah, “Effect of Plastic
Mulch on Growth and Yield of hot pepper (Capsicum annuum L.),” Brazilian Arshivesof
Biology and Technology, vol. 54, no. 2, pp. 321-330, 2011
[3]. D.Brault, K. A. Stewart, and S. Jenni, “Optical properties of paper and synthetic resin
mulches used for weed management in lettuce,” HortScience, vol. 37, pp. 87-91, 2002.
[4]. J. E. Brown, W. D. Goff, J. M. Dangler, W. Hogue, and M. S. West, “Plastic mulch color
inconsistently affects yield and timing of tomato,” HortScience, vol. 27, no. 10, pp. 1135, 1992.
[5]. D. M. Decoteau, “The emergence and early development of coloured reflective plastic mulch
technology in agriculture,” Recent Advances in Agriculture, 2008.