FEDERAL  DEMOCRATIC  REPUBLIC  OF  ETHIOPIA MINISTRY OF WATER RESOURCE
FEASIBILITY STUDY AND DETAIL DESIGN OF BALE GADULA IRRIGATION PROJECT
• I*
(WWDSE)
PVTITD(ICT)Federal Democratic Republic of Ethiopia - Ministry of Water Resources Feasibility Study and Detail Design of Bale Gadula Irrigation Project
VOL 7- ANNEX 9
Farm Mechanisation
FEDERAL DEMOCRATIC REPUBLIC OF ETHIOPIA
MINISTRY OF WATER RESOURCES
FEASIBILITY STUDY AND DETAIL DESIGN OF
BALE GADULA IRRIGATION PROJECT
FINAL FEASIBILITY REPORT
VOLUME 7- ANNEX 9
MAY 2010
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Final Feasibility Study ReportFederal Democratic Republic of Ethiopia - Ministry of Water Resources
Feasibility Study and Detail Design of Bale Gadula Irrigation Project
List of Volumes in the Final Feasibility Report
VOL 7- ANNEX 9
Farm Mechanisation
VOL 1
VOL 2
VOL 3
VOL 4
VOL 4
VOL 5
Executive Summary
Main Report
Annex 1           Meteorological and Hydrological Study
Annex 2 Geological and Geotechnical Investigations
Annex 3           Hydro-geological Study
I
(
Annex 4
Soil Survey
VOL 5
Annex 5
I
Land Evaluation
VOL 6
Annex 6
Socio Economic Study
VOL 6
Annex 7
Settlement Study
i
VOL 7                  Annex 8           Irrigation Agronomy
VOL 7
Annex 9           Farm Mechanisation
VOL 7
VOL 8
VOL 9
VOL 9
____________
Annex 13         Watershed Management
Annex 10         Agricultural Marketing
Annex 11          Livestock Study
Annex 12          Environmental Impact Assessment i
VOL 10
Annex 14
Institutionai Dev.
VOL 11
Annex 15
Financial & Economic Analysis
------------------------------ ------------------------------------
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VOL 7- ANNEX 9 Farm Mechanisation
TABLE OF CONTENTS
LIST OF TABLES
1.   INTRODUCTION
1
1 1 General Practice1
1.2 Use of Improved Farm Machinery 1
1.3 Objective of the study 1
1 4 Scope of’he study2
2.   METHODOLOGY OF THE STUDY
3. PERVIOUS AND CURRENT USE OF FARM MACHINERY IN THE AREA
3.1 Pervious use of farm machinery4
3.2 BAiE agricultural development enterprise5
3
4
3            2 1 Farming at the state farm........................................................................................... 5
3.2.2 Fully mechanized operations at tne farm6
3.2.3 Major Mechanization problems observed in Bale agricultural development enterprise (State Farms)3
3 3 Agricultural mechanization service enterprise11
3 4 Other existing private Commercial Farms14
3.5 Present status of use of farm machinery by the farmers in the area16
3.6 Farmers in the irrigation Command area18
3 7 The role of Government, farmer’s co-operatives and union to introduce improved farm machinery18
3.8 Small Sca e Irrigation practices and use of farm machinery19
l
4   CROP PRODUCTION AND MACHINERY OPERATIONS IN THE PROPOSED PROJECT AREA20
4 l Scope
4.2. identification of Machinery type and Determination of requirement
20
20
4 3 CROP PRODUCTION OPERATIONS THROUGH MACHINERY............................................. 21
4 4 Farm MACHINERY REQUIREMENT.................................... ........ 4 4 1 Method of approach
4 5 Crops and cropping area
4 6 Machinery Operational Cost
31
4 6 1 Fixed costs include
4 6.2 Variable costs include.........
25
31
31
46 3
Depreciation
31
4 64
Repair Cost
32
46 5
Laoour Cost.
32
4 66
Fuel cost
4 67
Lubricant
33
1 3
4 6 8    Overhead & Other costs! Interest, Insurance^ Shelter)
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VOL 7 ANNEX 9
Farm Mecnamsation
5.  WORKSHOP (MAINTENANCE)...........................................................................................................................39
5            l workshop objectives......................................................................................................... 39
5 2 Farm workshop task................ .................................................................................................. 39
5 2 1 Maintenance
5 2.2 Activities of the workshop...           ......................................... ... ......................... 39
5 2.3 The workshop plan/area Assumption................................ .......................... 40
39
6.    APPROACH TO PROPER UPGRADING OF THE WORKSHOP..................................................................... 42
C 1 Methods used to determine workshop load and manpower......................................................... 42
6 2 Work Norm..................................................................................................................................42
6.3         Required ^arm workshop Equipments................................................................................... 44
7.  CONCLUSIONSAND RECOMMENDATIONS.....................................................................................................45
7.1 Conclusions................................................................................................................................ 45
7 2 Recommendations........................................................................................................................ 46
LIST OF TABLES
Table 3 1 Different agricultural machinery available in the Enterprise in2009.6 Table 3 2 Statement showing yield in Q/ha of wheat and barely (main crops; of
THE FARM
................................................................................... 6
Table 3 3 information indicating details of Major work shop equipment 10 Table 3 4 Detail indicating number of Technicians and operators in the
workshop
.......................... ............................................io
Table  3 5 Detail  showing  Types  of  farm  machinery  available  in  the  enterprise  12
Table3 6 Information indicating detail oc Major workshop equipments
Table 3 7 Detail indicating number of Technicians and operators in the
Enterprise..................................................... ... Table 3 8 List OF agro industries IN the region
Table 3. 9 Productivity of crops in Dollo mana woreda
......... .
12
.13
16
18
Table  3 10 Distance  between  rows  and  plants  of  selected  fruits  and
VEGETABLE
Table 4 1 detail giving efficiencies and availabili^ of machinery
Table 4 2 information showing width of cut and speeds
able 4 3 Detail showing expected uiFE of Farm Machinery and Others 25 Table 4 4 information giving detail of vehicles and Heavy Machines working
hR/KM PER YEAR
Table 4 5 Cropping Pattern and Crof Calendar for Bale Gadula irrigation
23
24
25
PROJECT DURING MA1N(GENNA ) SEASON (SEPTEMBER - DECEMBER)                    26
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Farm Mechanisation
Table  4 6 Cropping  patterns  for  Ba_e  Gadula  irrigation  project  during  belg (Arfasa)season / March — June/
Table 4 7 Cropping Pattern and Crop Calendar for Bale Gadula irrigation PROJECT DURING MAIN(GENNA ) SEASON (SEPTEMBER - DECEMBER)
Table 4 8 Cropping patterns for Bale Gadula irrigation project during belg (Arfasa) season / March — June/
Table 4    9 Machinery Requirement of the area.
Table 4     w Detail giving investment cost for machinery
27
28
29
.30
30
Table 4     11 Maize Production operation ..................................................................................... 34
Table 4     12 Potato production operation .
Table 4 13 Rice wheat and barely Production operation
34
35
Table 4     14       Hair Cot been and pulses....................................................................................  35
Table 4    15 Garlic onion and vegetables Production operation
36
Table 4
16       Fruits Production Operations for irrigated Crops.
36
Table 4
17       Land Development Operation
36
Table 4
18 Can After Can
37
Table 4
19       machinery Operation Cost/ha for each proposed crop .
38
Table 6
1 Detail giving workshop repair norms ...
42
Table 6 2 Inforva’ion on Assumed man-hours required for unit repair and SERVICE WORK OF MACH+
Table 6 3 INFORMATION GIVING VARIOUS ASPECT OF REPAIRS
43
44
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Farm Mecnamsation
1. INTRODUCTION
1.1      GENERAL PRACTICE
In Ethiopia, oxen are the main power used for land preparation The traditional plough (Maresha) is  used to till the land and this  age-old local plough is  not properly turns or pulverizes the soil
Usually  primary  opening of the fields  is  done during the dry  months  of March to June It has  been noted tnat late season ploughing requires  high draught power which is  usually  difficult to meet by oxen having limited availability of dry  season feeds  Moreover, as  sowing/plantina season approaches  quick  preparation of land is  needed to accomplish the planting activity  for proper crop growth and yield LacK of aaequate draught power leads  to delayed and improper seedbed preparation and overall inefficient farm operations All operations from tillage up to harvesting etc  done manually, where as  threshing is  done by  oxen This  leads  to time consuming on one hand and inefficiency on the other
1.2 USE OF IMPROVED FARM MACHINERY
In the modem era of scientific development ana available technology, use of Farm Machinery has become tne only system in the developed countries and increasing the same with faster speed in the developing countries  to boost agricultural production Tractors  and otner farm macnineries  have Deen found very  helpful not only  in carrying out land preparation efficiently  in shorter time but also for planting/Sowing in line with proper spacing, tillage operation, use of fertilizers spraying and dusting pesticides, harvesting, threshing winnowing and transporting the produce for processing, storage marketing etc  Investors  who have large area of cultivation inevitably  need aaequate Farm Machineries. They can also hire to surrounding peasants  for selected farm activities  especially  for harvesting the crops
1.3 OBJECTIVE OF THE STUDY
Consiaering the usefulness  of tne farm machineries  i e tractors  and other farm equipments  for efficient and timely  farm operations  there is  a need to study  tne
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Farm Mechanisation
requirement,   cost   effectiveness,   past   and   present   status   and   future   requirement when  the  command  area  is  going  to  have  irrigated  intensive  agriculture  It  would need  proper  preparation  of  land  for  timely  and  line  sowing,  efficient  tillage  in  the standing    crop    more    use    of    fertilizers    and    pesticiaes.    harvesting,    threshing winnowing   mechanically   and   there   after   transportation   of   produce   for   storing marketing   etc   The   need   of   such   machineries   may   have   to   be   considered   for investors  and  farmers  their  hiring  rates  and  prices  for  purchase  credit  facility  and repair   services   etc.   The   study   will   find   out   as   to   what   would   be   the   role   of investors,  farmers  extension  workers  for  their  proper  use  and  what  facilities  would have  to  be  provided  by  the  government,  Self  Help  groups,  NGO  (s)  and  wnat expertise   would   be   needed   in   this   field   for   operation   and   maintenance   of   farm tractors and their equipments besides judging their economic perspectives
1.4 SCOPE OF THE STUDY
The scope of the study includes:
•      Assessment  of  present  status  and  availability  of  farm  machinery  both  with investors  and  farmers  in  Oromia  regional  sate  and  Bale  zone  where  bale gaaula irrigation command area is found
•     Their  efficiency  and  utilization  hours  per  day  per  month,  per  year  and  idle period or no work
•    Operations that are being carried out
•    Uses for other purposes
•    Facility for tractor operators and training
•       Repairing   facility   or   workshops   for   farm   machinery   ano   availability   of technicians
•      Perception  of  investors  and  farmers  about  the  work  of  farming  ano  otner activities ano use of farm machinery
•    Availaoility of credit facility
•    Availability of spare parts diesel engine oil and other necessities
•    Estimation of future requirement cased on discussion with farme s 
r
investors dealers and experts on farm machinery
•    Incentives if any from the Government in terms of reduction in interest rate on credit and increasing duration of returning period of the loan
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Farm Mechanisation
2. METHODOLOGY OF THE STUDY
Assessment of pervious studies
•    Collection of information from past studies conducted on farm
mechanization in the area
•    Other similar documents I reports available on farm mechanization
Field Survey
•    Prior to field survey questionnaires were prepared to fill in discussion with, Farmers. Investors and specialists at regional, zone woreda level,
researchers on mechanization & irrigation crop-production, Extension
workers, machinery dealers etc
•    And repairing workshops, technicians, and tractor operators
Future Requirement of Mechanization
Irrigation water is  a precious  resource and its  efficient utilization needs  to be planned to make the farming profitaole and sustamaDle After the introduction of irrigation in tne area, tnere will be a need for land levelling or easing of agricultural operations  where farm machinery  would be helpful Moreover the cropping intensity  would be increased which help in increasing agricultural production many  folds  Thus  2-3 times  farm machinery  operation, operators, technicians  and repairing workshops  would be required All these requirements  will be estimated based on established known norms.
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Farm Mechanisation
3. PERVIOUS AND CURRENT USE OF FARM MACHINERY IN
THE AREA
3.1 PERVIOUS USE OF FARM MACHINERY
Recent information of farm machinery  is  not fully  available, nowever tne study conducted by  Lahmeyer intentional and Yeshi-Ber consult on Genale-Dawa river Dasin master plan in 2007 have brought out certain information in respect of farm tractors  and machinery  oeing used in the in upper Bale zone by  Bale agricultural development enterprise which is  owned by  the state and some commercial farmers whose Drief account is given in succeeding paragraphs
I Tractors-
Information obtained from Bale agricultural development enterprise and Bale zone agricultural office indicated that there were more than 200 different tractors  in the Region There were different makes  of tractors  having 75-150 HP in the area
ii Implements-
a  Disc  plough  -  Nearly  90  percent  of  the  state  commercial  and  individual farmers use three to four bottom disc ploughs.
b.  Harrows  DLA  and  Nardi  disc  harrows  were  being  used  to  break  clouds after ploughing and some time for seed covering
c  Drills  -  There  were  drills  which  were  being  used  in  the  planting  of  wheat and barely
d Harvesting Equipments -There were many Harvesting equipments in the
area. These were of two types tne first type were self-propelled combine
used for harvesting wheat, barely bean and other crops, and the second
type were the small threshers usea to thresh wheat and barely in standing
position
e    Trailers.    -    They    were    being    used    primarily    for    hauling    water    and transporting   crops   from   farm   to   storage   and   market   Other   uses   includes transporting labours fooa and other supplies from town to farm
f Other farm Equipments - Other farm machinery included Lester planters chisels cultivators tandem disc harrows were available ano were oeing usea for different farm operations
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III Others farm machinery rental Service Company existing in the region
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Farm Mechanisation
Agricultural mechanization, government owned organization private companies  such as  Makia enterprise, Chombae Kebir hussan and other individuals  have got a hiring center in Robe town, which rent farm machineries either on hectors hourly or on Quintals bases
Yadot medium scale irrigation project feasibility  study  conducted Dy  food and agricultural organization of the United Nations  in 1992 also recommended different farm machineries  for small-scale irrigation on 56hecators  of land There are three small irrigation scheme established by  the government and IFAD
3.2 BALE AGRICULTURAL DEVELOPMENT ENTERPRISE
3.2.2  3.2.1 Farming at the state farm
In the past commercial farming was  carried out in Oromia regional state around Bale zone by  the state owned Bale Agricultural Development Enterprise under rain fed condition Reports  From Bale agricultural development enterprise indicated that there are four farms  Herero Huntae RoDae and Sinana under tne Enterprise which develops  3127.2002 2441 and 3838hactrors  respectively, ano the Maximum cultivated area was  about 11,498 ha which was  mainly  covered by Wheat. Bareiy  Beans  ano Rape crops  The Farms  are located in different Werada of Baie zone and they  have got their own workshops  agricultural professionals operators. Technicians  and others  To develop the area quite a large number of tractors  ComDine harvesters  and imolements  were imported The tractors  ano comdine harvesters  were imported mainly, from Yugoslavia Russia and East German Democratic  RepuDlic  on the basis  of Dilateral agreements  All these technologically  unfit farm machineries  have been replaced by  new tecnnologies that are favouradle to the Ethiopian condition
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Table 3.1 Different agricultural machinery available in the Enterprise in2009
VOL 7- ANNEX 9
Farm Mechanisation
Make
Qty
Machines
Horse
Power
Remark
MF399
470.Newnolland,
NTP1025 baltra
T ractors
72          85-120
Mostly European
Make
i
I
Class and
Newhollad
Combine harvesters
20          120             Germany
Ploughs
Disc narrows
Planters
Trailers
Nardi                          120       -
DLA
53      -
Mostly 4 bottom
Two gangue
3        —                    seed drills
IFA and Zmay           75
4- 6 tons
In spite of the huge investment injected to the farm the production per hectare was low.
Table 3. 2 Statement snowing yield in Q/ha of wheat and barely (main
crops) of the farm
No
Type of croo
Production year
_______________________ I
2007
2008
1
Wheat
24 79Q/hr
21 69Q/ha
2
Barely
17 46Q/ha
18 10Q/ha
The   Researches   and   some   studies   at   sue   snowed   that   if   proper   agricultural techniques were used it could get much more yield than that was being obtained
3.2.3   Fully mechanized operations at the farm
The farms  are fully  mecnamzed and most of tne farm operations  like primary tillage harrowing, planting spraying, harvesting ano transporting were done Dy machinery  Reports  delivered by  state farm in different time showed that tnere was  a shortage of daily  laoourers  during weeding and narvesting time Tne Machinery  operations  practiced in Bale agricultural development enterprise were indicated as follows
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I)   Primary   Tillage   -   Primary   tillage   is   comprised   of   sub   soiling   and   ploughing operations   Sub   Soiling   that   is   deep   ploughing   was   done   to   up   root   tree,   root remains  and  break  existing  hard  pans  to  facilitate  water  and  air  movement  as  well as  root  development.  This  operation  was  omitted  in  Bale  agricultural  development enterprise due to iacK of high-powered tractors and shortage of time
Ploughing was  done for all crops  using disc  plough and MF399and470 Newhollad 110 Batra BM120 and NTP 1025 Tractors  and it is  the most important operation in crop production and the following problems were ooserved on the Farm.
a)   Too many dead /back furrows and micro- undulations:
b)    Uneven ploughing depth in the field and at head lands
c)    Un ploughed spots, and
d)   Too many ridges throughout the field
ii) Secondary Tillage
Disc  harrowing and levelling are considered as  secondary  tillage operations  A clod left after ploughing is  broken aown by  one or more harrowing operations  to create the desired seedbed for subsequent sowing or planting For harrowing the farms  have been using DLA disc  harrows  Uneven ploughing and disking operations  result, in an undesirable seedbea not suitable for proper seed germination
lii) Planting and Fertilizer application
Planting in rows  provide favourable condition for seed germination and plants growth On the farms  seed drills  were available, but not used properly  They  used spreaders like RDMD and others for broad casting fertilizer and seed together
iv) Intercultural operations
These refer to those tillage operations  which are performed after planting These operations  are intendea to weed control pulverization of the soil to retain moisture, imorove aeration incorporating fertilizers  and providing Dlant support Damsn and other cultivators  were allocated for the farm but since planting was done by broad casting these operations were not fully practiced
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v) Harvesting
VOL 7- ANNEX 9
Farm Mechanisation
Harvesting operation for agricultural production system is  considered to be tne final stage of crop nusbandry  and combine narvesters  are used to harvest wheat, barely beans and rape croDS
vi) Transportation.
Tractor drawn IFA and zmay  Trailers  were used for transporting gram from tne field to the storage area, labourers  and water, food and other supplies  from the town to farm area and within the farm itself.
3.2.4   Major   Mechanization   problems   observed   in   Bale   agricultural development enterprise (State Farms)
i)   Machinery   selection   problem   Even   though   the   farm   itself   was   established without  feasibility  study,  there  had  been  a  problem  in  machinery  selection
Selection of machinery  was  normally  based on the test results  The testing and selection of agricultural machinery  could have been considered the type of soil, climatic  and topographic  conditions, type of crops  grown, power requirement, initial cost of operation, ease for operation, quick  change of unit, manoeuvrability comfort, reliability maintainability of the machine etc
Some of the equipments  especially  the power units  were not selected prooerly  as a result the economic  ano tecnmcai performance was  very  much below the normal level and this  problem nas  been solved after the introduction of free economy polices by government
ii)           Low  Machinery  availability  -  The  degree  of  mechanization  varies  with  type  of crop     production     system     According     to     tne     report     from     Bale     agricultural develoDment   enterprise   (state   farm)   in   20007/2008   the   degree   of   mechanized operation   on   state   farm   with   regard   to   seed   bed   preparation,   planting,   fertilizer application,  cultivation  weed  and  oest  control  ano  harvesting  was  estimated  to  be less  than  68%  Tractor  availability  on  the  average  was  estimated  to  be  about  49% The  low  level  of  availability  was  a  prime  indicator  of  basic  mechanization  problems in the state farm
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iii)  There  was  no  mechanization  plan  A  Farming  systems-program  needed  to  be researched  in  anticipation  of  developing  methods  of  crop  management  and  land use.  wnich  will  be  efficient,  economic  and  sustained  production  of  crops  on  the farms  Once  a  farming  system  is  developed  for  eacn  crop  production  system,  it would  be  simple  to  know  tne  mechanization  requirement  and  level  accordingly Then  a  mechanization  plan  could  easily  be  prepared  and  the  farms  have  no machination plan.
iv)  Improper operation ano handling of machinery The available equipment on the farm must be handled well and properly operated1  Exploited to attain its economic service life
Mechanization cost is  largely  influenced and determined by  the intensity  of equipment usage. The different agricultural operations  must be performed in accordance to tne agro- technical parameters  required to each operation. State farm research done on mechanization Indicates  most of the farm machineries were mishandled ano became out of use within short period of time
v)  Lack  of trained manpower When the farm was established there were no well- trained  technicians  and  operators  as  a  result  improper  operation  and  exploitation of agricultural equipment are ooservea in the farm
vi)   Equipment  Maintenance  problems.  The  effective  maintenance  of  agricultural machinery   and   equipment   is   necessary   so   as   to   perfect   substantial   capital investment  made  by  the  farms,  to  ensure  &  promote  macnmery  availability  ana minimize   tne   disruption   to   production   when   break   down   occurs   It   includes servicing,   repair,   remove   and   replacement,   modification,   inspection,   calibration, over  haul  and  condition  verification  Maintenance  has  a  direct  bearing  on  the readily   availability   of   equipment   for   timely   farming   operations   Low   availability (49%)  indicates  the  over  all  status  of  agricultural  equipments  which  was  not  in satisfactory condition This resulted in loss of production
vii) Equipment maintenance system problem
Maintenance concept has  Deen evolved from the deployment and distribution pattern of the equipment To strengthen the maintenance action it is  envisaged to adopt three level maintenance systems  consisting of periodic  checks  of equipment
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Beside agronomical problems, all the mechanization problems indicated resulted in
a)  Low production of crop per ha, and
b)  High cost of production
Table 3. 3 Information indicating details of Major work shop equipments
S N                 Machinery and model                    Quantity
Remarks
1        Work shop tools
Unknown
This workshop Equipment
2
Mobile welding machine
3
has been
!3
Lath machine
2
found very
4        Injector tester
1
useful
5
Battery charger
5
6
Torque wrencn
fs
J
p
Grinding machine
10
Table 3.4 Detail indicating number of Technicians ana operators in the workshop
S no
Particulars
Work shop head
Qty (No )
4
49
Remarks
I
1I
2 Mechanic
3       Welders                                                           18       • --------------------------------------- -—
4       Electricians
5 Mechanization head
6 Generator operators
12
4
7
—---------------------------------------- -I
7       Machinist                                                         1          Serve as clerk at the workshop
1
Tractor operators Technical dept head Technical expert
168
1
1
The farms  gve Tractor ana combine rental services  to tne needy  farmers  during harvesting period at a rate of birr 12/quantal and for ploughing at a rate of 400birr/hactor for model farmers
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The  enterprise  also  has  two  seed  cleaning  machines  that  helped  it  to  prepare  its own seed and give support to the farmers by supplying seeds
3.3 AGRICULTURAL MECHANIZATION SERVICE ENTERPRISE
i)          The rental services
Agricultural mecnamzation is  one of tne Commercial Farm machineries rental service enterprise in the Oromia regional state around Bale.Arsi and Shoa zones, which undertakes  farm machinery  rental service at present. The enterprise has  started machinery  rental service in 1988 to support farmers' co-operatives in different parts of the country such as
a. Gojam
b Arsi and Bale
c. Wellaga ana Shoa
ii) Mechamzation_extent
The office of the Enterprise is in Adais Abaoa town and organizes activities 
gives effective support and logistics for the farms rental service station.
The Enterprise gives Semi- mechanized farm operations for the farmers 
Plougnmg harrowing and harvesting operations are cone with machinery
iii) Workshop and allied facilities,
Eacn farm machinery  rental service station nas  its  own workshop Tecnmcal section, mechanization, technicians, operators  and other staff The worksnop also gives  maintenance services  with modest charge for other Governmental non-governmental ana investor's machinery
iv Type of machineries available in the farms
The types  of farm machinery  available in the farm mecnamzation enterprise are given in table 3 3 1 Major worksnop equipment and detail of technicians and operators are given in table 3 3 2 ana 3 3 3 respectively
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Table 3. 5 Detail showing Types of farm machinery available in the enterprise
No          Machinery type and model             Quantity               Remarks
1 Tractor Beltra 120
12
(80-85 Horse power I
2 Tractor ZT 300&303
21
I80-85 Horse power
3 Tractor Belarus'80/82                                    42
I
4 planters
8              Mounted type
5 Nardi disc harrow                                          19
I
6 iDLA disc harrow                                           20
7 MF Planters
28
8 Rigger
7
9 Trailers single & two axle
59
10 Water tankers
10
I
11 Chopper
2
12 Row planter
5
13 Disc piougn MF
2
14 Leveller
1
__
15 Rotary cultivator
1
Table 3. 6 Information indicating detail of Major workshop equipments
S.N
Machinery and model
Quantity              Remarks
1     Mobile air composer
5
This workshop
equipment
2     Mobile welding machine                      10                     has been
3     Electric generators                              2
found very
4     Injector tester                                      5
useful
5
Battery charger
i
8
I------------------------ !
6
Torque wrench
10
---------------------------1
7
Individual tool box 
L
Unknown
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Farm Mechanisation
Table 3.7 Detail indicating number of Technicians and operators in the Enterprise
S n Particulars
1 '  Work snop head
Qty (No )                 Remarks
5
2
Mechanic
25
I3
Welders
6
4
Electricians
5
I5
Tyre man                                  3
I
i 6     Generator operators                 2
I
7
Tools keepers
2 Serve as clerk at the
workshop
8
Tractor operators                    31
I
v) Farming Practices in Bale and Arsi farm machinery rental services 
stations
a)  Ploughing  The  enterprise  gives  service  for  ploughing  at  rate  of  birr  900- 1200/hactor depending on tne soil conditions.
b)   Planting  Row  planters  are  used  for  planting  Wheat.  Barely  and  other crops  were  broadcasted  by  spreader  and  covered  by  disc  harrows  at  fair service charge
c)  Harvesting - class comDines and others were useo to harvest Wheat
and Barely at charging of birr15-18/quantal
The major problem of the rental service enterprise is  that it operates  only  during rainy  seasons  for ploughing and harrowing ano harvesting periods  This  indicates that most of its  farm machineries  are idle for seven months  in a year The implementation of Yadot Welmel and Baie gadula irrigation projects  opens  an opportunity  for tne enterprise to use its  machineries  througnout the year and benefits tne farmers investors ano the enterprise itself
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3.4 OTHER EXISTING PRIVATE COMMERCIAL FARMS
VOL 7- ANNEX 9
Farm Mechanisation
The total Information gathered from Oromia regional state Bale zone agricultural development and Investment Bureau shows  that there are 192 investors registered, participating in agricultural project in Bale zone during the period of 2008 land holdings  of these projects  are I3 459 31nas  Theses  projects  are known to undertaKe production of wheat, Barely  and spices  under ram fed condition and fruits and vegetables using irrigation
Major Farm Operation done by the Investors
i)    Primary   tillage   Most   of   the   investors   have   limited   types   of   farm machinery  and  use  them  for  primary  tillage  and  the  common  farm machineries available are indicated below
•    Tractor Mf 399 470,290 NTP1025 etc having 85-120 Horse Power
•    Disc harrow DLA and nardi
•    Tractor drawn trailers mostly double axle
•    Class, new holland, fiat combine harvesters
To plough the land they wait until the soil gets optimum moisture It is very difficult to perform ploughing during the dry  season because the disc  cannot penetrate into the soil and when the soil gets more than optimum moisture tractors can't go easily through the farm This is the cnaracter of Vertisoils and this limited the time of operation to only  less  than three months  They  also use Minimum tillage operations tnat start in June and stay up to tne beginning of July
ii)  Harrowing Operation - For harrowing investors use tractor with DLA and nardi disc harrows It has two purposes
•   For harrowing and
•   For covering the seed
For  every  crop  they  use  disc  harrow  for  harrowing  as  well  as  for  seed covering
iii) Intercultural operations
Weeding is labour intensive and sometimes they use chemical
sprayers
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Farm Mechanisation
iv) Pesticide application - Pesticide application is done by motorized or
manual sprayers.
v)   Harvesting - Harvesting is done fully by combine harvesters.
vi) Transport - Produce transporting is done by tractors drawn trailers
Major Mecnamzation Problems Observed on Investors Farm
i)   Machinery  Utilization  -  The  cost  of  operating  Farm  machinery  varies  from  iarm to farm and place to place. Factors influencing costs, a part from the size and type  of  machine,  including  the  number  of  days  worked  annually,  the  type  of work  performed  the  care  the  tractor  received  etc.  One  of  the  most  important factors  influencing  cost  per  hour  is  the  amount  of  use  Low  hourly  costs  are achieved on some farms by using machinery nearly every day of the year and doing all kinds of work with them But Investors use their tractors less than five months a year that is during planting and harvesting time these two operations can't take more than five months and If irrigation is introduced, there will be a possibility to use their farm machinery throughout the year
ii)  Skilled manpower Problems
To utilize the machinery  properly  there must be well-trained technicians  and operators  Some investors  have small workshop but there is  no well-trained professional technicians  They  only  have a few technicians  that have got the Knowledge tnrough experience
iii)  Shortage of maintenance facilities
The effective maintenance facilities  for agricultural machinery  is  necessary  in tne surrounding area for investors  that don’t have their own workshops, there are few small farm machinery  and vehicle worksnops  in Robae and Goba towns  The workshops  are not equipped with necessary  tools  and equipments and they  don't have well trained manpower These workshops  perform small modification partial engine over hauling welding and parts  reDlacement They are not in apposition to satisfy  the maintenance demand for reconditioning and heavy maintenance
Iv) Snonage of spare parts
To ensure prolonged equipment life and there by to increase equipment availability there must be reliable spare parts and consumable items 
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suppliers   in   the   area   There   are   few   spare   part   shops   in   Robae   and   Rise Engineering representative in Awassatown
The spare part shops  in Robae mostly  imports  parts  and others  from Addis Ababa and their price is  relatively  cheaper than Rise Engineering The parts brought from the Addis  Abaoa by  spare part snop are not genuine Spare parts  suppliers  complain that buying spare parts  from Addis  Ababa is expensive as  compared to those parts  imported directly  To avoid the problem there must be reliable spare part supplies.
v) Agro-lndustry
Before few years  the number of agricultural product processing plant has been few In the year 2007 the number of agro-processing plants  has  been doubled
There  are  12  coffee  processing  plants  and  four  flourmills  with  a  big  capacity owned by private investors in the zone
Table 3. 8 List of agro industries in the region
NO Type of plant
quantity
1 Coffee processing plant
12
2 Flourmill
Most  of  the  processing  plants  are  under  utilized  and  when  the  irrigation  proiects are implemented there will be an opportunity io use their idle capacity
3.5 PRESENT STATUS OF USE OF FARM MACHINERY BY THE FARMERS
IN THE AREA
Recently  the life of farmers  around Oromia regional state ano Bale zone have been changing due to the effort done by  tne government to introduce proper agricultural practices  Out of the 67329 5 sq kilometers  of the zone 53414 8ha of land is  under cultivation in two seasons  Balg and Maher that distinauishes  tne zone form other zones of the region
The major crops of the area are indicated Delow a)         Wheat 60%
bj Barely         25 5%
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c) Maize 13%
d ) Teff                  12%
The average crop yield per hectare for the zone is indicated below a)   Wheat   = 41Qt/ha
0)    Barely    = 30Qt/ha
c)    Teff             = 8-9 Qt/ha
VOL 7- ANNEX 9
Farm Mechanisation
d)    Maize
=36Q/ha
roug
ht  animal
to
and
assessm
ent
In the major portion of the Bale zone, farmers  are planting serial crop The present
market  price  of  these  crops  is  increasing  As  a  result  of  the  high  price  their  living standard  is  changing  dramatically  and  there  is  a  shift  from  using  d
tractors   ana   other   farm   machineries.   During   tne   field   study 
survey, discussion has  been made with Bale Zone Administration Offices, agricultural department heads  Goro woreda agricultural office and farmers  tnose who are living in the irrigation Command area and there is  a demand to use improved farm machineries
Sources of Farm Machineries
In Bale zone farmers  are familiar witn the use of farm machineries  especially  for narvesting serials  There is  high scarcity  of combine harvesters  during harvesting Deriod that raises  the cost of harvesting serials  There are three sources  from which farmers can get machinery rental services
a) Private investor
b) Individual farmers those who nave farm macnmeries
c) State farms and agricultural mechanization
There are about 192 privates  investors  in the zone who are involving in agricultural especially  on serial production These investors  came to the area with different agricultural machineries  ana mostly  they  don t use tne full capacities  of their tractors  and tney  rent tneir extra capacity  for farmers  at a rate of 900-1200 Birr/ha for ploughing and 25birr/quantal for harvesting
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3.6FARMERS IN THE IRRIGATION COMMAND AREA
VOL 7- ANNEX 9
Farm Mechanisation
Bale gadula Irrigation Project command area is  located in Goro woreda of Bale zone and most of the farmers  in the woreda produce maize Sesame spices, teff and sorghum in two seasons as a major crop in the woreda more than 90% of the farmers  use ox  for farm operation. Even thougn there is  a demand from tne districts  farmers, the use of farm machineries  is  limited to ploughing and harvesting
The average land holding of each farmer in the woreda is more than 1 75 hectors The woredas are divided into two climatic zones, the mid high land and the lowland characterized witn erratic rainfall and in both climatic zones farmers are practicing mixed farming
Tabic 3 9 Productivity of crops in Dollo mana woreda
No        Type of Crop
Yield/ha in Quintal
1          Maize
15
2
Teff
i———J__________________________
6
3 L
Sorghum
4           Sesame
16
5
3.7 THE ROLE OF GOVERNMENT, FARMER'S CO-OPERATIVES AND UNION TO INTRODUCE IMPROVED FARM MACHINERY
The woreda agriculture department is trying to introduce proper extension system
to the farmers but there is a constraint of communication like road telephone etc 
There are few primary co-operatives and one union, that supply fertilizer chemical
and other inputs on credit bases These Co-operatives and union can play a ma:or
role in supplying improved farm machinery to the farmers
Due to poor infrastructure in the woreda the introduction of improved farm machinery  like threshers, ploughs  Trailer and other is  limited when compared with other Woreaas of the zone
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Farm Mechanisation
3.8 SMALL SCALE IRRIGATION PRACTICES AND USE OF FARM MACHINERY.
160  household  families  are  using  irrigation  and  cultivate  120  29  hectares  of  land The   major   crops   grown   are   Serials,   pluses   Banana.   Onion   Mango.   Tomato Guava. Cabbage etc
To lift the water from the river diesel pump with horse power ranging from 3.8 hp- 10  np  are  used  by  the  farmers.  They  also  use  gravity  and  treadle  pumps  for diversion  and  to  irrigate  their  farms.  Furrow  irrigation  is  extensively  used  in  the area with two irngation cycles
i) First cycle
ii) Second cycle
- September
- Feb
- Feb
- June
In tne Irrigation area vegetables are also used for Intercropping between fruits Table 3 10 Distance between rows and plants of selected fruits and vegetable
produced in irrigated area
No
L
Types of crop
Distance
between row
Distance
between plants
1
Banana
3mx3m
3m x 3m
2
Papaya
3mx3m
3m x 3m
3
Mango* Avocado
5mx5m
5m x 5m
4
Tomato
0 9m -1 Om
10 cm
5
Onion
0 5m - 0 6m
10 cm
Farm  operation  for  irrigation  like  ploughing  harrowing  levelling,  furrow  opening  is done by oxen drawn plough ano planting is done manually
The  Major  problem  of  farmers  using  irrigation  is  shortage  of  supply  of  diesel pumps and the diesel fuel
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Farm Mechanisation
4. CROP PRODUCTION AND MACHINERY OPERATIONS IN THE PROPOSED PROJECT AREA
4.1 SCOPE
In this section tne following aspects are analysed:
i)  Identify  the  types  of  machinery  &  determine  their  requirement  for  different agricultural   operations   that   would   be  developed  by   farmers,  investors   and other  under  Megech  irrigation  Project  The  operations  would  include  Primary and    secondary    tillage,    row    planting,    fertilizer    &    pesticides    application, harvesting and transportation of products,
ii) Analysing the cost of machinery for each operation i.e ;
lii) Identify need of maintenance & facilities for agricultural machinery;
v)  Determine manpower requirement for maintaining & operating agricultural
machinery:
vi) To show the roie of Government NGOs investors farmers, extension workers 
with regard to Mechanization in Bale gadula Irrigation project,
4.2. IDENTIFICATION OF MACHINERY TYPE AND DETERMINATION OF REQUIREMENT
i)  This  part  of  the  report  is  prepared  to  determine  the  machinery  requirement  for the whole irrigation project area.
ii)   Previous  geographical  soil  climate  condition  were  studied  thoroughly  and  are taken into consideration to tne farms for the selection of Implements
iii) Mechanization activity on peasant farms focused on Major and vital operations 
This include field clearing ploughing disking ridging threshing and in put
transport
iv)  Mechanization  aspects  to  determine  the  machinery  requirements  of  the  project are  based  on  the  cultural  practices  ano  operational  calendar  of  different  types  of crop  production  In  addition  to  this  agro  technical  recommendations  based  on  soil classification were envisaged for machinery selection
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Farm Mecnanisation
4.3.CROP PRODUCTION OPERATIONS THROUGH MACHINERY
Profitable crop production depends on proper machinery selection and application of appropriate cultural practices Optimum yield achievement is the over all goal to maximize profit or score the best cost benefit ratio. Therefore depending on the nature of the soils  agro technical requirement of crops  alternatives  of machinery combination should be strictly  analysed through research trials. Types  of mechanization activities are categorized into four main groups
1)  Pre planting operations
2)  Post planting operations
3)  Harvesting Operations
4)  Post harvesting Operations
Based on the aDove categories  and soil types  of tne project area important operations are recommended for different types of crops suggested to be grown in the project area. Main crop proposed in the area are Maize, rice, Pulses, vegetables  fodder crops  Fruits  etc  in different seasons  For cultivating them a sequence of operations is to De adopted
4.4FARM MACHINERY REQUIREMENT
3.2.5  4.4.1 Method of approach
Recommendations  on farm machinery  requirements  should have been based on intensive field test results  However, in tne absence of dependable information evaluation of actual field operation reports  backed with some theoretical consideration may suffice could work out more or less close to the actual results
Basis for Estimation
I Productivities or out put of a machine
The  following  formula  is  used  to  calculate  tne  out  put  or  productivity  of  the machine
Out put (hr) = 0 36Bx\/xZT (ha/hr)
Where B = Width of cut (m)
V = Speed(M/sec)
ZT = Labour efficiency (%)
0 36 = Coefficient
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II  Efficiency
= Heavy duty operation 65% = Light duty operation 70% = Harvesting operation 55%
VOL 7 ANNEX 9
Farm Mechanisation
Concerning   efficiency,   the   calculation   is   carried   out   on   the   basis   of   state   farm experience and research finding in Ethiopia.
III  Effective working hours per day
Three  alternatives  are  taken  into  consideration  depending  on  the  type  of  machine operation
a.   Eight hours shift per day
b.  Twelve hours shift per day
c.   Sixteen hours shift per day
IV) Availability
It is  assumed that when new machines  are used and proper management is practiced the availaoility  improves  Hence, during calculation of machinery requirement for practical purposes  availability  is  assumed to be 80% for agricultural machinery  This  is  based on joint field research results  of EMI (Ethiopian Management Institute) and MSFD (Ministry  of State Farm Development).
V) Efficiency and availabilities
Efficiencies   and   availability   of   different   agricultural   machinery   are   indicated   in   the table 4 1.
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Tabic 4.1 Detail giving efficiencies and availability of machinery
No
Machine
Efficiency         Availability        Remark
1 Slashers 70 80
2 Subsoilers 65 80
3       One way plough
|65
80
4 Chisel plough 65 80
5 Conventional plough 65 80
6       Disc narrows
7 Spike tooth harrows
8       Land planner
9       Riggers
10      Planters (Row)
11      Seed drill
I
I
I
r°
[70
ho
80
80
80
80
80
80
I
65
£5
12      Cultivators                                     65                  80
13      Ditchers
14      Tractors
15 Harvesters
ho
!70
,55
80
80
80
16      Trailers                                          70                 90
VI Numoer of tractors required
To determine the number of tractors required tne following formula is used
N=
A
W x C x D x sh
Where A = Total area to be covered N = Numbers of tractors W = Output or productivity
C = Calendar days D = Availability
SH = Shift hours
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Farm Mechanisation
VII. ASSUMPTIONS
To determine the output or productivity  of a machine the following width of cut and speed are assumed and are shown in Table 4.2, expected life span of Machinery and implement are shown in table 4 3-4 4 respectively
Table 4. 2 Information showing width of cut and speeds
No I
Machine type
1     Disc plougn 4 bottom 5 bottom 6 bottom
Width of cut
Im)
1.00
1 25
1.50
2 Mould Doard piojgh: 2 bottom 0.75
3 bottom              1.12
4 bottom,             1.50
3      Cultivators power harrow                             1 50
Time cultivator                           1 50
Recommended speed
(m/sec)
1 94
1.94
1 94
1.70
1.70
1.70
2.22
2.22
2.22
______
Tooth harrow
4      Fertilizer application
1.50
1 50
1 94
i
5      Planter
1 50
1 94
6      Sprayer
1 50                             1 94
7      Combine                                                       1 50                             1 39
8     Trailed thresher
9      Trailer Tractor trailer Tractor trailer
10     Rigger
5T
6T
3.20
11     Seeddrill                                                 3 20
4 17
4 17
1.94
1.94
12
Ditches Small
1.30
1 39
Large
1.35
1 39
Rotary
1 80
1 39
Rotary
2 10
1 39
Crawler
2 10
1 39
13
Leveller
4 00
1 11
14
Trailed water tank
1800 It
5 56
15
Groundnut digger
2 00
1 11
16
Slasher Drum mower
3 00
1 94
Chain mower
1 82
1 94
Binder
3 00
1 94
Binder
1 82
1 94
-    18 iLana clearing
19     Raking _                    ____ 2 50
Disc harrow
3 20
1 94
4 q 7m
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Table 4.3 Detail showing expected life of Farm Machinery and Others
VOL 7- ANNEX 9
Farm Mechanisation
No 'Type of Machine
'1        Plough
Annual working (Motor hrs)
250 ha
2        Disc harrow                        400 ha
3        Planter
4 Cultivator
250 ha
250 ha
■5
Combine harvester            300 ha
j Expected life Span ' (motor hrs)
2500
[4000
2500
2500
I
3000
Table 4.4 Information giving detail of Vehicles and Heavy Machines working
hr/km per year
No   Types of Machine Km to be covered/year
Km  to  be  covered  in  life Service
Vehicles                     30 OOOkms
300.000 km
2 Heavy  duty 1,400 motor hr
machine
14 000 motor hr
I
I
4.5 CROPS AND CROPPING AREA
The cropping area for Bale gadula irrigation project is 5,000ha The type of crops and area under each in Doth rainy  ana dry  season is  given on table_4 5 The machinery  and implements  requirement is  based on the types  of crops  and soil types  of the command area There will be two seasons  and two operations  of cropping pattern with ana witnout fruits
The farm operations would De neeaea to De aone in more than 10 000 ha annually in Doth two seasons  The cropping will De year round with cropDing intensity  of around 200% The machinery  requirement ana investment cost are given in table 4 5 and 4 6
25Federal Democratic Republic of Ethiopia - Ministry of Water Resources Feasibility Study and Detail Design of Bale Gafluia lmgation Proj^£^
VOL 7- ANNEX 9
Farm Mechanisation
Table 4. 5 Cropping Pattern and Crop Calendar for Bale Gadula irrigation project
during main(Genna ) season (September - December)
No
Crop
Area                of coverage/%/
LG P
Growing period laayl
remark
/days/
Planting
Harvesting
Second
planting
1
Cereals
65
11
Wheat
40
130
10-Jul
7-Nov
20-Jan
12
Rice
5
130
10-Oct
7-Fed
10-Apr
13
Maize
20
150
10-Aug
28-Dec
20-FeP
2
Pulses
14
21
Chick pea
7
120
15-Aug
13-Dec
1-Apr
22
Hricot
Bean
7
110
5-Sep
3-Jan
1-Apr
3
Spices
7
i3
I------
1
l
Black
cumin
5
150
5-Sep
3-Jan
5-Mar
32
Coriander
2
150
10-Aug
18-Dec
1-Apr
4
vegetables
4
41
Onion
2
130
1-Jul
29-Oct
10-Mar
42
Rec
pepoer
2
145
•i       ..
29-Oct
1-Jan
5
Fruits
3
51
Citrus
2
Perennial
i 15-Sep
■
Harvesting
5yrs
52
Avocado
1
*’
• 1 >•
-
Harvesting
7yrs
6
Forage croDs
7
7
30-Sep
■
■
Total
100
100
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26Federal Democratic Republic of Ethiopia - Ministry of Water Resources
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VOL 7- ANNEX 9
Farm Mechanisation
Table 4. 6 Cropping patterns for Bale Gadula irrigation project during belg
(Arfasa) season. I March - June/
Growing period/ day/
No
Crop
Area.
/%/
LG
P
/day/
Planting
Harvesting
2nd
planting
Remark
1
Cereals
25
11
Wheat
13
130
20-Jan
20-May
10-Jul
Rice
5
130
10-Apr
8-Aug
10-Oct
12 I
13
Maize
7
120
20-Feb
10-Jul
10-Aug
For
green
cob
2
Pulses
12
22
Chickpea
6
100
1-Apr
30-Jul
15-Aug
One
season
2 3    Hricot Bean
6
120
1-Apr
30-Jui
5-Sep
Vo
Spices
5
31
Black cumin
3
150
5-Mar
3-Jul
5-Sep
3.2
Coriander
2
1
1-Apr
9-Aug
10-Aug
4
Vegetables
4
41
Omon
2
130
10-Mar
8-Jul
1-Jul
42
Red pepper
2      145
1-Jan
1-May
» 1               e •
5
Fruits
3
51
Citrus
2
Perennial
15-Sep
52
Avocado
1
..
..
6
Forage crops
6
6
••
30-Sep
Total
55
55
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Option 2
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Farm Mechanisation
Table 4 7 Cropping Pattern and Crop Calendar for Bale Gaduia irrigation
project during main(Genna ) season (September - December)
No     Crop
Area of cove ‘rage/
%/
LGP
/days/
Growing period /day/
remark
Planting
Harvesting
Second
planting
’1
Cereals
53
11
Wheat
35
130
15-Jul
12-Nov
20-Jan
12
Rice
4
130
10-Oct
7-Feb
10-Apr
13
Maize
150
10-Aug
28-Dec
20-Feb
2
Pulses
12
14
21
Chick pea
7
120
15-Aug
13-Dec
20-Mar
22
Hncot Bean
5
110                 5-Sep
3-Jan
1-Apr
-------------------------------
1
3
Spices
7
31
Black cumin
___________
150                5-Sep —--------------- -
3-Jan
10-Mar
32
Corianoer
5
2
150
10-Aug
18-Dec
30-Mar
4
Vegetables
4
41
Onion
2
130
1-Jul
29-Oct
20-FeP
42
Red pepper
2
145
..
29-Oct
1-Jan
5
Fruits
3
51
Citrus
2         1 Perennial
15-Sep
-
Harvesting 5yrs
52
Avocado
1
-
Harvesting 7yrs
6
Forage
crops
7
7
• »   M
30-Sep
Total
86
86
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Farm Mechanisation
Table 4. 8 Cropping patterns for Bale Gadula irrigation project during belg
(Arfasa) season. / March - June/
Growing period/ day/
No
Crop
Area. /%/
LG P
/day/
Planting
Harvesting
2^0
planting
Remark
1
Cereals
25
11
Wheat
13
130
20-Jan
20-May
12-Nov
1.2
Rice
5
130
10-Apr
8-Aug
7-Feb
1.3
Maize
7
120
20-Feb
10-Jul
28-Dec
For green cob
2
Pulses
12
2.2
Chickpea
6
100
20-Mar
18-Jul
13-Dec
One season
23
Hricot Bean
6
120
1-Apr
30-Jul
3-Jan
3
Spices
5
31
Black cumin
3
15C
10-Mar
8-Jul
3-Jan
I
32     Coriander
2
1
30-Mar
7-Aug
18-Dec
—
4
Vegetables      4
41
Omon
2
130
20-Feb
20-Jun
29-Oct
42
Red pepper
2
145
1-Jan
1-May
29-Oct
5
Fruits
3
51
Citrus
2
Perennial
-
52
Avocado
1
..
-
6
Forage
crops
6
6
..
-
Total
55
55
—
L
Assuming certain other crops  would also cover in due course of time. The cropping will be year round with cropping intensity  of 200% The machinery requirement is indicated in table 4 6
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Table 4 9 Machinery Requirement of the area:
VOL 7- ANNEX 9 Farm Mechanisation
No
Type of Farm machinery
Requirment
Remark
1
Tracto's 75-120nc
20
3
Plows
20
Four-five bollon
4
Disc harrows
10
6
Riaars
6
8
Fertilizer spreader
6
9
Trailer 5T-7T
11
10
Row planter
6
12
T reshers
12
13
Comome harvesters
6
14
Water tanker
10
16
Knapsack sorayers
16
18
Vechicles
5
Table 4. 10 Detail giving Investment cost for machinery
No
Type of Machineries
Total
Required
average
Unit price
/Birr
I
Total Price
Birr
Remark
1
Tractor 75-120 hp
20
650,000 00
13,000.000 00
2
Plows
20
150.000.00
3 000 000 00
1
I
3
Disc harrows
10
150 000 00
1 500.000 0C
4
Ridgers
6
70 000 00
420 000 00
5
Fertilizer Spreaders
6
120 000 00
720,000 00
6
Traile 5T-7T
11
180 000 00
1.980 000 00
1
7
Row planters
6
200 000 00
1,200 000 00
8
Treshers
12
80 000 00
960 000 00
9
Combiner harvesters
6
800,000 00
4 800.000 00
10
Water tankers
10
50 000 00
500 000 00
11
Knabsack sprayers
16
25 000 00
400 000 oc
12
Vechiles
5
400 000 00
2 00C 000 00
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VOL 7- ANNEX 9
Farm Mechanisation
To   develop   the   10   000ha   under   irrigation   in   two   seasons,   a   minimum   of 34 630,000 00 Birr investment on Farm machinery and vehicles is required
4.6 MACHINERY OPERATIONAL COST
Machinery costs are divided into two categories, fixed cost and Variable cost
3.2.6  Fixed costs include
□     Depreciation
□     Interest
□    Tax
□     Insurance
□     Shelter
For practical purposes only depreciations are taken into consideration
3.2.7  Variable costs include
□      Fuel
□      Oil
□      Labour
_) Repair ana maintenance
3.2.8  Depreciation
It is  the largest cost of farm machinery  and measures  the amount by  which the value of a machine decreases  with the passage of time whether used or not The value decreases  because tne parts  of a machine become worn-out and cannot perform as  effectively  as  expected ana straight-line method is  used in aepreciation estimation
During calculation of depreciation the total operating hour per year is considered Depreciation            - New cost - saivaqe value
Totai service hr
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Farm Mechanisation
Usually salvage value is 10% of the new cost
Depreciation cost of Tractors = (650,000-65,000 )Birr
10,000 hours
= 5aBirr/Hr
3.2.9 Repair Cost
The cost of repair is  an important aspect as  it may  determine the point of replacement of a machine This  cost is  the expenditure on parts  and labour for installing and replacement of parts  after a pan failure and reconditioning renewable parts  as  a result of wear ano tear The anticipated annual cost of repair for any  one machine is  highly  uncertain However for practical purposes  it is generalized and calculated on the basis  of the formula of ASAE (Association of Society of Agricultural Engineers) for 1000nr of use per year and 10 OOOhr (10
Years  of  life)  use  per  hour  repair  charge  = 0  16638  *  List  Price  of  the  machine. Repair cost = 0 16638’' 650,000 Birr * 11 5 (Exchange rate)
10,000 hours
=       124 Birr/Hr
3.2.10Labour Cost
The  operators  labour  cost  is  the  rate  in  Birr/hr  Multiplied  by  the  Hour  of  use  for the machine For every operation the cost of labour Is shown below
L = Monthly Operator Salary
No Days/month x shift hr Where L = Labour cost
L = 1200Birr
24” 12Hrs
= OLBjn/tir
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3.2.11 Fuel cost
The fuel and oil consumption for an hour is  calculated on the basis  of specific  fuel consumptions  That is  the amount of fuel consumed per horsepower, per hour wmch is  equal to 157 gm/hp /hr This  specific  fuel consumption multiplied by  the horsepower will give the hourly fuel consumption in kg
The  hourly  consumption  multiplied  by  the  rate  of  fuel  cost  Birr/lt.  Will  give the total cost of fuel
Fuel Consumption for Different Tractors
1 Tractor 50 Hp 2.  Tractor 100 Hp 3.      “110Hp
4        “ 140 Hp
5       “160 Hp
6      “ 180 Hp
- 9 33 lit/hr
- 18 60 lit/hr
-20 50 lit/hr
- 26 00 lit/hr
- 30 00 lit/hr
- 33 60 lit/hr
7 Combine harvester (120-135Hp)
- 20 50 lit/hr
The average fuel consumption for 90-140 Hp Tractor=2l 7lt/hr
Current Diesel fuel cost=9 00 Birr/lit
Fuel cost per hour = 21 7lt/hr* 9 Birr/lt
= l95Birr/Hr
3.2 12 Lubricant:
Lubricant Consumption is 3% of the total fuel consumption
Lubricant cost = 0 03’ 195 Birr/hr
= 5 85 Birr/Hr
3 2 13Overhead & Other costs( Interest, Insurances Shelter)
is 30% of (Variable--- Fixed Cost;
=    0 30(59 00+124 00+4 16+195 00+5 85) Birr/hr =    116 40 Birr/hr
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Therefore the total tractor operating cost without profit margin per hour = (59 00+124 00+4 16+195+5 85+116 40) Birr/Hr
= 504 +10% for implement costs= 554 Birr/Hr
VOL 7-ANNEX 9
Farm Mechanisation
I I I I I I I I I I I I I I I I
To  determine  the  machinery  operation  cost,  the  machinery  combination  for  each crop production is indicated below
Table 4.11 Maize Production operation
No Operation
1        Field clearing
2        Ploughing
3        Harrowing
4        R.dgmg
5 Planting and Fertilizing I
6        Fertilizing II
7        Cultivation
Machine type
Slasher + Tractors
Disc plough + Tractor
Disc harrow + Tractors
Rigger + Tractors
ComDined planter + Tractors
Combined cultivator + Tractors
Cultivator + Tractors
8        Chemical Spraying
Sprayer + Tractors
9        Harvesting
Combine harvester
10
Input Transport
Tractor + trailer
11
Produce transDort
Table 4. 12 Potato production operation
No     Operation
1        Field clearing
2        Ploughing
Machine type
Slasher + Tractors
Disc plough + Tractor
3
Harrowing
Disc harrow * Tractors
4
Ridging
Rigger + Tractors
5        Fertilizer application
Spreader + Tractors
6        Planting
Planter + Tractors
'7         Chemical Spraying
8
l-------
Harvesting
9 Input Transport
10 Proauce transport
Sprayer + Tractors
Digger + Tractor
1 Tractor + trailer
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Tabic 4.13 Rice wheat and Barely Production operation
VOL 7- ANNEX 9 Farm Mechanisation
No Operation
Machine type
1     I Field clearing
Slasher Tractors
2       Ploughing
Disc plow + Tractor
3       Harrowing
Disc harrow + Tractors
4
Fertilizer application
Spreader + Tractors
5       Planting
Row planter + Tractors
6       Chemical Spraying
Sprayer ♦ Tractors
i 7       Harvesting                                           Manual
8       Input Transport
Tractor + trailer
9       Produce transport
<«                      II
TaDie 4.14 Hair Cot been ana pulses
No     Operation
1       Fiela clearing
2       Plougnmg
3       Harrowing
4         Ridging
5       Planting
Machine type
Slasher + Tractors
Disc plough + Tractor
Disc harrow + Tractors
Rigger + Tractors
Row planter + Tractors
I Cultivator + Tractors 
Sprayer + Tractors
Manual
Tractor + trailer
1
----------------------- -——1
6
i-----
Cultivation
7       Chemical Spraying
1 5       Harvesting
9       Input Transport
10      Produce transport
—
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Table 4.15 : Garlic, onion and vegetables Production operation
VOL 7- ANNEX 9 Farm Mechanisation
No    Operation                                              Machine type
1       Slashing
Slasher + Tractors
2       Ploughing
Disc plow/mola board + Tractor
3            Disking
Disc harrow + Tractors
4       Ridging
Rigger + Tractors
5       Transplanting                                        Manual
6       Fertilizer application                             Manual
7       Weeding                                               Manual
I  8      Chemical Spraying                               Sprayer (knapsack)
9       Picking
Manual
10     Input Transport
Tractor + trailer
11     Produce transport
U                       II
Tabie 4.16 Fruits Production Operations for irrigated Crops
No Operation
1 Slashing
Machine type
Slasher
2       Ploughing
Disc plough
3 Disking
4 Ridging
---------
Disc harrow
Rigger
5       Input Transport
Tractor + trailer
6       Produce transport
Table 4 17 Land Development Operation
“ 
«i
No
Operation
Machine type
------------ “1
lL|
i2
Land clearing
Land racking
D8L
FA-200
--------------------------------------------------- J
I
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VOL 7- ANNEX 9
Farm Mechanisation
No     Operation
Machine type
------
1
1       Up root
Tractor t Disc harrow a plough
2       Subsoil
Tractor + Sud soiler
3            Ploughing
Tractors + Plough
4       Harrowing
Tractor + disc harrow a plough
I  5      Land shaping
Tractor Land planer
!6
Furrowing
Tractor + Rodger
Machinery Operational Costs/he for each crop that was purposed is indicated on table 4 19
I
I
I
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Farm McthanuatiQn
Table 4 19 Machinery Operation Cost/ha for each proposed crop
No            1 ype of Crop
1         Papaya
2         Banana
3 Orange ■» Mandarin
4         Avocado
5         Mango
6         Coffee
7         Grapes & Raisin
8         Maize
9         Wheat
10       Rice
11      sesame
12       left
Field clearing Birr/ha 370
370 370 370 370
- 370 370 370 370
370
370
—
Planting Birr/ha/
370
370
370
370
370
-
370
555
555
555
-
-
Cultivation
Birr/ha
370
370
370
370
370
-
Spraying Birr/ha.
370
370
370
370
370
-
Harve
sting
Birr/ha
T ranspo-
rtation
Total
3515
3515
3515
3515
3515
13      Sorghum                         370
14       Barely
15 f aba been seeds
16       rield peas
17      Chick
18       1 entils
19       Hancot bean
20       Garlic
21       Cumin
370
370
370
370
370
370
370
370
Ploughing
Birr/ha
740
740
740
740
740
-
740
740
740
740
740
740
740
740
740
Harrowing two times
Birr/ha
740
740
740
740
740
-
740
740
740
740
740
740
740
740
740
555
555
555
555
555
555
555
370
370
740
-
-
-
-
740
-
370
740
740
740
740
1740
740
740
900
450
450
450
450
450
555
555
555
555
555
-
555
370
370
370
-
3515
5155
3965
3040
2590
3040
4705
3965
370
740
740
370
370
370
370
370
370
4335
740
740
740
740
740
‘740
740
740
740
740
740
370
370
4335
740
-
740
450
450
450
450
370
370
4335
3965
370
740
450
370
4335
370
740
-
555
3885
740
370
370
740
______
555              3885
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Farm Mechanisation
I
I
I
I
I
I
5.  WORKSHOP (MAINTENANCE)
5.1     WORKSHOP OBJECTIVES
The workshop should be designed for repairing tractors, agricultural implements, vehicles  etc. In general the workshop is  responsible for maintenance activities and reconditioning parts  and component items  which are removed from the machine on a periodic basis or due to un predictable ^auses of failure including engine, gearbox, radiator starter dynamo, injection pump, water pump hydraulic units  and Fast moving items  deal with replacing or changing of parts such as filters elements bearing, bushings, belts, chains, bolts nuts, bulbs, fuses etc.
5.2   FARM WORKSHOP TASK
5.2.1Maintenance
The maintenance operation could be broadly divided into planned and unplannea depending up on the incidence of break down
An efficient planned maintenance system lengthens  the life of machinery  That means, postponing replacement, which saves  foreign exchange that could be used for other purposes Unplanned maintenance is maintenance that can occur when the machine is on operation.
5.2.2  Activities of the workshop
i) Daily maintenance
Daily inspection should be carried out by the operators in the unit farms or in pool as the case may be under the supervision of the deployment section
li) Periodic Maintenance
This  type of service or repair is  planned or scheduled it could be programmed at time, when machines  are not operating or during slug seasons tc minimize break aown
Therefore, the maintenance section in accordance with the periodic maintenance chart supplied by  the manufacturers  will carry  out periodic maintenance
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iii) Break down (Accidental) Repair
VOL 7- ANNEX 9
Farm Mechanisation
This type of repair cannot be programmed. It is simply carried out to correct accidental failures  or problems  occurring due to lack  of proper handling or poor maintenance subjecting the machine to extra heavy duty work, defects of materials etc. These failures, which occur unpredictably during the regular use of the machines, require prompt repairs
5.2.3The workshop plan/area Assumption
The workshop has to be planned and built in accordance with local conditions and for tne magnitude of servicing required The workshop territory should be fenced separately
In the assumed area of the workshop passages  and motor roads  should be designed in such a way  that sufficient allowance is  made for traffic  flows  and provision of access.
Every unit farm (6,000 ha) should have it own workshop the workshops, which should be established must have at least the following section
A. Light vehicles and tractors repair section
B Welding section
C. Electric repair section
D. Component repair room
E Spare part store
F Tools room
Total  offices  area  of  the  assumed  workshop  for  the  farms  (11,204  na)  is indicated below
40Federal Democratic Republic of Ethiopia - Ministry of Water Resources Feasibility Study and Detail Design of Bale Gadula Irrigation Project
VOL 7 ANNEX 9
Farm Mecnamsation
No
Reoair seaion
Longth m
Wdtn m
Area m2
Remark
1
Light vehicle for repair seaion
15
13
195
2
Traaor repair section
20
13
260
3
Component repair section
10
13
130
4
Electnce repair section
10
13
130
5
Tyre repair
10
13
130
6
Spare pan store
10
13
130
7
Office (3
12
13
156
8
Tods room
4
13
52
1183 nV
The construction cost at present per unit area of m2 is approximately Birr 2500 and to build one unit farm work  shops  and other related office needs  an investment of 1183m2 ’ 2500Birr = 2.957,500 Birr
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6.  APPROACH TO PROPER UPGRADING OF THE
WORKSHOP
6.1 METHODS USED TO DETERMINE WORKSHOP LOAD AND MANPOWER
The workshop is assumed to be designed to repair and maintenance of tractors, combines, vehicles and agricultural machines
Over hauling capital repairs minor repairs and major services are the main repair works  expected in the workshop Basically  planned maintenance should be performed by type of machines according to manufacture recommendation
The recommendation of maintenance schedule or service life of machinery depends  on the type of machine and make However based on the work efficiency  of an agricultural machine in our condition and state farm work experience service life of the machines  is  considered to be 10 years  and suggested maintenance cycle is designee by its assumed generated working hrs covered “ha" and “kms" as stated in table 6 1
Table 6.1: Detail giving workshop repair norms.
No
Type of machine
Unit
Capital
over
hauling
Minor repair
Major service
1
2
_3 I4
Tractors
Heavy duty machine Combine harvestors Vehicle
Motor hrs
ii
ha
km
10 ooo
14 000
3 000
30 000
500
600
150
3 000
1000
1400
800
10.000
Depending on the above stated maintenance cycle the frequency of repair and maintenance work expected to De under taken oy the workshop has been calculated.
6.2   WORK NORM
In order to accomplish repair ano ma.ntenance activities of identified quantities of farm machine in accordance with a planned program, qualified technicians are needed.
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Farm Mechanisation
Annual productivity of any technician hr/person or annual working days per person should be considered excluding annual leave public holidays and weekends The number of daily working hrs is 8 with over all efficiency of 65% i.e. on the basis or state farm experience.
Therefore  for  determination  of  annual  working  hrs/person  the  following  formula has been used.
AN = (AD- AW-Ah-AL) DW- D K = hrs
s
AN - Annual working hrs of a person /year
AD - Number of days is a year (365)
AW - Number of weekend, (52)
Am - Holiday is a year (9)
Al - Annual leave of a person (20)
Dw - Working hrs/aay (65% efficiency 5.2 hrs)
Ds - No working shift days (1)
K - Correcting factor of absents of a person from work in a year due to various reasons such as sickness, accideni or personal cases etc (0 90)
AN - (365-52-9-20) 5 2 x 1 x 0 90 = 1329 12 hr/ person
Tabic 6. 2: Information on Assumed man-hours required for unit repair and
service work of mach+
Capital over
Major
Major
No
Type of machine
hauling repair
repair
repair
hrs/umt
(hrs/umt)
( hrs/umt)
Minor
servic 
(hrs/umt
1
Tractors
340
-
235
36
2
Combine harvestor
500
-
260
26
3
Vehicles Implements (plougn.
320
-
40
10
4
disc harrow planter
-
-
40
2
Total
calculated and assumed required man-hour per annum and workshop personnel need to accomplish the expected workload is determined as snown in table 6 4 for the whole project.
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Table 6. 3: Information giving various aspect of repairs.
VOL 7- ANNEX 9
Farm Mechanisation
No
Activities
Expected no
of reqairs
Annal
Required
Annual
working
Requir
ed
man hour
hrs per
employee
man
pawer
1
Capital overhauling repair
20
3,400
1329 12
3
2
Major repair
44
816
1329 12
2
3
Minor repa.r
414
7.451
1329 12
6
4
Major servic
20
23,500
1329 12
17
Grand Total
25
As it has been shown above, annual required man-hours for the expected repair and mainrenance is assumed to be 35,167 hrs and annual working hours/ person, witn 65% working efficiency per day is 1329 12 hours, and the total no. Of man power need to perform the expected work should be 28 ■ e.
= 35 167 =25
1329.12
The technical service personnel should have the qualification and must have practical experience in repairing and servicing agricultural machinery and at least 28 qualified technicians are required to perform the maintenance job
The manDower should include from the bottom junior level up to seniors The assumed basic average salary is 2500 Birr in Robaer and the total monthly salary of the technician can exceed 25’ 2500 = 62,500 Birr with 10% contingency = Birr 68,750 Annually = 68750x12 = 825 000 Birr
6.3      REQUIRED FARM WORKSHOP EQUIPMENTS
To accomplish the task  the work  should De equipped with all the necessary equipments. To equip the two unit workshops nearly aoout 79 line items which cost approximately 2 000 000 Birr is needed
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7.  CONCLUSIONS AND RECOMMENDATIONS
7.1 CONCLUSIONS
From the study made in the area, the following conclusions nave been drawn
•    Presently in Goro Worerda. where Bale gaduia irrigation commands area is found, land Dreparation is done by oxen driven plough (Maresha), prior to rainy  season.  Since  the  land  at  that  time  is  very  hard,  tne  seedbed preparation is not done properly
•   Sowing of crops is done manually by broadcasting method.
•    Intercultural and all other operations including dusting and spraying are also done manually
•     Presently,  there  are  a  number  of  investors.  Enterprises  like  Bale agricultural  development  and  agncultural  mechanization  enterprises, private commercial farms etc. who are having a number of tractors and farm implements Investors have more than 350 tractors and other farm machineries.
•   The Investors. Enterprise etc rent tractors and farm implements to the farmer for various farm operations. The rate of hiring has been noted around 900-1200 Birr per hector for ploughing and 12-25birr per quintal for harvesting
•   The investors and enterprise are not in a position to meet the full demana of the farmers at a proper time particularly for land preparation and harvesting purpose
•   To meet the requirement of iana preparation sowing intercultural and other operation, the requirement of farm machinery for proposed irrigation has been estimated taking certain assumptions like output of a machine efficiency, effective work time per day. etc The requirement of tractors has been worked out to to De 20 for irrigated agriculture of 5 000 ha to be covered under different crops in two seasons Beside tractors, a number of farm implements have been aiso proposed Tnese included plougns (20; disc harrows (10)). rigger (6j fertilize spreader (6). row planter (6) threshers (12). combine harvester (6). etc
WWDSE in Association with ICT
Final Feasibility Study Report
45Federal Democratic Republic of Ethiopia - Ministry of Water Resources Feasibility Study and Detail Design of Bale Gadula Irrigation Project
VOL 7 ANNEX 9
Farm Mechanisation
•    A cost estimate of 30,480,000 Birr has been made for investments on farm machinery and vehicles
•     The  cost  for  farm  machinery  hiring  has  been  worked  out  to  be  554 Birr/hour
•    Proper arrangement for repair and maintenance of farm machinery should be ensured Accordingly workshop equipped with about 79 line items has been proposed with the estimated cost of 2,000 000 Birr Skilled /trained and experienced manpower were proposed including administrative cost of 825,000  Birr  2,957  500  an  investment  on  workshop  for  maintenance  is recommended
7.2  RECOMMENDATIONS
•    It is expected that commissioning of the irrigation project would take around
8-10 years ana there would be considerable changes The study should be reviewed in accordance to the technologies  available and any  other changes
•    Need ana extent of tractors and related farm machinery has been assessed in  this  study  However,  there  are  a  number  of  Investors  and  Enterprises who are also having a number of tractors and farm implements, which may be  used  by  the  farmers.  However  government  may  help  and  encourage both   sides   Government   can   also   strengtns   the   existing   agricultural mechanization enterprise unit in the area to tne hiring charges modest
•    Farmers, farmers unions and co-operatives have »o be facilitated with credit for hiring of rice husking and polishing machine and tractors for timely and appropriate farm operations.
•     Investors have to be encouraged by the government to develop a good farm  mechanization  system  for  their  own  work  and  rent  to  the  farmers They have to be supported
To provide help in procurement of tractors and farm implements from abroad on easy terms of excise, import license etc
o i o get spare parts of agricultural machinery easily
o To provide facilities for modernizing / starting the workshop It would
WWOSEln Association with ICT
Fmal Feasibility Study Report
46Federal Democratic Republic of Ethiopia - Ministry of Water Resources Feasibility Study and Detail Design of Baie Gadula Irrigation Project
VOL 7- ANNEX 9
Farm Mechanisation
be of a great help if they are provided required loan on easy terms 
and land to establish the workshop
o In tne beginning farmers may be provided some subsidy for hiring of the  farm  machinery,  later  on  farmers  would  be  self-dependent  on economic front when irrigated agricultural attains potential yield
o Agricultural extension service support should be provided to farmers to introduce improved agricultural production technology, including land preparation, adequately  line sowing ano adopt timely  and proper fertilizer and pesticides applications.
•     Research  on  farm machinery may be initiated on different aspects of maintenance of machinery and taking up appropriate farm operations
•     Training  courses  on  maintenance  of  machinery  servicing  and  farm operations   may   be   taken   up   by   the   government   for   training   of technicians, operators and farmers.
•     Proper monitoring and evaluation system has to be developed by tne related  departments  to  examine  constraints  and  to  take  up  remedy measures as per the merit
Quarterly  and yearly  conference of related government offices, investors, technicians, experts  farmers  etc  for keeping transparency  and planning future vision must be organized
WWDSE In Association with ICT
Final Feasibility Study Report
47

Summery

Bale Gadula Irrigation Project - Farm Mechanization Study (Volume 7, Annex 9)

Overview

This feasibility study examines farm mechanization requirements for the Bale Gadula Irrigation Project in Ethiopia, covering 5,000 hectares across two growing seasons. Prepared by WWDSE in association with ICT in May 2010, it analyzes current practices and future needs for agricultural machinery in the region.

Key Sections

1. Current Agricultural Practices

Traditional ox-drawn plough (Maresha) dominates land preparation
Manual broadcasting for sowing
Limited mechanization with high demand during peak seasons
Existing state farms and private investors have about 350 tractors available for hire

2. Proposed Mechanization Requirements

Equipment	Quantity	Estimated Cost (Birr)
Tractors (75-120hp)	20	13,000,000
Plows	20	3,000,000
Disc harrows	10	1,500,000
Combine harvesters	6	4,800,000
Total Investment		34,630,000

3. Operational Costs

Estimated tractor operating cost: 554 Birr/hour including:

Depreciation: 59 Birr/hr
Repairs: 124 Birr/hr
Labor: 4.16 Birr/hr
Fuel: 195 Birr/hr

4. Workshop Requirements

Workshop construction: 1,183 m² at 2,957,500 Birr
Equipment: 79 line items costing 2,000,000 Birr
Personnel: 25 technicians at 825,000 Birr annual salary

Conclusions & Recommendations

Substantial mechanization investment needed (34.6 million Birr)
Existing rental services insufficient for projected demand
Recommend government support for credit, training, and spare parts availability
Study should be reviewed before project implementation (8-10 years later)
Need for research and extension services for proper machinery use