The silage-making industry in Punjab is gradually evolving into a more organised and essential sector. What was once a practice confined to large dairy farms has now permeated even small-scale operations, driven by the rising demand for consistent and nutritious fodder.
Silage, locally called ‘Pashuan da Aahar’ (food of the cattle), is the process of fermenting and storing green fodder for cattle. With the advent of bale silage, the practice has become more accessible and economically viable for dairy farmers. However, experts caution that silage-making and feeding require careful attention to avoid potential risks.
Punjab has witnessed a significant increase in silage-making units over the past few years. Dr Harinder Singh Khanna, a pioneer in the field, established India’s first commercial fodder processing company, Excellent Enterprises Private Limited, in Ludhiana in 1992. His company has since helped several others set up their silage-making units.
Dr Khanna’s company produced around 25,000 tonne of silage this year, supplying several states across the country. He said that there are currently 220 silage-making plants/companies/units for commercial purposes in Punjab.
This growth has been fueled by the efforts of entrepreneurs who recognised the potential of silage as a business opportunity. Demand from neighbouring states is also high, with 27-30% of the silage transported to Jammu & Kashmir, 22-25% to Rajasthan, 12-15% to Uttarakhand, 15-18% to Himachal Pradesh, and 10% to Gujarat from Punjab.
In 2022-23, the production of commercial bale silage reached 3.5 lakh tonne, with a market value of around Rs 210 crore — a significant leap from just 0.05 lakh tonne in 2015. This year, however, prolonged heat waves in May and June affected silage production, leading to a significant decrease in the amount prepared for commercial purposes compared to the previous year.
In Punjab, pit/bunker silage is prevalent, traditionally made by dairy farmers for their own cattle. In 2022-23, pit/bunker silage production amounted to around 35 lakh tonne. This method involves preparing silage in pits that are 5-6 feet deep, 15-16 feet long, and 8 feet wide.
Samrala-based Lakhbir Singh Gill of GN Food and Fodder said that their firm produced 7,000 quintals of silage this year and the demand is very high. He added that the potential for silage in the state is vast, and his firm supplies silage across India.
Gagandeep Singh, who has been running a dairy farm with 800 Holstein Friesian (HF) cows for the past 15 years, recently opened a commercial silage plant in Sangrur. He has been making silage for his farm in pits and bunkers but since 2019, he has also started producing silage for commercial purposes. This year, his unit produced 3 lakh quintals for sale across India, in addition to making silage for his dairy farm.
Gagandeep has entered into buyback agreements with several farmers to grow maize for his silage unit, providing them with an assured market and reducing their reliance on paddy cultivation. “Silage is highly nutritious and digestible if the quality is maintained,” Gagandeep said, adding, “At our farm, we have all HF cows, and an adult HF cow requires around 30 kg of silage daily, along with 1-2 kg of dry fodder and 12 kg of feed made from wheat, mustard, cottonseed, soya, etc.” In Punjab, maize is considered the best crop for making silage.
When maize is 90-95 days old, or at the milky stage, it is harvested, chopped, and packed into bales wrapped in plastic sheets to eliminate air. These bales are ready for feeding cattle after about 45 days. Companies produce bales ranging from 60-70 kg to five quintals, which can be stored long-term but must be consumed quickly once opened to maintain quality.
Pit/bunker silage is prepared by pressing the chopped fodder in pits, covering it with plastic sheets, and sealing it with wet earth to prevent air exposure. This method is economical, with farmers receiving Rs 5 to 6 per kg of silage. And they are not required to procure green fodder daily as it is difficult to maintain the quality of green fodder.
Farmers growing maize for silage can get between Rs 40,000 to Rs 58,000 per acre, depending on the yield. After accounting for input costs, they can get Rs 25,000 to Rs 40,000 per acre.
However, despite its potential, the industry requires caution. Experts said that 80% silage is prepared from spring maize, which requires significant water during the hot summer months, putting pressure on groundwater resources. Spring maize, sown in February or March, often requires a 15-19 irrigation cycle. In contrast, Kharif maize, sown during the rainy season, requires less water and can yield about 18 tonne per acre.
Also if Kharif maize is promoted for silage making then it will lead to diversification because Kharif maize is the best alternative for water guzzling paddy. Even farmers can take one crop such as peas and early table potato after harvesting maize for silage in early September and sow wheat in November.
Experts of Directorate of Extension Education Guru Angad Dev Veterinary and Animal Science University (GADVASU) in a panel discussion about silage recently highlighted that proper silage-making techniques are crucial to prevent the growth of harmful molds and fungi, which can pose serious health risks to cattle and humans.
Harvesting maize at the correct stage, maintaining appropriate moisture levels, and storing silage in airtight conditions are essential steps. Regular lab testing is necessary to ensure silage quality and prevent contamination, which could have severe consequences for both animals and humans.
GADVASU experts advised farmers to open silage pits after 40 or 45 days from one side, ensuring minimal contact with air. When taking out silage daily, farmers should cover it properly to maintain quality. The exposed layer of silage should be cut up to 6 inches deep, and only fresh silage beneath this layer should be fed to cattle daily from the bunker. Additionally, the disposal of plastic sheets used in silage bales needs careful consideration to avoid environmental issues.
By following these guidelines, the silage industry can continue to grow as a sustainable and beneficial practice in Punjab. However, vigilance is required to ensure that it remains a boon rather than a bane for the state, said experts.