Memoirs by Dr. George Kunju John
George Kunju John, BVSc; MRurSc ( A.N.)
PO Box 17077
Al Khaleej Sugar Co LLC
I am a controversial scientist
who work against normal theories. When I was asked to incorporate urea
in cattle feed produced by Amul, my colleagues warned me about urea
toxicity. When approached IVRI and NDRI, I got the advice that 1% urea
can be used as per ISI standard. But in an automatic feed plant where a
batch of 1 MT is made in 4 minutes mixing urea was an engineering
problem. Any how I accepted the challenge and found out a solution by
mixing calcite powder with urea to keep it in a mixing bin for free
Later, I was asked to make a feed with higher percentage of molasses.
While I was in Australia I saw the molasses block manufactured by ICI
Australia with MgO. The process was expensive which would be
unacceptable for India. Therefore, I developed an alternate process with
bentonite gelling at 120 Deg C. Later, I could patent it in India and
several manufacturing plants also could be developed. The usage of 15%
urea again paused a threat to me. I carried out feeding trials in
100,000 animals in 14 states in India with not a single case of urea
Still there were problems to be solved with the process. The energy cost
was high to heat molasses to 120 Deg, and moisture loss during process
increased the production loss. Over and above the melting of block due
to low cost packing. In order to overcome the above problems I developed
a Calcium soap which solidifes blocks, stops melting and adds bypass
energy. I had also tried microwave energy for the process. The above
hypothesis was accepted by a university in Australia to patent.
However; I was asked to abandon the work and return to NDDB for no
justification except a kitchen talk. This was revealed to me by Dr.
Kurien after 15 years I left NDDB. Today, NDDB accepted the obsolete
technology of CaO Blocks which increases the pH and reduces the intake
by the animals. My own friends propagated the above denouncing my
technology after I relinquished NDDB. Today, I have a better method by
spraying sugar syrup to make better blocks. Such blocks could be rumen
manipulator, bypass nutrient dispenser and non hygroscopic.
Bypass protein was my research work for 12 years. No one in India agreed
to go for bypass protein feed production for the following reasons:
feed cost will be high
analytical method available to test the feed
feeding trial result with bypass protein feed in India
I developed the test methods and trained my chemists. Moreover,
bypassability of various protein meals in India was identified. Carried
out a survey to examine the feeding regimen followed by the farmers in
Haryana. Based on the findings I formulated a bypass protein feed with
30% CP of 60% UDP and 12 MJ/kg ME. It was hypothesized that the above
feed is enough to be fed 60% of balanced cattle feed of ISI standard.
Feeding trial with 60 milking cows was carried out and showed the
result. By that time Amul Chairman late Mr. Babubhai Patel came to Dr.
Kurien for a help to set up another feed mill of 300 MT capacity. Dr.
Kurien called me to join the talk. The fund requirement for the
plant was Rs. 20 million. I just suggested to change the formula and
start bypass protein so no new plant will be required. Mr. Patel asked
me to carryout a trial in 12 villages of Amul. Accordingly the trial was
carried out by Amul Vets without my interference except that I
supervised the feed production. On December 16th 1988, Mr. Patel ordered
a complete change of feed formula with my bypass protein feed.
The results were so agonizing. The total milk collection in Amul dropped
by 100,000 litre a day. Lots of customer complaints came against the
feed. I could not walk in front of Dr. Kurien’s office. In 1989 January
there was an International conference in NDDB. My colleagues in NDDB
asked me why I did this gross mistake. None of my answers were
I went to a village which was supplying full truck load of milk daily. I
was known in that village as I had done lots of veterinary visits there
in the past. I asked the secretary what is wrong with the new feed. He
asked me to visit a farmer’ s house and get convinced my self. The
farmer told me that cows had diarrhea by feeding the new feed. I could
not see any loose dung there. He told me that it had in the morning and
now it is ok. I talked to several of the farmers and returned to the
society by silently praising God. Ultimately they told me that they have
never seen such a best feed in life but the price is high. Therefore,
help to reduce the price and every thing will be alright. Next day
morning with pride I went to Dr. Kurien and narrated to him the story.
He called Mr. Babu bhai Patel and offered him free milk powder to
subsidize the feed price and to increase it after 6 months gradually. On
July 14th the hottest day in Anand and the milk collection used to be
the lowest the record was 1.5 lakh litres more milk. Next day Dr. Kurien
approved my paper to leave for Australia for my PhD research.
Later, the rest of the dairies started to produce bypass protein feed. I
encouraged AICOSCA the cotton people to produce cotton seed meal. I
helped them a better extraction method. Also I wrote a booklet on Cotton
seed meal a good bypass protein ingredient. The BIS also included bypass
protein feed in its list.
My ambition for the development of a complete bypass protein feed had to
be accomplished as my PhD work. I wanted to manipulate the milk fats
with more PUFA through feeding. My observation of higher fat content in
buffalo rumen bug had to be exploited for feed technology development.
Anyway, the luck was not with me. NDDB asked me to abandon the work and
return. When I returned Dr. Kurien expressed his doubt that I may not
return to India after I get the patents in Australia. The desperate
position forced me to abandon NDDB job and return with open hand to my
poor state Kerala.
Today I find all the feed mills
produce bypass protein feeds in India. My ambition to complete a ‘bypass
nutrient feed’ (bypass protein, starch and fat) could not be
accomplished and I relinquished my position in NDDB and came back to
Kerala. In Kerala, I could set up 4 large scale feed plants including
Kerala Feeds for which I was the technical consultant to design and
select plant and machinery. I could develop a novel idea of ‘Broiler
Goat’ a revolutionary concept of rearing goats with zero grazing and no
fodder except 500g broiler goat feed per goat per day. I hope the
above concept which was opposed by the scientific community under cover
is not dead still.
Today I am working with the largest sugar refinery in the Middle East
with 5000 MT sugar production per day. My latest development is feeding
sugar for animal production. I am attaching a
technical paper published
in Watt Poultry on the
concept. The recent research trials carried out in UAE University
indicated the great potential of the concept to produce chicken meat and
egg with low cholesterol. I will be able to send the paper after it is
published in Poultry Science Association, North Carolina, USA.
I hope my friends would send me their valuable comments on the concept
which would help to refine it scientifically.
Dr. P. George Kunju John