Abaca Activities in Philippines

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ABACAImprovement of Fiber Extraction and Identification of

Higher Yielding Varieties

Final Technical Report

CFC/FIGHF/09

Activities in the Philippines


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Ref. No. CFC/FIGHF/09 CFC/UNIDO/FIDA 1

PROJECT SUMMARY

Name of Project: Abaca: Improvement of Fiber Extraction and Identification of Higher Yielding

Varieties (CFC/FIGHF/09)

Objectives: The central objective of the project is to contribute to a more stable relationship between demand and production of abaca fiber, by improving fiber quality, farm productivity and output.

Brief Project Description: The project was designed to develop efficient abaca extraction tools andmachinery and to identify high yielding and disease-resistant varieties selected from existing collections inthe Philippines and field test them for regional adaptability. Activities under the Component A focused on theevaluation of existing extraction tools and machinery for possible design modifications or development ofcompletely new designs, the production of test models and eventually, the fabrication of pilot models andfield testing for efficiency. Component B focused on the identification and selection of high yielding anddisease resistant abaca varieties in Bicol, Visayas and Mindanao. The selected abaca varieties in each regionwere exchanged for performance/regional adaptability trial. Their fiber characteristics were evaluated for present and future uses. Component C was responsible for the dissemination of the project results at thecompletion of the project.

Benefits to be derived from the project: Component A of the project was designed to result on theimprovement/ development of extraction tools/machinery that will ensure higher level of efficiency whilemaintaining or possibly improving fiber quality. Component B was aimed at identifying higher yielding,disease-resistant abaca varieties. The results are expected to increased farm productivity and production,thereby, increasing farmers’ income.

Main achievements of the project: Under the project, a mechanical tuxer and an auto-feddecorticating machine that can extract abaca fiber from the whole abaca leaf sheaths, instead of tuxies, whichis the traditional method, have been developed. Likewise, abaca varieties that are disease-resistant and those performing well in terms of fiber yield in Bicol, Visayas and Mindanao, have been identified. A Farmers’Manual on Abaca has been prepared for publication in English and Philippino and in two local dialects (Bikol

and Cebuano) for distribution to abaca farmers. An international and three regional dissemination seminarswere conducted to present the results of the project.

Beneficiaries: The primary beneficiaries of the project are the abaca industry in general and theabaca farmers, in particular. The introduction and adoption of improved extraction machines andrecommended higher yielding abaca varieties are expected to increase abaca production and generateadditional employment in the countryside, and therefore prevent rural migration. Local abaca processors andmanufacturers and foreign buyers will likewise benefit from the project with the expected increase in fiber production and the stabilization of supply. The country’s gain will be in the form of increased export revenuesas abaca, both in raw and processed forms, are generally for export.

Institutions involved:

Supervisory Body: FAO-Intergovernmental Group on Hard Fibers

Project Executing Agency: United Nations Industrial Development Organization

Implementing Agency: Fiber Industry Development Authority

Starting Date: July 1998

Completion Date: October 2004

Financing: Total Project Budget - US$1,456,134CFC contribution - - US$ 841,240GOP - US$ 614,894


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I. INTRODUCTION

Abaca ( Musa textilis Nee), is indigenous to the Philippines and its fiber is known

worldwide as Manila hemp. The fiber is obtained from the leaf sheaths of the abaca plant which issimilar to banana in appearance. At present, there are only two countries commercially producingabaca fiber, the Philippines and Ecuador. The abaca varieties in Ecuador originally came from thePhilippines, particularly from Mindanao.

Abaca fiber is considered the strongest among natural fibers and is used as raw material forcordage, fibercrafts and pulp for the production of specialty paper products like security papers, tea bags, cigarette papers, meat and sausage casings, non-woven and other thin printing papers.Specialty paper products account for about 80% of global abaca consumption, 14% by cordage products and the rest, by fibercrafts and other usage.

Abaca is grown practically all over the Philippines, except in the northernmost part of thecountry. At present, some 121,400 hectares are planted to abaca in the country involving 76,100farmers. The abaca areas are mostly located in Bicol, Eastern Visayas, Southern and WesternMindanao and Caraga.

The Philippines supplies about 84% of the world abaca fiber requirements while Ecuadorsupplies about 16%. During the last five years, the Philippines produced an annual average of about68,000 metric tons of abaca fiber. Of the total, 76% were processed locally into pulp, cordage andfibercrafts, mostly for export. The remaining 24% were exported in raw form.

Demand for abaca, particularly in pulp form has been increasing due to the growingconcern for environmental protection and forest conservation which provided more opportunities fornatural fibers, like abaca. It is expected that demand for abaca fiber, particularly by local pulp processors will continue to expand as world demand for abaca pulp continued to grow.

In spite of high demand for abaca and high abaca prices, local production has not kept pace

with demand. Owing to low income derived from abaca farming and the tedious process ofextracting the fiber, farmers especially the younger ones shy away from abaca farming and look forother jobs in the urban areas. Also, because most of the abaca plantations are already old, typhoon-damaged and infected with viral diseases, productivity is very low. The national average yield isabout 650 kg/ha/year. In Ecuador, the average yield is reportedly about 1,800 kg/ha/year and hasonly three abaca varieties – Tangongon, Bongolanon and Maguindanao -- which are Maguindanaovarieties are being cultivated. There are about 200 varieties existing in the Philippines.

II. PROJECT BACKGROUND

The Project was considered for funding by the Common Fund for Commodities (CFC) because it initially involved two countries: the Philippines and Ecuador. However, after CFC hasapproved the project for funding, Ecuador, then represented by a private company, decided to

withdraw from the project. The case was presented before the meeting of the IntergovernmentalGroup on Hard Fibers (IGGHF) in October 1996 held in Manila, Philippines. It was decided to proceed with the implementation of the project without Ecuador with the condition that if ever thatcountry would decide to join the project later, it would be accepted to participate in the projectactivities.

The project started in July 1998 in the Philippines without the participation of Ecuador.During the IGGHF meeting in Salvador, Brazil in July 2003, Ecuador through its Ministry ofAgriculture expressed its intention to rejoin the project, which was accepted.

The Intergovernmental Group on Hard Fibers of the Food and Agriculture Organization(IGHF-FAO) is the Supervisory Body while the United Nations Industrial DevelopmentOrganization (UNIDO) is the Project Executing Agency (PEA), with the Fiber Industry

Development Authority (FIDA) as the Implementing Agency.


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The project has three components, namely: Component A – Improvement of Abaca Fiber

Extraction and Processing Tools/Machinery, Component B- Identification and Field Testing of High

Yielding, Disease Resistant Varieties Selected from Existing Collections in the Philippines, andComponent C- Technical Assistance Support and Dissemination of Results.

The first component focuses on the development a tuxying tool/machine and a decorticatingmachine for the extraction of abaca fiber.

The activities under the second component are concerned with the identification andselection of high yielding, disease resistant abaca varieties which can be cultivated/grown in Bicol,Visayas and Mindanao.

The last component primarily deals with the documentation of the progress of the activitiesof the project, the preparation of annual work plan and regular progress reports.

The project hired international expert on agricultural/mechanical engineering and nationalexperts on plant epidemiology, virology, plant breeding, agricultural/mechanical engineering andtechno-economic evaluation to set the direction for the conduct of project activities relative to theirrespective fields of interests.

III. PROJECT OBJECTIVES

The main objective of the project is to contribute to a more stable relationship betweendemand and production of abaca fiber by improving fiber quality, farm productivity and outputthrough the mechanization of extraction process and identification, selection, exchange and fieldtrials of disease-resistant and higher yielding abaca varieties.

The project has three components: Component A -Improvement of abaca fiber extraction

and processing tools/machinery; Component B - Identification and field testing of higher yielding,disease-resistant varieties selected from existing collections in the Philippines; and Component C -Technical assistance support and dissemination of the results through publications and presentationsat both the national and international level, including one final project workshop.

The following are the main activities of the project:

1. Evaluation, testing and improvement of the decortication process of extracting abacafiber;

2. Development of a mechanical process of tuxying abaca leaf sheaths; and

3. Evaluation, selection, regional exchange and field trials of disease-resistant and higher

yielding varieties.


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IV. IMPLEMENTATION AND PROJECT RESULTS

A. Component A - Abaca Fiber Extraction and Processing Tools/Machinery

1. Introduction

Abaca ( Musa textilis Nee) is a superior fiber with its high tensile and folding strength,lustrous color, and high porosity. It is used as raw material for cordage, fibercrafts, and pulp for the production of specialty paper products like security papers, tea bags, meat casings, nonwovenmaterials, and cigarette papers.

In the Philippines, which supplies 84% of the world production of abaca fiber, this crop provides livelihood to 215,130 farm households and thousands of workers employed in tradingcompanies and processing plants. The 121,198 hectares planted to abaca are found mostly in the BicolRegion, Eastern Visayas, Caraga, and Western Mindanao. Production averaged to 65,000 mt a year.

Abaca fiber is extracted from the leaf sheath traditionally by stripping using either manual ormechanical process. When either of the process is used, tuxying is employed. Tuxying is the processof separating the outer leaf sheath, which contains primary fibers, from the inner leaf sheath, wheresecondary fibers are found. The separated outer leaf sheath is called tuxy.

An alternative method of extracting abaca fiber is by decortication. In this process, the wholeleaf sheath is used to extract the fiber, thereby, recovering both the primary and the secondary fibers.As such, production is higher compared to the traditional handstripping and spindle stripping methods.Studies show that the decortication method yields from 3.0 to 3.5% fiber. With the manual extraction process, fiber recovery is at 1.0%. The spindle stripping process yields from 1.5 to 2.0% fiber.

2. Objectives and expected outputs

The general objective of this Component is to increase the efficiency of fiber extraction process while maintaining or possibly improving fiber quality. The specific objectives are:

• review existing fiber extraction machines and tools

• develop an efficient tuxying machine/tool

• improve the existing decorticating machine

The expected outputs are:

Output 1.1 An assessment report on the efficiency of existing fiber extractionequipment including recommendation for possible improvement of existingequipment/methods

Output 1.2 A more efficient tuxying machine/tool designed, produced and tested

Output 1.3 An improved decortication machine designed, produced and tested.

3. Materials and methods

3.1 Assessment of the efficiency of existing fiber extraction equipment and tools

This was undertaken through interviews of abaca farmers, workers, andtraders; conduct of time and motion study, and measurement of relevant parameters. Theresults in the time and motion study appeared exaggerated compared with the interviews.Therefore, the results in the time and motion study were used in obtaining relationship

expressed in percentage. For others, adjustments in figures were made taking account the


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result of interviews. The study was done in three abaca production areas: Sorsogon in Bicol,Leyte in Eastern Visayas and Davao in Mindanao.

3.2 Development of abaca tuxer

3.2.1 .Evaluation of current practices

This was done through: a) review of literatures and existing patents; b)observation of practices in tuxying; c) interview of tuxeros; and, d) measurement of parameters in tuxying abaca leaf sheaths.

3.2.2 Preparation of design

This activity was undertaken with the guidance of international expert,Andrew Metianu, and national expert, Eugene Castro. Based on the results of thestudy on the efficiency of existing fiber extraction tools and evaluation of current practices in tuxying, the design of abaca tuxer was prepared. In the preparation ofdesign, separate criteria was set for the development of tuxying tools and mechanicaltuxer.

Criteria for tuxying tools:

• Efficient in terms of higher recovery of tuxy and bigger production perunit of time compared with the existing tuxying process

• Skill not necessary, that is; a new labor entrant can use the tool with easeand efficiency

• User-friendly, that is; easy to handle

Criteria for mechanical tuxer:

• maximum capacity of 500 kgs of tuxies to serve 13 has of abaca plantation

• easy to operate and maintain

• can be pulled by a carabao

• low cost, affordable to a middle income farmer or a small abaca farmers’association

3.2.3 Fabrication of prototypes

Guided by the above criteria, designs were prepared, prototypes of the toolswere produced in the Fiber Processing and Utilization Laboratory of Fiber IndustryDevelopment Authority (FIDA) while prototypes of the machine were subcontractedto the Metals Industry Research and Development Center (MIRDC). The prototypes

of the machines and tools were evaluated for functionality and then field tested.Three levels of design production and fabrication were done: study, working and afinal model. Based on the results of tests in each level, modifications were done andapplied to the subsequent level. For the tuxying tool, performance test was conductedin Sorsogon, Leyte and Davao.

Evaluation of the study model of the mechanical tuxer was confined in thelaboratory. For the working model, field testing was done in Malinao, Albay. Thefield test for the final model was held in Sitio Lip-ac, Bgy. Catagbacan, Goa,Camarines Sur.

The abaca variety planted in the test area was Bagacayan interspersed withnegligible quantities of T. Pula and T. Puti. The site is infected with bunchy-top

disease. For the test of mechanical tuxer, apparently healthy abaca plant was used.


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Three experienced tuxeros were employed. Since fiber extraction in the

area is done manually, all the tuxeros were trained in operating the mechanical tuxer

and the spindle stripping machine. They were then asked to manually tuxy a total of300 kgs of abaca stalks equivalent to about 21 stalks. The same volume of stalkswas used in tuxying employing the mechanical tuxer. For verification purposes, bothtests were repeated.

3.3 Development of abaca decorticating machine

3.3.1 Evaluation of ramie decorticator

Extraction of ramie fiber using a decortication machine was observed and performance parameters were measured.

3.3.2 Preparation of design

As in mechanical tuxer, the preparation of design for the abaca decorticatingmachine was guided by international expert, Andrew Metianu, and national expert,Eugene Castro.

3.3.3 Fabrication of prototypes

Guided by the design criteria, three models of abaca decorticating machinewere prepared: study, working and final models. Fabrication was subcontracted toMIRDC. The study model after fabrication was subjected to functionality test in thelaboratory. Based on the results of the test, a working model was designed,fabricated, tested in the laboratory, modified as necessary, and tested in the field.The final model incorporated the modifications observed as needed based on thefield evaluation of the working model. It, likewise, underwent similar process, that

is; from the preparation of design to fabrication, laboratory testing, modification, andfield testing. The field testing of the working model was done in the FIDA abacaseedbank in Casiguran, Sorsogon. Sixty abaca stalks of the variety Musa Tex 51were used. For the final model, field testing was conducted in Sitio Lip-ac,Barangay Catagbacan, Goa, Camarines Sur.

The machine was set up and several feeding tests were conducted. Whenthe machine appeared to be ready, test runs were undertaken. The test runs weredone in three sets. In each set, 400 abaca stalks were used. The duration and reasonfor stoppages in each run were recorded. The weight of the fiber produced was takenthe following day after drying.

3.4 Characteristics of decorticated abaca fiber

3.4.1 Gathering of samples

All the fibers used in the characterization analyses were produced duringthe testing of the working model of the decorticating machine in Sorsogon.


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3.4.2 SEM photography

This was done by the Industrial Technology Development Institute (ITDI).

The laboratory of this agency took photomicrographs of the samples using JBOLJSM 7330A Scanning Electron Microscope (SEM) at 20 KV accelerating voltageand at 75 and 500x magnifications.

3.4.3 Morphological analysis

The method of Jensen (1960) “Histological Procedures in BotanicalMicrotechnique” was used in the preparation of samples.

The fiber cell dimensions such as length, diameter, lumen width and cellwall thickness were determined using the stereomicroscope and compoundmicroscope attached with stage and ocular eyepiece micrometer, respectively.

3.4.4 Physical analysis

About 5 cm length of fiber samples were cut from the butt, middle, and tip portions of the strand and were made into ringlets, which were individually weighed.The tensile strength and elongation were taken using the Lloyds tensile strengthtester.

3.4.5 Chemical analysis

The fiber chemical composition such as lignin, solubilities in alcohol- benzene, hot water and 1% NaOH were determined following the TAPPIrecommended methods. Determination of cellulose was done following the methodof Stewart Allen (1974) “Chemical Analysis of Ecological Material”. The ashcontent was analyzed following the manual for the purpose published by the

Association of Agricultural Chemists.

3.4.6 Statistical analysis

For the chemico-physico-chemical analyses, comparison of means was doneusing DMRT at 5% level of significance.

3.4.7 Determination of the amount of helices

A pinch of macerated fiber sample was stained with safranin-O anddistributed well in an area of the slide measuring 22 mm x 40 mm (size of the coverglass). A compound microscope was used to count the helix strands, vertically fromtop to bottom and horizontally from left to right of the slide.

Three replications were used. Each replication consisted of four trials andeach trial was represented by a slide.

3.5 Uses of decorticated abaca fiber

3.5.1 Pulp

The fiber was pulped in a 6-cylinder multi-air heated.autoclave using thefollowing conditions:

Chemical charged : 16%NaOHLiquor to Fiber Ratio : 4:1

Maximum Temperature : 170°C


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Time to Tmax : 1.5 hrsTime at Tmax : 3.0 hrs

Analyses were done on spent liquor, yield, and Kappa number. Initialstrength properties such as tensile, burst and tear were determined.

For comparative evaluation, spindle stripped abaca of grades S2, G and JK,which were taken also from Sitio Lip-ac, Barangay Catagbacan, Goa, Camarines Surwere pulped employing the same conditions.

3.5.2 Textile

The test was conducted by the Philippine Textile Research Institute (PTRI)employing the following methodologies: for moisture content the PTRI StandardMethod of Test No. 37-1992/PNS 433 1992 was used; for residual gum content, themethod of Jute Technological Research Laboratories (JRTL), India was applied.

3.5.3 Wastes utilization

Uses for animal feeds and soil conditioning of the wastes from decorticationwere determined.

3.5.3.1 Fertilizer/Soil conditioner

Decorticated abaca wastes were composted following thecomposting procedure provided by the Bureau of Soils and WaterManagement (BSWM). The composted materials were then analysed fortheir nutrient contents.

3.5.3.2 Animal feeds

Wastes from decortication of abaca fiber were gathered and driedfor proximate analyses.

Dried samples were first cut into one (1) inch long and then groundin a Wiley mill using 1 mm mesh. About 500 grams ground sample weresubmitted to BAI Laboratory Services Division for proximate analysesfollowing AOAC Method (Association of Official Analytical Chemists).The samples were analyzed and the percentage values for fiber, protein, fat,moisture, ash, nitrogen-free-extract (NFE) and gross energy content weretaken.


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4.0 Results and discussions

4.1 Assessment of the efficiency of existing fiber extraction machines and tools

Production of abaca fiber involves the following step:

It starts with the tumbling of the stalk, which leaf sheaths are either tuxied orseparated depending on the extraction process employed. If the process is stripping, tuxiesare used; if decortication, the raw materials are leaf sheaths.

A stalk of abaca contains fiber equivalent to 3-4% of its weight depending onvariety, maturity, and source of the plant. The method of extraction influences fiber recovery.At 3.5% fiber content of abaca stalks, manual stripping yields 1% fiber or 28% of therecoverable fiber; spindle stripping recovers 1.5% or 43% of the total fiber content while thedecortication process produces 3.34% fiber by weight of the stalk or 95% of the totalrecoverable fiber.

An assessment was, likewise, conducted on the cost of labor involved in fiber

production.

Based on the amount of time spent to undertake an activity, tuxying comes out asthe highest cost in fiber production, accounting for 45.79% of the total cost. The second mostexpensive labor is stripping or fiber extraction with 19.87% share of the total fiber productioncost. Similar situation was observed in Sorsogon and Davao, where the highest cost is intuxying followed by stripping. In Leyte, the high cost of tuxying is followed by hauling,which takes 22.47% of the total cost. Stripping comes third as the most expensive labor.

tumblestalk

manual(handstripping)

manual

(handstripping)

tuxy

leafsheaths areseparated

decortication

(29%)

(95%)

(43%)

fiber recovered

Figure 1. Abaca fiber production flow


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4.1.1 Tuxying tools

The tuxying knife is made of a straight pointed blade of about 150-200 mmin length. In tuxying, the knife is thrust to one side of the leaf sheath to make a cut between the upper and the inner portions of the material. The exposed part is then pulled out to detach the tuxy from the leaf sheath while it is still adhering to thestalk. The area pierced by the knife covers 6-9 cm width and a depth of 1-3mm.

Based on the fresh weight of the stalk, tuxeros in Davao recover more tuxy,at 20.1% and produce more with 36.3kgs/hr of tuxying. Those in Leyte recover leasttuxy with 14.1% but more efficient with 29.9 kgs/hr production compared to 17.5kgs/hr output in Sorsogon. The tuxeros in these provinces produce thicker tuxy at

18.4% recovery but are slower in tuxying at 17.5 kgs/hr.

Figure 2. Existing tuxying knife

pointed blade

Table 1. Comparative cost of labor to produce 1 kg of abaca fiber

Sorsogon % Leyte % Davao % Average % Cost

Dist Dist Dist Dist

Time to produce 1 kg

fibers, min 30.17 29.67 23.11 27.65 -

Average wt of stalk, kg 14.26 25.92 29.72 23.33 -

Underbrushing/Tumbling*, P 1.51 17.76 1.86 15.54 1.48 12.02 1.62 14.83

Tuxying*, P 3.67 43.18 5.15 43.02 6.20 50.37 5.00 45.79

Hauling*, P 0.35 4.12 2.69 22.47 1.31 10.64 1.45 13.28

Stripping*, P 2.57 30.24 1.67 13.96 2.27 18.44 2.17 19.87

Drying*, P 0.40 4.70 0.60 5.01 1.05 8.53 0.68 6.23

Cost of 1 kg fiber, P

share of the workers 8.50 11.97 12.31 10.92 -

Stripping process manual spindle spindle - -

Total 100.00 100.00 100.00 100.00

Particulars


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According to tuxeros, tuxying induces back pain that they need to rest after

an hour of work.

Table 2. Efficiency in tuxying, by selected province

Particular Sorsogon Leyte Davao

Recovered tuxy(% of stalk)

Time to tuxy, kg/hr

18.4

17.5

14.1

29.9

20.1

36.3Common complaint: backache after an hour of tuxying

Lessons learned:

• The amount of tuxy recovered by weight of the stalk and the quantity produced per unit of time are dependent on the skill of the tuxeros.

• The use of existing tuxying knife is not user-friendly.

4.1.2 Decorticating machines

There are two types of decorticating machines available in the country. Thedifference between the two is in the size of output. A 40 kg/day decorticatingmachine is in operation in a number of abaca producing provinces. It was produced by a private entrepreneur and patterned after the multifiber decorticating machine,which is an improvement of the raspador, a decorticator for ramie. The multifiberdecorticating machine has a capacity of 80 kgs/8hrs and was developed by the FiberIndustry Development Authority.

The major parts of the multifiber decorticating machine are the extracting cylinder, the breastplate and feeding chute. The machine is mounted on a chassis with pneumatic tires and is powered by a5hp diesel engine. To operate the machine, about half of the leaf sheaths are fed to the extracting chamberwhere beating and partial scraping takes place. Complete scraping of non-fibrous materials takes place as theleaf sheaths are being pulled out. The other half of the leaf sheaths are fed and undergo the same process.

4.2 Development of abaca tuxer

Figure 3. Multifiber decorticating machine


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4.2.1 Tuxying tools

The following tools were developed: knife with roller guide; knife with blade guide;

roller support for stalk

4.2.1.1 Knife with roller guide

It is made of a straight pointed blade, which is similar to the traditionaltuxying knife; a roller, a roller arm and a handle. The roller guide isattached to the curved arm to act as a point allowing the knife to penetratethe leaf sheath from the side at a predetermined depth of 2 mm. Thematerial used for this tool is mild steel with wooden handle. The same process of tuxying as in using the traditional knife is employed.

4.2.1.2 Knife with blade guide

It has a sharp curved blade, a handle and a curved guide. The guideand handle are made of wood and the blade is of steel plate. The blade ismounted at 25 degrees angle for easy pushing of the tool and curved foreffective cut.

handle

Rollerarm

Roller

Straight pointed blade

Figure 4. Knife with roller guide

Figure 5. Knife with blade guide

curved guide

handle

blade


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Cutting starts at the base of the stalk. The guide, which acts overthe length of the tuxying blade, limits the depth of the blade to 3 mm. Thetool is pushed into the leaf sheath to start the tuxying process.

4.2.1.3 Roller support for stalk

It is made of a stand with support legs, roller arm, and threewooden rollers. The rollers are attached to the revolving stand to keep thestalks aligned during turning. The support legs stand and roller arm aremade of steel pipe welded together.

The set consists of two pairs of stand. They are placed about ameter apart such that the base of the abaca stalk is supported by one stand

and the top by another. This enables the tuxero to rotate the stalk freelyduring the tuxying process especially when tuxying larger and heavierstalks.

4.2.1.4 Performance of tuxying tools

The performance of these tools were tested by experienced tuxerosin Sorsogon, Leyte, and Davao. The results show more tuxies are recoveredusing the knife with blade guide. This is the situation in all the three provinces. Based on output per unit of time, the knife with roller guideshows higher production in Sorsogon. It is the traditional knife that produced the highest output in Leyte, and it was the use of roller support inDavao.

roller

roller arm

stand

Figure 6. Roller support for stalk


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Table 3. Comparative performance of tuxying tools

Sorsogon Leyte Davao

Tools % tuxyrecovery

Qty.Kg/hr

Output/time

% tuxyrecovery

QtyKg/hr

Output/time

% tuxyrecovery

QtyKg/hr

Output/Time

Knife withroller guide

Knife with blade guide

Roller supportfor stalks

Traditionaltuxying knife

19.03

21.03

-

18.40

20.08

16.14

19.33

17.50

12.14

15.50

-

14.14

21.07

25.79

29.41

29.90

18.50

19.69

-

18.10

37.46

38.73

42.64

36.30

4.2.1.5 Conclusion

• Because the developed tools have set the size of tuxy, the tuxero produces uniform size of tuxy resulting to higher recovery and bigger production per unit of time

• The developed tools are user-friendly

- the component guides made tuxying easy- the roller support made tuxying or heavy stalks lighter

4.2.2 Mechanical tuxer4.2.2.1 Conceptual design

To guide in the development of a mechanical tuxer, a conceptualdesign was developed.

With the results obtained in the performance test of tuxying tools, a tuxying

machine was developed. But before design specifications were made, a conceptual

design of a mechanical tuxer was prepared.

There are two pairs of rollers. One pair has a larger diameter thanthe other. Each pair of roller is pressed together. The first pair acts asFigure 7. Conceptual design of a mechanical tuxer


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flattener while the second pair is used to pull the tuxies. This is how itoperates: the leaf sheath inserted between the first two rollers passesthrough a knife which separates the outer from the inner part of the leaf

sheath. The second pair of roller pulls out the tuxy.

4.2.2.2 Study model

Based on the concept of a mechanical tuxer, a detailed designspecifications was prepared and fabricated. In this model, only one of therollers was used. Here is how the machine operated: the leaf sheaths werefed to the feed rollers which gripped and flattened the leaf sheaths then pushed towards the blade. The leaf sheaths hit the blade causing theseparation of the inner and outer layers of the leaf sheaths. Tuxies werecollected and separated from waste materials at the discharge end.

The problems encountered in this model were inability to tuxy theedges of the leaf sheaths and the accumulation of materials on the edge of

the blade.

4.2.2.3 Working model

To address the problems identified in the earlier model, two pairsof rollers with drives were added. The first pair of rollers flattened and pushed the leaf sheath to the second pair of rollers. These rollers directedthe leaf sheath to the knife. The third pair of rollers pulled the tuxy. Anadjuster for the blade assembly was also provided so that the knife could bemoved in any direction. This was done to establish an effective set-up for producing the tuxy over the full length of abaca leaf sheaths.

Figure 8. Study model ofmechanical tuxer


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After thorough and continuous testing, it was observed that thedesign improvements did not function effectively as expected.

The tuxying capability of the machine was limited to softer andthinner leaf sheaths. Tougher and thicker leaf sheaths are either stuck-up between the flattener and blade mounting or passed through the knifewithout recovering the full width of the leaf sheaths. Difficulty in removingthe short fibers accumulated at the blade was also experienced. Tuxies andwaste materials mixed up at the discharge end and needed additionalmanpower to recover and arrange the tuxies produced.

4.2.2.4 Final model

Based on the results of the test on the working model, changeswere made on the final model.

The machine now consists of a feeding table, guide roller, knifeassembly, presser, puller, power drive, pedal, and frame assembly. A set ofrollers is mounted in the feeding table to allow the leaf sheath to movefreely towards the knife. This is followed by a guide roller which directs theleaf sheath to the blade assembly. A roller is mounted and pressed on top ofthe knife assembly. It flattens the leaf sheath as it goes through the knife.The knife then cuts and separates the outer from the inner portions of theleaf sheath as it is pulled out by two contra-rotating rollers. The wholeassembly is mounted on a frame with two wheels and handle for easy

transport. In operating the machine, the foot pedal is pressed down to createan opening between the presser and the puller. The leaf sheath is theninserted in the opening between the two rollers. The foot pedal is releasedand the tuxy is manually pulled. A 4Hp gasoline engine is used to power themachine.

Figure 9. Working model of mechanical tuxer


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The final model produces tuxies that are thicker with wider ends comparedto tuxies produced by the traditional method. These tuxies are thinner andtaper towards the end.

Figure 11. Final model of themechanical tuxerand its mobility

Figure 10. Final model of mechanical tuxer

puller knife assembly guide roller feeding table

presser

frame assembly

power drive

pedal


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4.2.2.5 Comparative performance of mechanical and manual tuxying

Since leaf sheathing is included in the work flow in mechanicaltuxying, total manhour spent is higher, that is; 3:37 compared to 1:28employing the manual process. An advantage of the mechanical tuxer isthat it produces more tuxies, with 78.12 kgs and, therefore, higher fiberyield, by 22.75%.

Table 4. Comparative performance of mechanical and manual tuxying,300 kgs of abaca stalks

Particulars Manual Mechanical Difference

Leafsheating, mhTuxying, mhWt. Of tuxy, kgFiberyield, kgCost to tuxy 1 kg of fiber

-1:2859.043.784.86

0:462:51

78.124.64

21.84

199.1732.3222.75

349.38

With fuel and depreciation added to the cost of production, the use ofmechanical tuxer shows to be expensive.

Table 5. Comparative cost to tuxy using manual and mechanical

method, 300 kgs abaca stalks, P

ParticularsManualtuxying

Mechanicaltuxer

%difference

Labor 18.38 45.25 146.19

Fuel - 51.21

Depreciation costTools - -

machine - 4.87

Total 18.38 101.33 451.31

Figure 12. Tuxies produced by (L) traditional method and (R) mechanical tuxer


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Using the spindle stripping machine, S2 and S3 grades of abacafiber were produced. Since the tuxies produced by the manual method aremade almost all of primary fibers, the amount of S2, which is 91.25%, is

slightly higher than the 90.73% produced from the mechanical tuxer. But because the mechanical process produces more fiber, income is higher withPhp181.64 compared to Php148.80 from the traditional method. However,the high cost involved in mechanical tuxying made the use of the manual process more profitable.

Table 6. Comparative quality of abaca fiber and income advantage, by tuxying method, 300 kgs abaca stalks

Particulars Manual Mechanical

Quality of fiberS2, kg/%

S3, kg/%TotalWorth of fiber produced

S2 @ P41/kgS3 @ P21/kgTotal

Less: cost of tuxyingEarningIncome advantage

Manual/Mechanical, %

3.45/91.25

0.35/8.753.78/100

141.457.35

148.8018.38

130.42

62.40

4.21/90.73

0.43/9.274.64/100

172.619.03

181.64101.3380.13

4.2.2.6 Conclusion

In its present stage, the mechanical tuxer can effectively tuxyabaca leaf sheaths. The tuxy produced covers the full width of thehalved leaf sheaths and runs through its entire length. Thus, the fiber produced is 22.75% more than from the manually tuxied leaf sheaths.

However, manual tuxying proves to be more efficient. A tuxeroneeds to spend only 1/3 of his time to equal the production of a mechanicaltuxer. Because his only tool is a stripping knife, which is decades old, thecost to tuxy abaca is only his time spent. Thus, the cost to tuxy a kilogramof fiber using the labor of a tuxero is only Php4.86 compared to Php21.84using a mechanical tuxer.

To beat the pace of manual tuxying, the mechanical tuxer shouldhave an effective mechanism in pulling the tuxies, that is: manual laborshould be engaged only in feeding the leaf sheaths and gathering the tuxies.The working model has this feature but somehow was set aside in thedevelopment of the final model.

4.2.2.7 Recommendation

• Improve the efficiency of the mechanical tuxer by working on thefollowing areas:

- automatic pulling of materials- quality and size of materials of rollers and puller


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4.3 Development of abaca decorticating machine

4.3.1 Study model

It was made of a single decorticating chamber with 400 mm diameter decorticatingdrum and a concave anvil; feed conveyor consisting of 3 pieces double V-belts pressed on a1000 mm diameter – 3 grooves V-pulley, and two prime movers of 10 hp diesel engine for theextracting drum and 10 hp electric motor for the feed conveyor. This is how the machine wasoperated: the leaf sheaths were laid down in the feed conveyor. One at a time, the leaf sheathwas caught by the decorticating drum. Since the machine had only one decorticating drumonly half of the leaf sheath could be defibered. The leaf sheath had to be refed to the machinewith the undefibered half laid to the side of the decorticating chamber.

The test results show the machine could not extract the materialseffectively. The gripping pressure of the conveyor belts was not sufficient to hold thematerial as it was being defibered at the decorticating chamber. Thus, the material isthrown out of the machine without defibering.

4.3.2 Working model

The working model was designed guided by the objective to complete thedecortication process, that is; the whole fed leaf sheath should be decorticated whenthe machine releases the material. Thus, the working model consisted of twodecorticating chambers, two sets of feed conveyors made of steel chains and

sprockets with presser, and driven by two 8 hp diesel engines. The machine ismounted on chassis with pneumatic tires.

Figure 14. Workingmodel of autofed

decorticating machine

Figure 13. Study model of abaca decorticating machine


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The machine could extract good cleaned fiber with a recovery of 3.34%.However, there was difficulty in transferring the materials from the first to thesecond conveyor. To effect the proper transferring of material, it has to be guided

manually. The steel chains caused the staining of the fiber (blackening of the portiongripped by the chain), particularly in the second conveyor where the material beinggripped was already defibered.

4.3.3 Final model

With the problems encountered in the working model, the machine wasredesigned and the final model was fabricated. The machine is similar to the workingmodel. It has two decorticating chambers to effect the complete decortication of the wholelength of the material. The other components are two sets of conveyors made of flat rubber belts; roller presser to grip and convey the materials effectively while being decorticated;and a prime mover - a 35hp diesel engine. Conveyor belts are also laid out to effectivelytransfer the materials from the first to the second conveyor. The structure was alsoredesigned for rigidity and ease of fabrication and assembly. Like the working model, themachine is mounted on a chassis with pneumatic tire.

4.3.4 Work flow

Back View Side VieFigure 15. Final model of autofed decorticating machine


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The extraction of abaca fiber using the autofed decorticating machineobserved the following work flow:

The figure above each work unit represents the number of laborers needed for each phase. As such, a total of 13 laborers will be employed to operate the autofeddecorticating machine continuously for 8 hours.

4.3.5 Performance of autofed decorticating machine

For the first set of 400 stalks, 9.5 days were spent to decorticate 5.600 kgs

of abaca stalk. On the first day (September 03), stoppages were experienced due toslippage of materials and too much wetting of the belt from abaca sap, whichresulted to very low production of 2.85 kgs. In an effort to correct the slippage ofmaterial, the existing drive pulley was dismantled and sent to machine shop formodification. Grooves were added to control the wetting of and add traction to the belt and thus improve conveyance of materials to the second drum. Thismodification reduces the slippage of materials. On September 07, spur gear brokedown. It was replaced the following day. On Sunday, September 12, auxiliary drivewas installed and this prevented the stoppage of the machine due to the wetting ofthe conveyor belt.

Set 2 took 2 days and an hour to decorticate 4,920 kgs of abaca stalks.Higher speed was tried on the first day, when the highest production of 404.7

Figure 16. Work flow in the extraction of abaca fiber using autofed decorticating machine

Figure 17. Decorticated abaca fiber (L) being dried under the sun and (R) in hanks

3hauling of

stalks

4splitting ofleafsheaths

2feeding ofmaterials

1gathering of

fiber

1delivery of

fiber fordrying

2drying of

fiber


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gm/min was achieved. This caused the winding of fibers in the shaftings and rollersthat they had to be dismantled and cleaned the following day.

The third set completed the 400 stalks of 5,840 kgs in one day and 6 hrs.Moderate increase in production was observed. (Table 6, Figure 17)

Table 7. Performance of autofed decorticating machine

Set 1 400 stalks; 5,600 kgs; ave. wt. = 14 kgs

DateTime(min) Kgs

Average (gm/min)

Sept 3Sept 6Sept 9

Sept 10Sept 11Sept 13

616271

13624242

2.858.506.05

18.4029.0015.90

46.72138.7185.21

135.29119.83198.9

Total 654 80.80 123.5

Set 2 400 stalks; 4,920 kgs; ave. wt. =12.3 kgs

Set 3 400 stalks; 5,840 kgs; ave. wt. =14.6 kgs

DateTime(min) Kgs

Average(gm/min) Date

Time(min) Kgs

Average(gm/min)

Sept 13

Sept 14Sept 15

63

23797

25.5

42.822.05

404.7

6.0180.5

Sept 15

Sept 16Sept 17

41

254137

9.0

57.635.75

219.5

226.77.0

Total 397 90.35 227.58 Total 432 102.35 236.92


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4.3.6 Economic viability of the autofed decorticating machine

Table 6 and Figure 17 demonstrated that the production of 300 kgs/day isattainable. Likewise, the working model showed a fiber recovery of 3.34%. Withthis information, an estimate of the profit and loss statement was prepared. As shownin the following table, an ROI of 6.18% is attainable.

Figure 18. Performance of autofed decorticating machine

0

50100

150

200

250

300

350

400

450

3 4 5 6 7 8 9 10 11 12 13 13 14 15 15 16 17

A v e . p r o d u c t i o n ,

g m s / m i n

0

50100

150

200

250

300

350

400

450

Production

Time

Table 8. Estimated profit and loss statement

Assumptions:

Fiber production, kgs 300

Fiber recovery, % 3.34

Stalks, kgs 8,982

Sales, 300 kgs x Php20/kg 6,000

Less expenses:

Cost of stalk, Php0.30/kg 2,695

Cost of hauling, Php0.1/kg 898

Labor: 13 x Php100 1,300

Fuel, 20 li x Php22/li 440

Repair, Php550,000 x 10%/288 days 191

Depreciation cost, Php550,000/15years/ 127

288 days

Total cost 5,651

Profit 349

ROI 6.18%


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4.3.7 Conclusion:

The autofed decorticating machine can extract quality fiber from abaca.

However, due to the fact that the machine was sent to the field for testingdirect from fabrication and without sufficient laboratory test, the performance testwas besieged with problems due to construction and design.

Stoppages were experienced due to:

• slippage of materials

• slippage of drive and conveyor

• winding of fiber in the shaftings and rollers

• too much wetting of the belt

• misalignments of sprockets

• loosening of belts

Corrections were being made as the performance test was being carried out.

Deficiencies in the construction and design were corrected during Set I;adjustments in inputs were made in Set 2; and in Set 3, a trend of moderate increasesin production was achieved.

However, the field test failed to obtain the optimum capacity of themachine. Theoretically, based on the speed of the conveyor, fiber recovery andfeeding capacity, the autofed decorticating machine can extract a ton of abaca fiber aday. The machine is still a work in progress needing improvements to attainoptimum capacity.

4.3.8 Recommendation

• Continue to work on the refinements of the machine particularly in providing solutions to the following problems:

- too much wetting of the belt- misalignments of sprocket- loosening of belts- slippage of materials- slippage of drive and conveyor- winding of fiber in the shaftings and rollers


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4.4 Quality of decorticated abaca fiber

4.4.1 SEM photography

At 500x magnification, decorticated abaca fiber using the autofeddecorticating machine is comparable to handstripped S2.

4.4.2 Physical properties

4.4.2 Physical Properties

Decorticated abaca fiber is comparable in tensile strength with spindlestripped JK and handstripped G. However, it has the lowest elongation compared toJK, G, and S2 of both cleaning.

Method of extraction/

grade

Decorticated abaca 32.58 bc 3.08 c

Hand stripped - JK 49.05 a 4.06 b

Hand stripped - G 33.94 c 2.39 d

Hand stripped - S2 51.95 a 3.66 b

Spindle stripped - JK 43.37 b 3.90 b

Spindle stripped - G 48.34 ab 5.39 a

Spindle stripped - S2 50.98 a 3.84 b

Note: Means with the same letter are not significantly different at 5%

level.

(kgƒ/g.m.) (%)

Tensile strength Elongation

4.4.3 Morphological properties

Statistically, the fiber length of decorticated abaca fiber is not significantlydifferent from JK, G, and S2. It has wider diameter and lumen and thicker cell wall. Nonetheless, the figures are within the desired limits (fiber length: 4-6 mm;diameter: 17-21 µ).

H-S2 Deco

Figure 19. Comparative SEM photographs of H-S2 and fiber produced from autofed decorticating machine

Table 9. Comparative physical properties of decorticated abaca, HS-JK and SS-JK


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Table 10. Comparative morphological properties of selected grades of abaca fiber,

by method of extraction

Method of extraction/grade

Decorticated abaca 4.45 ab 21.69 a 13.21 a 4.07 b

Hand stripped - JK 4.28 b 20.28 ab 11.40 ab 4.44 ab

Hand stripped - G 4.95 a 19.27 b 12.72 a 3.28 c

Hand stripped - S2 4.99 a 19.93 ab 9.71 bc 5.11 a

Spindle stripped - JK 4.14 b 19.55 ab 10.05 bc 4.75 ab

Spindle stripped - G 5.05 a 18.56 b 10.26 bc 4.15 b

Spindle stripped - S2 4.72 ab 18.81 b 9.46 c 4.67 ab

Note: Means with the same letter are not significantly different at 5% level.

Fiber length

(mm)

Diameter

(µ)

Lumen width

(µ)

Cell wallThickness

(µ)

4.4.4 Helices

Helical xylem, which is coil like in structure, is a water-conducting tissue that providesstrength to the abaca plant. When pulped, it is thread-like in appearance. The presence of toomany helices block the entry of water and air. As such, it is not recommended for pulp productionif the intended use requires high porosity like tea bags and non-wovens unless special process isapplied.

Ta e 11. Average num er o e x stran sMet o o extract on

gra e

Decort cate a aca 173.50 aHan str ppe - S2 91.33Han str ppe - G 84.00Han str ppe - JK 77.67Spindle stripped - S2 41.33 cSp n e str ppe - G 37.83 cSp n e str ppe -JK 31.92 c

Note: Means with the same letter are not significantly different at 5% level

Average number of

per slidehelix strands

Figure 20. Photomicrographs of (L) decorticated abaca fiber showing cells, helices, and parenchyma;and (R) handstripped JK grade showing cells and parenchyma.

helicesfiber cells fiber cells parenchyma parenchyma


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In hand- and spindle stripping method, the leaf sheath is tuxied prior toextraction to separate the primary from the secondary fiber, where the helices areconcentrated. In decortication, the whole leaf sheath is extracted, thereby, higheramount of helices remain in the fiber.

As shown in Table 10, higher number of helices are found in decorticatedabaca fiber.

4.4.5 Chemical properties

Decorticated abaca fiber is lower in ash, solubilities, and lignin content andis high in cellulose. This confirms the SEM photography, which shows thedecorticated abaca fiber comparable in cleanliness with S2.

Table 12. Comparative chemical properties of selected grades of abaca fiber, by method of cleaning

Hand stripped JK 1.83 a 3.05 a 21.33 b 2.05 a 9.86 a 83.37 e 61.95 c 14.94 cd

Spindle stripped JK 1.28 bc 1.71 bc 16.11 c 1.71 ab 9.45 b 86.34 d 62.19 c 15.50 bc

Hand stripped G 1.49 b 1.87 b 22.40 a 1.62 abc 9.34 b 86.54 d 63.79 b 14.78 d

Spindle stripped G 1.16 c 1.26 de 14.38 g 1.54 abc 9.08 c 87.03 c 63.91 b 15.72 b

Hand stripped S2 1.31 bc 1.04 e 17.84 d 1.35 bc 8.86 d 87.89 b 64.12 ab 14.49 d

Spindle stripped S2 0.85 d 0.72 f 15.78 f 1.14 c 8.44 e 88.92 a 64.69 a 15.49 bcDecorticated fiber 1.33 bc 1.47 cd 20.37 c 1.80 ab 8.56 e 87.50 b 63.97 ab 17.64 a

Note: Means with the same letter are not significantly different at 5% level

(%)

Alpha

(%) (%)

1% NaOH

(%)

Ash

(%)

Hemi

(%)

Solubilities in: Cellulose

(%)

Lignin

(%)

Alc-ben Hot water Holo

5.0 Utilization of Abaca Fiber

5.1 Pulp

Decorticated abaca fiber shows lower pulp yield of 63.91% and comparativelyhigher rejects of 0.35%. Because of the presence of higher number of helices and parenchyma, chemical consumption is high at 90.78. Kappa number is highest at 9.68 but stillwithin the range of easy bleaching.


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Ta ble 13. Pu lping analysis of decor ticated and spindle stripped abaca fibers

Deco Abaca

Fiber S2 G JK

% Pulp yield

% Accepts 63.56 70.75 65.44 66.52

% Rejects 0.35 0.27 0.24 0.27

Total 63.91 71.02 65.68 66.79

% Chemical Consumption

Based on chemical charged 90.78 88.02 88.11 88.45

Kappa Number 9.68 7.52 8.60 9.31

Spindle Stripped Abaca F ibers

At zero beating, the freeness value of decorticated abaca pulp is relatively low at 520CSF. Its tear index is lower at 7.88 mN-m2/g, but tensile index is highest at 142.541. Air permeability is high or less porous compared with the spindle stripped S2, G and JK abacagrades.

5.2 Textile

Preliminary results of the test on the use of decorticated abaca fiber for textile show

this fiber to have passed initial quality requirement tests, but needs machine run test forconfirmation.

Table 15. Laboratory test results for textile use*

Property S2 Deco

Moisture content, %Residual gum content, %Tensile strength

10.8028.7040.80

9.8138.4042.15

*Analysis was done by the Philippine Textile Research Institute

Table 14. Properties of decorticated and spindle stripped abaca pulp

Deco S2 G JK

Freeness 520 665 647 620

Basis Weight, gsm

as tested 65.79 66.99 66.90 66.27

oven dried 60.004 61.681 61.307 60.723Thickness, mm 0.1054 0.1254 0.1254 0.1218

Density, g/ml 0.5693 0.4919 0.4889 0.4985

Tear Index, mN-m2/g 7.88 12.37 12.85 11.77

Tensile Index N-m/g 142.541 120.222 112.624 127.965

Air Permeability, GuS 15.86 1.29 1.42 1.81

Particulars


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6.0 Utilization of wastes from decortication of abaca fiber

6.1 Fertilizer/soil conditioner

Organic fertilizer must contain a minimum of 7% nitrogen. Because of the very lownitrogen level of only 0.66%, wastes from decortication of abaca fiber can be used best as soilconditioner. It can help aggregate soil particles, add some nutrients and increase waterholding capacity.

Table 16. Analysis of composted wastes from decortication of abaca*

Content %

NitrogenPhosphorusPotassiumOrganic carbon

0.660.320.21

12.77

* Analysis was done by the Bureau of Soils and Water Management

6.2 Feeds

Wastes from decortication of abaca fiber contain low protein. Feed maintenancerequirements for ruminant animals should contain at least 8% crude protein; lower than thisvalue will depress rumen micro-organisms resulting to loss in weight of the animal. Also, thehigh fiber content of the material will result to lower digestibility of the animal.

Table 17. Complete proximate analysis of wastes from decortication of abaca*

Content %

ProteinFatFiberMoistureAsh Nitrogen

free extractGross energy

2.441.19

36.959.66

11.04

38.723491.17 cal/g

*Analysis was done by the Bureau of Animal Industry


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B. Component B – Identification of Field Testing oh Higher Yielding, Disease-Resistant

Varieties

B.1 Search for Abaca Varieties Resistant to Bunchy-Top and Mosaic Viral Diseases inthe Philippines1

ABSTRACT

Field screening of eight selected abaca varieties for resistance to bunchy-top and mosaic diseaseswas undertaken in three abaca-growing areas in the Philippines specifically in Albay, Leyte and Davao. Thevarieties were selected based on their reactions to bunchy-top and mosaic diseases among forty (40) abacahigh yielding cultivars/strains commonly planted in the regions evaluated during the regional field screeningdone in 1998 until 2001in the same locations. Musa tex 51, Lausigon and Abuab are the varietiesrecommended for Luzon; Laguis, Linawaan and Inosa for the Visayas while Tangongon and Maguindanaowere recommended for Mindanao. Evaluation was done based on the reactions of the varieties to the diseasein the area where they are commonly planted with respect to percent disease incidence, infection rate and thearea under the disease progress curve (AUDPC). The eight selected varieties representing regionalrecommendations were further evaluated for resistance to the disease prevalent in the area throughsimultaneous planting in Albay, Leyte and Davao from 2001 until 2003. General model of disease incidenceas affected by infection rate, incubation time and AUDPC was developed from data obtained from theexperiments. The selection index used in ranking the varieties for their resistance to bunchy-top disease isexpressed through the following equation Yƒ = a + bx1 + b x 2 + bx3 where Yƒ represents disease incidenceof the variety, a is regression constant; b = coefficient values; bx1 is mean incubation time after emergence;bx2 is mean infection rate after 30 months after planting; and bx3 is mean AUDPC after 30 months after planting. Regression coefficient for all the varieties were all significant in the three experimental setups.Based on the selection index, ranking of the varieties for their resistance to bunchy-top and mosaic differed ineach regional location.

Keywords: screening for resistance of abaca varieties, abaca bunchy-top, abaca mosaic

1Paper presented in the International Dissemination Seminar on Abaca: Improvement of Fiber Extraction

and Identification of Higher Yielding Varieties held on October 19, 2004 at NewWorld Renaissance Hotel,

Makati City, Philippines. CFC-UNIDO-FIDA funded-project (FC/INT/97/021).


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1. Rationale

Abaca (Musa textilis Nee) of the family Musaceae is indigenous to the Philippines. It is planted

mainly as a source of fiber either raw, pulp or use for cordage and fibercraft. The Philippines supplies about84% of the world requirement while Ecuador supplies 16% (FIDA, 2003). This major agricultural crop is planted to 121, 839 hectares with a production of 62,796 metric tons on which more than 1.5 millionFilipinos, with an average of 2.5 hectares farm size, depend for a living, both directly and indirectly (FIDA,2002). The recent fiber production has declined from year 2000 which could be attributed to the prevalence ofthe viral diseases which affected major abaca-growing areas. As of February 2003, a total of 22,518 hectaresare affected by the disease with a slight to severe disease incidence.

Bunchy-top was first reported in 1915 in Silang, Cavite (Ocfemia, 1924). It wiped out a total of12,000 hectares in the provinces of Laguna, Batangas and Cavite and spread to nearby towns in the BicolRegion until Sorsogon Province. Bunchy-top was reported existing in Davao area in 1937 at a time whenlarge plantations of abaca were under the control of the Japanese. It had slowly reached the areas of EasternVisayas and affected several barangays. It was undoubtedly the most important disease which affected abacafrom the time it was reported until now. Similar scenario was observed for abaca mosaic and bract mosaicdiseases which also affected several farms in Albay, Sorsogon, Leyte and Samar areas and reached untilAgusar Sur.

Unless a new abaca variety is developed through unconventional means like genetic engineering and become available, it is important and practical alternative to identify which among our present varieties cancontinuously produce a profitable harvest even in the presence of these diseases. Thus, the Fiber IndustryDevelopment Authority (FIDA) with the additional financial support from the Common Fund forCommodities (CFC) through United Nations Industrial Development Organization (UNIDO) implementedthis project to address this problem.

2. Objectives

To identify which among the high-yielding abaca varieties possess some degree of resistance to

abaca bunchy-top and abaca mosaic diseases and to determine the stability of resistance when planted in threedifferent locations

3. Methodology

Selection of Varieties

All varieties deemed suited for commercial planting were identified but only 40 varieties passed the high yield criteria of 800 kg/hectare/year . The performance of the 40 varieties wereevaluated based on the primary data generated in previously conducted agronomic trials (Catiempo& Macarayan, 2000; Lomerio & Oloteo, 2000; Romero et al. 2000).

Field Testing of Varieties

The protocol followed in the screening trials developed by Dr. Avelino D. Raymundo is analternative methodology of screening for reaction of abaca germplasm to bunchy-top and mosaicviruses (1998). It is a quantitative approach to screening in a system where the disease is systemicand where resistance appears elusive and seemingly non-existent, as in abaca bunchy-top topdisease.

3.1 Regional screening trials

Selection of sites

The trials were undertaken in the field where “hot spot ” was well-chosen. A “hot spot ” is aconcentration of high inoculum which should sustain at least 50% disease incidence. Diseased plants were

transferred to the area when needed. When the incidence was above 50%, the population of the diseased


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plants were reduced in order to maintain uniformity of the inoculum throughout the area. The test sites for theregional screening trials are abaca-growing areas in Albay where two sites were chosen, one for bunchy-topand one for mosaic; in Leyte, one site for mosaic only while in Davao, two sites, one for bunchy-top and one

for mosaic.

The experiment was laid-out in randomized complete block design (RCBD) with 4 replications, planted at a distance of 1 m x 1 m. Data were gathered from 20 samples from each replicate. Goodagronomic practices, such as fertilization and ringweeding were followed except spraying of insecticide. Assoon as shoots/suckers were observed, it was made sure that vectors were present in the infected sources ofinoculum and the area was disturbed from time to time to induce movement of vectors.

Disease measurement

The varieties were assessed based on the following parameters observed and measured for a periodof 8–15 months from emergence.

1. Incubation time –the time from estimated transfer of inoculum by vector to appearance of visualdisease symptoms

2. Kinds of symptoms – yellowing, stunting, bunching – top, leaf curling, etc.3. Stage of plant growth when specific symptoms appeared – developmental stages of the abaca plant

will be monitored4. Percentage disease incidence at weekly interval – the number of diseased plant relative to the total

number of plants being tested5. Area under the disease-progress-curve –representing the cumulative amount of disease at the end

of a specified period computed as: A = Σ1/2 (X1 – Xi-1) where Xi = amount of disease at one point

6. Infection rate – estimated by the equation r = (1/t 2 – t 1) (1n(x2 /1- x2)- (1n(x1 /1- x1); it is anindication of the speed of disease development

The varieties were rated based on the analyses. In general, a variety with lower infection rate,

smaller AUDPC, flatter disease progress curve, longer incubation time was considered more resistant.

Virus indexing of selected varieties for the national screening

Indexing of selected entries by enzyme-linked immunosorbent assay (ELISA) in FIDA diagnosticlaboratories in Albay, Leyte and Davao was undertaken before "exchange of planting materials" andtransporting them to respective regions. Entries were indexed for the three viruses specifically bunchy-topvirus (BTV in abaca), abaca mosaic virus (AbaMV) and bract mosaic virus (BrMV in abaca).

3.2 National Screening Trials

Based on the results of the regional screening, the top three to four varieties per region wereidentified and subjected to national screening to determine the stability of the resistant varieties. It was also

assumed that different virus strain might exist in each test location. Three varieties were identified for theBicol Region namely Abuab, Lausigon and Musa tex 51; three for the Visayas namely Linawaan, Laguis andInosa; and four for the Mindanao area namely Tangongon, Maguindanao, Kaunayan and Kutay-kutay.Unfortunately, varieties Kaunayan and Kutay-kutay were not included in the trial due to political crisis in thearea during the time of exchange, thus only eight varieties were multiplied, indexed by enzyme-linkedimmunosorbent assay (ELISA) and included in the regional exchange.

The national screening trials were located in a hotspot area as earlier defined also established insimilar locations; Albay : two sites, one for bunchy-top and one for mosaic; Leyte: one site for mosaic;Davao: two sites, one for bunchy-top and one for mosaic. The experiments were laid out in RCBD with 4replications, planted at 2.5 x 2.5 distance between hills and observed 20 samples per replicate. Initial diseaseobservation was undertaken as in regional screening and continuously done at monthly intervals to ascertainthe tolerance/resistance of the varieties based on their reaction to the virus. In addition, the following

parameters were also considered;


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1. Fiber yield, biomass – measured by weight per unit area2. Loss in yield as a measure of host resistance – estimated based on a control which could be obtained

from agronomic evaluation trial. Compute losses in yield due to diseases. Use the equation, %

Loss = (Yield of healthy plants - yield of diseased plants)/ Yield of healthy plants x 100. Yield ofhealthy plants can be from agronomic trials. Loss is an indication of tolerance. When twovarieties have the same amount of disease but different losses in yield, it means that the one withthe lower loss is more tolerant/resistant.

Analysis of data

Disease incidence on the selected varieties were observed through qualitative description of the kindof symptoms manifested on 20 samples in each replication from the time of planting. The percentage diseaseincidence were statistically analyzed particularly analysis of variance (ANOVA) to compare possibletolerance/resistance of the varieties. The rate of disease development and areas under the disease progresscurve to determine quantitative differences brought about by the different types of resistance was also doneand to ascertain the relationship between disease incidence and plant growth development, regression andcorrelation analyses were undertaken. The regressions were performed on means of infection rate, AUDPC,incubation time over four replications with the disease incidence as the dependent variable. Regressionmodel with predetermined combination of predictors was tested. The resulting equation:

Y disease incidence = a + b x1 + b x 2 + b x 3

where a = intercept or constantb = coefficient value

x1 = mean incubation period x2 = mean infection rate x3 = mean AUDPC

The resulting analysis was assessed by aptness of residual plot, coefficient of determination and F test.Multiple regression analysis was also done to determine the effect of independent variables (incubation time,

infection rate and AUDPC) on the expression of the disease (bunchy-top and mosaic) manifested on the eightvarieties. Yield loss relative to the degree of host tolerance to the virus was also analyzed.

Ranking of entries

Resistance analysis was used to rate the varieties. Lower infection rate, smaller AUDPC, flatterdisease progress curve, longer incubation time were considered as the criteria in evaluating varieties forresistance. When resistance was observed, it was considered as the primary parameter in varietal selection.The varieties were evaluated based on a Selection Index = ƒ(fiber yield, Y disease incidence) where resistance to theviruses and good agronomic characteristics are given relative weights. Since viral diseases constitute thecurrent problem, more weights were put on resistance.

4. Results and Discussion

4.1 Result of evaluation of varieties used for the regional screening

There are about 200 abaca varieties/accessions widely planted in the different parts of thecountry in Luzon, Visayas and Mindanao where the prevailing conditions suit abaca production.These varieties are characterized and maintained in FIDA seedbanks and experiment stations inSorsogon (Luzon varieties), Leyte (Visayas varieties) and Davao City (Mindanao varieties). Samegermplasm are kept in genebank collection of the National Abaca Research Center in Leyte StateUniversity and Abaca Seedbank Collection in the College of Forestry, University of the PhilippinesLos Baños (UPLB). Together with a plant breeder from the Institute of Plant Breeding in UPLB, primary data on the agronomic characteristics of the varieties/accessions generated by FIDAseedbanks were used to select varieties used for the regional screening. Among the collection, 40


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varieties/hybrids/accessions were chosen based on the average yield of 800 kg/harvest/year and thevarieties are listed as follows;

Luzon varieties

1. Musa tex 50 (Lausigon x Maguindanao) 5. Tinawagan pula 8. Luno2. Musa tex 51 (Itom x Lausigon 45) 6. Tinawagan puti 9. Socorro3. Musa tex 52 (Itom x Lausigon 39) 7. Lausigon 10. Lagonoyon4. Abuab

Visayas varieties

1. Inosa 5. Lagurhuan 9. Musa tex 80 (Linawaan x Linino) 13. Sogmin2. Itisog 6. Linawaan 10. Musa tex 81 (Linawaan x Laylay 14..Soglin3. Laguis 7. Laylay 11. Soglagur (Sogmin x Lagurhuan) 15. Sinamoro4. Layahon 8. Minenonga 12. Tangongon-visayan. 16. Putian

Mindanao varieties

1. Bongolanon 5. Tangongon 9. Kutay-kutay 13. Putian-Jolo2. Bontang (Bongolanon x Tangongon) 6. Tange 10. Kaunayan 14. Kutay-kutay-Jolo3. Maguindanao 7. Puti 11. Igit4. Maguino (Maguindanao x Inosa) 8. Pula 12. Parang

4.2 Result of evaluation of varieties in the regional screening trials

Out of the 40 varieties evaluated based on high yield for the regional screening, only 38 varietieswere evaluated of which ten (10) varieties were screened in Albay, 16 varieties in Leyte and 12 varieties in

Davao due to difficulty in propagating the planting materials needed for the trial. All the varieties identifiedwere observed for tolerance/resistance to the diseases and those which really showed relatively high degree ofseverity were completely eliminated. The experimental plants were observed and infection rate, incubationtime and disease incidence were noted and computed. An abaca plant grown in Albay, infected with bunchy-top disease (BTD) caused by BTV showed stunted growth, rosette arrangement of stiff narrow, erect leavesemanating from the upper end of the pseudostem and the leaves are starting to show abnormal color (dark-green or uneven distribution of green leaf color) (Fig. 1).

4.2.1 For the bunchy-top trial4.2.1a Albay

The bunchy-top trial for Luzon varietieswas conducted in Tabiguian, Tabaco, Albay. Out

of eight Luzon varieties planted, only five wereincluded in the analysis and these are: Musa tex 50,Musa tex 51, Lausigon and Abuab. Luno,Lagonoyon and Socorro were not included becauseof low survival rate. Figure 4 shows theconstructed disease progress curve for bunchy-topinfection in abaca varities in Albay. The computed percent infection are as follows; Musa tex 50,31.90%; Lausigon, 25.80%;

Fig. 1. Stunted abaca plant showing rosette arrangementof stiff, narrow erect leaves and abnormal leaf colorduring early stages of growth.


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Musa tex 51, 28.30%; Abuab, 20.4% and thelowest was Musa tex 52, 17.7%. Based on theconstructed disease progress curve, it was Abuab which

showed a flatter progress curve, hence, had the highest degree of resistance.In terms of infection rate, Lausigon had the lowest at 0.178 rate, thus had the highest degree of

resistance while Abuab showed the highest infection rate and therefore considered having the least degree ofresistance. However, the appearance of bunchy-top symptoms slowly developed in Abuab and the degree ofseverity was least from 34 to 60 weeks from planting. Thus, the computed AUDPC of Abuab in terms of areaduring the progress of the disease was the smallest while Musa tex 50 having the largest AUDPC (154.00)had the least degree of resistance (Table 1).

After ranking, the Luzon varieties with regard to their reaction to the bunchy-top disease, Abuab,Lausigon and Musa tex 52 were the top three varieties selected for the national screening. However, Musatex 52 had poor acceptability to abaca farmers, thus Musa tex 51 was used instead (Table 1)Table 1. Selection of top three Luzon abaca varieties grown in Albay based on their reaction to bunchy-topdisease

VARIETIES INFECTIONRATE

AUDPC DISEASEINCIDENCE(%)

OVER-ALLRANKING

Musa tex 50Musa tex 51Musa tex 52LausigonAbuab

0.218 (2)0.249 (4)0.223 (3)0.178 (1)0.318 (5)

154.00 (5)99.04 (3)89.18 (2)

128.21 (4)60.50 (1)

31.90 (5)28.30 (4)17.7 (1)25.80 (3)20.4 (2)

12 (5)11 (4)

6 (1)8 (2)8 (2)

4.2.1b Davao

In Mindanao, early bunchy-top symptoms observedwere vein clearing and slight yellowing of the margin of theyoungest opened leaf. As the disease progressed, succeeding

leaves became narrower and smaller, and yellowing of leafmargins progressed towards the midrib. Also, petioles wereobserved to be shorter resulting to clustering of leavesforming a rosette (Fig 3).

Fig. 3. Bunchy-top symptom in abaca inDavao

For the Mindanao varieties, infection rate of bunchy-top ranged from 0.30 to 0.119 per unit per weekwith Maguino having the lowest rate of infection followed by Maguindanao and Kutay-kutay. The highest

infection rate was registered by Igit with 0.119 (Table 2). The plotted area under the disease progress curve

Fig 2. Disease progress curve for bunchy-topinfection in Albay


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showed that Maguino, Kutay-kutay and Kaunayan showed smaller AUDPC and a flatter disease progresscurve as a result of lower percent infection or disease incidence indicating that these two varieties areshowing degree of resistance in terms of their reaction to the bunchy-top disease (Fig 4).

0

2

4

6

8

10

12

14

16

14 18 22 26 30 34 38 42

Weeks after Planting

D i s e a s e i n c i d e n c e ( % )

Bongolanon

Bontang

Igit

Kaunayan

Kutay-kutay

M aguindanao

M aguino

Parang

Pula

Puti

Tange

Tangongon

Based on overall ranking of the Mindanao varieties, the top three varieties recommended for thenational screening are Maguino, Maguindanao and Kutay-kutay. However, Maguino is considered a hybridof Maguindanao and Inosa and the resistance genes could already be present in the parental lines. Through proper consultation, Maguino was replaced by a variety in the next rank which is Bontang but since it is alsoa hybrid with parental lines of Bongolanon and Tangongon, it was decided that the Maguino be replaced byKaunayan, which ranked fifth among the 12 varieties evaluated (Table 2).

Table 2. Selection of top three Mindanao abaca varieties grown in Davao based on their reactionto bunchy-top disease



OVER-ALLRANKING

Bongolanon

BontangIgitKaunayanKutay-kutayMaguindanao

0.080 (7)

0.070 (4)0.119 (11)0.079 (6)0.069 (3)0.058 (2)

33.13 (9)

19.65 (5)58.27 (11)17.09 (3)16.88 (2)17.46 (4)

7.98 (8)

5.20 (3)14.81 (11)

6.32 (5)6.25 (4)3.88 (2)

24 (8)

12 (4)33 (11)14 (5)9 (3)8 (2)

MaguinoParangPulaPutiTangeTangongon

0.031 (1)0.094 (10)0.077 (5)0.091 (9)0.077 (5)0.082 (8)

10.11 (1)30.91 (8)26.25 (6)43.75 (10)26.25 (6)26.95 (7)

2.56 (1)8.82 (9)7.50 (7)10.0 (10)7.50 (7)

6.69 (6)

3 (1)27 (9)18 (6)29 (10)18 (6)21 (7)

4.2.2 For the Mosaic Trial4.2.2a .Albay

Manifestations of Abaca Mosaic Disease (AMD) caused by abaca mosaic virus (AbaMV) in theBicol Region is characterized by the presence of light yellowish streaks on petioles which come in variousshapes and sizes. The pseudostem show mottling, and are usually thin and slender and the number of suckersare reduced. Alternate greenish and yellowish streaks appears in young and older leaves (Fig 5).

Fig 4. Disease progress curve of bunchy-top infection inDavao


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The mosaic trial for Luzon varieties was also held in Tabiguian, Tabaco, Albay since the location isalso identified as a hotspot for abaca and bract mosaic diseases. Results of screening of five varieties (Musatex 50, Musa tex 51, Musa tex 52, Lausigon and Abuab) for resistance to mosaic as shown by disease progress curve indicated Lausigon having the lowest percentage of infection and flatter curve while Musa tex50 had the highest percentage of infection (Fig 6). With regards to infection rate, AUDPC and diseaseincidence, Abuab, Lausigon and Musa tex 51 ranked 1, 2 and 3 interchangeably (Table 3).

Based on overall ranking of Luzon varieties with regard to their reaction to abaca mosaic and bractmosaic diseases, the top three varieties are Lausigon, Abuab and Musa tex 51.

Table 3. Selection of top three Luzon abaca varieties grown in Albay based on their reaction toabaca mosaic and bract mosaic diseases



OVER-ALLRANKING

Musa tex 50Musa tex 51Musa tex 52LausigonAbuab

0.4149 (5)-0.3317 (3)0.0206 (4)-0.4030 (1)-0.3279 (2)

120.8470 (5)32.5200 (3)41.0940 (4)30.0000 (2)29.1600 (1)

36.3 (5)11.4 (2)15.2 (4)8.9 (1)12.3 (3)

15 (5)8 (3)12 (4)4 (1)6 (2)

Fig. 5. Typical symptoms of the abaca mosaic disease in Albay

Fi 6. Disease ro ress curve of the mosaic infection in Alba


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4.2.2b Leyte

In the Visayas, field screening of sixteen (16) abaca varieties for abaca mosaic resistance was

conducted in Barangay Liberty in Hilongos, Leyte from April to December 1999. But frequent floodingoccurred in the area causing high mortality in some experimental plants which resulted to high variability inobservations among the varieties as reflected in the 44.32% coefficient of variation although replanting wasdone. The results were found unreliable, thus, the conduct of another trial was recommended. Due to timeconstraint, a greenhouse screening was undertaken on varieties which showed possible resistance to thedisease. Among the 16 varieties, the following seven varieties were chosen for the pot experiment; Musa Tex80, Musa Tex 81, Laylay, Laguis, Lagurhuan, Soglagur, and Inosa. However, the planting materials of MusaTex 81 were not sufficient for the designed experiment, thus Minenonga, which ranked fifth was chosen.

The screening was undertaken in March 2000 at EVIRFES, Abuyog, Leyte wherein 30 suckers foreach variety were planted in plastic bags kept in a screenhouse. Mosaic-infected plants were, likewise,maintained in a separate screenhouse from which aphid vector of the AbaMV were allowed to feed fortransmission of the virus. A protocol was followed in performing virus transmission by aphid andmaintenance of the experimental setup from which the number of plants and percent mosaic infection weregathered at four observation dates. To determine the reactions of the varieties to mosaic infection, a measureof their resistance was necessary. This was done through virus-indexing using ELISA of every test plants foreach variety. Leaf samples were collected starting at 30 days post-inoculation (dpi) and repeated samplingwas done at 45, 60, 75 dpi. Selection of the top three varieties was based on the manifestation of the diseasethrough percent mosaic infection and the results of ELISA through the mean absorbance values read at 405nm using microplate reader (BIORAD, USA) of the Plant Virology Laboratory of the Department of PlantPathology in UPLB.

In the field screening conducted in Hilongos, Leyte appearance of the initial symptoms such aswhitish streaks along leaf veins from midrib of the leaf margin was observed on the third week from plantingwhile in the greenhouse screening, the first symptoms appeared 100 days after inoculation. This explains therelative importance of the inoculum pressure that exist under the natural condition wherein the abaca actuallyexist. However, symptom appearance in both experiments which appeared in succeeding days were similar.

Manifestation of the disease is more pronounced and diverse. In Linawaan, leaf curling was observed whilein Lagurhuan, whitish streaks were smaller. In Laylay, white band chlorosis which run across the midrib wasevident. In Laguis, yellow to bright orange streaks which run parallel to the vein appeared on younger leaves. Necrotic lesions appeared on petioles in all varieties (Fig. 7).

Fig 7. Symptoms of abaca mosaic disease on abaca plants grown in Leyte

Results of greenhouse screening and absorbance values obtained by ELISA showed that Inosa,Lagurhuan, Linawaan and Laguis showed degree of resistance to abaca mosaic disease than Laylay,Minenonga and Musa Tex 80 (Table 4). Based on the results of greenhouse experiment, the top three selectedVisayan varieties to be included in the national screening are Inosa, Linawaan and Laguis. Lagurhuan wasnot chosen because it is not commonly planted in the region.


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Table 4. Results of greenhouse screening of seven Visayan varieties for theirresistance to abaca mosaic disease

VARIETIES PERCENT

MOSAICINFECTION1

MEAN

ABSORBANCE2

(5 Sampling Dates)

OVERALL

RANKING

InosaLaguisLagurhuanLaylayLinawaanMinenongaMusa Tex 80

6.25 (1)12.5 (2)25.0 (4)25.0 (4)12.5 (2)12.5 (2)18.75 (3)

0.296 (1)0.336 (4)0.309 (2)0.403 (5)0.319 (3)0.412 (6)0.430 (7)

2 (1)6 (3)6 (3)9 (5)5 (2)8 (4)10 (6)

1Obtained from experimental plants inoculated in November 2000 and observeduntil June 2001. 2Mean of five samplings from January to June 2001.

4.2.2c Davao

In Mindanao, early symptoms of mosaic infection on varieties were small yellowish streaks whichran parallel to the midrib until they became pronounced. In some plants, the streaks became numerous onnewly opened leaves and on petioles giving rise to alternate dark and yellow bands which run across themidrib and showed a mottled appearance.

Fig 8. Mosaic symptoms on Mindanao abaca varieties

In Davao, all the 12 abaca varieties tested were infected with the disease. Among the varieties,Bontang, Tangongon, Maguino and Maguindanao showed some degree of resistance to mosaic infection.Bontang had the lowest percentage infection of mosaic virus at 34 weeks after planting with a mean of 33.8%followed by Tangongon, Maguino and Maguindanao with a mean of 50%, 51.5%, and 68.6%, respectively(Table 5).

Rate of mosaic infection ranged from 0.1958 to 0.3428 per unit per week with Bontang having theslowest rate followed by Maguino and Tangongon. Parang recorded the highest infection rate (Table 5). In

addition, Bontang, Tangongon and Maguino showed flatter disease progress curves than the rest of the abacavarieties. Correspondingly, Bontang, Tangongon and Maguino had smaller values for their computed areaunder the disease progress curve (AUDPC) than the rest of the varieties (Fig 9).


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Ref. No. CFC/FIGHF/09 CFC

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