Rising harvesting costs and a growing labour shortage are posing serious challenges to India’s sugar industry. The contrast between two major sugarcane-producing states—Maharashtra and Uttar Pradesh—highlights how policy frameworks and technology adoption can significantly shape outcomes. While Maharashtra has rapidly embraced mechanized harvesting, Uttar Pradesh continues to rely heavily on manual labour.
In Maharashtra’s Latur district, Vikasratna Vilasrao Deshmukh Manjara SSSK Ltd has emerged as a frontrunner in mechanization. During the 2025–26 crushing season, the mill achieved nearly 100 percent mechanized harvesting. Across the state, mechanized harvesting has already crossed 30 percent and continues to expand. In contrast, Uttar Pradesh has made limited progress. Despite being the country’s largest sugarcane producer, the use of harvesters remains negligible.
Uneven Adoption of Mechanization
The disparity is evident in the distribution of sugarcane harvesters across India. Of the approximately 3,218 harvesters in the country, nearly 2,200 are concentrated in Maharashtra. Karnataka has around 660 machines, while Tamil Nadu (145), Telangana (54), and Punjab (37) have modest numbers.
Uttar Pradesh, despite leading in sugarcane production, has only five harvesters, with little clarity on their usage. This imbalance reflects deeper structural differences in how the sugar economy operates across states.
A key factor behind Maharashtra’s success is its centralized harvesting model. In states like Maharashtra and Karnataka, sugar mills are responsible for harvesting and transporting cane. This encourages mills to invest in mechanization to improve efficiency and reduce dependence on labour.
In Uttar Pradesh, however, farmers bear this responsibility. They arrange labour and cover harvesting and transportation costs, making investment in expensive machinery unviable. This perpetuates a labour-dependent system.
Maharashtra’s reliance on migrant labour has also contributed to this shift. Rising costs, labour shortages, and issues of reliability have pushed mills to adopt mechanization as a scalable and dependable alternative.
The Manjra Model
The Vikasratna Vilasrao Deshmukh Manjara SSSK Ltd in Latur offers a compelling example of this transition. In the 2025–26 season, the mill harvested nearly all its sugarcane using machines. At the state level, Maharashtra’s mechanized harvesting rate has exceeded 30 percent, while Uttar Pradesh continues to lag far behind.
Managing Director Pandit Sahebrao Desai said the shift was driven by necessity. “Labour shortages have become a major challenge. As sugarcane acreage increases, the crushing season often extends into May. By March, rising temperatures reduce labour productivity and delay harvesting. In such conditions, harvester machines have emerged as a reliable alternative,” he said.
However, the high cost of machines—over one crore rupees per harvester—remains a major barrier. Despite this, Dilipraoji Deshmukh, Chairman of Manjra Mill and former minister, spearheaded mechanization efforts. In the 2022–23 season, 31 harvesters were deployed with financial guarantees from the Latur District Central Bank.
Currently, the mill owns 25 machines, while 54 more operate under its guarantee. Operators contract harvesting work with the mill, creating new livelihood opportunities for local youth while promoting mechanization.
Efficiency and Farmer Benefits
Mechanization offers clear advantages. It reduces dependence on manual labour, lowers long-term costs, and improves operational efficiency. Productivity can increase by 20 to 30 percent, while faster harvesting helps maintain cane quality and improve sugar recovery.
Machines cut cane at the root, ensuring that sucrose-rich portions reach mills. This not only boosts output but also improves ratoon crop performance. However, mechanization requires skilled operators. Monthly salaries can reach Rs 55,000, and each machine requires additional support staff. To address this, mills and manufacturers are investing in training programs.
According to Prakash Naiknavare, Managing Director of the National Federation of Cooperative Sugar Factories (NFCSF), mechanized harvesting in Maharashtra has reached 40–45 percent and is expected to grow further. Faster harvesting has also improved crushing efficiency, with cane processed within 12 to 15 hours of cutting, enhancing sugar recovery.
Private companies are also playing a key role. Rajkot-based Tirath Agro Technology Private Limited’s “Shaktiman Tejas Ultra Harvester” has gained traction and is being exported. Designed for Indian conditions and smaller farms, it helps reduce costs and improve farm incomes.
Challenges in Uttar Pradesh
In Uttar Pradesh, sugarcane harvesting remains largely labour-driven, with farmers paying Rs 55 to Rs 60 per quintal. The regulated “slip system” for cane supply further limits flexibility and discourages mechanization.
The state’s 4.5 million sugarcane farmers are mostly smallholders, and fragmented landholdings make large machines impractical. Concerns also persist that current harvesters cut cane into smaller pieces, which can reduce sugar recovery if crushing is delayed. As a result, there is a growing demand for smaller, more adaptable machines suited to local conditions.
At the National Consultation on Sustainable Sugarcane Economy organized by Rural Voice, farmers emphasized the need for such technologies. Experts argue that coordinated efforts between government, sugar mills, and the private sector are essential to accelerate mechanization in Uttar Pradesh. This includes financial support, targeted training, and technology tailored to small farms.