He chewed wheat and stuck the leftover on a wall: How a Maharashtra man’s strange discovery led to an award-winning herbal bulletproof jacket, 2000 DRDO order

Makarand Kale spent years experimenting with food grains in an effort to develop a lightweight alternative for bulletproof protection. He says he tested 280 types and varieties of grains before developing a plant-based compound that could be layered with cloth and fibreglass to create a protective plate.

The material, which Kale claims is significantly lighter than conventional bulletproof materials, was tested on several occasions. Early trials included firing a gun at the plate in 2001, while later testing involved weapons used by the police and Army. In 2008, Kale claimed that the material was tested by the Defence Research and Development Organisation (DRDO) and that he received orders for bulletproof helmets and jackets.

Kale has kept the exact ingredients and manufacturing process of the compound confidential, saying he fears his years of research could be replicated. He has revealed, however, that wheat plays an important role in the formulation.


The compound takes the form of a gel, which is applied to cloth along with fibreglass. The material is built by layering cloth and gel and allowing it to harden, producing a plate that resembles a metal sheet but weighs considerably less.

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With a strong interest in finding solutions to everyday problems, Kale has also worked on ideas beyond defence and sports. On one occasion, he wrote to the Australian Prime Minister with suggestions for tackling bushfires in Sydney. His ideas were appreciated by the Australian Prime Minister as well as then Indian Prime Minister Atal Bihari Vajpayee.

Kale has also been involved in social initiatives in his area, earning appreciation from local residents and government officials. He was among the recipients of recognition at the 4th National Grassroots Innovation event in 2007.

How Makarand Kale got the idea for the bulletproof material

The idea for the bulletproof jacket emerged from an unusual observation made while Kale was chewing wheat grains.

While chewing the grains, he noticed a sweet taste. He repeated the process several times and experienced the same result. Kale then removed the chewed wheat, which had taken on a gum-like consistency, and pasted it onto a wall.

After two or three days, he attempted to break the dried material using a hammer. To his surprise, he was unable to crush it, although the plaster on the wall was damaged slightly.

Kale tried hitting the dried paste several more times but still could not break it. He observed that the hardness of the material appeared to have increased considerably after drying.

The experiment led him to explore whether plant-based products could be used to develop a bulletproof jacket. He then began research aimed at identifying suitable herbal and plant-related materials for the product.

Lightweight material with bullet resistance

The resulting bulletproof jacket is described as being lightweight while offering resistance to bullets. The material is also said to remain stable across temperature fluctuations and can be moulded into different shapes and sizes.

The development was also aimed at keeping the cost of the bulletproof jacket below Rs 10,000.

The material has been described as having potential applications in areas involving shock protection, helmets and fireproof equipment. According to the available account, herbal products of this type were not otherwise available in the market for making bulletproof jackets.

Tests conducted on the herbal jacket

GIAN-West, through the L.D. College of Engineering in Ahmedabad, conducted tests to assess the hardness, compression and impact resistance of the jacket. The results were reported to be satisfactory.

Further testing was carried out at the Central Institute of Plastic Engineering and Technology in Ahmedabad, where tensile strength at break and compressive strength were evaluated.

Based on these results, additional testing was being planned at the Defence Research and Development Organisation (DRDO), with discussions underway at the time regarding the proposed tests.

Kale’s work represents an effort to explore plant-based materials for a field traditionally associated with heavier conventional protective materials, while the development and testing process was continuing.