This application claims priority from Italian Patent Application No. 102019000003689 filed on Mar. 13, 2019, the disclosure of which is incorporated by reference.
The present invention relates to a system and method for cultivating plant products without soil. Particularly, the present invention regards a method and system for vertically cultivating plant products without soil (Vertical Farms) with hydroponic and/or aeroponic feeding.
As is well known, methods for cultivating plant products implemented by the current vertical cultivation systems, the so-called soil-free or above-ground systems, provide for using horizontal support trays or shelves suspended and stacked upon several vertical levels, and controllably feeding fertilizing substances to the same by means of hydroponic and/or aeroponic feeding systems.
Referring to
However, using the support/gripping layer has the following technical problems.
Firstly, the support/gripping layer is degraded by the roots and cultivation operations and therefore has to be replaced by a new support/gripping layer upon the completion of each production cycle. The operation of replacing the support/gripping layer on support shelves entails costs that significantly affect production costs.
Secondly, root anchorage on the support/gripping layer during the growth steps following seeding makes the so-called “replanting” operations particularly complex and therefore costly, as they provide for the transfer of plant products from one shelf to other growth shelves so as to control their density based on the size increase of said plant products.
Moreover, using the support/gripping layer, particularly the non-woven layer in the cultivation methods described above, has the technical problem of causing the proliferation of undesired fungi and bacteria, referred to as FB in the picture of
U.S. Pat. No. 4,028,847 describes a traditional hydroponic system provided with trays comprising support bars and a series of plant containers removably coupled with support bars. Each plant container internally contains a support block which in turn is designed to support the plant. The support block is arranged so as to rest on the inner surface of the container and, in use, the plant roots pass through and grip onto the same.
A technical problem of the system described in U.S. Pat. No. 4,028,847 is that the support blocks used in the trays, besides promoting the proliferation of fungi, algae, molds and bacteria affect the total production costs of plant products since they have to be replaced and disposed of at each production cycle.
Another technical problem of the system described in U.S. Pat. No. 4,028,847 is that the use of plant containers which can be coupled to support bars affects the total production costs.
WO 208/117829 A1 describes a hydroponic system provided with floating stackable trays made of polystyrene. Each tray has grooves extending straight and parallel to one another. Each groove is filled up with a substrate and has a plurality of seeds and plant products planted in the substrate.
A technical problem of WO 208/117829 A1 is that the substrate present in the grooves, besides promoting the proliferation of fungi, algae, molds and bacteria, affects the total production costs of plant products since it requires loading operations in the grooves at each production cycle.
Furthermore, the arrangement of the grooves in the tray at fixed distances between each other does not satisfactorily resolve the problem of the complexity of “replanting” operations (transplanting) of plant products from a shelf described above in detail.
To this end, the Applicant carried out an exhaustive study with the aim of identifying a solution, which allows to resolve the above-mentioned technical problems.
Hence, the object of the present invention is to provide a vertical cultivation system and method which is capable of: reducing the proliferation of undesired fungi and bacteria on the support shelf, simplifying the product density control operations during the various growth steps following seeding, eliminating costs associated with the use of a cultivation layer.
This object is achieved by the present invention by the fact that it relates to a vertical system and method for cultivating plant products as defined in the corresponding attached claims. The present invention will now be described with reference to the accompanying drawings, illustrating a non-limiting implementation example:
Figures from 11 to 14 schematically show the same amount of operating steps of the cultivation method according to the present invention.
The present invention will now be described in detail with reference to the attached Figures to allow a person skilled in the art to produce and use the same. Various modifications to the described embodiments will become immediately apparent to those skilled in the art and the described general principles can be applied to other embodiments and applications without departing from the protective scope of the present invention, as defined in the attached claims. Therefore, the present invention should not be considered limited to the described and illustrated embodiments, but it is intended to have the widest protective scope in accordance with the principles and characteristics described and claimed herein.
According to an exemplifying embodiment schematically shown in
The cultivation module 2 can comprise, for example, a cultivation container 4, which internally bounds/contains the above-mentioned artificial cultivation environment. It is understood that “artificial cultivation environment” means a production soil-free/over-ground (grow area) area/space, in which the cultivation method is performed.
It is understood that in the following description the term “soil-free” cultivation system means a system that involves the cultivation of plant products without using support layers/substrates that are designed to support/grip the roots and are based on soil/loam and/or fabric and/or inorganic granular compounds, or the like.
It is also understood that the term plant product, according to the present invention, preferably means any plant products for food use, such as, for example, salads, vegetables, green vegetables, aromatic herbs (for example, basil, mint), or the like. It should be understood, however, that the above invention is not limited to plant products for food use of the above-mentioned type by way of example, but can also be applied to the cultivation of other types of plant products generally cultivated in traditional “in-soil” greenhouses, such as flowers, plants or the like.
The cultivation container 4 is closed and can have, for example, a suitably parallelepipedal shape, which internally bounds the artificial cultivation space/environment.
With reference to
The cultivation module 2 also comprises: a sensor system 8 (partially and schematically shown), which is arranged inside the cultivation container 4 and is configured so as to determine/detect predefined cultivation parameters associated with the implemented cultivation process. According to a possible embodiment, the cultivation parameters measured by the sensor system 8, for example via sensors thereof, can comprise, for example, one or more of the following parameters: parameters indicating humidity, parameters indicating temperature, parameters indicating carbon dioxide.
The cultivation module 2 also comprises a fertigation system 13 (only partially and schematically shown in
In addition, the cultivation module 2 can comprise a lighting system 16 (only partially and schematically shown in
With reference to
The Applicant also found that a particularly advantageous material for constructing the seeding and growth bars 9 can derive from PPE-modified resins. For example, it is advantageous to use PPE resins consisting of amorphous blends of PPO resin (polyphenylene ether) and polystyrene. For example, the Applicant found it advantageous to use PPE-modified resins belonging to the NORLY™ product family.
Each seeding and growth bar 9 extends along a longitudinal axis A and is provided with a plurality of recesses or seats 10 designed to house seeds.
The seats 10 are made on the upper surface of the bar 9 and are spaced apart from each other along the longitudinal axis A. The seats 10 are formed by recesses or concave cavities having on the bottom 11 a through opening 12 structured so as to be passed through by, and remain in direct contact with, the roots of the plant product during growth thereof. Preferably, the seats 10 have approximately a cup shape. Preferably, the seats 10 are approximately arranged at equal distance from each other along axis A. Preferably, the opening 12 has a cross-like shape and is made on the bottom wall 11 of the cup-like seat.
The inner surface of the seats 10 where the seeds SM are arranged is devoid of, i.e. not coated with, support/gripping layers. The seats 10 are devoid of any support layers/substrates on the inside, and the seeds SM are arranged resting upon, i.e. in direct contact with, the polymer-based inner surface of the seats 10. The seats 10 are devoid of, i.e. without, any layers/substrates/soils/loams for the support/gripping of said roots of said plant products.
The openings 12 made on the bottom walls of the seats 10 communicate directly with the inner gap of the seats 10 thereof, whose inner surface is entirely exposed, i.e. it is not covered/coated with any layers/substrates/soils/loams for the support/gripping of plant products.
In use, the seeds SM are arranged inside the seats 10 so as to be resting upon, i.e. in direct contact with, the inner surface of said seats 10, without any interposition of support/gripping layers (
The Applicant found that the use of seats 10 provided with through openings 12 on the bottom wall 11 allows, on the one hand, to house the seeds SM on the bar 9 and, on the other hand, to grip by means of the openings 12, the roots to said bar 9, without the need to utilize any intermediate support/gripping layer between the seed SM and the bar 9.
In addition, the Applicant found that the cross shape of the opening 12, unlike a completely circular opening, for example a hole, has the technical effect of increasing the surface tension of the water deposited on the bottom wall 11 of the seat 10, and therefore retains a high moisture content on the contact surface with the seed/product present in said seat 10.
Preferably, the seeding and growth bar 9 are substantially straight, having a substantially parallelepipedal shape. Preferably, the bars 9 laterally have two vertical containment bands 14, approximately of elongated rectangular shape, extending parallel to each other and axis A, preferably for the total length of the bar 9 and are arranged by opposed bands of the seats 10.
The seats 10 are attached to one another on top by intermediate round portions 18, namely curvilinear, laterally bounded by the two opposite containment bands 14.
The Applicant found that using intermediate curvilinear portions 18 bounded by the two side bands 14 has the technical effect of, on the one hand, facilitating cleaning, particularly the washing of the bar 9 and seats 10 thereof, and on the other hand, self-centering seeds SM in the seats 10 during the seeding step.
With reference to
According to a possible embodiment, the supporting frame 19 can comprise at least two sections 19a in hard material approximately C-shaped arranged parallel to each other and inserted onto the opposite ends 9a and 9b of the bars 9 so as to fixedly retain them.
Preferably, the bars 9 of a cultivation shelf 7 preferably have the same size in length, width and height.
Preferably, the width of the bar 9 (measured transversely to axis A) can be approximately 1.2 cm. Preferably, the length of the bar 9 can range between approximately 18 cm and approximately 20 cm, preferably 19 cm.
Preferably, the bars 9 can be black. Preferably, at least the upper surface of the bars 9 can be black. The Applicant found that using black bars, at least on the upper part, has the technical effect of increasing the plant product image definition and resolution captured by an artificial viewing system (not shown) as to the underlying background defined by the upper surface of the bars 9 in the shelf 7. The black background has a further technical effect of simplifying the identification of the plants contained in a picture thereof acquired by the artificial viewing system.
Preferably, each bar 9 comprises a single body, i.e. a monobloc. Preferably, the bars 9 are monolithic. Preferably, the bars 9 can be made by means of a plastic material injection molding method.
With reference to
To this end, according to an embodiment shown in the attached Figures, the opposite axial ends 9a and 9b of each bar 9 have respectively one upper rectangular flap 21 and one lower rectangular flap 22. The upper flaps 21 and 22 cantileverly protrude from the respective ends 9a, 9b opposite to the bars 9 and are structured and sized such that, in use, they overlap with a lower flap 22 and respectively an upper flap 21 of two axially adjacent bars 9. From the lower surface of the upper flap 22 of the bar 9 pins 23 protrude towards the bottom, which, in use, are inserted in respective holes 24 made on the lower flap 22.
In addition, the upper 21 and lower 22 flaps are provided with respective central holes coaxial with each other when the flaps are arranged on top of each other, receiving fixing screws (not shown). On the upper and lower surfaces of the flaps 21 and respectively 22, a gear teeth 23 is made transversally oriented to axis A, which extends at least partially on the upper and respectively lower edges of the two bands 14.
Preferably, the bars 9 can be axially connected to each other so as to extend up to reaching a length that depends on the size of the supporting frame 19.
With reference to
With reference to
Preferably, the cup-shaped seat 10 can be substantially complementary to the shape of the pill P1 so as to form a containment cradle of said pill P1. Preferably, the cup-shaped seat 10 can have a minor diameter, transversal to axis A, less than approximately 0.7 cm; a major diameter, coaxial to axis A, more than approximately 1.2 cm, and a central depth, transversal to axis A and measured on the axis of the opening 12, less than approximately 0.4 cm.
With reference to
In the seeding step, the method comprises the step of placing the pills P1 in the seats 10 (
After completing the seeding step, the cultivation shelf 7 is arranged in a germination control area present in the cultivation module 2. It is understood that in this step the fertigation system 13 and the lighting system 16 are driven by a central control unit of the cultivation process (not shown) such that the light emitted towards the cultivation shelf 7 and the substances fed at said cultivation shelf 7 are controlled based on a germination program.
When at least one of the plant product sizes present in the cultivation shelf 7, for example width, reaches a pre-set threshold, a procedure for reducing the density of the products present in said cultivation shelf 7 is performed from the first density to a second pre-set density (the so-called replanting step).
The density reduction procedure can comprise the steps of selectively decoupling the pre-set seeding and growth bars 9 from the supporting frame 19 of the cultivation shelf 7 and coupling them to the supporting frame 19 of another cultivation shelf 7 such that the adjacent seeding and growth bars 9 are arranged at a pre-set distance from one another (as shown in the example of
Conveniently, the distance between the bars 9 can be a multiple value of the width of the bars 9. According to a possible embodiment, a procedure is carried out which provides for decoupling the bars 9 from the supporting frame 19 of the cultivation shelf 7 and dividing them into N groups and coupling each group of bars 9 to N cultivation shelves 7.
The N number of groups can vary depending on the density required in each shelf 7 in the operational cultivation step being carried out. For example, in the operational cultivation step following the germination step, N can be 2, i.e. the N bars 9 present in the first shelf 7 are divided into two groups containing N/2 bars 9, and the N/2 bars 9 are coupled with the supporting frame of the respective shelf 7 at the pre-set distance DB based on the density and/or size of the products (
Preferably, the free gaps of the shelf 7 in-between the spaced apart bars 7 can be covered by an equal number of elongated rectangular lids 34 structured for being coupled with the supporting frame 19 of said shelf 7 (
Preferably, the steps of selectively decoupling the pre-set seeding and growth bars 9 from the supporting frame of the cultivation shelf 7 and coupling them to the supporting frame 19 of another cultivation shelf 7, can be carried out by an automated mechanical system 40 (
After arranging shelf 7 with a low-density, said shelf is placed in a pre-set cultivation area associated with modified density thereof.
It is understood that the distances between the bars 9 in the respective shelves 7 can also depend on: the duration of the high density step, the duration of the low density step; the low density to high density ratio expressed by 1/N fraction, the width of the bars 9, the size of the opening 12, the number of seats 10 for each bar 9.
Tests performed by the Applicant showed that the method described above is particularly advantageous for the cultivation of ready-to-use salads (baby leaf salads) with rapid cultivation cycle (2 to 5 weeks). The advantages of the method described above are also the following.
Firstly, the method allows to rearrange in a simple and cost-effective way plant products in relation to their development stage (static management).
The method eliminates the need for employing the cultivation layer. Eliminating the cultivation layer results in an elimination of the related disadvantages , i.e. costs relating to: purchase, installation and assembly on shelves, dismantling and disassembling from shelves, washing, and disposal. In particular, eliminating the support layers and/or cultivation layers, and using bars made of recyclable-type plastic material allows to strongly reduce the amount of waste produced during cultivation.
The elimination of the cultivation layer also results in a significant reduction of the fungi and bacteria or algae proliferation on the shelves.
The elimination of the cultivation layer also results in a lower evaporation of water and therefore in a maximization of the water utilized.
Another technical effect of the bars devoid of cultivation layers/supports is the elimination of the presence of polluting substances which are generally present in said cultivation layers/supports such as, for example, heavy metals and allergens.
The bar washing, sterilization and sanitation procedures at the end of a production cycle are simple and convenient to carry out. The 70-cm longitudinal bar management is quick and simple. It should be highlighted that in the shelf described above, the only access to nutrients by the plant product occurs via the through opening made on the bottom of the seat, which is occupied by the roots emerging from the seed pill. Owing to this, free areas of the shelf which are moistened and lit are significantly reduced if not eliminated and therefore are traditionally subject to proliferation. In fact, in the high density step, plants rapidly cover all the cultivation shelf surface preventing proliferation. In the low-density step, the filling areas between the bars are not reached by nutrient solutions and consequently cannot be colonized by fungi.
Finally, it is clear that the vertical cultivation system and method described and shown above can be modified and changed without for this reason departing from the scope of the present invention as defined by the attached claims.
Number | Date | Country | Kind |
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102019000003689 | Mar 2019 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2020/052273 | 3/13/2020 | WO |