Report On Trellising System

Hydroponic
Agriculture
Trellising System
SEMESTER 6th GROUP #05

BSc Agricultural Engineering
DEPARTMENT OF AGRICULTURAL
ENGINEERING FAE&T
PMAS ARID AGRICULTURE UNIVERSITY
RAWALPINDI
Group Supervisor:
Engr. Fiaz Hussain
Group Members:
1. Ameen-Ul-Zaman
2. Abdul Waqas
3. Abid Ali
4. Awais Ahmed
5. Hamza Arshad
6. Hamza Muneer
7. Umair Younis Cheema
8. Ameer Hamza
9. Mutasaddiq Ali
10. Muhammad Asfand Ijaz
11. Muhammad Yasin Tahir
12. Muhammad Zubair Saeed
13. Mushtaq Ahmed
14. Saad Ali
15. Shujaa Arshad
16. Zeeshan Ali
(13-Arid-3928)
(13-Arid-3909)
(13-Arid-3910)
(13-Arid-3915)
(13-Arid-3919)
(13-Arid-3920)
(13-Arid-3924)
(13-Arid-3914)
(13-Arid-3935)
(13-Arid-3930)
(13-Arid-3938)
(13-Arid-3939)
(13-Arid-3940)
(13-Arid-3941)
(13-Arid-3942)
(13-Arid-996)
Contents
3
Chapter-1........................................................................................................................................
INTRODUCTION............................................................................................................................. 3
1.1
General .............................................................................................................................
1.2
Basic Requirements of Hydroponics Agriculture .............................................................
1.3
Basic Nutrients Required for Plant Growth ...................................................................... 5
1.3.1
Macronutrients .......................................................................................................... 5
1.3.2
Micronutrients............................................................................................................ 5
1.4
Classification of Hydroponic Agriculture ..........................................................................
1.4.1
Deepwater Culture (DWC) ........................................................................................
1.4.2
Nutrient Film Technique (N.F.T) ...............................................................................
1.4.3
Aeroponic System .....................................................................................................
1.4.4
Wicks System.......................................................................................................... 12
1.4.5
Ebb and Flow System (Flood and Drain) ............................................................... 12
1.4.6
DRIP SYSTEM (Recovery or Non-Recovery) ........................................................ 13
1.5
Basics of Hydroponics.................................................................................................... 13
1.5.1
Which crops can be grown in hydroponics?........................................................... 13
1.5.2
Where can you buy seeds? .................................................................................... 13
1.5.3
Taking care of plants............................................................................................... 14
1.6
Advantages of Hydroponics ........................................................................................... 14
1.7
Disadvantages of Hydroponics ...................................................................................... 14
1.8
Differences Between Hydroponic Vegetable Production and Soil ................................ 15
1.9
Growing Substrates/ Media............................................................................................ 15
1.9.1
Types of Growing Media ......................................................................................... 16
1.10 Nursery Techniques for Hydroponics ............................................................................ 20

1.11 Nutrient Solution for Hydroponics .................................................................................. 22
1.12 Irrigation Water Quality .................................................................................................. 25
Chapter-2 ......................................................................................................................................
26
Farmer Market Pvt. Ltd & Hydroponic Agriculture ................................................................. 26

2.1
General ........................................................................................................................... 26
2.2
Farmer Market Pvt. Ltd. (FMP) Rawat........................................................................... 28
2.2.1
The Success Story of Hydroponic Agriculture........................................................ 31
2.3
Hydroponic in Pakistan .................................................................................................. 31
2.4
Scope and Objective of Work ........................................................................................ 34
Chapter-3......................................................................................................................................
35
Systems of Hydroponic Agriculture ......................................................................................... 35

3.1
Greenhouse Structure System....................................................................................... 35
3.1.1
AutoCAD Design and Dimensions of Greenhouses .............................................. 36
3.1.2
Dimensions of Greenhouses in Phase-1................................................................ 38
3.1.3
Cost Estimation of Sheds ....................................................................................... 38
3.2
Seed Germination and Nursery Growing & Transplantation System............................ 40
3.2.1
Seeds and Seedling Management ......................................................................... 41
3.2.2
Transplanting .......................................................................................................... 41
3.3
Irrigation System ............................................................................................................ 41
3.3.1
Emitter with Feeding Tube ...................................................................................... 42
3.3.2
No. of Plants and Discharge Per day in Shed 3 ..................................................... 42
3.3.3
Reverse Osmosis Unit ............................................................................................ 43
3.3.4
Ultra Violet (UV) ...................................................................................................... 43
3.3.5
Nutrient Tank........................................................................................................... 44
3.3.6
Process of Water Supply for Irrigation.................................................................... 45
3.3.7
Flow chart of irrigation system ................................................................................ 45
3.4
Cooling System .............................................................................................................. 46
3.4.1
Cooling Pads ........................................................................................................... 46
3.4.1.1
Working Principle ................................................................................................ 46
3.4.2
Exhaust Fan ............................................................................................................ 47
3.4.2.1
Estimation of Electricity Consumption of Cooling/ Exhaust Fans ...................... 47
3.4.3
Submergence Pump ............................................................................................... 48
3.4.4
Hydrophore Pump ................................................................................................... 48
3.4.5
Anti-Virus Net .......................................................................................................... 48
3.5
Heating System .............................................................................................................. 49
3.6
Ventilation System ......................................................................................................... 50
3.7
Drainage System............................................................................................................ 51
3.7.1
Drainage Pump ....................................................................................................... 51
3.7.2
Drainage Tank......................................................................................................... 51
3.8
Electrical System............................................................................................................ 52
3.8.1
Electricity Cost Estimation ...................................................................................... 52
Chapter-4......................................................................................................................................
55
Trellising Systems of Hydroponic Agriculture ........................................................................ 55

4.1
General............................................................................................................................... 55
4.2
Main Types of Trellising ........................................................................................... 56
4.2.1
Basket weave Trellising .................................................................................... 56
4.2.1.1Basket weave Trellising Setup .................................................................... 57

4.2.2
Stake-&-Wire/Hanging-String Trellising System.................................................. 58
4.2.2.1
Stake-&-Wire / Hanging-String Set-Up ............................................................... 59
4.2.3
Stake-&-Trellis-Netting System .............................................................................. 60
4.2.3.1
Netting Trellis Set-Up .......................................................................................... 61
4.3
Plant Training ................................................................................................................. 62
4.4 Plant Support Systems................................................................................................... 66

4.5 Components of Trellising System .................................................................................. 68
4.5.1
Free Fall Hook & Twine .......................................................................................... 68
4.5.2
J-Hooks ................................................................................................................... 69
4.5.3
Roller Hook ............................................................................................................. 70
4.5.4
Tomato Clips/ Clippers............................................................................................ 71
4.6 Some Quick Tips on Training and Supporting Different Types of Plants ..................... 72
4.7
Pruning Tomatoes .......................................................................................................... 74
4.8 Cost Estimation of Trellising System ............................................................................. 75
Chapter-1
INTRODUCTION
1.1
General
The word hydroponics means water working. The word comes from the Greek words
hydro (water) and ponos (labor) literally water working. These include water
(solution) culture.
Hydroponics, by definition, is a method of growing plants in a soilless medium with
nutrient rich solution. In hydroponics agriculture plants use inert medium such as perlite,
rock wool, clay pellets, peat moss, coco husk, rice husk, gravel with coco peat or
vermiculite the growth of root system instead of soil. Hydroponic Agriculture is like a
Protected Agriculture (PA) use greenhouses as a natural control environment to achieve
optimum plant growth and crop yield.
There are two forms of hydroponics, soilless culture and true hydroponics. Generally,
and according to principles of hydroponics, the hydroponic systems use substrates
(soilless culture). Therefore, hydroponics must include not only the true hydroponics
(water culture) but all systems using substrates (soilless culture).
Fig 1.1: Hydroponic Agriculture
The crop yield depends upon two limiting environmental factors i.e. light and
temperature assuming that nutrition is provided at relatively optimum levels. For this
purpose, the hydroponic agriculture fully based upon control environment of
greenhouse. The greenhouse offers the ability to manage the growing environment in
order to increase control over quality and productivity.
Fig 1.2: Hydroponic Agriculture Greenhouse in FMP Rawat Pakistan
1.2
Basic Requirements of Hydroponics Agriculture
Soils naturally maintain the temperature and aeration needed for root growth. When the
soil is poor, plant growth and yield decline also due to unsuitable aeration and
temperature. Plant cultivation is impossible under hostile drained condition due to these
conditions. Soil adjusts itself to provide suitable conditions for plant growth. It is called
the buffer action of the soils.
Plants also absorb nutrients released through natural mineralization. In a solution or inert
medium, maintenance of acidity or alkalinity (pH) and electrical conductivity

suitable ranges for plant root system is called buffer action. This requirement
(Ec) in
must be
artificially maintained in hydroponics. In any hydroponics system the following basic
requirements must be maintained at optimum levels.

Buffer action of water or the inert medium used.
The nutrient solution or the fertilizer mixture used must contain all micro and
macro elements necessary for plant growth and development.
Buffer action of the nutrient solution must be in the suitable range so that plant
root system or the inert medium is not affected.
The temperature and aeration of the inert medium or the nutrient solution is
suitable for plant root system.
1.3
Basic Nutrients Required for Plant Growth
Below is a list of both macro and micro nutrients for soilless growing which are necessary
in any hydroponic system.

1.3.1 Macronutrients
1. Nitrogen (Nitrate or Ammonium are both typically used)
2. Potassium (Potassium Nitrate or Potassium Sulfate are most commonly used.
Sometimes Potassium Chloride is used)
3. Phosphorous (Phosphates containing Ammonium and Potassium are commonly
used. Also, Phosphoric Acid)
4. Calcium (Calcium Nitrate)
5. Magnesium (Magnesium Sulfate)
6. Sulfur (Sulfur is sufficient with the sulfates present in Potassium Sulfate and
Magnesium Sulfate)
1.3.2 Micronutrients
1. Iron (A multitude of forms are used: Ferrous Sulfate, Ferric Sulfate, Ferric
Chloride, Iron Ammonium Sulfate)
2. Copper (Copper Sulfate)
3. Zinc (Zinc Sulfate)
4. Chlorine (Chlorine does not usually have to be added to the solution, since it is
already present in most water)
5. Boron (Boric Acid, Solubor, Borax)
6. Cobalt (Cobalt Nitrate)
5
1.4
Classification of Hydroponic Agriculture
Hydroponics is a science and have many simplicity and complexity application levels, based
upon its application levels the different types of hydroponics systems are as under:
1) Deep Water Culture

2) N.F.T (Nutrient Film Technique)
3) Aeroponic System
4) Wicks System
5) Ebb and Flow System (Flood and Drain)
6) Drip System (Recovery or Non-Recovery)
Hydroponics systems are further categorized as open (i.e., once the nutrient solution is
delivered to the plant roots, it is not reused) or closed (i.e., surplus solution is recovered,
replenished and recycled).
The following factors should be considered before selecting a hydroponic type.
Space
and
other
resources
available Expected productivity

Availability of suitable growing medium
Expected quality of the produce color, appearance, free from pesticides, etc.
1.4.1 Deepwater Culture (DWC)
It is also known as the reservoir method. In this system, the roots are suspended in a
nutrient solution. An air pump used to oxygenate the nutrient solution. The most important
precaution of system is, prevent light to penetrating this system, as this can cause algae to
grow which will create damage to plant system. The primary benefit is, there are no drip or
spray emitters to clog. This makes DWC an excellent choice for organic hydroponics, as
hydroponics systems that use organic nutrients are more prone to clogs.
Fig 1.3: Deep Water Culture of Hydroponic Agriculture
1.4.2 Nutrient Film Technique (N.F.T)

NFT is a true hydroponics system where the plant roots are directly exposed to nutrient
solution. A thin film (0.5 mm) of nutrient solution flows through channels. The main
features of a NFT system are shown in figure
Fig 1.4: Nutrient Film Technique of Hydroponic Agriculture

7
The channel is made of flexible sheet. The seedlings with little growing medium are
placed at the center of the sheet and both edges are drawn to the base of the seedlings
and clipped together (Figure 1.5) to prevent evaporation and to exclude light. The cross
section of the channel is shown in Figure 1.5. The growing medium absorbs nutrient
solution for young plants and when the plants grow the roots form a mat in the channels.
Fig 1.5: Cross-section of Channel made in Nutrient Film Technique

The maximum length of the channel is 5-10 m and is placed at a slope drop of 1 in 50 to
1 in 75. The nutrient solution is pumped to the higher end of each channel and flows by
gravity to the lower end wetting the root mat.
At lower end of the channels nutrient solution gets collected and flows to the nutrient
solution tank. The solution is monitored for salt concentration before recycling. Some
growers replace the nutrient solution every week with fresh solution. Adjust the flow rate
of the nutrient solution to 2-3 liters per minute depending on the length of the channel.
Provide enough support for tall growing plants in this technique.
Fig 1.6: Nutrient Film Technique in Green House

8
This type of system works very well because the roots of a plant absorb more oxygen
from the air than from the nutrient solution itself. Since only the tips of the roots come in
contact with the nutrient solution, the plant is able to get more oxygen which facilitates a
faster rate of growth.
1.4.3 Aeroponic System
Aeroponics is an advanced form of hydroponics that uses air as a growing medium
instead of a solid substrate. Seedlings are anchored in holes in Styrofoam platform with
the roots dangling below in a growing chamber or channel. The platform comprises a
sealed box to prevent light penetration to encourage root growth and prevent algae
growth. The nutrient solution is sprayed from below the roots in a fine mist. Misting is
done for a few seconds every 2 3 minutes. This is sufficient to keep roots moist and
nutrient solution aerated. The plants obtain nutrients and water from the solution film
that adheres to the roots. The aeroponic culture is usually practiced in protected
structures and is suitable for low leafy vegetables like lettuce, spinach, etc.
Fig 1.7: Aeroponic System
Aeroponics is the most futuristic of all hydroponics techniques. It uses the most
advanced technology, and has been studied and developed by advanced scientists at
NASA to possibly be used during spaceflight and on the mars space station.
It is also the most efficient. Because the nutrient solution is delivered directly to the roots,
there is no waste due to evaporation and no decrease in the potency of the solution as it is
recycled. Efficient Aeroponics systems see as much as a 98% decrease in water used
compared to traditional hydroponics and gardening. Aeroponics is incredibly efficient due to
its precise nature and controlled environment. Some studies have shown increased yields of
hundreds of percentages over traditional farming. Plants grown this way are less
susceptible to disease because they are grown in a closed environment, and when they do
get diseases they are much easier to eradicate because the plants do not share substrate
or nutrient solution. This lack of risk and competition for nutrients allows growers to plant far
more seedlings per square foot, thus increasing their total yield.
The most important, and expensive, feature of an Aeroponics system is the atomizing
sprayer, mister or fogger. The size of the water droplets sprayed onto the roots is very
important to plant development. Droplets that are too large mean that less oxygen is
available to the roots, while too fine of a droplet can cause the plant to grow excessive
root hair without developing a large enough root system for long term growth.
Aeroponics systems can be either horizontal, with a flat plane that looks much like a
Depp Water Culture system from the outside or an A-Frame, a cone shaped structure.
A-Frames have the advantage of taking up less space for greater plant density.
There are three main types of Aeroponics systems:
Low-Pressure
In a low-pressure system, the roots are either suspended directly above the reservoir or
inside a channel connected to the reservoir. A low pressure pump sprays the nutrient
solution directly on the roots via jets, sprayers or foggers. Any unused solution drips back
10
down into the reservoir to be recycled. This system is the least expensive and can be
used by home growers for no more than the cost of a good mister.
High-Pressure
High-pressure systems use a high-pressure pump connected to a separate reservoir of
nutrient solution. The reservoir is closed and protected from contamination, and the
solution is never recycled. High-pressure pumps give a finer spray but are also extreme
ly expensive. The cost means that these systems are usually reserved for high-value
plants, and rarely used in home systems. These systems usually integrate different
sterilization techniques to ensure that the nutrient solution is sterile each time it delivers
a spray to the roots.
Commercial
Commercial systems are high-pressure systems on a larger scale. It incorporates largescale technologies for sterilization, optimum water droplet size calculation, complete
control over the environment and temperature, advanced pH monitoring systems, data
collection and data analysis.
Fig 1.8: Aeroponic A-frame unit, developed by Jensen and Collins in 1985 at
the University of Arizona
11
1.4.4 Wicks System

The Wick system is a passive system, which means there are no moving parts. The
nutrient solution is drawn into the growing medium from the reservoir with a wick. This
system can use a variety of growing medium, Perlite, Vermiculite, Pro Mix and Coconut
Fiber. The drawback of this system is that plants that are large or use large amounts of
water may use up the nutrient solution faster than the wick(s) can supply it.
Fig 1.9: Wick system

1.4.5 Ebb and Flow System (Flood and Drain)
This hydroponic system works by temporarily flooding the grow tray. The nutrient
solution from a reservoir surrounds the roots before draining back. This action is usually
automated with a water pump on a timer.
Fig 1.10: Ebb and Flow system

12
1.4.6 DRIP SYSTEM (Recovery or Non-Recovery)

Drip system is widely used hydroponic method. A timer will control a water pump, which
is used to pump the growth technology nutrient solutions through a network of elevated
water jets. A recovery system will collect excess nutrient solution back into the reservoir.
A non-recovery drip system will not collect excess nutrient.
Fig 1.11: Drip system
1.5
Basics of Hydroponics
To be able to produce vegetables successfully year after year, one needs to be familiar with
the basics of hydroponics in term of the plant, growing medium, water and nutrients.
1.5.1 Which crops can be grown in hydroponics?

Basically all high value crops can be grown. Popular are tomatoes, cucumbers and
peppers in drain to waste systems and lettuce and herbs in gravel flow systems.
1.5.2 Where can you buy seeds?
Seeds are available in small or large packages. Small packets are sold at nurseries, co-ops
and retail stores and are suitable for garden and small-scale hydroponic units. Large
packets, suitable for commercial scale production are available from seed companies.
13
1.5.3 Taking care of plants

Different crops are planted at different spacing. Small-growing plants can be planted
close to each other. Large-growing plants need more space to grow and must be
spaced further apart.
Water flow must be checked every day and adjusted when necessary.
If plants turn yellow, it is normally a symptom of nutrient deficiency, too little light
or a disease.
Inspect the leaves every day for disease symptoms and insects. Act immediately
if a problem occurs.
Tall plants need to be trained and pruned to make optimal use of the expensive
greenhouse space.
1.6
Advantages of Hydroponics
Soil is not required for hydroponics
The desired nutrient environment can be easily provided for plant growth
Water stays in the system thus labor for watering of plants can be avoided
Lower water costs as water is reused in these systems
Less water is lost through evaporation and runoff
Acid-base balance can be easily maintained.

No mulching, tilling, changing of soil and weeding
No scope of pesticide damage
Easier to get rid of pests and diseases
Easy to harvest
1.7
Disadvantages of Hydroponics
Limited production according to variety in comparison to field conditions
Initial setup cost is high, as the necessary equipments are
expensive Technical skill is required to maintain the equipments
Hydroponic gardens are influenced by power cut
14
If a disease appears all plants in the container will be affected. Water borne
diseases can quickly spread right through the hydroponic gardens
If the hydroponic system fails, it can lead to rapid plant death without soil as a
buffer
1.8
Differences Between Hydroponic Vegetable Production and Soil

Production
1.9
Growing Substrates/ Media
The media should be made of locally available materials. The media material must be
flexible, friable, with water and air holding capacity and can be drained easily. In
addition, it must be free of toxic substances, pests, disease causing microorganisms,
nematodes, etc. The medium used must be thoroughly sterilized before use.
What makes a good media?
Provides support
15
Good pore size

Does not clog system
Does not affect nutrient solution
1.9.1 Types of Growing Media

1. Inorganic natural media (gravel culture etc. Grow Stones, Expanded clay
pellets, Pea Gravel, Coarse Sand)
2. Organic natural media (smoked rice husk, saw dust,
coconut fiber, coir dust peat moss, Saw Dust)
3. Inorganic artificial media (Rockwool, perlite,

vermiculite, Oasis Cubes)
4. Organic
artificial
media
(polyurethane,
polyphenol, polyether, polyvinyl)
Rockwool
o Widely used
o High-water holding capacity
o Good aeration
o Need spare-soak to lower pH
o Irritant when dry
o Not recyclable,
o Not reusable
Fig 1.12: Used Rockwool
16
Fig 1.13: Different sizes of Rockwool used in Hydroponic as a growing media

Expanded Clay Pellets
o Hydroton/Grow Rocks
o Can be reused (wash and sterilize)
17
o Inert
o Free-draining
o May get too dry for ebb & flow systems
o Not good for starting seed germination
Fig 1.14: Expanded Clay Pellets used in Hydroponic as a growing media

Coconut Slab
o Many different sizes
o Good water holding capacity
o Different grades based on salt concern
o Cost is about. Rs130/- per growing Slab
Fig 1.15: Coconut Slab of size 36 x 3 x 8 used in Hydroponic as a growing media

18
Grow Stones
o 99% recycled glass
o Similar to lava rock
o Not good for starting seeds
o Not compostable,
o Reusable with sterilization
Oasis Horti-cubes
o Similar to florist foam
o Non-reactive in nutrient solution
o Can crumble
o Not compostable, not reusable
o Good for seed starting
Fig 1.16: Grow Stones
Fig 1.17: Oasis Horti-cubes
Rapid Rooters
o Tree bark/compost based
o Some crumbling
o Good for seed starting
o Usually need additional support
Fig 1.18: Rapid Rooter

19
1.10
Nursery Techniques for Hydroponics
The growing medium must provide satisfactory conditions for seed germination and to
raise pest and disease free seedlings. A material that is friable, moderately fertile, well
drained yet have sufficient water holding capacity and good aeration and free of pests
and disease causing organisms must be selected as medium for seed germination or
rooting the planting materials. The following materials can be used as medium to raise
seedlings or to root planting materials.
- Old coir-dust
- Carbonized rice husk
- Fine sand or fine sand and old coir dust mixture Rockwool, Peat, perlite or vermiculite, etc.
Sterilize the medium before use. For coir-dust, add hydrated lime to bring its pH to
neutral. For a 05 kg coir-dust block, about 100 250 g hydrated lime is needed.
Sow seeds in small 1 1/2 x 1 1/2 x 1 1/2 rockwool cubes are superior. They have
better drainage, oxygenation and structural integrity. They do not break apart during
transplanting.
Fig 1.19: Rockwool cubes used for nursery growing in Hydroponic

Thorough cleaning of the pots followed by washing with 10% Calcium or Sodium hypo
chloride will ensure disease free condition. Place one seed per block filled with growing
medium at the correct depth in the pots or trays. Such necessary conditions for seed
germination as moisture, temperature, humidity must be provided. Germination trays can be
covered with wet papers or cloth to provide adequate temperature for germination until the
seeds sprout. Remove these papers at the time of seedling emergence.
Maintain the moisture level of the medium at correct level for uniform germination
2
0
and application of water in the mornings is preferred.

Nutrient supply is not necessary until the emergence of first two true leaves. Until such
time apply only clean water. However, when they unfold, nutrient supply must begin
gradually as the growing medium contains very little plant nutrients. The fertilizer mixture
meant hydroponics plants could also be used for nursery plants. Diluted nutrient solution
can be applied every day or nutrient solution prepared by dissolving 10 g of Alberts
mixture in 10 liter of water can applied every other day.
At the early stage, place the trays or pots in shallow containers that is filled with nutrient
solution in such a way that the trays or pots lower portion is submerged in the solution.
The nutrient solution will reach the media through the holes at the bottom of the pots or
nursery trays by capillary action. Vegetative parts for propagation planted in individual
containers or trays are also placed in shallow nutrient solution containers as seedling
trays.
The nutrient solution can also be applied directly to nursery pots after seed
germination or sprouting of planting materials. When applying nutrient solution directly
to nursery pots,
place the pots or trays on a flat plane and pour solution so that it does not come
into direct contact with the small plant;
at the early stage apply 5-10 ml solution once a day; and
when plants grow, 10-25 ml a day once or twice till establishment.
Once the seedlings or planting materials reach the correct size for planting, they can be
planted with the medium. When the tomato seedlings are 7- to 8- days old break the
cubes apart and lay each one on the side separating them to about 28 per tray.
Tomatoes are transplanted to 3 rockwool blocks after 14 to 18 days. They are placed
on their sides into the rockwool blocks so that roots will form along the stems. Grow for
2 to 3 weeks longer before transplanting to the final growing system.
2
1
The nursery period varies with the crops.

Tomato
3 - 4 weeks (2-3 true leaves stage)
Cabbage
4 - 5 weeks (3-4 true leaves stage)
Salad cucumber
3 weeks (3-4 true leaves stage)
Lettuce
2 - 3 weeks
Bell Pepper
4 - 5 weeks
Rockwool slabs come in various sizes. Those most suitable for

tomatoes measure 36 x 3 x 8. They are wrapped with polyethylene so require that
place drainage holes in them.
However, before cutting drainage holes you must soak the slabs for about 24 hours to
completely moisten them. This can be done by placing several drip lines into the top of the
slab. Generally, it is best to place the slabs on special drainage-return channels to
recirculate the nutrient solution. Up to 4 to 6 plants may be placed in each slab. After the
slabs have been soaked slit three angled drainage cuts of 2 inches in length at the bottom
edge between plant locations. Then cut X openings in the top plastic at the plant sites.
Place the seedling with its rockwool block directly on top of the slab at the cut holes. Place a
drip line at each plant about 1-inch away from the base of the transplant.
Whether use perlite or rockwool culture there must install a drip irrigation system
consisting of nutrient tanks, pumps, plumbing and irrigation lines. The irrigation cycles
should be automatically timed with an irrigation controller. Irrigate sufficient to get at
least 25% leachate (drainage) during any given cycle. This will keep the nutrient
solution concentration stable in the rockwool or perlite substrate.
1.11
Nutrient Solution for Hydroponics
Plants require 17 essential elements for their growth and development. Without these
nutrients plants cannot complete their life cycles and their roles in plant growth cannot
be replaced by any other elements. These 17 essential elements are divided into macro
elements (required in relatively large quantities) and micro or trace elements (required in
considerably small quantities).
The macro elements are carbon (C), hydrogen (H), Oxygen (O), nitrogen (N),
phosphorous (P), potassium (K), calcium (Ca), magnesium (Mg) and Sulphur (S).
22
The micro elements are iron (Fe), chlorine (Cl), boron (B), manganese (Mn), copper
(Cu), zinc (Zn), molybdenum (Mo) and nickel (Ni).
All essential nutrients are supplied to hydroponics plants in the form of nutrient solution,
which consists of fertilizers salts dissolved in water. The hydroponic grower must have a
good knowledge of the optimum nutrition. Below is a general formulation for various
crops are.
Fig 1.20: Hydroponic Nutrient Recipes
23
The acid or basic property of the nutrient solution is measured by pH. The pH of the
nutrient solution must be maintained between 6.0 and 6.3 for tomatoes The optimum pH
range for hydroponic nutrient solution is between 5.8 and 6.5. Nutrient deficiencies will
become apparent or toxicity symptoms will develop if the pH is higher or lower than the
recommended range for individual crops. Monitor the pH with a pH meter or indicator
paper. To adjust the pH, add an acid such as sulfuric (battery) acid to lower the pH or a
base as potassium hydroxide, sodium hydroxide or baking soda to increase the pH.
Wear gloves and protective goggles when handling these substances. Always add acid
to water, never the opposite.
The concentration of the nutrient solution is measured by its electrical conductivity (EC),
which is its ability to conduct electricity. That property of the solution is a function of the
elements in the solution which conducts the electricity.
Generally, ideal Ec range for hydroponics is between 1.5 and 2.5 dS/m. Higher Ec will
prevent nutrient absorption due to osmotic pressure and lower Ec severely affect plant
health and yield. As the EC falls below an acceptable percentage, change the solution
or add a percentage of all the elements according to the percentage of decline in the
EC. It is best to eventually, perhaps every 3 to 4 weeks, to change the nutrient solution
as the plants take up the elements at different rates and therefore, some may be in
deficiency while the EC still indicates there are adequate total solutes in the solution.
When plants take up nutrients and water from the solution, the total salt concentration,
i.e., the Ec of the solution changes. If the Ec is higher than the recommended range,
fresh water must be added to reduce it. If it is lower, add nutrients to raise it.
24
1.12
Irrigation Water Quality
Use good quality water with its pH and Ec suitable for plant growth. Based on pH, Ec
and soluble salt content, water quality can be divided into 03 classes (Table 1.1). Nonhazardous and medium class water can be used for fertigation. However, when latter is
used for fertigation, thoroughly leach the growing medium at least once a year.
Table 1.1: Irrigation Water Quality Standards used in Hydroponic Agriculture
25
Chapter-2
Farmer Market Pvt. Ltd & Hydroponic Agriculture
2.1
General
On the earth water is the most important value able thing just like saying water is the life
no water no food and life becomes end. And there is no alternate source of water in the
world. When all people at all time have physical and economic access to safe enough
nourishing food to meet their dietary needs for an active healthy life style that known as
food security. We need a ceiling amount of water for the growing purpose in agriculture.
Due to lack and unpolluted water disturb the term of food security. Loss of water caused
small amount the available food and serious crisis in future. People are demanding a
pesticide free and fresh yield with the investment of very less amount. From recently
passed out years agriculture related people moves to grow vegetables and fruits without
soil and used very less amount of water that term is called as hydroponics. Hydroponics
term was first time used by California researcher name W.F Gerike and he also called
father of modern hydroponics.
With the advent of civilization, open field/soil-based agriculture is facing some major
challenges; most importantly decrease in per capita land availability. In 1960 with 3 billion
populations over the World, per capita land was 0.5 ha but presently, with 6 billion people it
is only 0.25 ha and by 2050, it will reach at 0.16 ha. Due to rapid urbanization and
industrialization as well as melting of icebergs (as an obvious impact of global warming),
arable land under cultivation is further going to decrease. Again, soil fertility status has
attained a saturation level, and productivity is not increasing further with increased level
of fertilizer application. Besides, poor soil fertility in some of the cultivable areas, less
chance of natural soil fertility build-up by microbes due to continuous cultivation,
frequent drought conditions and unpredictability of climate and weather patterns, rise in
temperature, river pollution, poor water management and wastage of huge amount of
water, decline in ground water level, etc. are threatening food production under
conventional soil-based agriculture. Under such circumstances, in near future it will
become impossible to feed the entire population using open field system of agricultural
production only. Naturally, soil-less culture is becoming more relevant in the present
scenario, to cope-up with these challenges. In soil-less culture, plants are raised without
2
6
soil. Improved space and water conserving methods of food production under soil-less
culture have shown some promising results all over the World.
In 2003 south pacific soilless culture conference Alexander said hydroponics is growing
rapidly everywhere and within 5 to 10 years will be established as a major part of our
agriculture and horticulture production industries. In hydroponics we provide the
nutrients to the plants along with the water. In the soil cultivation nutrients slowly
dissolved in surrounding soil water solution and after this root absorb the nutrients from
the soil water. Basic needs for the growing of plants are same whether we grow them in
soil are or in hydroponic system. In hydroponics system all the nutrients are rendered in
a water solution that passes over the roots or floods around them at usual interval. In
hydroponic plants grow faster because nutrients are instantaneously available.
Hydroponic system fills the requirements of the plants root just like soil would be
provided support, oxygen and carbon dioxide, water and nutrients. We conserve or safe
a sufficient amount of water in hydroponics. In the hydroponics practice only used 1/10th
to 1/5th of the water in the agriculture. In this cultivation there is no disturbance of
weeds. Weeds are the major problem of soil cultivation and use of herbicides cause
massive amount of money for weeding purpose. In hydroponics farmer control the
environmental conditions and also yield is the expected. Hydroponics solution can be
modified according to the plants requirements. Hydroponics produces all the macro and
micro nutrients which are required for the human body. Hydroponics can reduce the
irrigation water usage by 70% to 90% by recycling the run-off water. In hydroponics
there is less chance of fungal disease because we control the moisture level in the
environment. Hydroponics eliminates the chances of root diseases by appropriating the
sufficient porosity for drainage of the excess water to the root zone.
Near about 120000-hectare area is used under greenhouse hydroponic production in
the world. In Pakistan Tahir Rana is a nuclear physicist who works on hydroponics and
set up a vegetable farm named Fareed farmhouse in Faisalabad. He produces three
varieties of tomatoes (cherry tomato, strawberry tomato, and beef tomato), cucumber
and capsicum. Through this technique, farmers can get between 450 and 550 tons of
vegetables per acre, compared to the average yield of 15 tons per acre using traditional
farming. Hydroponic farming requires an investment of up to Rs1.5 million per acre,
though it can yield net profits of up to Rs3 million per acre annually.
27
2.2
Farmer Market Pvt. Ltd. (FMP) Rawat
Hydroponic is name of Hi-Tech Agriculture and is the Agricultural Science of 21
st
Century. The Farmer Market Pvt. Ltd introduce first Hydroponic Research Farm with the
help of Holland in 2006. After two years i.e. from 2009 to date this Research Farm is
under PMAS-Arid Agriculture University Rawalpindi. It is situated near Rawat on main
G.T Road Rawalpindi.
This is the one of the unique facility which possesses all cutting technologies and
related to different sectors of engineering and sciences i.e. Horticulture Engineering and
Sciences, Irrigation and Hydrology, Water Conservation Engineering, Agricultural
Engineering and Agronomy, Environment and Climate Control, Bio System Engineering
and Other Engineering and Sciences.
Pakistan may enhance vegetable and fruit crops yield with hydroponic farming
technology to overcome the food shortages and price hike tendency. According to the
Ministry of Agriculture sources, this technology would not only raise yield, but would also
enhance nutrition abilities of plants. A hydroponic pilot project has recently been started
in Rawat (Islamabad) under the name bio-blitz over just five acres of land.
This Hydroponic Research Farm under the supervision of PMAS-AAUR and Worthy
Vice Chancellor Prof. Dr. Rai Naiz Ahmad is a next step to produce and utilize the
agricultural valuable products on commercial level also help and benefits new students,
scientists, and community related to agriculture.
The Hydroponic Research Institute under FMP and PMAS-AAUR is certified with ISO
9001:2008 and its food production is certified with Global American Standard HACCP,
ISO 22000:2005. The ISO 9001 is code for Quality Management Systems while ISO
22000 is for Food Safety Management Systems.
2
8
Fig 2.1: A visit of Worthy Vice Chancellor Prof. Dr. Rai Naiz Ahmad in FMP Rawat
29
Fig 2.2: Scientific Team of FMP Hydroponic Institute
Fig 2.3: FMP Hydroponic Institute Building Front View

30
2.2.1 The Success Story of Hydroponic Agriculture

After 2013, when Worthy Vice Chancellor Prof. Dr. Rai Naiz Ahmad take his step for
FMP rehabilitation and development and take initiative for its production on commercial
level. He performs his duties with the help of core team and now this FMP became the
new Innovative Agriculture Research Farm. Due to this success the Govt. of Punjab
Pakistan granted Rs. 125 Million for development of Hydroponic Farms at all Agriculture
Research Institute on low cost basis.
This Hydroponic Research Farm is made of glass house which produce fresh, high
quality vegetables and fruits free from pests and diseases attack. All types of vegetables
and fruits can be grown and in this farm different types of tomatoes, peppers and
cucumber are being grown. Through this technique the production is 50 to 100 times
more than any other conventional methods for example the production of cucumber is
15 20 tons / acres using conventional method while on the other hand the per acre
production of cucumber is 200 - 250 tons.
The Holland Model of Hydroponic Agriculture is costly and is not in the range of farmers
keeping in view its initial and operational costs, Prof. Dr. Rai Naiz Ahmad win the Project
from Pakistan Science Foundation for development of Indigenous Hydroponic
Agriculture Research Farm. This model cost is 100 times less than the Holland Model
and it is according to the local conditions and climate, after its complete research and
standardization this local model will be easily affordable to the farmers on commercial
level.
2.3
Hydroponic in Pakistan
A report from Article High-tech agriculture: The extraordinary profits of hydroponic

vegetable farming By Imran Rana Published: March 23, 2012, Dawn News.
Tahir Rana is a nuclear physicist who gave up a job in Canada to set up a vegetable
farm in Faisalabad. He is part of a growing number of people worldwide who have been
drawn in by the extraordinary profits in hydroponic vegetable farming, a new method
that dramatically increases productivity and thus farmer incomes.
31
Hydroponic farms are unique in that they do not require any fertile soil. Indeed, many of
the worlds largest hydroponic farms are set up in the deserts of the Middle East or
unfertile soils in other parts of the world. Seeds are placed in a growing medium which
can be either solid or liquid in trays made from steel pipes. The advantage of this
system is that nearly all of the nutrients poured into the growing medium are absorbed
by the plant, making it exponentially more efficient and increasing productivity manifold.
Rana has set a small company just outside Faisalabad called Fareed Farmhouse, where he
produces three varieties of tomato (cherry tomato, strawberry tomato, beef tomato),
cucumber and capsicum. His production capacity is significantly above the norm.
Through this technique, farmers can get between 450 and 550 tons of vegetables per
acre, compared to the average yield of 15 tons per acre using traditional farming, said
Rana Zahid, the project director at Fareed Farmhouse.
Rana uses coconut waste imported from Sri Lanka as the solid medium in which he
grows his plants. The vegetable plants are then irrigated through a water injection
system. Fareed Farm uses reverse osmosis water purification systems to ensure the
quality of the water.
Each plant requires up to two liters of water per day, which needs to be slightly acidic,
with a pH of 5.8, according to Zahid.
Fareed Farmhouse produces relatively high-end vegetables that are consumed by
higher income customers. His buyers include some of the large retail and wholesale
chains in the country as well as hotels that have traditionally imported many of these
vegetables from Europe.
Rana sells the tomatoes for about Rs. 225 per kilogram, compared to the cost of
importing them from the Netherlands, which can run as high as Rs800 per kilogram. The
seeds for the tomatoes at Fareed Farmhouse are imported from Canada and many of
the other raw materials from China and Sri Lanka. Yet while the imported raw materials
can be expensive, the method allows the company to save on other expenses.
Our production method allows us to not use any kind of pesticides, said Rana Arshad,
a quality control officer at Fareed farmhouse.
The methods used by Fareed Farmhouse, however, do not come cheap. Hydroponic
farming requires an investment of up to Rs1.5 million per acre, though it can yield net
profits of up to Rs. 3 million per acre annually. Tahir Rana, however, is not content with
3
2
just reaping the rewards of the existing techniques. He plans to spend up to Rs. 4
million in researching new methods and new variants of seeds. He is also planning on
rapidly expanding his production base to up to 20 acres in the Faisalabad area.
Rana is a firm believer in the potential of hydroponic farming to transform Pakistani
agriculture. Every year, we import vegetables from India. If the government takes an
interest in promoting these new technologies, we would not need to import from other
countries. In fact, the country could earn a lot of foreign exchange by exporting to other
countries.
While Fareed Farmhouse is thus far focused on high-end vegetables, it appears that the
company believes this method can be used to produce more mass market products as
well.
Fig 2.4: FMP Hydroponic Institute Tomato Crop
33
2.4
Scope and Objective of Work
This report comprised of the work and internship of semester 06 group #05 of B.Sc.
Agricultural Engineering under Faculty of Agricultural Engineering and Technology,
PMAS- Arid Agricultural University Rawalpindi.
The main objective of this internship is to get knowledge and understanding of
hydroponic agriculture system and crop support system at initial level.
34
Chapter-3
Systems of Hydroponic Agriculture
The hydroponic agriculture is modern technique of farming and require a control
environment for vegetable and fruit production. For this purpose, the hydroponic model
should consist of following systems.
1. Greenhouse Structure System
2. Seed Germination and Nursery Growing & Transplantation System
3. Irrigation System
4. Cooling System
5. Heating System
6. Ventilation System
7. Drainage System
8. Electrical System
9. Trellising System
The detail description of these systems are given below.
3.1
Greenhouse Structure System
Greenhouses are used for the production of vegetable crops. The greenhouse offers the
ability to manage the growing environment in order to increase control over quality and
productivity. Greenhouses should be built relative means in which plants are protected
and can grow in temperatures and other environmental conditions that produce higher
yields and healthier crops.
For the purposes of greenhouse design, the need for adequate light and ventilation,
protection from rain and, insect exclusion are primary concerns. An effective design
uses insect-proof netting for side walls and a passively-ventilated polyethylene or
polycarbonate panel roof. In many developing countries, a need exists for a low-cost
greenhouse, using locally available materials where possible (Hickman, 2010).
35
In selecting the site for the structure, much attention should be given to orienting it for
maximum light intake so ensuring that there are no large trees, buildings, etc, casting a
shadow onto the structure.
The following factors should be considered in the site selection:
environmental conditions i.e. ambient temperature, rainfall, humidity, wind, etc.
physical features (slope of the land and exposure to the sun).
access to utilities (adequate amounts of good quality water and electricity).
access to a main transportation corridor and supporting infrastructure e.g. roads,
drainage, etc.
access to labor.
proximity to markets.
space for future expansion.
zoning requirements or limitations/local building codes/permits.
potential environmental hazards such as industrial pollution and contaminated
water.
There are three types of greenhouses having different material of
construction. a) Glasshouse b) Glass fiber c) Polythene sheet
The greenhouse made of glasshouse developed by the Holland company and is the
part of Phase-1 in institute of hydroponic agriculture.
The dimensions and cost estimation was done for greenhouses in Phase-1. The
dimensions of greenhouse shed 3 & 5 are same while others are smaller.
The covered area of shed 3 and 5 is one acre.
3.1.1 AutoCAD Design and Dimensions of Greenhouses

The front and back view of all the sheds are same
36
Fig 3.1: Front View of Glasshouse Greenhouse in FMP Hydroponic Institute
Fig 3.2: Back View of Glasshouse Greenhouse in FMP Hydroponic Institute
37
3.1.2 Dimensions of Greenhouses in Phase-1

Length of
Width of
Area
Area
Width of
Total
Shed (ft)
Shed (ft)
ft2
(Acre)
Bed (in)
Beds
211
164
34604
9.9
60
184
131
21484
9.9
342
164
56088
9.9
Shed #
51824
342
164
56088
65
60
9.9
65
3.1.3 Cost Estimation of Sheds

The material cost estimation of greenhouse shed#1 is given below. Using this detail
estimation per unit cost of material was determined and then used for the remaining
sheds.
For Shed #1
a) Glass Quantity and Cost
Length of greenhouse
211ft
Width of greenhouse
164ft
Area
No. of fans
=
=
34604 ft
16
So, No of triangles on roof =

Glass on one triangle
16
= 92 x 2 x 164 x 12=362112 inch
92inch
45
157.8 inches
38
Glass on one triangle
362112/144
2514.6 ft
Glass on all triangles
2514.6 x 16
40234.6 ft
Glass on walls
(164 x 17 x 2) + (211 x 17 x 2)= 12750 ft
Total glass used in shed 1 =

Cost of glass per Sq.ft
=
12750 + 39504.32 = 52254.32 ft

Rs. 60
Total Cost of glass (Rs.)
52254.32 x 60
Rs. 3135259.2/-
b) Aluminum Material Quantity and Cost

Aluminum strip used in walls and roof has a dimension of 4.5 x1.9 inches.
No. of Strips on roof from front
84
Resultant Length of each strip
16x 2 x 7.52
240.64ft
Total Length of strip used on roof =
240.64 x 84
20213.76ft
As the distance between each strip is 27.5 inches. So by taking width in inches,
No. of strips in front wall
1968/27.5
71
Resultant Length of strip in front wall = 71 x 17
1207ft
No. of strips in side wall
2532/27.5
92
Resultant length of strip
92 x 17
1564ft
Total length of strip used in greenhouse walls
= 1564+1564+1207+1207
=
5542 ft
Total Strip length
5542+20213.76=
25755.76 ft
Cost of one Strip per ft
Rs. 35/-
Total Cost of strips
25755.76 x 35
No. of Pillars
42
Length of pipes used as pillars
42 x 17
714ft
Cost of small pillars
714 x 140
Rs. 99960/-
No. of pillars (5.5x5.5 inch)
Length of pipe used in big pillars
8 x 17
136ft
Rs. 90145/-
c) Pillar and Pipe Cost
39
Cost of big pillars
136 x 285
Total Structural cost
3135259+901451+99960+38760
Rs. 4175430/-
4175430/34604
Cost per Sq. ft
Structural Material Cost (Rs.)
Shed No.
1
2
3
4
5
Rs. 38760/-
Rs. 120.66/-
Total Structural cost (Rs.)

120 x 34604
=
4175430
120 x 21484
=
2578080
120 x 56088
=
6730560
120 x 51824
=
6218880
120 x 56088
=
6730560
8000000
7000000
6000000
5000000
4000000
3000000
2000000
1000000
0
Shed 1
Shed 2
Shed 3
Shed No.
Shed 4
Shed 5
Fig 3.3: Structural Cost Comparison of Glasshouse sheds in phase-1
3.2
Seed Germination and Nursery Growing & Transplantation System
The basic requirement for this system in hydroponic agriculture is the growing media.
Commercially coir, perlite and rockwool are used as growth media for tomato and others
are perlite/sawdust, perlite/coir, coir/sand, sand/rice husk.
The grower has several options from numerous seed companies. The selection of a
variety is made after careful considerations. The grower needs to remember that the
product must meet the needs of the consumer on one hand and must be adaptable to
the growing environment prepared for the establishment of the particular variety. Seeds
harvested from hybrids are not recommended as they will not be true to type.
4
0
3.2.1 Seeds and Seedling Management

1.
Always select high quality seeds from reputable seed companies.
2.
Open field varieties are not bred for greenhouse conditions.
3.
When buying seeds, make sure that they were stored under cool dry
conditions.
4.
Check the packaging for the number of seeds, test date, the percentage
germination and, the presence of any pesticides which might be harmful to
the handler.
5.
After opening packages which must be returned to storage, make sure

that seeds are dry and the package contains very little air.
6.
Store seeds in the vegetable compartment within a refrigerator.
To prepare seedlings, a commercially-prepared seed starting mix, usually a combination

of peat moss, vermiculite and perlite, is recommended. Avoid mixes that have a high
fertilizer content, as this can burn the seedlings. The mix is placed in containers such as
commercial seedling trays made of plastic or cardboard; small growers use Styrofoam
or plastic drinking cups with holes poked in the bottom. Just about anything will work as
long as excess water can drain out. Before planting seeds, you must determine when
your plants can be safely placed into the greenhouse (GardenWeb, 2013b).
3.2.2 Transplanting
Transplant seedlings when they have more than four true leaves and a
considerable amount of roots show up in the base of the block.
Discard
plants
damaged
or
not
healthy. Irrigate prior to transport.

Protect from wind and heat.
Note: For further information, see section 1.8 and 1.9 of chapter 1
3.3
Irrigation System
The irrigation system at FMP is drip irrigation system which consist of following
components.
Emitter with Feeder Tube
Lateral
41
Sand Filter
Pump (7.5kW and 5.5kW)
Valve
Reverse Osmosis
UV Filter
3.3.1 Emitter with Feeding Tube

Dripper/Emitter should be ideal for soilless substrates and hydroponic applications
because each rockwool cube receives an equal and precise amount of water nutrients.
These have a unique flow channel down the length of the stake directing the water into
the container. It also has a pointed end
for easy container insertion. The emitters
are also attached with feeder tube made
from the highest quality plastics with
excellent UV resistance. The reflective

white tubing is completely opaque to
prevent algae growth. The tubing is not
coated or layered white, it is solid white
for long-term durability.
Typical discharge of these emitter is 1.25
liter per day.
Fig 3.4: Emitter and Feeding Tube
3.3.2 No. of Plants and Discharge Per day in Shed 3

1 bed have
42 slabs
Total bed
65
1 slab
2 emitters
Plant in one slab
Total Plants in one bed
424
168 plants
Total Emitters in one bed
422
84 emitters
Discharge of emitters per day
1.25 lit/day
42
Total Plants in Green house
65 168
10920 plants
Total Emitters
65 84
5460 emitters
Total discharge
5460 1.25
6825 lit/day
3.3.3 Reverse Osmosis Unit

Reverse osmosis (RO) is a water purification technology that uses a semipermeable
membrane to remove ions, molecules, and larger particles from drinking water. Reverse
osmosis can remove many types of dissolved and suspended species from water,
including bacteria, and is used in both industrial processes and the production of
potable water. The result is that the solute is retained on the pressurized side of the
membrane and the pure solvent is allowed to pass to the other side.
Fig 3.4: R.O Unit

3.3.4 Ultra Violet (UV)
After mixing of recipe and water the water pass through UV unit for filtration and then
water supply to greenhouse through irrigation pipes and supply to plants.
Fig 3.4: U.V Unit
43
3.3.5 Nutrient Tank

In nutrient tank the recipe for plant prepared by mixing different nutrient (like K, N, P)
required for plant for its growing. In Rawat hydroponic farm the nutrient required for
tomatoes at different stages are following.
The nutrient solution for tomatoes is generally made in two or three levels for the various
stages of growth Table 3.1. Only the macro nutrients change, becoming progressively
more concentrated as the crop matures. The micronutrients remain the same throughout
the growth cycle. The first stage of growth (Level A formula) is for seedlings from the first
true leaf until the plants are 24 inches (62 cm) tall, when initial fruit is 1/4 - 1/2 inches (1
to 1.5 cm) in diameter. After that, Level B formula is used. While the formula in Table 2
has been standard for many years, some new tomato varieties may require much higher
nitrogen and potassium. It is advisable for commercial growers to consult their seed
company for the recommended nutrient formulas for the tomato variety grown.
Optimizing the N: K ratio is important as the crop matures and as the available light and
day length changes. Under high light conditions, plants use more N. High K during the
fall and early winter months improves fruit quality. It is common practice to double the
ratio of K: N during winter months when plants receive less light. The optimum pH of the
nutrient solution should be 5.5-6.0. The pH of the nutrient solution can be lowered with
phosphoric acid.
Table3.1: Preparation of macronutrient and iron solutions for tomato
Chemical
compound
(fertilizer grade)
Magnesium
sulphate (Epsom
salts)
Monopotassium
phosphate (022.5-28)
Potassium nitrate
(13.75-0-36.9)
Potassium
sulphate (0-043.3)
Level A seedlings
to first fruit set
(g/1000 liters)
Level
B Fruit set
to harvest
(g/1000
liters)
Nutrient
Level
A
Level
B
Mg
(ppm
or
mg/L)
50
(ppm
or
mg/L)
50
500
500
270
270
199
199
200
200
62
62
100
100
113
144
4
4
Calcium nitrate
(15.5-0-0)
Chelated iron
500
680
Ca
122
165
25
25
Fe
2.5
2.5
3.3.6 Process of Water Supply for Irrigation

First rain water collected in lagoons pumped to tank No 3 then move to Reverse Osmosis
System for cleaning rainwater and move to tank 1 & 2 and then pump to mixing tank where
recipe and water mixed and then pass through sand filter or UV filter and apply to plant
through lateral and emitter and then extra water drain to tank No 4 & 5.
Irrigation room of hydroponic Rawat FMP has 3

pumps. Filling pump (3.5 kw)
Irrigation pump(7.5kw)
Small pump for nutrients (25w)
For rain water harvesting there are ponds (40ft x 60ft). In green houses we are having
small drainage pumps of about 3kw for drainage. There are 5 tanks for water storage
having capacities 80,000 liters per tank.
3.3.7 Flow chart of irrigation system
Lagoon
Tubewell
Revers
osmosis
Nutrient
solution
Green
houses
Irrigation
Fig 3.5: Flow chart of irrigation system used in Hydroponic Institute

45
3.4
Cooling System
It consists of following components.
Cooling Pad
Exhaust Fan
Submersible Pump
Hydrophone pump
Anti-virus net
3.4.1 Cooling Pads

Dimension
5x6x2
Cooling tank dimension
810x7x43 = 262.8 ft
Material
Hard Paper imported from china
Angle
45 (The shape of these cooling pads are

=
such that they are designed at angle of app. 45 so that it can
jet cooling effect on plants those are at some height.
3.4.1.1
Duration
cooling pads mostly last for 2 years.
Cost
Rs. 7000-12000/cubic meter
Working Principle
Cooling pads consists of one major pipe (on its above surface), which has small holes
on it and through these holes water falls on pads and they get wet and causes cooling
effect by throwing air and water on plants and thus evaporation takes place and as a
result cooling. Different techniques are use in hydroponic for absorption of humidity and
evaporation e.g. Sulphur box those are having capacity to absorb moisture.
46
Fig 3.6: Cooling Pads

3.4.2 Exhaust Fan
For cooling exhaust fans are used in hydroponic, having 4.5ft x 4.5ft and of 1.5Hp.
Fig 3.6: Exhaust Fans system
3.4.2.1
Estimation of Electricity Consumption of Cooling/ Exhaust Fans
No. of fans in hall no 1
16
No. of fan in hall no 2
10
26
24
47
26
Total
102
Power Required of one fan
1kw
No. of hours use in summers
9 Hrs.
Electricity consumption of fan
102x9
918kwh
Consumption in one month
918x30
27540kwh
Bill for one month
27540x15
Rs.413100/-
3.4.3 Submergence Pump

2Hp for 1 greenhouse and use for the sucking of useless water from greenhouse.
3.4.4 Hydrophore Pump
A scientific instrument for obtaining samples of water from a body of water from any
desired depth. It stores, pump and supply water while regulating temp and pressure. At
FMP Rawaat 7.7kw Hydrophore pump is use.
3.4.5 Anti-Virus Net
An Israels invention use for the supply of air in to sheds and save the plants from insects.
Fig 3.7: Anti-Virus Net

48
3.5
Heating System
Heating system of phase-1 consist of following components.
Boiler
Pipes
Fringes
Blower
Inlet/outlet pipes
This system takes air from inlet pipes which is connected through one shed and take
cool air from that specific shed and after passing through boiler and fringes, this cool air
gets converted into hot air and goes to another shed through outlet pipe, in this way air
gets recycling itself and by outlet pipes hot air goes to pipes of greenhouse shed and
when we require to use hot air for plants control valve opens.
Boiler heating system of FMP is not working and its operational cost is very high which
is not affordable, so for heating system an indigenous heating system was developed
which use air for heating purpose. This heating system consist of a furnace connected
with pipes and bowlers as shown in Fig.3.8
Fig 3.8: Air Heating System at FMP Hydroponic Research Institute

49
Fig 3.9: Air Heating inlet and outlet Pipes
3.6
Ventilation System
It consists of following 2 components
Top airing screens
Screen (manually operated)
Top airing screen of green house has 30 windows for ventilation on roof. When
temperature inside greenhouse increases, window opened or closed.
Window size: 5ft x 2ft (Rectangular-shape)
Ventilation design and its requirement depend on two factors; the volume of the greenhouse
and the number of air changes required.it has been found that one air change /min is
adequate in colder climate but in arid areas this should be increased to 1.5 air change/min.
increasing the rate of air change will stabilize greenhouse temperature
50
Fig 3.10: Ventilation System at FMP Hydroponic Research Institute
3.7
Drainage System
Components are
Drainage Pump
Drainage Tank
3.7.1 Drainage Pump

Hall no 3 & 5 have same power drainage pump but hall 1, 2 & 4 have different power
drainage pump.
3
Discharge range
Head (min)
=
=
18 - 45 m /Hr
15m
Head (max)
29.5m
Frequency
50 Hz
Power
3kW
Voltage
400 V
Inlet and Outlet pipe diameter
3.7.2 Drainage Tank

Diameter
=
54 inch
Depth
39 inch
Volume
51.6 ft
3 inch
51
Fig 3.11: Drainage System at FMP Hydroponic Research Institute
3.8
Electrical System
Electrical system of hydroponic consist of exhaust fans, lights, pumps (irrigation and filling)
irrigation pump is of 7.7 kw and filling pump is of 5kw and drainage pump is of 3.5 -
4kw. Fan is of 4.5x4.5 and use 1.5 hp. electricity is use to run heating unit, boilers,
blowers etc.
3.8.1 Electricity Cost Estimation
If one Furnace Runs 12 Hours daily in winter, it consumes
Discharge
Power of 1 blower
=
=
50 m /hr.
3.7 KW
It means it consumes 3.7 KW of power in one hour

Electricity rates per unit is as following:
52
Electricity units per day
3.7x12
= 44.4 units or KW/h
Electricity units for whole month
44.4x31
= 1376 units
As for over 700 units, price for single unit
= Rs 15/-
So total monthly Bill for one blower
= 1376x15 = Rs.20646/-
Therefore,
There are two blowers on a single Furnace,
So
20646x2 = Rs. 41292/month (In winter)
Similarly, Green House # 1, 2 & 3 have single Furnace having same capacity of Blowers
=
Rs.41292/month (In winter)
Total amount consumed for all the sheds=
41292x2 = Rs.82584/month
a. Electricity requirement of Irrigation Pump

Total No. of irrigation pump
Power of irrigation pump
7.5 kW h
No. of hours irrigation pump used in 1 day
1 hour
Electricity consumption of pump in one day
7.5x1 = 7.5 kW h
Electricity consumption of pump in one month =
7.5x30 = 225kW h
Electricity bill in winter
=225x12.09 =Rs. 2720/-
b. Electricity requirement of Filling Pump

53
Total No. of filling pump
Power of filling pump
3.5 kW h
No. of hours filling pump used in 1 day
1 hour
Electricity consumption of pump in one day
3.5x1 = 3.5 kW h
Electricity consumption of pump in one month =

3.5x30 = 105 kW h
=105x8.1
=Rs. 850/-
c. Heating system requirement

Blower power
3.7kw
No. of Hrs blower used in a day
12hour
Electricity consumption in 1 day
12x3.7x2
= 89 kWh
Electricity consumption in 1 month
89x30
=2670 kWh
Total electricity consumption in one month =
210+225+105+2670+4 = 3214 kWh
3214x25 =
Rs.80000/-
d. Electricity Cost Estimation of Fans

16
10
26
24
26
Total
102
Power of one fan
1kw
No. of hours use in summers=
9 hours
Electricity consumption of fan=
102x9 =
918kwh
Consumption in one month =918x30
27540kwh
Bill for one month
Rs. 413100/-
= 27540x15
Total electricity Bill per Month in Winter Season of Phase-1

=
82584+2720+850+80000+413100
Rs. 579254/54
Chapter-4
Trellising Systems of Hydroponic Agriculture
4.1
General
In a traditional soil-grown garden, plants put down roots deep and wide as they search
for necessary food and moisture. This anchors the plant securely and provides a sturdy
base. Plants grown in the hydroponic method have a much smaller root ball, as they
don't have to spread out looking for nourishment. So the larger and taller vining
hydroponic plants must be supported as they grow tall towards the light.
The advantages of trellising make it a popular technique for use with many vining crops.
Growing the vines on a trellis will keep them out of pathways.
Trellising makes fruit easier to find, speeding and improving the ergonomics of
harvest.
Trellised vines can be grown at a higher density than vines that are sprawled,
since they can make use of the vertical space over the plant, instead of
growing into each other which optimizes yield.
It increases yield per square meter up to 40%
Reduces the risk of disease development
Improves ventilation between plants
Allows for higher plant densities
Allows for easier picking

Mature fruit are easier to spot
Allows for more effective pesticide and fungicide application
Trellising is especially important for tomatoes, where all these advantages apply and
then some. Keeping the vines off the ground reduces exposure to soil borne pathogens,
which will keep the foliage healthier. Airflow is better around trellised plants, which
keeps the canopy drier and less vulnerable to fungal diseases. For these reasons, most
fresh-eating tomato crops are trellised.
55
4.2
Main Types of Trellising
There are a lot of different options for trellising tomatoes. The system that will work best
for you depends mostly on
The
type
of
tomato
you
are
growing Where you are growing it

How much labor you want to put into it
Most tomato trellising methods are variations on either the basket weave system or
the stake-&-wire/hanging-string system. Each has its merits, and growers prefer to use
them in lots of different ways.
Generally, basket weaving methods are best-suited to the bushier types of tomatoes
determinates and semi determinate varieties and the hanging trellises most useful
for the rangier, indeterminate varieties.
4.2.1 Basket weave Trellising
Basket-weaving is the most common way to trellis determinate tomatoes in open field or
protected culture, and it is occasionally used for indeterminate tomatoes. It is a laborsaving method of tomato trellising, when pruning is not important. Though it is quicker
than other trellising methods, it makes the plants difficult to prune when they are
surrounded by support strings. That is why this method is so well suited to determinate
tomatoes, sometimes referred to as "self-pruning," since they grow to a certain size and
then concentrate on fruit production. Most determinate and semi determinate tomato
varieties can be basket-weaved without any pruning at all.
Indeterminate tomatoes can be basket-weaved as well, with one of two disadvantages.
If they are pruned, this will be more difficult and time consuming. And if they are not
pruned, fruit size will go down due to the sheer number of fruit set on an unpruned
indeterminate plant. Also, unpruned, basket-weaved indeterminate plants will form a
hedge of foliage which is susceptible to fungal diseases that can get started in the
dense canopy. Unpruned, indeterminate basket-weave tomato production is mostly
confined to arid areas because disease problems can be severe in humid areas.
56
Fig 4.1: Basket weave Trellising

4.2.1.1
Basket weave Trellising Setup
Stakes. Strong cedar or hardwood stakes, or metal T-posts, should be driven into the
soil at the end of each row, and between every other plant. Start each row with a post,
skip two plants, drive a post, and keep driving a post every two plants all the way down
the row. Use posts that are as tall as you expect the tomatoes to be, taking into account
the foot or so that will be driven into the ground: 4-foot posts may be used for some
bushy determinates, whereas 7-foot posts may be necessary for tall in determinates.
Fig 4.2: Twine in a Box with Belt Loops

57
Wand & Twine. When plants are about a foot tall, before they start to flop over, twine is
tied to the end post, then looped around each stake down the row. At the end of the row,
the twine is looped around the post at the opposite end, then looped around each stake
on the way back so there is a string running along both sides of the plants to keep them
upright. Additional strings are added higher up as the plants grow, every 8"12", or
before they flop out of the trellised area.
4.2.2 Stake-&-Wire/Hanging-String Trellising System
The stake-&-wire/hanging-string system can be used both in the field and in protectedculture settings, and works well for pruned, indeterminate tomatoes. This system makes
it easy to prune and trellis indeterminate tomatoes because each stem gets a string, and
any additional suckers are pruned off. An indeterminate tomato plant with five or six
fruiting clusters can exert 1012 pounds of downward pull on its trellis, so pruning is
essential, and the support system needs to be both tall and strong.
Fig 4.3: Stake-&-Wire Method in the Field
58
4.2.2.1
Stake-&-Wire / Hanging-String Set-Up
Stakes & Wire: To set up a hanging-string trellis, start with tall, strong posts, driven into
the ground every 20 feet, with a line of strong wire, such as12-gauge high-tensile wire,
stretched tightly, between the posts.
If wooden or steel T-posts are used, a hole can be drilled at the top of each post through
which the wire can be threaded and secured. If you are a welder, you may be able to
burn the holes more quickly through metal T-posts. Steel U-posts come predrilled,
eliminating this step.
Hanging Strings: A length of twine is tied to the wire at every point where a vine will be
suspended, and then loosely tied at the base of the plant with an overhand knot.
Hanging strings made of biodegradable sisal trellis twine facilitate clean-up at the end of
the plants' lifecycle.
It is important not to make the knot at the base of the plant too tight, because it will cut
into the plant as it grows. You can use a tomato trellis clip to attach the string instead of
a knot. Tomato trellis clips are designed to bite onto the string securely, but to gently
encircle the vine stalk.
As the vines grow, they can be attached to the string with additional trellis clips, or they
can be twisted around the string to support the plants. Just make sure you always twist
in the same direction, or you will unwind the string you have already twisted!
This method is more labor intensive, but works better for pruned indeterminates, than
the basket-weave method.
The vines climb up the twine, suspended from overhanging pipes via Rollerhooks or
Tomahooks, which are shifted to lower & lean the plants as they grow and produce.
59
Fig 4.4: Hanging-String Trellising System in the Greenhouse

Protected Culture: The hanging-string method as described above can be used in a
hoophouse, but within protected-culture settings, it is more common to run pipes or
wires above the crop rows, to which you can attach the hanging strings. This eliminates
the need to pound posts inside your hoophouse, plus it allows for a taller trellis for the
longer hoophouse season.
Another variation on the hanging-string method in a greenhouse or hoophouse is to use
Tomahooks or Rollerhooks to attach the overhead strings. These are strong, and
conveniently allow the vines to be lowered and leaned, since they may outgrow their vertical
space in a greenhouse. With this method, a spool is attached at the overhead wire, and
when the plants run out of growing space, you can play out some of the string, about a foot
at a time, and move the plants one position to the side so the vines don't pool up at the
bottom and break. The plants at the ends of rows go around to the other side. This requires
plants to be planted in double rows, two feet apart being a common spacing.
4.2.3 Stake-&-Trellis-Netting System

One variation on the hanging trellis system that can be set up either in the field or a
protected culture setting uses trellis netting instead of hanging strings to the vining crop.
60
The exact dimensions needed to reduce waste, cost, labor and trip hazard.
Fig 4.5: Vertical Netting Trellis in the Greenhouse

4.2.3.1
Netting Trellis Set-Up
The first step of installation is just like the hanging-string method, where tall posts with
holes at the top of them are pounded every 20'. With this method, as you are threading
the heavy-gauge wire through the tops of the posts, you weave it through the mesh at
the top of a piece of Hortonova.
As the plants grow up, they can be clipped to the Hortonova with trellis clips, or tucked
into the square mesh, weaving them into the mesh.
We use this method on my farm for cherry tomatoes, because sometimes we like to let
our cherry tomatoes develop more than two heads, and the mesh can accommodate
any number of heads. This method also works well for crops like climbing beans or peas
that don't have a discrete number of vines.
61
So whether you grow in the field, high tunnel, glasshouse, patio, backyard, hoophouse,
or warehouse, give thought to what types of tomatoes you want to grow, consider the
ergonomics involved and the resources you can apply, and choose the trellising option
that best fits your needs. You will find you can customize the system to suit your
preferences and the conditions at hand.
When your vining crops are provided appropriate trellising and support, your growing efforts
will be more efficient and deliver optimal yields of premium fruit with fresher flavor.
Trellising tomato plants is only done in greenhouses or when the tomato crop is grown
under a structure where a trellis wire can be installed. As the plants grow, the growth
point is moved along the wire while the growth bag with root system stays put.
4.3
Plant Training
Indeterminate types of the tomato plant are vine-like in nature and may run for
distances exceeding 12m.
Fig 4.6: Training the tomato plant (attaching to trellis or twine and cable system
left; lowering and leaning right)
Plants are trained so they initially grow vertically, being supported by poly twines attached to
a plant support cable approximately 3m tall. When the plants grow until their growing tips
reach near plant support cables they have to be lowered and leaned horizontally, and only
raised back to a height approximately 12cm tall, making sure that no fruits or leaves are
touching the ground after plants are lowered. Tomato plants will require pruning every
62
3-4 days.
Lower leaf removal, de-suckering, de-flowering and, cluster pruning, are best done
before leaning and lowering. The use of a fungicide to spray or paint unto open wounds
on the stem after these activities is recommended.
The grower must maintain a good fruit to leaf ratio (Figure 4.7) making sure there are
enough leaves to manufacture sufficient food, leaves to support the transpiration
process, and to provide shade for fruits. In general, there should be a minimum of 1m of
foliage measuring from the growing tip to the last set of leaves on the stem. No more
than four healthy leaves should be removed from the plant at one time.
Fig 4.7: Maintaining a good fruit/leaf ratio through de-leafing. (Source: Burrell, 2013)
63
De-flowering (Figure 4.8) and cluster pruning (Figure 4.9) on tomato is done to promote
the development of fewer, more uniform and larger fruits suited for the market. The
number of fruits that are allowed to remain and develop on each cluster is determined
by the variety and the general health of the mother plant. Generally, for larger fruits,
three to five are allowed to develop per cluster and as the fruit size reduces, the number
of fruits left increases; as such, cherry tomatoes are rarely cluster-pruned. The objective
should be to thin the cluster to a group of fruits that are most uniform in size and are
near the same stage of development.
Fig 4.8: De-flowering (numbers show the fruits that are allowed to develop). (Source:
USAID, 2010a)
64
Fig 4.9: No cluster-pruning done (developed fruits are not uniform in size).
(Photograph provided by J. Rowe).
Tomato plant training activities are made easier with the use of vine clips (Figure 4.10)
attached to the poly twine which is attached to the plant support cables. The Poly twine
with clips in place is secured to the lower portion of the plant, usually below a leaf or fruit
cluster, the string is then thrown over the support cable and brought back to the plant for
a second connection via another clip on another point of the stem above the previous
clip. Maintain some tension but not too much to break the stem or damage the plant.
Allocation must be made for excess string to service the plant as the vine grows longer.
Other methods of trellising using tomato reels and hooks can also be used.
65
Fig 4.10: Clips, reels and hooks used to train the plants up the trellis or
twine/cable System. (Sources: Benny Hill Drip Irrigation, 2013; Roscam Young
Plants Pty Ltd., 2013).
4.4
Plant Support Systems
The most common internal structures are plant support systems in greenhouse crop
production. The plant support systems are of two types, namely, stand-alone systems
which are independent of the main greenhouse structure and, the integrated structures
which are part of the main greenhouse structure.
The selection of a particular system is dependent on structural design and structural
strength of the materials with which the greenhouse is constructed. Plant support
systems consist of three levels of support, namely:
1) Primary level: This consists of those structural members on which the main cumulative
loads of the system rest and include stanchions, posts and large cross braces.
66
2) Secondary level: The load distribution system where loads are borne in sections
between primary level members. These include pulling wire (8 -10 guage galvanised
wire), light cables (1cm diameter or less) and/or light small diameter (2.5cm or less)
support bars.
3) Tertiary level: This consists of hooks, lines, nylon strings, clips, reels, clamps and/or
other individual plant supporting mechanisms (Figure 4.11) often suspended from the
secondary support system and attached to the plant especially vining crops.
Fig 4.11: Tertiary level plant support accessories and tools required for greenhouse
operations. (Sources: Treforest Glass, 2007; Superior Growers Supply Inc., 2012;
Gabriel, 2013)
In addition to these, other specialized structures can be found in greenhouse crop
production. These include independent low benches and plant supports that are used to
support plant pots or grow bags and stems to facilitate air movement and to prevent
67
contact of vining crop stems with the ground thereby stopping the establishment of
secondary roots. These structures are common in indeterminate tomato production
systems.
4.5
Components of Trellising System
Hooks & Clips are the tertiary level plant supporting system
4.5.1 Free Fall Hook & Twine
Stainless Steel Tomahooks can holds up to 39 feet of twine. One turn lowers the plant
the correct distance. Tomahooks are used to secure the vine and twine to the overhead
support cable. The vine twine is wrapped around the tomahook then when leaning and
lowering the twine is unwound and the Tomahook is slid along the support cable.
Fig 4.12: Freefall Hooks and Twine

Stronger "lower and lean" devices for heavier producing vine-crop varieties. Great for
beefsteak tomatoes and long greenhouse cucumbers. Heavy-duty stainless steel hooks
hang on a high wire to support crops and release about 7" of twine each time they are
turned over. Each includes 50 ft. of UV-resistant white twine, rated to 79 lb. 40 ft.
68
prewrapped on the hook and 10 ft. loose, so it can freefall out of the case to speed
installation.
This twine holder also called free fall hook used to guide tomato, peppers, cucumbers
upwards. The 18 cm hook hangs from your overhead support wire. One turn lowers the
plants to the correct distance. Twines are for use with free fall hooks and provide strong
support for greenhouse crops. pp life = 1 year. Jute life < 1 year.
Fig 4.13: Freefall Hooks and Twine hanging system with overhead stainless steel wire
4.5.2 J-Hooks
J-Hooks support the cluster. The top goes over the twine, while the fish-hook end is pulled
behind the first tomatoes in the truss. Used to hold plants upright, such as Tomatoes.
69
J-Hooks for tying up vines and holding the plants upright. Usually used in Greenhouses
and Hydroponic growing. Perfect for Tomatoes, Cucumbers and Peppers grown inside.
A cluster of ripening tomatoes can be very heavy and so you may want to support the
clusters with a "tomato hook" or "truss".
Fig 4.13: J-Hooks

4.5.3 Roller Hook
The roller hook is a state of the art trellising
hooks. The unique design of the rollerhook
enables the worker to easily, rapidly and safely
lower and lean tomato or cucumber plants.
Good control of lowering length
Maximum twine length 36 m
Will not slip back on the trellising cable
Fig 4.14: Roller Hooks
70
4.5.4 Tomato Clips/ Clippers

Tomato Clips used for training vines up a string or trellis. Easy to use because they clip
on and off quickly and easily.
Plant clips are used to support the weight of the plant when they start to get to their mature
size.
The back of the clip goes on a piece of twine then around the stem of the plant.
The clip is designed to hold the twine tightly and won't slip.
The clips are a must with heavy plants like tomatoes and cucumbers.
Unclips easily so they can be removed and Re-Used.
provides non-restrictive plant stem guidance and eliminates turning. Increase in yield &
quality. Easy & efficient. Also available in a bio-clip. Different sizes are 20mm, 23 mm
and 25 mm.
Fig 4.15: Tomato Clips/ Clippers
71
You can harvest an amazing amount of produce from one square foot of garden bed by
growing UP. The vining plants must be trained and supported by stakes, strings or
trellises. And they must be limited in growth to the max height of the light system. So it's
a little tricky, but well worth learning how. The weight of these plants must be supported
by clipping the vines to strings or wires attached to the ceiling or plant bed frame.
They sell plastic vine clips to attach the vines to the string, but we just use thin garden
wire and form a loop loosely around the stems to support it as it grows up.
The vine clips do have the advantage of not cutting into the stem. They are cheap and
widely available, as pictured above.
4.6
Some Quick Tips on Training and Supporting Different Types of Plants

Peppers: Bush variety peppers can grow three feet tall and may need support
either with a stake or string. They can be very weak at the root ball and fall over if
not supported.
Cucumbers: Definitely need training. Support them with string tied up to an
overhead hook or framework. You can actually wrap the string around the main
stem as it grows, or use plastic vine clips.
Green beans: Need no help at all, they support themselves by clinging with
tendrils. You may want to eliminate many of the tendrils, as they can wrap around
leaves and stems and choke them.
Tomatoes: Train your tomatoes to a single stem straight up, pruning off any
secondary shoots. This keeps the plant from getting too bushy. Use plastic vine
clips to hold the tomato to the string or stake.
Don't let the tops of your plants get too far away from the root system. Hydroponic
plants will grow larger than soil-grown ones, and will go crazy if you let them.
For bush variety plants, like patio tomatoes, pinch off the tops of the plants at 3
feet or so. Cucumbers, pinch off after 7 sets of leaves.
For vining tomatoes, it is important to pinch off the suckers as soon as they
appear. As the lower leaves turn yellow, strip them from the stem to allow more
airflow and light below. When the tomatoes start to cluster, prune each cluster to
only 4 to 5 flowers.
72
These are suckers.

Pinch them off!
For vining cucumbers, remove the suckers from this plant also and remove all
tendrils as they appear. You can also prune lower yellowed leaves as they die off.
For the other vining varieties of crops, let them go, then prune when they get up
too close to the lights.
Pruning is a necessary task to keep the plants manageable, under the lights and
transfers the plant's energy from vining into fruit production.
It is very important to train your plants correctly in order to maximize your production. we
use staking varieties of tomatoes, so they must be trained vertically. As soon as the
seedlings are transplanted into their final growing system, rockwool or perlite, etc. training
must begin. Support the plants from strings attached to overhead wires that can be attached
to hooks in the ceiling or use a supporting frame above to tie the strings. Use
Tomahooks with string wound on them to provide the support string for the plants.
These metal hooks are suspended from the overhead support wire. The string is
unwound until it reaches the base of the plant where it is attached to the plant under a
strong leaf by a plastic plant clip.
The Tomahooks permit the plants to be lowered and leaned, as they grow up approaching
the ceiling. Lower the plants about 1 foot every week as you remove suckers and lower
leaves up to the ripening fruit. Do not remove more than 3 to 4 leaves at any given time or
the plants may undergo stress. Removing the leaves permits good air flow at the base of the
plants and therefore will reduce disease infection. By pushing the plants along the support
wire you lean them over so that the upper part of the plant bearing fruit is suspended above
the pots or slabs. The end plants will be positioned to the row on the other side as the plants
are supported in two rows. The plants are trained in a V -cordon configuration whereby
alternate plants are tied to strings on the opposite support wire.
73
This gives the plants more even spacing as they grow vertically. Attach a plant clip
below a strong leaf about every foot of the stem. Train each plant to a single stem by
removing the suckers or side shoots that form at each leaf axil. Break the suckers off
by hand when they are about 1- to 2-inches long. Do not permit them to grow larger or
they will take food away from the fruit formation making the plant vegetative.
4.7
Pruning Tomatoes
Pruning tomatoes is an essential activity during the maintenance of the tomato crop. Just as
the plants should be trellised every week, so should each tomato plant be pruned in order to
obtain maximum yields. Pruning tomatoes ensures that the energy is used in developing
fruit and the main stem. The pruning and trellising (also referred to as
training) activities are quite often the first to lag behind as soon as harvesting starts.
This results in plants that look neglected due to suckers growing out of the main stem
and the growth point growing far above the main trellising wire. Neglecting these two
activities can result in reducing yields of up to 50%.
Determinate tomato plants do not have to be pruned or trellised. They are designed to
grow a limited period after which the die. The indeterminate types must be pruned and
trellised otherwise yields will be reduced considerably. The best method is to prune
indeterminate types to one stem, thus removing all suckers (also referred to side
shoots). Suckers are small growth points that develop into a stem with leaves and more
tomato trusses. They can be located between the stem and a leaf axil. Leaving the
sucker to long can result in a reduction of at least 10% in total yields.
The ideal length of the sucker is between 50-70 mm. At this length they can easily be
broken off by hand without injuring the stem or the leaf under it. If the sucker is smaller,
it is difficult to brake of. The importance of removing suckers is:
Side shoots are removed in order to maintain one
stem Must be removed when smaller than 70 mm
Side shoots must be removed weekly
Never use finger nails to remove side shoots
Side shoots should be broken off by hand and not cut off by scissors
Suckers forming at the base of the plant should be removed
74
Shoots must be removed close the base of the plant. Early removal of side shoots
allows for more energy available for fruit development.
Many experts and growers are of the opinion that the removal of the lower leaves will
have a negative effect on production. This however has never been experimentally
proved. There are more negative influences than positive in keeping the lower leaves on
the plant. The reasons for removing the lower leaves are:
Leaves that are old and that have turned yellow are susceptible to diseases
Removal of leaves makes harvesting easier
Leaves covering the truss that will be harvested the following week should be
removed
The removal of leaves increases air movement in the tunnel and reduces disease
development
Remove the leaves every second week
Do not remove more than two leaves
It is important that removed leaves should not be left inside the tunnel for longer than a day
and the dead leaves should either be burnt or placed far from the production site. There
should be at least 1.5 m of healthy leaves left on the plant. When removing leaves, they
should be bent upwards first, then pulled down in order to prevent the epidermis
(skin) of the stem pealing of and exposing a view centimeters of the stem to diseases.
Never use a knife or scissors to remove leaves since this just help in spreading diseases.
4.8 Cost Estimation of Trellising System

Item code
Description
Qty.
1001
units
cost/item
Overhead wire
overhead wire
made up
iron
total cost
Rs
is
of steel
having
the
diameter of 4mm.
Length
of
overhead wire
is
100
ft
16 Rs/ft
262,400
75
164/wire.
Total
length is 16400Ft.
1002
Tomo hook
Tomo
hook
made
up of steel
iron
the
and
is
having
diameter
3mm and
of
0.3cm.
Tomo hook is use

to
support
4200
1 hook/plant
Rs. 10
42000
105000 1 hook/cluster
Rs. 2.5
262,500
42000 1 clip/1ft height
2.5 Rs
105,000
the
plant and place the

j hook to
support
the cluster at
the
plants
1003
J-hook
j hook is made up
of plastic
having
the
length
approximately
cm. it is used
to
support the cluster

@25 cluster/plant
1004
Clipper
clipper is made up
of plastic and have
the shape
round.
Clipper is used to
support the stem
of the plant and to
76
stick the plant with

the twin string
1005
Twin String
twin string is used
to
support
the
plant and stick the

plant growth with it
by the help of tomo
hook and j hooks.
Also
clipper
attached
twin
51219.5
0.24 Rs/m
12293
Rs
1000 per day
31,250
is
with the
string
40ft/plant
1006
Labor cost
labor cost includes
the cost of spray of
per row and tomo
hook removal and
maintenance
of
the tomo
hooks
and again
thread
round on the tomo

hook.
Cost
of
spray of one row is

Rs. 250.
TOTAL COST
715443
77

Report On Trellising System

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Hydroponic

SEMESTER 6th GROUP #05

Basic Requirements of Hydroponics Agriculture .............................................................

Basic Nutrients Required for Plant Growth ...................................................................... 5

Classification of Hydroponic Agriculture ..........................................................................

Deepwater Culture (DWC) ........................................................................................

Nutrient Film Technique (N.F.T) ...............................................................................

Aeroponic System .....................................................................................................

Ebb and Flow System (Flood and Drain) ............................................................... 12

DRIP SYSTEM (Recovery or Non-Recovery) ........................................................ 13

Which crops can be grown in hydroponics?........................................................... 13

Where can you buy seeds? .................................................................................... 13

Taking care of plants............................................................................................... 14

Advantages of Hydroponics ........................................................................................... 14

Disadvantages of Hydroponics ...................................................................................... 14

Differences Between Hydroponic Vegetable Production and Soil ................................ 15

Growing Substrates/ Media............................................................................................ 15

Types of Growing Media ......................................................................................... 16

1.10 Nursery Techniques for Hydroponics ............................................................................ 20

Farmer Market Pvt. Ltd & Hydroponic Agriculture ................................................................. 26

Farmer Market Pvt. Ltd. (FMP) Rawat........................................................................... 28

The Success Story of Hydroponic Agriculture........................................................ 31

Hydroponic in Pakistan .................................................................................................. 31

Scope and Objective of Work ........................................................................................ 34

Systems of Hydroponic Agriculture ......................................................................................... 35

Greenhouse Structure System....................................................................................... 35

AutoCAD Design and Dimensions of Greenhouses .............................................. 36

Dimensions of Greenhouses in Phase-1................................................................ 38

Cost Estimation of Sheds ....................................................................................... 38

Seed Germination and Nursery Growing & Transplantation System............................ 40

Seeds and Seedling Management ......................................................................... 41

Irrigation System ............................................................................................................ 41

Emitter with Feeding Tube ...................................................................................... 42

No. of Plants and Discharge Per day in Shed 3 ..................................................... 42

Reverse Osmosis Unit ............................................................................................ 43

Ultra Violet (UV) ...................................................................................................... 43

Process of Water Supply for Irrigation.................................................................... 45

Flow chart of irrigation system ................................................................................ 45

Cooling System .............................................................................................................. 46

Cooling Pads ........................................................................................................... 46

Working Principle ................................................................................................ 46

Exhaust Fan ............................................................................................................ 47

Estimation of Electricity Consumption of Cooling/ Exhaust Fans ...................... 47

Submergence Pump ............................................................................................... 48

Hydrophore Pump ................................................................................................... 48

Anti-Virus Net .......................................................................................................... 48

Heating System .............................................................................................................. 49

Ventilation System ......................................................................................................... 50

Drainage Pump ....................................................................................................... 51

Electricity Cost Estimation ...................................................................................... 52

Trellising Systems of Hydroponic Agriculture ........................................................................ 55

Main Types of Trellising ........................................................................................... 56

Basket weave Trellising .................................................................................... 56

4.2.1.1Basket weave Trellising Setup .................................................................... 57

Stake-&-Wire/Hanging-String Trellising System.................................................. 58

Stake-&-Wire / Hanging-String Set-Up ............................................................... 59

Stake-&-Trellis-Netting System .............................................................................. 60

Netting Trellis Set-Up .......................................................................................... 61

Plant Training ................................................................................................................. 62

4.4 Plant Support Systems................................................................................................... 66

Free Fall Hook & Twine .......................................................................................... 68

Roller Hook ............................................................................................................. 70

Tomato Clips/ Clippers............................................................................................ 71