a project report [10me85] on design and fabrication …

A PROJECT REPORT [10ME85]

ON

“DESIGN AND FABRICATION OF MANUAL AND AUTOMATED

SYSTEMS FOR HYDROPONIC FODDER”

Submitted in partial fulfillment of the requirement for award of degree in

Bachelor of Engineering

In

Mechanical Engineering

Of

VISVESVARAYA TECHNOLOGICAL UNIVERSITY, Belagavi

By

ANEESH GOPAL 1NH12ME012 KRISHNA MARUTHI 1NH13ME411

NAGA CHOWDARY 1NH13ME417 UMAKANTH. B. S 1NH13ME430

Under the guidance of

Mr. RAVI KUMAR .M

Asst. Professor, Mechanical Department, NHCE

Department of Mechanical Engineering

NEW HORIZON COLLEGE OF ENGINEERING (Accredited by NAAC with 'A' Grade, Permanently Affiliated to VTU)

A Recipient of Prestigious Rajyotsava State Award 2012 by

Government of Karnataka

Ring Road, Kadubisanahalli, Bellandur Post, Near Marathalli, Bangalore -560 103

Ph.: +91-80-6629 7777. Fax: +91-80- 28440770

Web: www.newhorizonindia.edu

2015-2016

http://www.newhorizonindia.edu/

NEW HORIZON COLLEGE OF ENGINEERING (Accredited by NAAC with 'A' Grade, Permanently Affiliated to VTU)

A Recipient of Prestigious Rajyotsava State Award 2012 by Government of Karnataka

Ring Road, Kadubisanahalli, Bellandur Post, Near Marathalli, Bangalore -560103 Ph.: +91-80-6629 7777. Fax: +91-80- 28440770

Web: www.newhorizonindia.edu

CERTIFICATE

This is to certify that the Project Report on “DESIGN AND FABRICATION OF

MANUAL AND AUTOMATED HYDROPONIC FODDER” [10ME85] is a bonafide

work carried out by ANEESH GOPAL (1NH12ME012), KRISHNA MARUTHI (1NH13ME411),

NAGA CHOWDARY (1NH13ME417), UMAKANTH B S (1NH13ME430) in partial fulfillment for the

award of degree of Bachelor of Engineering in Mechanical Engineering of Visvesvaraya

Technological University, Belagavi during the year 2015 - 2016. It is certified that all

corrections/suggestions indicated for Internal Assessment have been incorporated in the Report

deposited in the departmental library. The Project report has been approved as it is satisfies the

academic requirements in respect of Project Report prescribed for the Bachelor of Engineering

degree.

Signature of the guide Signature of the HOD Signature of the Principal

Mr. RAVI KUMAR.M Dr. M S GANESHA PRASAD Dr. MANJUNATHA

Name of the Examiner Signature

1.

2.

ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of Project would be

incomplete without mentioning the people who made it possible through constant guidance

and encouragement.

I would take this opportunity to express the deepest gratitude and appreciation to all those

who helped me directly or indirectly towards the successful completion of the project.

I would like to thank Dr. MOHAN MANGNANI, chairman of NHEI, for providing all the

faculties for carrying out the project work.

I would like to thank Dr. MANJUNATHA principal of NHCE, for providing a friendly

atmosphere to work in.

I would like to thank Dr. M S GANESHA PRASAD, HOD of Department of Mechanical

Engineering, NHCE, for his support and encouragement that went a long way in successful

completion of this Project work.

I consider this as a privilege to express my heartfelt gratitude and respect

Mr. RAVI KUMAR M, Assistant professor of department of Mechanical engineering,

NHCE, for being my guide, for his integral and incessant support offered to us throughout the

course of this Project and for constant source of inspiration throughout the Project.

I would like to thank my parents and friends for their support and encouragement throughout

the development of this Project.

ANEESH GOPAL

KRISHNA MARUTHI

NAGA CHOWDARY

UMAKANTH B S

ABSTRACT

On the surface, the concept of putting one kilogram of grain into a hydroponic system and

producing 6 to 10 kilograms of lush green sprouts, independent of weather and at any time of

year, is appealing. Though it seems like growing a lot of feed, the increase in fresh weight is

due to water and most often there is a reduction in dry matter weight compared with the

initial grain.

Hydroponically sprouting grain is less a case of growing feed and more a case of buying in

grain and spending additional, sizeable quantities of time and money to change its quality and

reduce its dry matter weight. The economics and application of such a production system

should be carefully examined.

This report evaluates the economics of producing cereal sprouts for commercial cattle

production through a hydroponic system. It looks at aspects of sprouts dry matter content and

nutrient quality as well as provides methods of costing and comparing sprouts with other

supplements.

DESIGN AND FABRICATION OF MANUAL AND AUTOMATED SYSTEM FOR HYDROPHONIC FODDER

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1 MECHANICAL DEPARTMENT,

NEW HORIZON COLLEGE OF ENGINEERING.

TABLE OF CONTENTS CHAPTER 1 ........................................................................................................................................... 1

1.1 INTRODUCTION ........................................................................................................................ 1

1.2 OBJECTIVE ................................................................................................................................. 1

1.3 LITREATURE REVIEW ............................................................................................................. 2

1.4 METHODOLOGY ....................................................................................................................... 3

1.5 SUCCESS IN ACHIEVING OBJECTIVES ................................................................................ 3

1.6 IMPACT ON MEAT AND LIVESTOCK INDUSTRY .............................................................. 3

CHAPTER 2 ........................................................................................................................................... 4

2.1 HOW HYDROPONIC FODDER SYSTEMS WORK ................................................................. 4

2.1.1 THE SPROUTING PROCESS .............................................................................................. 4

2.1.2 PROCEDURE FOR HYDROPONIC GREEN FODDER PRODUCTION .......................... 5

2.2 PRODUCTION OF HYDROPONIC GREEN FODDER OBSERVED IN BLOCK TYPE ........ 7

2.3 PRODUCTION CYCLE ............................................................................................................... 8

CHAPTER 3 ......................................................................................................................................... 10

3.1 HYDROPONIC FODDER ......................................................................................................... 10

3.2 THE HISTORY .......................................................................................................................... 11

3.4 WHY PHOTOSYNTHESIS? ..................................................................................................... 15

3.5 CARBON DIOXIDE (CO2) INJECTION .................................................................................. 18

CHAPTER 4 ......................................................................................................................................... 19

4.1 MANUAL MACHINE ............................................................................................................... 19

4.1.1 AIR COOLER ...................................................................................................................... 19

WHAT IS AIR COOLER? ...................................................................................................................... 19

4.1.2 TYPES OF AIR COOLERS ................................................................................................ 19

Direct, Indirect and two-stage evaporative cooling.......................................................................... 19

Difference between desert coolers and room coolers ..................................................................... 20

4.1.3 COMPARISON OF AIR COOLERS AND AIR CONDITIONERS .................................. 20

4.1.4 CHOOSING AIR COOLER SIZE ....................................................................................... 20

4.1.5 AIR COOLER FEATURES ................................................................................................. 21

Cooling Media ................................................................................................................................... 21

4.2 HEATING COIL ........................................................................................................................ 22

4.3 SUBMERSSIBLE PUMP ........................................................................................................... 23


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4.4 DESIGN ...................................................................................................................................... 25

CHAPTER 5 ......................................................................................................................................... 26

5.1 AUTOMATED SYSTEM FOR HYDROPONIC FODDER ...................................................... 26

CHAPTER 6 ......................................................................................................................................... 28

6.1 CONCLUSION ........................................................................................................................... 28

CHAPTER 7 ......................................................................................................................................... 29

7.1 FUTURE SCOPE ........................................................................................................................ 29

REFERENCES ..................................................................................................................................... 30


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CHAPTER 1

1.1 INTRODUCTION

Hydroponics fodder can be grown in low cost greenhouses with locally available grains.

Production of hydroponics fodder in low cost greenhouses is an effective solution for fodder

scarcity and is a very promising technology for sustainable livestock production in different

regions of India.

Green fodders are staple feed for dairy animals. Dairy animals producing up to 5-

7 litters’ milk per day can be maintained exclusively by feeding green fodders. Hydroponic

farming is the art of growing plants without the use of soil. This technology is old as history.

Hydroponic fodder production involves supplying cereal grain with necessary moisture and

nutrients, to enable germination and plant growth in the absence of a solid growing medium.

For economical and sustainable dairy farming, fodder production round the year is highly

essential.

1. We have developed block type structures which is easy to build and low cost

structure, having very good structural strength.

2. For building hydroponics green fodder system we need strong structure to cover it

with shed net and/or plastic sheets as covering material to maintain required humidity

and temperature.

3. Block type would be ideal structure to be used as hydroponics fodder cultivation, this

document will prepared to explain experiments conducted at NHCE on using geodesic

dome structures for hydroponics fodder cultivation.

4. Hydroponics experiment is used to check to test its feasibility.

5. Block type structure use is used for these experiments.

1.2 OBJECTIVE

1. To document feasibility of use of “Pabal dome” (Geodesic dome) structure as

potential hydroponics fodder cultivation unit.

2. Effective temperature and humidity control.

3. Faster seed germination.

4. Compact system for better utilization of floor space.

5. Selection of the system based on productivity.


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1.3 LITREATURE REVIEW

Sprouting grains for human consumption has been used for centuries in Asian countries to

improve food value. Hydroponics and sprouting cereals for livestock fodder has a shorter

history.

In 1699 an English scientist, Woodward attempted to grow plants in various sources of water

(Withrow and Withrow 1948 as cited in Myers 1974). In the mid1800s, the French chemist

Jean Boussingault verified nutritional requirements of plants grown without soil and by 1860

the techniques of “nutriculture” were being perfected by Sachs and Knop working

independently in England (Hoagland and Arnon 1938 as cited in Myers 1974). About this

time European farmers also began sprouting cereal grasses to feed to dairy cows during

winter. In the 1920s and early 1930s Dr W. F. Gericke developed procedures to grow plants

in nutrient solution on a large scale (Butler and Oebker 1962 as cited in Myers 1974).

In 1939 Leitch reviewed a range of experiments using sprouted fodder for dairy cows, beef

cattle, calves, pigs and poultry. The introduction to Leitch's thesis commences “The present

lively interest in sprouted fodder has arisen from the commercial exploitation of processes of

water culture of plants to produce stock fodder”. Leitch referred to five commercial

hydroponic fodder systems. Two British commercial systems, “Cabinet Culture” (also called

“Crop-a-day”) and “The Sprout Process”, two German patents and interestingly an

electrically heated cabinet in Australia called “Vitaplant” which was marketed by “British

Cultivations, Ltd.” In the 1950s fodder sprouting chambers had moved from Europe to the

USA.From the early 1970s a range of units were designed and manufactured in Europe and

the USA.One Irish company manufactured a machine to produce hydroponic barley grass.In

1973 in South Africa, D. A. Harris (1973) estimated that “no more than 400 units of all types

of fodder sprouting chambers are in use in South Africa” and also raised the question of the

economics of such a production system. Meanwhile in 1974 in Arizona, John Myers

commented,

“Thus it is that we find nothing but contradictory and conflicting research reports in a

literature search today” (Myers 1974). Fodder sprouting chambers have been used in Britain,

Europe, Canada, USA, Mexico, Ireland, South Africa, India, Russia, New Zealand, Australia

and no doubt many more countries.

In Australia in 1992, 1997 and 2003 journalists reported that ‘The Fodder Factory’ was the

answer to drought for livestock producers. In March 2003 in Western Australia Tudor et al.

(2003) found conflicting results feeding cattle with sprouted barley.


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1.4 METHODOLOGY

1. Literature review

2. Informal interviews - phone and/or face-to-face (where practical) with key representatives

from the following groups of hydroponic fodder stakeholders, including suppliers; producers

currently growing hydroponic fodder for feeding beef cattle or the ruminants; nutritionists;

and others, e.g. extension staff.

3. Analysis of the information gathered from points 1 and 2 above in terms of the nutritional,

economic, infrastructure and labour advantages and disadvantages of growing and feeding

hydroponic fodder for beef cattle compared to comparable conventional feeding regimes (e.g.

paddock feeding whole barley grain).

4. Identify issues and opportunities for further research.

5. Peer review results of points 1-4 with beef cattle producers, husbandry officers and

nutritionists.

1.5 SUCCESS IN ACHIEVING OBJECTIVES

An extensive literature review was conducted, however not a lot of current information was

available. One recent Australian paper (Tudor et al. 2003) recorded a period of higher than

expected performance when steers fed hay were supplemented with barley sprouts. They

concluded that further work was needed under rigorous research conditions to better evaluate

the performance potential of sprouts and the reasons for the response. Without fully

understanding the performance of sprouts, it is difficult to calculate the economics

conclusively. Methods for calculating the cost of hydroponic fodder are included in the report

so that producers can use them to do their own figures. This report clarifies the dry matter and

nutrient changes that occur with sprouting. It also provides a method for costing dry matter

and nutrients from sprouts and some examples of economics. The report confirms that while

sprouts are highly nutritious they are expensive.

1.6 IMPACT ON MEAT AND LIVESTOCK INDUSTRY

Hydroponic fodder has been advertised and perceived by some producers as a solution to

drought. Hydroponic fodder production systems are potentially very high capital, operating

and lifestyle investments. Some producers were having trouble evaluating the cost-benefits

for their business. This report provides independent information and tools to evaluate the cost

and nutrient value of hydroponic sprouts to assist producers’ decision making to minimise the

risk of unprofitable and/or unsuitable investments.


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CHAPTER 2

2.1 HOW HYDROPONIC FODDER SYSTEMS WORK

2.1.1 THE SPROUTING PROCESS

Producing sprouts involves soaking the grain, most commonly barley, in water until fully

saturated, followed by draining and placing it in trays or troughs for sprouting, usually for 5

to 8 days. The grain is kept moist during this period. Pre-soaking is important as there is a

rapid uptake of water which facilitates the metabolism of reserve material and the utilisation

of these reserves for growth and development (Thomas and Reddy 1962 as cited in Morgan et

al. 1992). Grain is often soaked or washed with a sterilising solution to help minimise the risk

of mould.

The yield and quality of sprouts produced is influenced by many factors such as soaking time,

grain quality, grain variety and treatments, temperature, humidity, nutrient supply, depth and

density of grain in troughs and the incidence of mould. To achieve maximum yield and

nutritional benefits of sprouts the grain should be clean, sound, free from broken or infested

seeds, untreated and viable.

Cereal seeds germinate equally well under dark or light conditions (Whyte 1973, Bartlett

1917 and Miller 1978 as cited in Chavan and Kadam 1989). Domestic or household sprout

production does not require special equipment and containers such as plates, bowls or pans

will do. There are many different commercial sprout production systems and versions of

controlled atmosphere sheds using heating and air conditioning available. They are usually

constructed on a slab of concrete and require access to electricity and water as well as a

storage tank for nutrients in solution.

Grain storage and handling equipment and often nutrients and sterilising agents are also

required. Regarding the growth process, Scott (2003) from the Nerang Hydroponic Centre

web site (www.hydrocentre.com.au) comments that, “in 24 hours they sprout a root, green

shoots day 2 and 3, by 5 days you can early harvest, 7 days is about max before they slow

down and behave more like slow growing grasses.

High levels of light are not necessary, but cool temperatures are. I recommend shade.”

Hygiene is essential. In between crops, the trays must be cleaned, often with chlorine based

cleaning solutions, to minimise the risk of mould.


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2.1.2 PROCEDURE FOR HYDROPONIC GREEN FODDER

PRODUCTION

Green fodder was grown up by maize seed during experimentation. And this seeds should be

pesticide and impurity free and are of best quality.

The following steps are carried out for green fodder production:

1. Soaking of seed

2. Germination of seed

3. Transfer the seed in greenhouse

4. Irrigation

5. Complete growth of green fodder

1. Soaking of seed

Weigh the correct amount of 1 kg of seed and wash it with clean water. Add the

appropriate amount of water in seed so that it is thoroughly wet. Allow it to soak for 12 hr.

Figure 2.1 Soaking of seed

2. Germination of seed

Keep the soaked seed in wet gunny bag and allowed to germinate (sprout) for 48 hr.at

temperature 17 to 19ºC.

1. Transfer the seed in dome

Dimension of plastic tray of 56 cm (length) x 40 cm (width) x 7 cm (height).The seed

was scattered uniformly within the tray. This tray must keep in controlled temperature, light,

irrigation and humidity because successful growth was observed in controlled environment.


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Figure 2.2 Transfer the seed in dome

2. Irrigation

Sprouted seed irrigated by sprinklers or fogging. Water must be provided at interval

of 1hr for 21sec.During experiments 400 ml of water was given for single tray with the help

of foggers for 21 sec duration. Excess water leads to the fungal diseases to the fodder.

3. Harvesting green fodder

The sprout allowed germinating in greenhouse for period of 8 days. Height of green

fodder is 13 cm, color is Flush/dark green, and without fungus and odor .This fully grown

fodder is then given to the Cattles as whole feed. Yield - from 1kg of dry seed around 7 to 8

kg green fodder can be made hydroponically.


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2.2 PRODUCTION OF HYDROPONIC GREEN FODDER OBSERVED

IN BLOCK TYPE

Table 2.1 Stages of growing fodder

Sr. no. Day Growth Stage Height cm) Weight

(kg) 9.00AM 5.00 PM

1. Day 1 Overnight soaked

seeds

0 0 1.460

2. Day 2 White Sprout are

seen

0.8 1 1.820

3. Day 3 Light green

sprouting is seen

2 2.5 2.89

4. Day 4 Leaf formation 3.5 4.2 3.21

5. Day 5 Leaf formation and 6 6.8 4.67

6. Day 6 Well-developed

leaf with light red

stem.

9 9.5 5.190

7. Day 7 Well-developed

leaf with dark red

stem.

11 11.5 6.55

8. Day 8 Flush/dark green

with well-

developed roots

12.5 13 7.94


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2.3 PRODUCTION CYCLE

Day 1 Day 2

Day 3 Day 4

Day 5 Day 6


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Day 7 Day 8

Green fodder mat

Figure 2.3 Day wise growth of cereals to Fodder.


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CHAPTER 3

3.1 HYDROPONIC FODDER

Hydroponic Fodder is essentially the germination of a seed (such as malt barley or oats) and

sprouted into a high quality, highly nutritious, disease free animal food. This process takes

place in a very versatile and intensive hydroponic growing unit where only water and

nutrients are used to produce a grass and root combination that is very lush and high in

nutrients. This green fodder is extremely high in protein and metabolisable energy, which is

highly digestible by most animals.

This method of producing green fodder has many advantages for the farmer, the economy

and the environment. These advantages include –

1. Reduced Water Usage Marginal Land Use

2. Constant Food Supply

3. Reduced Growth Time

4. Reduced Labour Requirement

5. Cost effective

6. High Nutritional Value

7. Completely Natural

Unfortunately there are also disadvantages in growing fodder in such a controlled, humid,

moist environment. Some of the problems that effect the yield production are MOULD,

BACTERIA and FUNGI. However this problem can be combated through –

1. Sterilising the grains surface to eliminate any mould spores on the grain

2. Sterilising all surfaces in the growing area with chlorine or iodine

3. Excellent shed ventilation

4. The use of sufficient and the correct ratio balance of nutrients in the watering system.


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Through the use of Sulphur, a natural substance, found in an organic matter known as –

Superior (a crushed rock product) – has mould-inhibiting properties.

To improve this method of growing cattle fodder, CO2 can be injected into fodder sheds.

Research under taken in Canada with Jim Ennis of Lethbridge, demonstrated that CO2

injection into the fodder shed cuts the growing time of Malt Barley from 7 days to 4 days

therefore increasing the shed production output by 75%.

The Egyptians, Inca Indian tribes, the Aztecs, The Maya's and the Babylonians are examples

of ancient civilizations which practiced hydroponic gardening without even realizing it, way

before the word "hydroponics" was ever thought of. Although many of us think of

hydroponics as a relatively new method in agriculture, our ancestors, in their efforts to always

improve their technology in farming, have already been working and learning whatever their

gardens could teach them, including soilless gardening.

3.2 THE HISTORY

The growing of fodder using soil-less growing systems is by no means a new concept to

Australia or the world. These systems have been in use for over 50 years to supply a wide

range of livestock types for many different purposes in varying living environments

(Aerotech Greenhouse fodder systems, 2002). During the war, the Australian Army used a

similar system to produce feed for their horses (as shown in Picture 2). South Africa, South

and North America were also using similar types of systems during this era and beyond

(Chris Gatti in the Daily News, 2002).

As early as the 1930’s ‘crop-a-day’ culture, as it was known then, was being practiced

throughout Great Britain. The fodder was considered then as sprouted forage, which would


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provide a variety of livestock and birds with a highly nutritive food with important mineral

and vitamin contents (Harris, Republic of South Africa).

There, however, remains a lot be learned in the science of hydroponic gardening. Because of

its low cost and easy workload, hydroponics captures the interest of many professionals. New

methods in hydroponic gardening are always being explored and will continue to be studied.

3.3 THE ADVANTAGES OF GROWING CATTLE FODDER

HYDROPONICALLY

Any environmental, ethnic and political tragedies of the past have resulted from what would

now be called ‘ineffective agriculture’. Such disasters include the deforestation of

Greece, the desertification of Northern Africa, and the environmental destruction of

Central Asia. The questions of how to rationally use land resources both ecologically and

economically are becoming more crucial for many countries with each passing year.

Australia, for all its agricultural bounty, is a land all too frequently ravaged by drought, fire,

flood and extreme seasonal conditions. The continued lack of good seasonal rain, the hot

summer weathers which burn off natural field feed and grasses, the winter frosts that slow the

growth and burn off valuable livestock food continue to devastate the lives of many farmers

year in and year out.

Hydroponics - the science of growing plants in nutrient-rich solutions instead of soil – has

proven itself to be efficient both financially and environmentally. Hydroponic methods have

been used for a long time to grow plants, primarily vegetables, but hydroponics is now being

used across many countries to take pressure off the land and grow green feed for livestock,

birds and carp raised for agriculture. This method of producing green fodder has many

advantages for the farmer, the economy and the environment. These advantages include:

Water usage

The hydroponic system requires a fraction of the water usage of conventional farming while

still supplying high quality stock feed. It takes between 1 to 2 litres of water to produce one

kilo of fodder as compared with 80 – 90 litres of water to grow a kilo of green grass (Calder,

2002). Therefore it uses minimal water for maximum fodder production.

This water, which is not used by the growing fodder, is not wasted, as it can be recycled.


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The left over water still contains many nutrients and therefore can be reused to water small

areas of pasture or collected and used on gardens, lawns or vegetable patches (Gatti, 2002).

Because this water contains no chemicals (only natural supplements), it can be recycled or

filtered for use within the shed without harming the environment

Air temperature control, Air flow, Water Treatment, Water Temperature, Air cleanliness,

Airborne Bacteria removal, Water circulation, Automated controls with alarms, Drainage,

LED Growing light technology (option), tested technology through NASA USA, and a

practical system to off load readily, are all incorporated in the design and are either standard

or available in options depending on what you as a client want

Marginal Land Use

This type of fodder production provides huge ecological and economical advantages, as the

production of this lush fodder requires minimal land usage as compared to field-grown

grasses and feeds. For example research shows that fodder grown in a 9m x 6m shed can feed

(supplement) daily, the same amount of cattle that graze on 1200 acres of pastured country in

our area of Queensland. Therefore hydroponic fodder does not require acres and acres of land

to produce the feed required fatten or maintain livestock thus allowing the farmer to enhance

the value of marginal land. Others studies completed in South Africa by Harris demonstrated

that land usage by animals could also be decreased. For example information emerged

demonstrating that using the pen system for sheep, where by the sheep were feed

hydroponically grown green fodder, 250 animals could be raised in an area of some 520m2

whereas by conventional South African standards 1sheep per 2.5 ha is normal. Pavel Rotar,

Russia, states that ‘The reduction in the amount of land required for maximum fodder

production is an asset for both regions where agriculture is difficult and in densely populated

regions that lack sufficient growing space’. This is a crucial factor for Asia and other third

world countries, as the lesser grazing area required to feed stock would provide more acreage

for food crop production.

Constant Food Supply

Hydroponic technology has removed the need for long-term storage of feeds.

Unfortunately, Hay, silage and other feeds lose some of their nutritional value during storage.

This technology according to a veteran Kiwi, Tom Hayes has also provided farmers with the

opportunity to take control over something they have at present little control over - grass

growth. Farmers using this type of fodder production are guaranteed a consistent supply of

quality fodder 365 days of the year irrespective of rain, hail, sunshine or snow. Therefore the

farmer knows exactly what feed they have available every day of the year regardless of the

seasonal conditions as it takes just six to eight days for the fodder to grow from a seed into a

mature plant of 25cms. This knowledge then allows the farmer to send stock to the markets at

peak or near peak condition. Having this constant food supply also allows farmers to retain

their stock, selling them when the prices are suitable without having to accept poor market

prices because of lesser quality livestock. Hydroponic techniques have also proven very

successful in other countries where extreme environments exist. Pavel Rotor commented on a

hydroponic system that was set up in eastern Kazakhstan, three kilometres from one of the

largest titanium/magnesium plants in the world. In this area, where winters can last 250 days,


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the death rate of new born cattle was extremely high. The contaminated environment and

unfavourable weather conditions made healthy fodder difficult to come by. With the

introduction of hydroponically grown feed, the death rate fell sharply and the surviving

animals were stronger and healthier.

Similar results have been seen in the Voronezh region of Russia, near the Novo

Voronezh Atomic Energy Station. There hydroponically produced fodder has been used to

feed swine, reducing death rates and improving the general health of the animals, while

reducing feed expenses.

Growth Time

Case studies completed by Bill Calder have shown that the growing time of hydroponic

plants takes as little as 7 days from seed germination to a fully grown plant as at a height of

25 – 30cm ready for harvest. All though Bill does suggest that for an even better result use an

eight-day growing cycle.

Joe Mooney Hydroponic Fodder Production Meat and Livestock Australia 14

During recent droughts, which turned many farms into dust bowls, deer and cattle farmer?

Peter Ryan had no troubles keeping his livestock alive and healthy as he started producing

hydroponic fodder in eight days from seed to harvest. Peter stated that ‘for every 1kg of seed,

7 – 10kg of edible fodder is produced. However to grow the same amount of fodder in a

paddock situation, if there was sufficient water for irrigation, would take up to 12 weeks from

seed germination until ready to feed out to livestock’. Thus showing the great advantage this

system has for farmers.

Cost effective

Studies have concluded that the production of hydroponic fodder is an extremely cost

effective and financially viable. Warmblood breeders Chris and Liz Gatti have considered

hydroponic fodder as ‘cheap fresh green feed’. Their system can produce 350kg of green feed

(wet) for a low cost of $40 a tonne and little maintenance. Deer and cattle farmer

Peter Ryan also proclaims that his system can yield up to 960 kg of nutritious fodder (wet)

per day for a cost of approximately $40.Remembering that what ever animal you are feeding

still lives in its normal environment thus obtaining some dry matter requirements from that

environment.

Completely Natural

An important factor about growing this type of feed is that it is a completely natural product.

The fodder is produced without the use of any hormones, synthetic growth stimulant or

chemical fertilisers, as any fertilisers that are used are totally organic.

Therefore there are no pesticides or fungicides used that could alternately contaminate the

meat or milk that are being produced. Fodder grown hydroponically is also free of dust and

any other agriculturally related contaminants and toxins.

Studies completed by the Agricultural College of Ayr in West Scotland discovered that the

use of a completely natural sprouted fodder in beef production produced a beef that is

‘particularly pleasing, of exceptionally fine quality and produces an exceptional carcass for

MSA grading’.


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3.4 WHY PHOTOSYNTHESIS?

All living creatures require energy and nutrients to survive. Animals can be divided into

autotrophs and heterotrophs according to how they acquire this energy and nutrients.

Autotrophs make their own food from inorganic nutrients and obtain energy from non-living

sources. Heterotrophs must consume other living creatures to gain the energy and nutrients

they need to live. Plants, as autotrophs, must make their own food and do so from sunlight,

carbon dioxide and water through a process called photosynthesis

Tray

Barley grass improves milk production in dairy cows. Additionally, milk from cows fed

barley grass contains higher grades of butter fat.

• Barley grass increases energy levels in horses while adding shininess to the horses' coats.

Supplementing with barley grass helps improve fertility and foal health for broodmares on

pasture with poor-quality grazing. Recovery time after a hard workout is lessened for horses

fed barley grass, and hoof quality and strength is improved.

• Sheep and goats display improved digestion and health as well as good weight gain on

poor-quality pasture.

• Feeding barley grass improves the milk yields in dairy goats and improves the appearance

of fleece in goats.

• Barley grass supplements also enhance swine production

• Reduces illness such as colic and gut ulcers

• Improves appearance of coat or fleece

• Improvements in hoof strength and quality

• Improved conception and birth rates

• Improves milk yield and levels of unsaturated fatty acids (UFA)

Benefits for dairy cattle

It is well known that a cow only gets 20% of the energy produced through digestion of a

grain based diet such as alfalfa and maize to produce milk.


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Hydroponic fodder is so much more easily digestible, full of nutrients and enzymes that the

energy spent on this digestion process would be far less with the resultant extra energy being

diverted to milk production and growth.

Independent trials and studies also point to improved milk yields and content:

Benefits for sheep

• Improved wool quality

• Higher fertility

• Less teeth wear

The benefits for sheep are well documented. These range from merely keeping a large number of

sheep alive in extreme weather conditions to improvements in condition of the wool, increased

fertility/conception rates and improved birth rate/ lower infant mortality.

Worldwide conducted trials with race horses you can say with a high degree of credibility

that after being fed with sprouting fodder as a supplement for 3 months the win and place

ration was better than ever before.


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In addition the incidence of colic, respiratory illness and gut ulcer were significantly reduced

across the stable. The superb digestibility of the fresh sprouting fodder helps with colic and

ulcers. The lack of dust from dry feed, in turn helps with the respiration.

Benefits for pig

• Improved weight gain

• More piglets

In addition the sows came into heat much quicker, they were visibly more healthy and had a

longer milking period. This enabled the piglets to hang on for longer and grow fatter faster.

Once off the milk the piglets were given a “snack” of hydroponic sprouting barley and at the

same age were significantly bigger than the piglets.

Benefits for wild park/Zoo’s/Deer

The vast majority of feed for Wild Parks & Zoo’s is purchased and transported from external

sources.

More and more Wild Parks & Zoos are now looking at how they can feed their animals in a

responsible manner with food produced locally, that in turn reduces their costs and more

importantly will benefit the health of their animals.

A huge majority of zoos have ruminants and other grazing animals that feed predominantly

on grass or grass substitutes when in captivity such as hay.

Benefits for poultry

• More eggs

• Larger eggs

• Deep yellow yolk


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Trials in Tasmania have shown that when fed fodder, 20 x 1 year old free range chickens

increased their egg laying by from a total of 5 per day to 15 per day within 3 weeks of being

introduced to the fodder.

Benefits for Rabbits

"Farmed rabbits are grown for their meat and we trailed fodder to test for increased weight

gain in a shorter period of time.

Rabbits take very well to sprouting fodder. Our trials showed them consuming all the fodder

given to them by the 2nd day.

On average a Doe has 10-12 sets of babies per year, with an average of 6-8 babies per set

dependent on the age of the doe, although to be viable we need to produce 8 kits per set."

3.5 CARBON DIOXIDE (CO2) INJECTION

People laughed when it was claimed the playing music to plants made them grow better. It

really did because the sound vibrations actually strengthen the stem fibres, shorten the

internode length, and cause stress growth reactions from the plant. Then people continued to

laugh when it was claimed that singing to plants made them grow better. However, it is true.

The CO2 from human breath actually makes plants grow faster (Reinders, 1996).

All plant dry matter is 90% carbon, hydrogen and oxygen. All the carbon has to come from

the Carbon Dioxide (CO2) in the air. Studies have shown that plants do not need

CO2 in the dark period, only during the light times and the lighter that is available the more

CO2 it requires for photosynthesis. Experiments have revealed that during photosynthesis, it

takes about 10 photons to make enough electrons to create sufficient energy to split one CO2

molecule into carbon and oxygen atoms to form sugar. There are trillions of photons striking

the plant leaves, but if there is not enough CO2 provided, the photons will just bounce off the

leaves without doing much at all (Reinders, 1996).

Research completed in Canada with Jim Ennis of Lethbridge, demonstrated that CO2

injection into the fodder shed cuts the growing time of Malt Barley from 7 days to 4 days

therefore increasing the shed production output by 75%. This is because the amount of carbon

dioxide has increased from an ambient level of 300 PPM to a high level of 2000

PPM, the amount a plant can process if in full sunlight.

This increase in fodder production comes at an expense of 1 gas cylinder of CO2 per month

and the initial set up cost of the Carbon dioxide emitters. This means that a shed, which was

producing 100 trays or approximately 1 tonne of feed per day, can now produce 175 trays or

approximately 1.75 tonne of feed per day.


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CHAPTER 4

4.1 MANUAL MACHINE

4.1.1 AIR COOLER

WHAT IS AIR COOLER?

Air cooler works simply where water is put in the cooler. The air is circulated by the pump in

the cooler as water is sprinkled on the pads of the cooler. This evaporates the heat and cool

air is circulated in the room.

Figure 4.1 Air cooler

4.1.2 TYPES OF AIR COOLERS

Direct, Indirect and two-stage evaporative cooling

Direct evaporative coolers are the most common, used to lower the temperature of air by

using latent heat of evaporation, changing water to vapour.

Indirect evaporative cooling uses some form of heat exchanger. The moist cooled air does


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not come in touch with the environment outside. Two stage cooling goes through 2 stages.

In the first stage the air is precooled by heat exchanger. The precooled air in second stage

through water soaked pads. Since precooled air goes through in the second stage, in this

type of cooler the humidity will be less.

Difference between desert coolers and room coolers

Desert cooler is better and provides better cooling. However desert cooler requires more

power, more space and more water. In a hot place this type of cooler should be preferred.

In a smaller room and less hot environment, room coolers should suffice.

4.1.3 COMPARISON OF AIR COOLERS AND AIR CONDITIONERS

1. Air coolers use less energy than an AC. 2. Air coolers need less maintenance than an AC. Also does not need

elaborate installation and hence this cost is almost negligeble unless you have some special requirements.

3. Air coolers have environmental benefits with no harmful Chlorofluorocarbons (CFC) or gases emissions and very low power consumption.

4. Air conditioners are more effective in extreme temperatures and also in humid environments.

5. Air conditioners can control temperature which an air cooler cannot do. 6. Air coolers increase humidity which reduces evaporative functions of

human organs. 7. Air coolers require regular supply of water to wet the pads. In areas where

water supply is not constant, this may not be a feasible option

4.1.4 CHOOSING AIR COOLER SIZE Air coolers are rated by air delivery or the cubic feet per minute of air that the cooler can

blow into your home. You can use simple formula to identify the proper size of air cooler

that you need.

(SQUARE FEET AREA X CEILING HEIGHT) / 2 = CFM OF AIRFLOW NEEDED.

So if you have a room of 500 sq feet with ceilings of 8 feet high then

(500 X 8 / 2) = 2000


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Hence, you will need a cooler with minimum air flow of 2000 cfm.

All air coolers will clearly define the air delivery.

4.1.5 AIR COOLER FEATURES

Cooling Media

Cooling media today is mostly honeycomb nowadays. It is made from specifically

engineered cellulose paper that is chemically treated to resist deterioration.

Honeycomb cooling pads are designed to provide maximum cooling, low pressure drop and

longevity.

Figure 4.2 Working of air cooler


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4.2 HEATING COIL

Figure 4.3 Heating coil

A typical heating element is usually a coil, ribbon (straight or corrugated), of strip of wire

that gives off heat much like a lamp filament. When an electric current flows through it, it

glows red hot and converts the electrical energy passing through it into heat, which it radiates

out in all directions.

Heating elements are typically either nickel-based or iron-based. The nickel-based ones are

usually chrome, an alloy (a mixture of metals and sometimes other chemical elements) that

consists of about 80 percent nickel and 20 percent chromium (other compositions of chrome

are available, but the 80–20 mix is the most common). There are various good reasons why

chrome is the most popular material for heating elements: it has a high melting point (about

1400°C or 2550°F), doesn't oxidize (even at high temperatures), doesn't expand too much

when it heats up, and has a reasonable (not too low, not too high, and reasonably constant)

resistance (it increases only by about 10 percent between room temperature and its maximum

operating temperature).


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4.3 SUBMERSSIBLE PUMP

Figure 4.4 Submersible pump

The submersible pumps used in ESP installations are multistage centrifugal pumps operating

in a vertical position. Although their constructional and operational features underwent a

continuous evolution over the years, their basic operational principle remained the same.

Produced liquids, after being subjected to great centrifugal forces caused by the high

rotational speed of the impeller, lose their kinetic energy in the diffuser where a conversion of

kinetic to pressure energy takes place. This is the main operational mechanism of radial and

mixed flow pumps.

The pump shaft is connected to the gas separator or the protector by a mechanical coupling at

the bottom of the pump. When fluids enter the pump through an intake screen and are lifted

by the pump stages. Other parts include the radial bearings (bushings) distributed along the

length of the shaft providing radial support to the pump shaft turning at high rotational

speeds. An optional thrust bearing takes up part of the axial forces arising in the pump but

most of those forces are absorbed by the protector’s thrust bearing.


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Figure 4.5 Complete setup of Manual Machine

There are 12 trays installed in our setup and our racks are made up of mild steel. We have

covered it with poly sheet for racks so that in order to control the damage of fodder from ultra

violet rays.

The setup is completely cost effective which can be used by the normal farmer who has cattle

range of 4 to 5 herbivorous. So the cooler and heater can be installed very effectively within

the minimum space available. The trays are placed at a certain angle so that the water can

flow freely due to gravity through perforated holes.


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4.4 DESIGN

Figure 4.6 2D sketch of Manual fodder

Figure 4.7 3D MODEL


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CHAPTER 5

5.1 AUTOMATED SYSTEM FOR HYDROPONIC FODDER

Figure 5.1 Automated system (Prototype)

Figure 5.2 Top view


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System Set Up

There are a number of sophisticated systems specially developed for the production of

hydroponic fodder. One of the more common systems internationally, and one that is

available in New Zealand is FodderTech (www.foddertech.com). Other systems include

Fodder Factory, Green Feed Solutions and Fodder Solutions. Each of these are based largely

on the same principles.

Purpose built sheds house the fodder production systems. A range of shed sizes are available,

from 50m2 to 300m2. A mid-sized unit, producing 1 tons of wet fodder per day, will

typically measure 10m x 13m. Fodder sheds consist of two areas – a growing area where the

fodder is grown, and a pump area where grain is prepared for sowing and is where nutrient

tanks, pumps and associated systems are located. In a 100sqm shed, the growing area

represents approximately 70% of the total floor area.

Figure 5.3 Large setup of Automated system


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CHAPTER 6

6.1 CONCLUSION

Our aim was to setup a model hydroponic apparatus which could be easily built by any Indian

farmer in order to meet the fodder needs of his cattle.

Producing green fodders under controlled conditions is economical and suitable for adoption

by this country. There exists a great need for scientists and engineers across the globe to take

up research in this challenging and interesting field for application in hydroponics.

The challenge here is to produce a system viable and adaptable throughout the year in a cost

effective and energy sustainable manner.

1. It is low cost system which can be used round year for green fodder production.

2. Block type structure has low maintains and easy operations.

3. Nutritional value of milk is not checked because we are doing it as the experiment.


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CHAPTER 7

7.1 FUTURE SCOPE

Economics aside, sprouts have shown instances of significant performance improvements,

however it is uncertain if these results are repeatable. Tudor et al. (2003) had intriguing

results using hydroponic fodder as a supplement to steers on low protein hay. Over a 48-day

period steers on restricted hay intake given 1.8 kg DM of barley sprouts produced 1

kg/head/day live weight gains and 5:1 feed conversions. The same cattle for a further 22 days

given 1.5 kg of sprout DM and ad lib hay gained 0.41 kg with a 22.8:1 feed conversion ratio.

More work is needed to confirm if the exceptional performance was due to sprouts and if so

why the performance was so much higher in the first 48-day period. It would be valuable to

understand which circumstances lead to high performance responses.

Taking economics into consideration, if sprouts cost 2 – 5 times the original grain DM, could

similar results be achieved with feeding grain or protein meals at a similar cost and without

having the large capital outlay and daily workload of a hydroponic shed? For example,

assuming sprouts cost $120/t as fed, it would be possible to feed almost 5 kg of a protein

meal or grain ration at $380/t for a similar cost as 1.8 kg DM sprouts. With more

conventional supplements, McLennan (2003) pers.comm. Has found substantial live weight

performances in penned weaner cattle fed hay and supplemented with protein meals between

0.5 to 1% of live weight. To better evaluate the supplementation potential of sprouts under

Australian conditions, compared to conventional supplements, requires further rigorous,

independent research.

Morgan et al. (1992) found dramatic reductions in DM loss with improved irrigation

techniques. They concluded that DM gains in a short growth cycle (eg 6-8 days) are not

possible. Claims of 10- fold sprout yields and 15-20% dry matters would theoretically

produce significant DM gains. If further research is done on sprouts it would be worthwhile

evaluating the productivity of current hydroponic systems to determine if DM gains are

possible as well as the economics.


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REFERENCES

1. Chavan, J. & Kadam, S. S. (1989). Nutritional improvement of cereals by sprouting.

Critical Reviews in Food Science and Nutrition. 28 (5), 401-437.

2. Dung, D. D., Goodwin, I. R., & Nolan, J. V. (2010). Nutrient Content and in sacco

Digestibility of Barley Grain and Sprouted Barley. Journal of Animal and Veterinary

Advances, 9 (19), 2485-2492.

3. Fazaeli, H., Golmohammadi, H. A., Shoayee, A. A., Montajebi, N., Mosharraf, Sh.

(2011). Performance of Feedlot Calves Fed Hydroponics Fodder Barley. Journal of

Agricultural Science and Technology, 13, 367-375.

4. Finney, P.L. (1982). Effect of Germination on Cereal and Legume Nutrient Changes

and Food or Feed Value: A Comprehensive Review. Recent Advances In

Phytochemistry, 17, 229-305. Hinton, D. G. (2007). Supplementary Feeding of Sheep

and Beef Cattle. Collingwood; Australia: Landlinks Press.

5. Kohler, G.O., Elvehjem, C. A., & Hart, E.B. (1938). The relation of the grass juice

factor to guinea pig nutrition. The Journal of Nutrition, 15 (5), 445-459.

6. Marisco, G., Miscera, E., Dimatteo, S., Minuti, F., Vicenti, A., & Zarrilli, A. (2009).

Evaluation of animal welfare and milk production of goat fed on diet containing

hydroponically germinating seeds. Italian Journal of Animal Science, 8 (2), 625-627.

7. Miscera, E., Ragni, M., Minuti, F., Rubino, G., Marisco, G., & Zarrilli, A. (2009).

Improvement of sheeo welfaee and milk production fed on diet containing

hydroponically germinating seeds. Italian Journal of Animal Science, 8 (2), 634-636

8. Myers, J. (1974). Feeding Livestock from the Hydroponic Garden. M. Sc. Thesis,

Arizona State University. Sneath, R. & McIntosh, F. (2003).

9. Review of Hydroponic Fodder Production for Beef Cattle. North Sydney; Australia:

Meat and Livestock Australia Limited.

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