Performing Department
(N/A)
Non Technical Summary
Small to mid-sized farms are in dire need of innovative yet affordable agriculture tools that maximize profitability potential of their businesses. The CWDT hydroponic system will increase leafy green, herb, and strawberryproduction capacity through the utilization of the dead-space alongsidewalls and connection bays in greenhouses ofexisting horizontal NFT hydroponic system users. Unlike other systems offered today, the CWDT is innovative in its ability to integrate with established systems as a companion product. In addition to adding value to existing hydroponic operations, the CWDT will be a best in class option compared to existing hydroponic tower systems available today. The system is nimble, lightweight, and has minimal components, making it easy to use, clean, and store. Though it was developed for hydroponic farmers, anyone with limited space yet a desire to grow fresh produce can benefit from the CWDT. The goal of the SBIR project was to research and analyze how a hydroponic tower could be simplified to meet market demands and lower production costs. The CWDT will be a catalyst for scientists looking into the capabilities of hydroponic technologies working together as companion products verses competative. This not only benefits farmers, but anyone looking to use hydroponic systems to maximize a food producing space.GSS Group will approach Phase II objectives with experienced product development specialists and hydroponic farmers. These participants are an essential component to the project. Product development professionals will help to identify critical control points of the hydroponic system design before major investments are made to manufacture the parts. Farmers will provide essential feedback on how the system integrates, effects, and/or adds value to thier existing operation. As a result, the CWDT hydroponic system should be affordable to any middle-class citizen, simple to use, and produce high quality produce.
Animal Health Component
0%
Research Effort Categories
Basic
25%
Applied
25%
Developmental
50%
Goals / Objectives
Phase II efforts will culminate in a low-cost hydroponic tower system designed for small and mid-sized hydroponic farmers looking to scale-up production with minimal investment. GSS Group's patent-pending Cascading Water Disbursement Tower or CWDT, a hydroponic apparatus, is unlike other vertical hydroponic tower systems in its ability to add value to existing farm operations. The tower is a companion product, innovative in its ability to utilize "dead-space" found alongside-walls and connection bays of existing hydroponic operations utilizing horizontal Nutrient Film Technique (NFT) hydroponic systems. The result for the hydroponic farmer is a more productive greenhouse.Phase II objectives will focus on researching and testing a prototype of each CWDT system's components to create a final-stage-prototype of the CWDT Stack-Unit, irrigation/drainage, and mounting frame.During Phase II, the PI will work with engineer, manufacturer, and product development professionals to transition the tested design concept created in Phase I into a functioning prototype to conduct trial tests on active farms.Objective 1: Optimize the CWDT Stack-Unit to Create Prototype "Tower-Sets" Suitable for Trial RunsTo conduct trial tests on existing farm operations, the PI must first determine how the CWDT Stack-Units will attach to each other as an injection molded part to create a "tower-set." In addition, the part must be affordable mass-produced to meet wholesale buyer requirements. During Phase II, the PI will work with Proto Research, a reliable product development company that assisted the PI during Phase I, and other product development companies to analyze the current design from a manufacturing perspective, create design variations that are manufacturable, and fabricate those design variations to run initial tests.Objective 2: Research and Develop a Prototype CWDT "System-Package" to Simulate an End-Product for Trial Run ParticipantsIn Phase II, GSS Group will address the hurdle of creating a complete system package to provide trial run participants. The goal is to simulate the a realistic CWDT hydroponic system experience. Hydroponic systems generally include the growing apparatus (tower, gully, bucket, etc.), a frame, and irrigation and drainage components. As this project also addresses the priority crosscut area Agricultural-Related Manufacturing Technology, in objective 2 the PI will continue working with Proto Research to focus on determining how manufacturing restrictions will affect the overall system package design, how it is best assembled, and which strategic procurement partnerships will result in a CWDT system package production cost goal of under $500 to meet wholesaler demands.Objective 3: Assemble Complete Prototype CWDT System-Packages to Conduct Trial Runs In order to simulate a new product launch using a final stage prototype, the PI needs to understand how system packages should be procured and assembled in a production setting. To do this, the PI will conduct research on vendors, experiment with various production plan layouts to build the prototypes, and design and test an inventory management system.Objective 4: Test the Effects of Integrating a Prototype CWDT System-Package into Existing Farm Businesses with Trial Runs Once the research participants have received their prototype CWDT package, the PI will conduct field tests that assess the prototype's feasibility on active small and mid-size farm sites. The trial tests will take place at Reeves Family Farm, Profound Microgreens, MO Veggies Please, East Texas Aquaponics, Siloam Springs High School, and a CropKing™ test greenhouse. During Phase I, the PI used 3D printed CWDT tower-sets to grow lettuce crops along the greenhouse sidewalls adjacent to horizontal NFT systems at North Arkansas College. The PI learned that the CWDT design concept was viable to produce marketable product. Now the goal is to quantify the potential revenue increase (percentage) for an average greenhouse facility when the CWDT system is integrated into an existing production's dead-space. The PI will also measure the long-term impact of potential shading caused by installing the systems within greenhouses with North/South orientation vs. East/West orientation. Another question to be answered is in regards to how GSS Group's prototype CWDT system will integrate into the various plumbing designs of trial run participants. Each participant has a unique operation; giving the PI an opportunity to research "best practices" of plumbing integration. In addition, the PI will use surveys to gather qualitative rating/ feedback from trial run participants in regards to using the prototype instruction manual to assemble the product, what crops are were grown and why, and if they will likely purchase a CWDT system when available.
Project Methods
Objective 1: Optimize the CWDT Stack-Unit to Create Prototype "Tower-Set" Suitable for Trial RunsThe PI and product development companywill conduct design sessions that focus on researching and designing attachment specifications compliant with the identified manufacturing process.In order to test each CWDT Stack-Unit design, Proto Research will use computerized machining to create a working version of the optimized CWDTs. Computerized Numeric Control (CNC) machining is a subtractive manufacturing process that involves using computer g-code to mill blocks of plastic into a specific design. The precision is within thousands of an inch of submitted designs and results in a smooth surface as it would be if injection molded. Tight tolerances and exact surface finishes are not possible with 3D printing.The PI, Proto Research, and Enventys Partners will down-select possible variations based upon an understanding of manufacturing limitations and the Stack-Unit's design requirements. Proto Research will then CNC machine three CWDT Stack-Units of each variation resulting in a middle Stack-Unit having a unit connected above and below it. To test the machined CWDT Stack-Units, the PI will perform a functional test by attaching and detaching the units while both dry and wet. The next test will be to spray the tower-set with a salt solution and dry it to simulate a hydroponic system with nutrient solution that has dried in the sun. The result is dried particulate on the part, a common occurrence in hydroponic production. The goal will be to determine which variation will become too difficult to attach and detach once the particulate dries onto the part. This process (design, fabricate, test, modify) will be repeated until a design that passes the initial tests is secured.Objective 2: Research and Develop a Prototype CWDT "System-Package" to Simulate an End-Product for Trial ParticipantsObjective 2: Task 1: Mount DesignTo start, Proto Research will utilize their engineering software to simulate how a mount design variation will respond when weight is applied, what components are required for assembly, and how much the mount will weigh before and after the towers are installed. The first milestone of this objective will be to identify two to three CWDT Mount design variations that are adjustable, sturdy, lightweight, and securely host the CWDT Stack-Units. The PI will then procure the components to initiate procurement and assembly tests. The PI will first analyze the procurement process to answer technical questions including; are the components readily available, what is the cost, and are the parts affordably available in large quantities? The next test is the assembly process. The PI will assess how long the assembly process takes for each variation, level of complication, how easily the mount's height can be adjusted, and how the tower-sets and mount respond once they are attached.Objective 2: Task 2: Irrigation and Drainage System: During Phase II, the PI will not only reduce overall production costs, but will simplify the assembly and integration process. To do this, the PI will continue working with Proto Research and repeat the methodology used in task one, that is, utilize engineering software to create design variations for testing.Objective 2: Task 3: Instruction Manual: By now, the PI will have decided upon a system package design that includes the mount, irrigation, and drainage components. The decision will be based upon assessing how the developed variations addressed technical requirements, complexity, and cost. The PI will then determine how the prototype system should be assembled. To do this, the PI will take notes, pictures, and recordings of the assembly process. Then the PI will develop a simple document with step-by-step instructions. This manual will be assessed on its effectiveness during the trial run.Objective 2: Task 4: Research Material Suppliers to Complete the Prototype System-Package DesignThe goal of this task is to identify suppliers that are most competitive in regards to not only price, but also quality, shipping time, and customer service. To do this, the PI will create a "vendor-assessment-form" for each component of the system package. The forms will be used to rate each supplier on the mentioned characteristics. The vendors with the most promising results will be used when ordering parts to assemble the prototype system packages for trial runs in Objective 3.Objective 3: Research and Test Production Strategies to Assemble Complete Prototype CWDT System-Packages for Trial RunsObjective 3: Task 1: Research Work Order and Inventory Management SoftwareThe PI and Proto Research will work together to find various inventory management software to create work orders that are "built to order" instead of "built to stock." The key difference being that built-to-order products are assembled during the fulfillment process rather than in advance. Preliminary research has indicated that such software is available including; Net Suite, Zenventory, and Inflow.Objective 3: Task 2: Research Production Layout Methods while Assembling Complete CWDT System-PackagesNext, the PI will organize the procured materialsusing shelving and/or racks with wheels will help the PI to make quick layout modifications once critical control points that could negatively affect the production process are identified. It is important that these hurdles are found and addressed before making intensive investments in inventory, warehouse space, and labor in Phase III. To do this, the PI will work with Proto Research to implement a production layout that results in less time spent on finding and packaging system materials.Objective 4: Test the Effects of Integrating a Prototype CWDT System-Package into Existing Farm Businesses with Trial RunsDuring Phase II, the PI will conduct field tests on a complete prototype CWDT System-Package in five different locations.Objective 4: Task 1: Collect Harvest Data from Participants Before They Install PrototyeThe PI will start by visiting each participating farm location, on a harvest day, before the prototype CWDT System-Packages are shipped to collect at least 2 harvests of lettuce crops grown in the existing horizontal NFT systems. Data to be collected from the plants during harvest includes each crop's height, width, and weight. The data will be used as a control to determine if/how the CWDT systems affect plant growth in existing systems.Objective 4: Task 2: Silently Monitor the Prototype Installation Process at Participating LocationsOnce the participants have received their packages, anticipated to arrive by the end of September, 2021, the PI will travel to each location and silently monitor each participant as they assemble and install the prototype. The participants will be expected to use the prototype instruction manual. The PI will not interfere with the process unless the participant cannot assemble the system and/or asks for assistance. The PI will take notes during the monitoring process and as well as use surveys to gather feedback to understand the prototype package's strengths and weaknesses during the installation process.Objective 4: Task 3: Conduct Monthly Data Collection on Prototypes and UsersOnce each system is installed, the PI will schedule a visit once per each month during a harvest day to collect measurements (height, width, weight) of harvested crops from both the prototype CWDT System-Package and the existing systems. The data will be assessed to determine if the CWDT produces quality products without inhibiting the growth of crops within adjacent systems. During each monthly visit, the PI will also distribute surveys to gather user feedback regarding the system ease of integration, maintenance, potential issues encountered, and testimonials.