Living Lettuce

1. Medium Filling

The production of lettuces and herbs starts with the seedling production. Plant trays are filled with growing substrate such as peat or rockwool. Typically, our systems use paper or plastic pots inside the tray to ensure safe and efficient transplanting. 

2 . Sowing

Next, seeds are sowed to the pots. The sowing process is PLC controlled and various types of seeds can be used. Trays of pots are irrigated and stacked onto a pallet to be transferred to the germination room.

H. Handling of Plants

Trays of pots are transported into and out of the germination room with a pallet which can hold up to 120 trays. 

3. Germination

The germination room is a climate-controlled space, which has systems for humidity control and heating, providing a perfect environment for seeds to germinate and grow before moving them to the growing area.

H. Handling of Plants  

Trays of pots are transported into and out of the germination room with a pallet which can contain up to 120 trays.   

4. Nursery Tables

After the trays have been placed on the nursery tables, they are irrigated from overhead with moving irrigation booms. These booms are regulated by our control system. During their days on the nursery tables, plants grow strong roots and are ready to be transplanted to the hydroponic NFT system.

T. Transplanting

The transplanting from trays to gutters is done in one efficient step using a simple transplanting tool.  After transplanting, the empty trays are washed with a tray washing machine and used again. After transplanting, the empty trays are washed with a tray washing machine and reused.

5. Growing

The gutters with the plants move automatically through the greenhouse toward the harvesting end. During that process, the distance between the gutters is adjusted according to the space requirements of the plants in each growing phase, giving the plants as much space as necessary, but as little as possible, ensuring maximal usage of the greenhouse growing area. The plant density achieved with the adjusting gutters is unmatched and a key component in efficient growing.

6. Harvesting

During the growing process, the plants have moved through the greenhouse toward the harvesting area. Harvesting takes place at the end of each line and is usually done manually. Harvested lettuce heads and herbs can be packed directly at the harvesting station or can be transferred via conveyor to a centralized packing station.

7. Cleaning

Once the lettuce is harvested, the empty gutter is fed into an automatic washing machine.  Automated harvesting waste management solutions are available.

Gutter Management

The clean gutter is then placed on the gutter wagon and returned to the transplanting area, where it will be ready for a new growing cycle.    

8. Additional Process Steps

Supply of Growing Medium

When using loose medium, such as peat, the system features a bale breaker which is re-filled with large bales.

Waste Stream of Substrate

The standard system is equipped with a single conveyor which takes the waste substrate stream from the removal site to a mobile dumpster. Alternative solutions are available.

Irrigation and Fertigation System

Plants are irrigated and fertigated automatically by our control system. In the irrigation system the water is dosed to the gutters from drip emitters. Excess water flows from the gutters to the return water tanks, which can efficiently be placed under the growing lines. By using this smart irrigation system, we make certain plants get the correct amount of both water and nutrients. Water which is not consumed by plants is cleaned, returned to water tanks and then reused for irrigation. A powerful and robust filtration system ensures highest water quality for your leafy greens. Using a hydroponic NFT system and re-circulating the unused irrigation water reduces water consumption by up to 95% compared to open-field farming.