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Commercial Aquaponics
Commercial Aquaponics Ken Semmens Matthew Ferrell This presentation is intended to help you understand more about aquaponics on a commercial scale. Examples – “Business Model” Production System University of the Virgin Islands Recirculating Aquaculture System Flowing Water System at Reymann Memorial Farm Business Model Restaurant, Farm Market, System Sales Rob Nash Commercial system Started as tilapia, but it was found to energy intensive in the winter Sells at local farmers market, contracts with restaurants 2-3 dollars a head lettuce, sells kale, peppers, and tomato's as well Brings lettuce still attached to net pots and roots His farmers market activities drive system sales Business Model Retail and System Sales Nate Story- Zip Grow Towers Commercial Vertical system Aim is to locate very close to city markets Sell live products in store Use as much space as possible within grow house At one point used tilapia, but has moved on to non food fish Business Model Off the farm, grocery, and franchises Marc Laberge from Quebec (http://www.culturesaquaponiques.com/team.htm). He raises rainbow trout and lettuce. He sells about $1000 worth of smoked trout a week and 6,800 heads of lettuce. He has survived for 8 years just doing production. Now he sells franchises. Business Model Wholesale , CSA , tours and education Green Acre Aquaponics Based on modified UVI system Been in operation 3 years Supplement their organic wholesale food and CSA products Large percent of income directly related to their teaching. Commercial guide cost $995 Classes are $1295 per person Growhaus - Variation on the UVI Design Hybrid System 25% Beds with substrate 75% Rafts Plants primary Fish secondary Tilapia Fingerlings Tilapia grow out Settle solid waste Substrate Reservoir Pump 3rd raft channel 2nd raft channel 1st raft channel Growhaus - Denver Growhaus - Denver Tilapia Fingerlings Tilapia grow out Settle solid waste Substrate Reservoir Pump 3rd raft channel 2nd raft channel 1st raft channel Business Models Nonprofit, Educational and Agri-tourism Will Allen’s Growing Power Is a multi disciple agriculture learning center Aquaponics is a small part of the system Charge for tours and sell produce Use mostly volunteer labor and “internships” Many paid positions are grant funded or through Americorps. Business Model Nonprofit - contributors Foundation City of Chicago Community Development Grants Administration City of Milwaukee, Community Development Grants Administration Clif Bar Family Foundation Community Benefit Trust Fund Cream City Foundation Joseph R. Pabst LGBT Infrastructure Fund Critical Mass Leadership Education Dagoba Organic Chocolate David & Julia Uihlein Charitable Foundation Farm Aid First Unitarian Society of Milwaukee GE Foundation Matching Gifts The Goggio Family Foundation After School Matters Allen Foundation Andrah Foundation, Ruth Knoll Anonymous Family Foundation Bayshore Community Foundation Fund Bradshaw Knight Foundation Brewers Community Foundation, Inc. Brico Fund Bruce and Muriel Hach Scientific Foundation C.G. Schmidt Construction Company Ceres Foundation Chicago Community Trust, Searle Family Fund Chicago Department of Family and Support Services Chicago Police Department Force for Good Chicago State University Greater Milwaukee Foundation Greater Milwaukee Foundation, Henry & Mary Franke Idea Fund Greater Milwaukee Foundation, Frank Kirkpatrick Fund Greater Milwaukee Foundation, Kopmeier Family Fund Greater Milwaukee Foundation, Walter and Olive Stiemke Fund Green Bay Packers Foundation H.H. Camp Foundation Headwaters Foundation for Justice – Young Donors Circle Fund Business Model Nonprofit - contributors Helen Bader Foundation Jane Bradley Pettit Foundation Jessie Smith Noyes Foundation JPMorgan Chase Foundation J.R. Albert Foundation Kohl’s Stores A-Team LaSalle Bank Lawson Valentine Foundation L.E. Phillips Family Foundation, Inc. Liberty Property Trust Linda and Jock Mutschler Foundation Lubar Family Foundation - Sheldon & Marianne Lubar Charitable Fund Manaaki Foundation Medical College of Wisconsin, Healthier Wisconsin Partnership Program Meshewa Farm Foundation Miller Brewing Company Milwaukee Area Workforce Investment Board Milwaukee County Community Development Block Grant National Education Association Foundation Northwestern Mutual Foundation Patrick and Anna Cudahy Fund Parkways Foundation Richard and Ethel Herzfeld Foundation Rotary Club of Mitchell Field Charitable Foundation Scott’s Miracle Grow Service Club of Milwaukee Silver Spring Neighborhood Center St. Pius Congregation State of Wisconsin Office of Energy Independence The 11-10-02 Foundation The Barnwood Foundation The Cleveland Foundation The Community Foundation Serving Boulder County The E-Z Coffee Stand The Gardner Foundation The J.M. Kaplan Fund The John D. and Catherine T. MacArthur Foundation The McCormick Foundation The Monches Foundation The Robert R. McCormick Foundation The Seed Fund University of Wisconsin Extension USA for Africa US Environmental Protection Agency Environmental Justice Grants Program USDA Community Food Projects USDA Farmers Market Promotion Program The following businesses and individuals have contributed their time, money, and materials: Growing Power's Board of Director's and the Chicago Advisory Board for their guidance and generosity with their time Will Allen, Milwaukee Business Model Nonprofit - contributors Joan Jacobs, Milwaukee Alterra Coffee Jonathan’s Bagel, Milwaukee Avec, Chicago Lakefront Brewery, Blackbird, Chicago Milwaukee Bleeding Heart Bakery, Kitchen Chicago, Chicago Chicago Magilo's Produce, Breadsmith Bakery, Milwaukee Milwaukee Columbia College, Chicago Elizabeth Malone, Milwaukee Dagoba Organic Chocolate Marburg, Dave Ditscheit, Milwaukee Arthur Milwaukee First Slice Cafe, Chicago Marcus Corporation, Floriole Bakery, Chicago Milwaukee Fraiche Kitchen, Chicago Outpost Cooperative, Get Me Greg's, Chicago Milwaukee Gino's Deli & Catering, The Publican, Chicago Milwaukee Red Hen Bread, Chicago Goodness Greeness, Seedling Fruit, Michigan Chicago Sendik's Grocery, Milwaukee The Signature Room, Chicago The Simple Soyman, Milwaukee Sprecher Brewery, Milwaukee Sunday Dinner, Chicago Dave Swanson, Milwaukee Vella Cafe, Chicago Whole Foods, Chicago Wild Flour Bakery, Milwaukee Take home message: Currently aquaponics is a viable business that seems to require diversification of products and services. It is difficult, though possible, to run a farm with revenue from the produce alone. Reymann Memorial Farm (WVU) Cold Flowing Water System Wardensville, WV Cold Flowing Water System Spring Trout Raceway Aquaponic Channel with rafts Polishing Pond Discharge to Stream Facility Components at Reymann Memorial Farm Greenhouse Plants adapted to cool root zone: • Watercress • Lettuce • Swiss Chard • Kale • Kohlrabi • Broccoli • Cabbage • Nasturtium • Calendula • Dianthus • Mums High Tunnel Reymann Memorial Farm (WVU) Nutrient levels low, do not accumulate Seeking to determine what grows well and rates of production First goal - product value, second goal - improve water quality. More information on this work covered in Research Update part of today’s program. UVI -best known, most well researched aquaponic production system Diagram from Recirculating Aquaculture Systems by Timmons et al 2002, pg 637. NRAC pub 01-002 Slides from Plant Production Presentation at the 2012 Aquaponics Association Meeting James Rakocy, PhD Director/Consultant of The Aquaponics Doctors http://theaquaponicsdoctors.com/ Formerly: AES Director, Professor of Aquaculture at University of the Virgin Islands Pioneered Aquaponics research and development. Nutrients Required for Plant Growth Macronutrients – – – – – – – – – C O H N K Ca Mg P S Carbon* Oxygen* Hydrogen* Nitrogen Potassium** Calcium** Magnesium Phosphorus Sulfur Micronutrients – – – – – – – Cl Fe Mn B Zn Cu Mo Chlorine Iron** Manganese Boron Zinc Copper Molybdenum * Supplied by CO2 and H2O ** Must be supplemented Rakocy 2012 Production Methods Staggered Allows weekly harvests Facilitates market development Maintains uniform nutrient uptake Batch Easier management Can deplete nutrients Rakocy 2012 Seedling Production Greenhouse or shade house Protected area Keep it clean Metal tables Install drain if concrete floor Weed barrier if gravel floor Planting media and dead plant material can harbor insects and disease Rakocy 2012 Planting Media Soilless potting mix Coir (coconut fibers) + Vermiculite 60% + 40% mix Free from pythium Requires fertilizer supplementation Labor required to prepare mix Rakocy 2012 Planting Media Peat potting mix (i.e. Promix BX) – Inexpensive – Readably available – Contains micronutrients for seedling growth – Can have pythium spores Jiffy peat pellets – Expensive – Easy to use – Can have pythium spores Oasis root cubes – Expensive – Requires additional nutrients – Dries out quickly in greenhouse Rockwool – Expensive – Non-biodegradable Rakocy 2012 Seedling Production Fill flat with mix Seed at required depth for plant variety Automatic seeder for small and surface planted seeds Cover flat until seeds germinate Many seeds germinate better in the dark Keeps mice from stealing seeds Keeping covered too long causes seedlings to elongate and have weak stems Water as needed Some seeds prefer dryer conditions than others Use mist nozzle for first week Fertilize 2-3 times weekly Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Watering Equipment Hozon Siphon Mixer – 1:16 proportioning device Rakocy 2012 NPK Nitrogen, Potassium, Phosphorous N - Nitrogen - shoots P - Phosphorous - roots K - Potassium - flowers and fruit Use 9-45-15 for seedling production – Promotes strong root formation Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Deep Flowing Channels Six channels 100 ft x 4 ft x 16 in Total water volume 18,000 gallons 3 hr retention time 72 rafts 8 ft x 4 ft Growing area 2304 ft2 Rakocy 2012 Raft Preparation Closed-cell polystyrene (Dow blue board, not scored) Dow Styrofoam® Square Edge Extruded 4 ft x 8 ft x 1.5 in Paint White, latex, non-toxic, roof paint Plant holes – 1.87 in Use template for spacing Spacing varies for vegetable variety Net pots: 2 in x 2 in Rakocy 2012 Rakocy 2012 Production Management pH maintained at 7.0 KOH Ca(OH)2 Chelated iron 2 ppm (mg/liter) Chelated iron is 13% pure so multiply by 7.7 (i.e., 15.4 mg of product gives 2 mg of iron) Manage net tanks with cleaning schedule to control nitrate levels Biological pest control Rakocy 2012 Integrated pest management Rakocy 2012 Rakocy 2012 Lettuce High nitrogen levels promotes leafy growth Short production cycle generates steady cash flow Strong demand Rakocy 2012 Lettuce Production Cycle Greenhouse Phase Week 1 – Day 0: seed Week 2 – Day 7: thin flat – Day 7, 10, 13: fertilize Week 3 – Day 14, 16, 19: fertilize Aquaponic System Phase Week 4 – Day 21: transplant to aquaponic system – Day 23, 26: spray with BT Week 5 – Day 30, 33: Spray with BT Week 6 – Day 37, 40: Spray with BT Week 7 – Day 42, 45: Spray with BT – Day 49: Harvest Rakocy 2012 Rakocy 2012 Lettuce Harvest Procedures Move sheets with mature plants to one end of the raft Lift sheets to harvesting stand or harvest in place Cut off lettuce stalk with a sharp knife and remove lower poor quality leaves Discard any poor quality lettuce Pack 24 lettuce heads to a box Weigh several randomly selected boxes minus the empty box weight to calculate total harvest weight and average weight per head of lettuce. Count box to determine total lettuce number and percentage of marketable yield Rakocy 2012 Lettuce Harvest Procedures Lettuce that is not distributed immediately should be stored in a moist refrigerated room Surface of the sheets should be washed with dechlorinated water to remove any dead leaves and quickly returned to hydroponic tanks Plants roots and growing media should be removed from net pots and discarded Cleaned net pots should be disinfected by soaking them in water containing bleach, rinsed and then dried before they are used again. Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Rakocy 2012 Lettuce Production Values Type Variety Romaine Crisphead Leaf Bibb Parris Island Montello Sierra Boston Bibb Density (plants/raft) 48 60 60 88 Harvest (cs/sheet) 2 2.5 2.5 3.67 Value ($/case) 30 25 25 20 Total 60 62.5 62.50 73.4 Leaf Lettuce Sierra 20/m2, 60 per raft Staggered production 18 rafts harvested/week Market value $1.00/head Value $196/m2/year ~$41,900/system/year Rakocy 2012 Rakocy 2012 Romaine Lettuce Parris Island 16/m2, 48 per raft Staggered production 18 rafts harvested/week Market value $1.25/head Value $157/m2/yearr ~$33,600/system/yearr Rakocy 2012 Pythium spp. Root fungus No IPM control Low temperature reduces growth and impact of some Pythium species Select resistant varieties Rakocy 2012 Basil Production 48 plants/sheet Staggered production Complete harvest recommended Cut and come again at 4 week intervals is alternative Grow for 3 months Harvest (cut) three times then remove Reduces survival and increases pythium Seedlings 3 weeks in greenhouse Rakocy 2012 Basil Genovese 16/m2, 48 per raft Market value $10.00/lb Value $515/m2/yr $110,210/system/yr Rakocy 2012 Melon Production 2 plants/sheet Use one side only and allow plants to run on ground Plant other side with companion crop Or construct narrow hydroponic tanks < 3 month crop Plants die as melons ripen on the vine Seedlings 1-2 weeks in greenhouse Rakocy 2012 Cantaloupe Jaipur 0.67/m2, 2 per raft Market value $3.99 each Value Each: $46.28/m2/yr $9,900/system/yr Rakocy 2012 Revenue for Various Crops $/m2/yr $/ft2/yr Leaf lettuce (20/m2) 196 18.22 Romaine lettuce (16/m2) Basil (16/m2) 157 14.59 515 47.86 Okra (3.7/m2) 15 1.39 Cantaloupe (0.67/m2) 46 4.28 Crop Rakocy 2012 Plant Pest and Disease Control No synthetic chemical pesticides Biological IPM controls used to control insects to reduce pest pressure Rakocy 2012 Biological Controls Dipel Bacteria Controls caterpillars BotaniGard Fungus Controls soft bodied insects (white flies, aphids) Armicarb Potassium bicarbonate Controls fungus, powdery mildew. Changes pH of leaf surface making it unsuitable for fungus growth Rakocy 2012 Application of Dipel with gas powered backpack sprayer Rakocy 2012 Soaps and Oils Coats insect causing death. Kills all insects Including beneficial Ladybugs, wasps, bees Rakocy 2012 Barriers Shade cloth Tangle foot Rakocy 2012 Thank you, Jim, for sharing these slides. Questions?
