Hydroponics I

Lesson 3
This is just a cover sheet, turn to the next page to continue.
Hydroponic Systems
Lesson Aim
Compare a range of hydroponic systems.

INTRODUCTION
Hydroponic systems are not a magical way to grow plants. Good growing conditions, including optimum
nutrients, light and correct temperature control are vital elements in the health and growth of the plants
growing in the system.

For plants to grow successfully it is important to understand a plant’s nutrient requirements and how it grows.
This applies to conventional soil-grown crops and hydroponic crops alike, the only variation between the two
methods being:

 The way the plant is supported, i.e. in ground or with a soil-less media etc.
 The way the plant receives its nutrient supply, i.e. organically through the soil or through a
nutrient solution.

WHAT MAKES UP A SYSTEM?

A hydroponic system comprises the following components:

The Location
This is a key factor because it influences everything else.

 If the system is indoors, then the environmental conditions are being controlled. There will be
fewer temperature extremes and fluctuations; wind exposure is minimised; pests and disease
problems may be reduced.
 If the system is outside it will be exposed to temperature and light fluctuations, drying and
damaging winds, and rain which may dilute the nutrient solution. Outdoor systems can be
vulnerable to damage from dogs, cats or other animals, but may have fewer fungal problems
(due to reduced humidity).

The Container or Bed

The roots (as well as the nutrient solution and medium) need to be contained in something.

You may use gravel, sand or perlite contained by bags, pots or tubs.

You may have rockwool fibre or scoria contained in a raised bed built from timber, metal or concrete.

You may use polystyrene boxes, hanging baskets, prefabricated fibreglass tanks etc. the list of possibilities is
endless.

Watering/Nutrient Application Equipment

Nutrient can be applied dry on the surface and then watered in or mixed with water and applied as a nutrient
solution.

Solution may be applied automatically at predetermined times or as required.

It may be applied at the bottom of the media and allowed to move up via capillary action, or alternatively at the
top and allowed to filter down.

It may be pumped on, or moved manually or by gravity.

Excess may be collected and reused, or allowed to be lost after passing through the media.

Trellising
This is not always necessary. When growing tall or creeping plants: (eg. tomatoes, cucumber, chrysanthemum,
carnation, roses), the root medium alone may not be strong enough to support the plant. A trellis of wire mesh,
strings or stakes may be necessary to just prevent the plants from falling over and being damaged.

Root Media
The media which the roots grow in affects your decisions about all of the above. You must consider rooting
media with respect to its ability to hold water, air, nutrients, support the plant etc.

TWO SIMPLE SYSTEMS

System 1
There are many and varied ways of doing hydroponics; some very complicated, controlled by electronic devices
and very costly to set up. Here is a system at the other end of the scale. It is cheap to set up, simple to operate
and is a useful starting point for novice hydroponic growers.

Materials required:

 1 ice cream container (plastic bin) or a plastic bucket

 1 terra cotta (clay) pot (not glazed)
 Coarse granitic sand/aquarium sand
 Vermiculite or peat moss (the sand and vermiculite needs to be a quantity which will fill the clay
pot)
 2 lettuce seedlings
 1 small pkt soluble fertiliser (e.g. Aquasol)
 Gypsum
 Epsom salts
Procedure:

1. Mix 60% sand with 40% vermiculite or peat.

2. Fill clay pot to within 3cm or so of its lip.
3. Wash soil off roots of lettuces (as much as you can without harming the roots.
4. Plant the lettuces in the pot.
5. Mix 6 parts Aquasol to 5 parts gypsum to 1 part Epsom salts.
6. Mix one spoonful of the mixed fertiliser powder with 2 gals (one bucket) of water.
7. Measure roughly the depth of the medium (i.e. sand and vermiculite) in the pot.
8. Place the pot with the lettuces in the bucket or ice-cream container and pour nutrient into the
bucket or ice-cream container until it reaches a level about one-third the depth of the medium
as calculate in Step 7.
9. Top up the nutrient solution as often as is necessary to keep the level always between 1/4 and
1/3.
NB: The nutrient is soaked up into the medium from below: this is called capillary action.

There are endless possibilities. The options open to you with creating a system are only limited by your
imagination and your budget. Provided you can supply the plant with those things which it needs to achieve
growth, you can develop a system any way you wish. Systems can be very simple or very complex! They can be
very inexpensive or very expensive!
System 2
Another basic hydroponic system can be built for experimental purposes using black polythene bags about 30 x
45cm or 50 litre black plastic nursery pots.

Growing Media

A mix of vermiculite with peat moss, coarse river sand and charcoal to the following proportions:

 4 x 1.2 cubic metre bales of vermiculite

 1 x 3.6 cu metre bale peat moss
 2.4 cu metres (2 wheelbarrows) of coarse river sand
 1.2 cu. metres of charcoal.
 To this add 6.5 kg of agricultural gypsum and 3.5kg of triple superphosphate.
 Mix thoroughly dry.
Then use the following chemical nutrient solution:

 60 litres of water mixed with...

 1.8kg potassium nitrate
 0.5kg pound epsom salts
 60ml Sequestrene (provides iron)
 30ml borax (be careful...more borax can cause boron toxicity)
The solution should be bright red when well dissolved.

A trickle irrigation system provides a constant flow of nutrient solution.

SOIL-LESS MIXES
There are many kinds of soil-less, organic mixes that can contain an assortment of ingredients. Most contain
things like sphagnum moss or coconut fibre, perlite and vermiculite. This type of medium is frequently used for
container gardening, wick systems and non-recovery drip systems. The fine particles can clog pumps and drip
emitters so a filtration system would need to be used soil-less mixes usually have very good water retaining
qualities, excellent wicking action and are able to hold a good amount of air. This makes them an ideal growing
medium for a variety of hydroponic and organic gardens.

Wood chip compost Scoria Coarse organic sand

Expanded clay Perlite

ROCKWOOL
Today rockwool is probably the most popular growing medium on earth, particularly for use in the drip-type of
hydroponic growing system. Rock and sand are spun to create fibres which can then be pressed into various
shapes and sizes from small starter cubes to large slabs, or used in its loose form.

Advantages of Rockwool
Rockwool has the ability to:

 Retain water – it holds a large amount of water which is an advantage during power outages or
equipment failure.
 Hold air – it holds at least 18% air as long as it is not sitting directly in water. This helps to
supply the plant’s root zone with adequate oxygen making over-watering unlikely.
It is also sterile and light, which reduces the possibility of disease and makes it easy to work with.

Disadvantages of Rockwool
 It is not environmentally friendly. Rockwool is hard to dispose of; if buried it will last indefinitely
however it does not harm the environment
 Dust and fibres are a health risk. The fibres and dust from the rockwool are a health risk when
breathed into the lungs - a dust-mask should be used at all times when handling this material.
The following excerpts are from a CSR seminar on Horticultural Rockwool. Although it is based on the Australian
use of rockwool, it provides a useful background on this subject for hydroponic growers in all areas.

HORTICULTURAL ROCKWOOL
In Denmark during the late 1960's a rockwool was developed for horticultural use and then marketed under the
trade name "Grodan". From slow beginnings, its commercial use began to expand significantly from the mid
1970's, especially for the production of glasshouse vegetables and cut flowers. A high rate of growth of
rockwool use has been maintained ever since.

As an Australian manufacturer of insulation rockwool, Bradford Insulation (part of CSR Limited) had taken an
interest in this trend. Following approaches from several Australian growers the decision was taken to develop a
local horticultural rockwool. This development took two years, resulting in the release of an Australian
rockwool, known by the trade mark "Growool", onto the local market in mid-1982.

Rockwool Manufacture
Rockwool has been manufactured as an acoustic and heat insulation material for over 70 years. The production
technology has been extensively improved over the intervening period, but the basic product has remained
virtually unchanged.
The raw materials are natural rocks such as basalt plus coke as the fuel. These are fed into a blast furnace
through which air is blown so that the coke burns and lifts the temperature to over 1600C. Consequently, the
rocks melt to form a type of lava which settles to the bottom of the furnace and is tapped off.

The stream of lava flows onto a series of high speed rotors. These spin off molten droplets which lengthen into
fibres and are then cooled by a blast of air. Binder is sprayed into this air stream which also carries the fibres
clear of the rotors and deposits them on a conveyor as a thick felt. The felt is conveyed along a production line
where it is pressed, hardened, trimmed and finally cut into slabs. One aspect of the manufacture the mat of
rock fibres is that the fibres orientate in a horizontal plane. This has implications that are important when the
material is used for horticultural purposes.

Insulation rockwool and fibreglass are useless for horticultural purposes. However, the rockwool manufacturing
process can be modified to produce a suitable horticultural product. The slabs of base material can be shaped
into the specialised forms of product. The slabs of base material can be shaped into the specialised forms of
product such as propagating blocks, etc.

Rockwool Properties
As rockwool has properties which often differ significantly from other growing media these properties should
always be considered if the material is to be used effectively.

Density
When dry, rockwool is a very lightweight medium with its density averaging 70 kg/m2.

Rigidity
Although granulated forms are available, basic rockwool is bonded into relatively rigid slabs which can then be
shaped to make up the component parts of complete horticultural systems.

Sterility
Because of the high temperature of its manufacture (1600 C), rockwool is sterile when packed. If it is to be
reused, e.g. slabs in a soil-less system, it may be sterilised with steam or appropriate chemicals - it will
withstand low pressure steam or steam/air treatment but no high temperature autoclaving which tends to
break down the bonded structure.

Solubility
Rockwool is insoluble in normal water or nutrient solutions, i.e. those with a pH between 5 and 8. Because the
material is inert, all nutrition must be supplied and fertilisers used must be balanced and complete.

Cation exchange capacity

This is effectively zero and the material will not absorb or exchange nutrient ions from solution. One effect is
that the material can be leached clean of any solution it contains.

Biodegradability
Rockwool is a bonded form of natural rock fibres. Although it can be physically broken down by expanding roots
or by mechanical action, it is not biodegradable. It causes no environmental problems as it may easily
incorporated through the soil where it should improve aeration and drainage.

Void space
The rock fibres making up the bonded structure occupy only 3% of the material volume, leaving 97% void space.

Air/water-holding capacity
Because of its void space rockwool can retain a very high volume of water while continuing to hold a high
production of air.

The water content (and hence air content) of any piece of rockwool is influenced by the thickness of the
material, the drainage characteristics of the surface upon which it stands, and the method of watering. For
example, 75 mm rockwool slab standing on polythene holds an average of 80% water and 17% air. The water
content also varies through the thickness of the slab starting from very wet at the base and getting drier with
increasing height. The water in the rockwool is also only lightly bound and hence is readily available to the plant.
pH Buffer Capacity
Rockwool has no long-term pH buffer capacity, however, an initial pH rise. The rate and degree of reaction are
dependent upon the pH and buffer capacity of the solution used to wet the rockwool.

Propagation of microcuttings from tissue culture

There has been considerable expansion in using rockwool for de-flasking tissue cultured plants. It has proved to
be a very compatible medium for this purpose and particularly in the case of microcuttings it enables good
support of these very small plants.

Several trial shipments of plants using rockwool as the propagating and growing medium have been exported to
countries where the import of soil and similar growing media is not permitted. This use could have considerable
potential particularly because of the beneficial effect on plant quality.

Recommended Practices for Propagation

In consequence of its properties, the following principles need to be considered when using rockwool
propagating blocks:

 Select the appropriate block size for the plant and the propagating system.
 If the sheets of blocks will later have to be moved then it is preferable that they be supported,
e.g. placed in a tray. Otherwise some form of lifter or spatula will be needed.
 The blocks must be thoroughly wet before using, either by quickly dunking or by hosing until
water runs out of the blocks. Soaking is unnecessary.
 Take special care with hygiene for, although rockwool is sterile when unpacked, disease can
spread easily. Clean water, trays, propagation facilities and cuttings are essential, along with a
sensible handling and maintenance system.
 Insert the cutting only as far as necessary for support. Do not push it in too far as the cutting is
then in a zone of lower air content.
 If liquid feeding is required, then a complete feed including race elements must be used.
Normally the plant is not fed before it has struck. However, if nutrient is needed from the start,
e.g. with tissue culture plants, then the wetting solution pH should be lowered to allow for the
initial alkaline reaction. With rooted cuttings that have small roots, it is advisable to add some
nutrient solution to the block before transplanting so the roots can continue to grow out into
the medium.
 Control the water content (and hence air content) to a suitable percentage for the plant.
Consider the height of the block, the depth of insertion of the cutting, the drainage
characteristics of the supporting surfaces on which the blocks stand (remembering that there
will be interactions between trays and the supporting surfaces) and the method and frequency
of watering.
The authors have prepared a paper on the air/water characteristics of rockwool and other mediums used in
propagation systems. Some results of interest are that the fibre orientation has no influence on the water
holding capacity, and the grooving of rockwool propagating blocks increases the air content within the block by
about 5%.

 Allow for the influence of the propagation system and environment upon the blocks. Rockwool
has proved compatible with all types of propagation systems, e.g. closed tent, wet tent and
open systems, heated and unheated beds, all with and without mist. These can have different
effects upon the blocks, e.g. heavy misting can cause water-logging, open heated beds will
increase evaporation.
 Most watering systems work well with rockwool, e.g. hand, sprinkler, mist, or capillary matting
(using weed mat on top to prevent weed penetration). However, modifications may be
advisable, especially to the frequency of watering.
 Allow for the effects of change of environment upon the blocks, e.g. in summer evaporation will
increase hence there will be some concentration of liquid fertilizer.
  It is advisable to transplant the propagule as soon as the roots are showing. This takes full
advantage of the beneficial properties of the material and avoids the potential problem of root
growth into adjacent blocks. The simplest technique for separation is to split off a long row of
blocks from the sheet, then split off the individual blocks (similar to separating postage stamps).
 When converting from another propagating medium to rockwool it can be vital to recognize any
differences and allow for them as indicated above. For example, a recipe for failure would be to
push susceptible cuttings through to the bottom of the blocks, place these on a nondraining
surface and then use frequent, heavy mist.

Benefits of using Rockwool Propagation Blocks

In any technical investigation it is important to consider systems that are comparable. In this case the use of
rockwool propagating blocks to produce plants for subsequent potting must be compared with the complete
process of producing similar plants by traditional methods. In Australia, the traditional method of pot plant
production is to strike cuttings in a small tube containing a mixed propagating medium. Once rooted the cutting
is "knocked out" of the tube and transplanted into a pot.

The use of rockwool for propagation can be of advantage to nurseries of all sizes from one man operations to
large mechanised one. Typical benefits to be obtained are as follows:

 Being supplied in cartons weighing only 10 kg, the material can be conveniently stacked ready
to immediate use. It can also be carried where ever required by any staff member, who
therefore is not dependent upon anyone else to do the mixing, sterilising, etc.
As rockwool propagating blocks come as sterile light rigid sheets, they make preparation to
propagate very quick and easy. All that is required is a cleaned tray into which the sheets are
laid and wetted.
This substantially reduces the time-consuming and costly work spent in preparation, i.e. mixing
and sterilising propagating mix, cleaning, sterilising and filling tubes, placing tubes into trays,
and cleaning up afterwards.
 Cuttings are easily inserted. Soft cuttings may require a hole to be "dibbed", but most cuttings
can be pushed directly into the rockwool.
 Experience has shown that a wide range of plants are quicker to strike in rockwool than in
conventional media. The accompanying table of results, published by Andrew Burton, appears
to represent results obtained in general with indoor plants.
 Plants propagated in rockwool can be transplanted as soon as the roots are emerging from the
block, or even earlier in some circumstances. By comparison, with a tube the root system must
develop sufficiently to bind the medium together before it can be transplanted. In our
experience this has resulted in the great majority of plants propagated in rockwool being ready
to pot significantly sooner than tube propagated plants.
If this potential benefit is fully utilised, then not only do direct cost savings result, but output
could be increased or propagation areas converted to other uses. Also, the shorter the time in
propagation: the less chance of disease and less cleaning up.
 Because the blocks are so easy to separate then potting costs are significantly reduced. Much
of the boring and costly work has been eliminated, i.e. knocking out of tubes, re-tubing and
separation of plants insufficiently rooted. The time saved is substantial Andrew Burton has
doubled the output of his potting machine with the same manpower.
 Because the block is taken complete then transplant shock is virtually eliminated and the plant
is not set back. This factor, combined with others mentioned earlier, can result in pot plants
being ready for sale far earlier than those grown by conventional methods.
 Overall cost comparisons are difficult to establish in general terms because they depend upon
the individual grower's capital investment, for example. However, if those costs are assumed
constant, then there are some aspects which can be compared.
Comparison of days to strike and percentage strike - rockwool vs. conventional mix (peat:perlite 1:1)

Item Rockwool Peat:Perlite

Days % Days %

Aeschynanthus javanicus 20 90 26 90

Arisia Crispia 18 100 24 90

Begonia Semperflorena 12 100 1416 100

Begonia Orange Rubra 12 100 17 100

Bougainvillea Var. 21 70100 26 70100

Cissus discolor 9 100 14 100

Clerodendron Thom. 8 100 13 80

Fatshedera green 17 90 2024 90

Fatshedera var. 21 80 24 80

Fittonia 10 100 11 100

Ficus radicans 17 90 21 90

Hoya carnosa 1011 100 1317 100

Impatiens ‘Yellow 8 100 1112 100

Dragon’

Ixora chinenis 15 90 28 90

Maranta 11 100 18 100

Oxalis rubra 9 100 16 90

Pothos 15 100 17 100

Columnea varieties 1315 100 1215 100

Peperomia 'Aztec' 20 100 17 100

Columnea microphylla 30 100 17 90

Tolmiea menziesii* 0 14 100

*(leaves) failed
Limited cost comparison propagation (cents per plant)

Component Rockwool Tube + Mix

Material (block, mix incl. preparation) 1.3 1.0

Labour in potting 2.0 4.0

Cost of slower turnaround of propagating space nil 0.5

Cost of mixing and storing propagating medium nil 0.5

Total: 3.3 6.8

These figures assume plant densities and losses, etc., remain unchanged. In practice further cost benefits can
be gained using rockwool. Details provided by Andrew Burton, N.S.W.

Limitations Experienced in the Use of Rockwool

These limitations are cited from Australian experiences and many have been overcome as growers become
more familiar with the products and their properties.

 There will obviously be cuttings which are too large for standard propagation blocks. If they are
forced into the blocks these tend to split. "Dibbing" can help, otherwise a larger block or
wrapped cube should be used.
 Propagating blocks are rarely suitable for holding plants for extended periods once they have
rooted. If plants are fed as they need to be, then their roots will eventually grow into the
adjoining blocks. This makes them difficult to separate and will cause root damage at that time.
A tendency to dampening off has been reported for some plants held for long periods, although
in some cases additional drainage has helped. The material certainly gives its optimum benefits
when cuttings are transplanted soon after striking.
 Transplanting rockwool blocks into soil may result in failure if the soil has draining capacity.
Because the water in the rockwool is only lightly bound, it can be drained away before the plant
roots have grown into the soil. Consequently, care must be taken to keep the blocks moist after
planting. This may require watering and mulching.
NFT SYSTEMS
NFT stands for Nutrient Film Technique. NFT involves running nutrient solution continuously along an enclosed
channel, collecting it and recycling it. The channel is normally made from plastic (rigid or flexible polythene or
PVC). The plants roots grow in the channel, and the top is usually supported by a wire mesh or trellis
framework.

The film of nutrient must flow continuously. If it is being pumped by an electric motor, there should be a backup
facility to cover power failure. NFT is perhaps the most popular hydroponic system used in the UK.

The key requirements in NFT are:

 To have a gradient which water flows along which will achieve an even flow: not too steep or
low gradient: no depressions or uneven spots.
 Inlet flow rate must be controlled: not too fast or slow.
 Width of channels where flow occurs must be wide enough to avoid damming up of solution by
the root mat.
 Base of channel must be flat to ensure even depth of solution across the width.

Alternative Layouts for NFT

A Horizontal Rectangular Plane
This is the most common NFT system. The area being used has a slope both along and across the plane. The
slope on the land should be graded evenly to achieve a smooth slope.

A catchment trench is dug along the low side of the area, and a watertight lining is put into the trench. NFT
channels are laid across the slope at right angles to the trench. Nutrient solution is pumped into top end of the
channels and allowed to trickle to the bottom end where it flows out into the catchment trench for recycling.

Vertical Tubes
EXAMPLE: PVC pipes hanging vertically from a framework.

Nutrient solution is sprayed into the top of the pipes where it creates a film.

The film of nutrient solution runs down the inside of the pipe.

Holes cut at intervals down the pipe have plants inserted into them.

Tier System
This involves a series of tubes mounted one above another, frequently on a wall. he nutrient solution is pumped
to the top from where it is fed simultaneously into the ends of each of the tubes at the high ends of those tubes.

Solution trickles down the tube, is drained off at the low end and recycled into a storage tank from where it is
pumped back to the top of the system.

METHODS OF SOLUTION DISPENSATION

Closed System
Solution is re-circulated around the system (e.g. by means of a pump and returned to a storage tank by gravity
as with an NFT system).

Flow rate is controlled by valves, drippers, micro-tubes emitters etc.

There is minimal wastage of water or nutrients, but it is more difficult to control nutrient concentration in the
solution.

Open System
Solution is not re-circulated, but applied to plants and any excess is drained away and lost. This method has
fewer problems with spreading disease and development of salt toxicity.
TECHNIQUES

Drip
Solution is exuded in slow continuous dripping from a micro orifice.

Slop
The solution is flooded over the beds at regular intervals, percolating down through the growing medium, and
draining off to a catchment tank. Root temperature and aeration are influenced by the frequency of irrigations.

Open manual slop system. Apply solution with a bucket.

Wick
A glass wool wick draws nutrient solution from a nutrient tank below the medium and distributes it through the
root zone using capillary action.
Misting
Nutrient solution applied by a fine mist. (Aeroponics). This can cause leaf burn on some plants under some
conditions. Air movement (wind) can cause uneven distribution of solution.

Dry Fertilisation
Dry mix of nutrients is sprinkled over the beds periodically and immediately watered in. This can sometimes
cause temporary toxicity problems.

Capillary
Solution is applied to the bottom of the media beds, and soaks up into the media by capillary action. Excess is
then drained off. Effectiveness depends on quality of medium for transfer and capacity to hold water and
nutrients.

Injector or Proportioner System

Quantities of a pre prepared concentrated stock solution are injected into the water feeding lines
proportionately: normally this is used in an open system.
Run off is collected and piped to a sump for re-circulating.

SET TASK

Set Task 1
Pumps are used in automatic systems to circulate nutrient solution. Corrosion can be a problem if the nutrients
come in contact with some types of metals. The other major consideration is to maintain an appropriate (slow)
flow rate through the system. Automatic systems can be catastrophic if the pump stops, particularly where the
root zone has minimal ability to retain water (such as NFT systems). Sometimes a backup pumping system is
used. The main pump should be reliable and, in the case of systems like NFT, able to run constantly 24 hrs per
day all week long.

Given these considerations, find out what is available in pumps and try to discover pumps suitable for the
following types of systems:

 NFT in a 60ft igloo growing carnations

 Rockwool in a small home system growing vegetables (under cover on a balcony or veranda
 Troughs filled with gravel growing strawberries supplied by trickle irrigation

Set Task 2
Visit at least three suppliers of hydroponic equipment. Find out what types of products they supply. Find out all
that you can about these products, including costs. If possible obtain literature/brochures, etc. on as many
different types of equipment as possible.