Patent Description:
The environment within a greenhouse may be closely monitored and controlled. In particular, the temperature and humidity may be kept within a narrow range to best favour the healthy growth of plants therein. Greenhouses lend themselves in particular to the growing of plants by means of hydroculture in its broadest sense (that is, the growing of plants in the absence of soil), in particular hydroponics, basic-hydroculture/passive-hydroponics, aeroponics, fertigation, aggregate culture and/or aggregation; that is, the growing of plants in the absence of soil. In addition, plants grown within a greenhouse (e.g. having a controlled internal environment) and/or by means of such hydroculture methods may be done so without the use of pesticides (e.g. herbicides, insecticides, fungicides, antimicrobials and/or other forms of pesticides), and in some jurisdictions may be referred to as organic agriculture. Conventional greenhouses are designed not only to hold plants, but also to provide access to the plants by growers. Space within the greenhouse is not utilised efficiently. In addition, while sophisticated systems are often employed to provide feed and water to the plants, they are generally inefficient and result in a significant amount of the feed and water being wasted. Typically greenhouse crop production uses <NUM>% of the floor area for growing crops. <CIT>, <CIT> and <CIT> each describe growing systems in which tracks or conveyors are utilised in an attempt to increase the yield of a greenhouse.

Some background information can be found in <CIT>, <CIT>, and <CIT>.

Embodiments are provided in accordance with the appended claims.

The present invention concerns a soilless plant growing system according to claim <NUM>.

The conveyor is configured for moving a series of carriages around a closed loop. In this way, plants grown in the absence of soil may be moved around a growing room such that each plant receives a more even exposure to light than would be the case if static in the growing room. The growing room may be for instance approximately <NUM>, <NUM>, <NUM>, <NUM> or <NUM> meters long, and may be oriented in an approximately East-West direction. The growing room may be for instance approximately <NUM>, <NUM>, <NUM>, <NUM> or <NUM> wide.

The system may comprise any number of carriages, for instance approximately <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM> carriages. The conveyor may be operable with a maximum number of carriages thereon, the conveyor may be operable with a minimum number of carriages thereon, and/or the conveyor may be operable with an intermediate number of carriages thereon.

The closed loop may have a serpentine form. In particular, the closed loop may comprise a series of parallel and/or antiparallel legs. In this way, a maximum and even exposure to natural and artificial lighting for each tray may be achieved.

Each leg of the serpentine may be spaced from each other leg by between <NUM> and <NUM>, in particular between <NUM> and <NUM>, more particularly approximately <NUM>.

The conveyor may comprise a track, and may be arranged such that the track may trace out a closed-loop pathway. The closed-loop pathway may be in two- or three-dimensions, for instance, arranged on a substantially flat floor, on a sloping floor, and/or on a tiered floor. In this way, the conveyor may be shaped to fit within any size and/or shape of building without wasting valuable growing space. In particular, the conveyor may include slopes of up to approximately <NUM> degrees, in particular up to approximately <NUM> degrees, more particularly up to approximately <NUM> degrees.

The pathway may be substantially polygonal in form. The pathway may have a form substantially that of a non-convex polygon and/or a concave polygon. That is, the pathway may have interior angels that are greater than <NUM> degrees.

The conveyor system may further comprise a second conveyor arranged such that the track traces out a second closed-loop pathway in three dimensions that substantially interweaves a first pathway of the first conveyor. The second conveyor may be configured to convey carriages in a sense opposite that of the first conveyor. The term 'sense' is intended to describe either substantially clockwise or anti-clockwise motion; that is, the rotational direction of the carriages around the conveyor. The first and second pathways may have the form substantially of a double helix.

The conveyor may drive the carriages. Alternatively, each carriage (or each group of carriages) may be individually powered.

The conveyor may comprise a track and a drive mechanism located adjacent to (and stationary with respect to) the track, for pushing the carriages around the track. The drive mechanism may be hydraulic and/or pneumatic. The drive mechanism may comprise only one, at least one, or a plurality of arms for pushing the carriages along the track.

The conveyor may comprise a track and a propulsion cord. The propulsion cord may be a rope, chain, cable, nylon cord, and/or other known type of cord. In one particular embodiment the conveyor may comprise a track and a cord parallel to the track. The track may be a tube, pipe or similar arrangement. In particular, the track may comprise a guide, through which the cord may be arranged to pass. The cord may be driven by a motor, such that the cord moves relative to the track.

The conveyor may comprise a belt conveyor.

The conveyor may comprise an inverted conveyor chain (e.g. with steel chain links) is used to pull carriages around the growing room. The chain may be housed in a flanged fabricated track which allows fixture of carriages thereto. The carriages may rotate on their axis for example for loading and unloading. At each end of conveyor run the gondolas may be individually re-orientated to change direction and follow track onto adjacent run.

The conveyor may be driven at a maximum and/or average speed of between approximately <NUM>/minute and <NUM>/minute, in particular between approximately <NUM>/minute and <NUM>/minute, more particularly between <NUM> and <NUM>/minute, for instance approximately <NUM>/minute.

The conveyor may be driven by only one or at least one motor, for instance between <NUM> and <NUM> motors, in particular, between 4and <NUM> motors more particularly <NUM> or <NUM> motors. Each motor may have an output of between approximately 75W and <NUM>,000W. For instance, in the case of a plurality of motors, each may have an output of between approximately 100W and <NUM>,000W, in particular between 250W and <NUM>,000W, for example approximately <NUM>,000W. Alternatively, in the case of a single motor, it may have an output of between approximately <NUM>,000W and <NUM>,000W, in particular between <NUM>,000W and <NUM>,000W, more particularly approximately <NUM>,000W. The conveyor may be between approximately <NUM> and <NUM>,<NUM> in length, for instance between approximately <NUM> and <NUM>,<NUM>, in particular between approximately <NUM> and <NUM>,<NUM> in length, more particularly approximately <NUM>, <NUM>,<NUM>, <NUM>,<NUM> or <NUM>,<NUM> in length.

The carriages may reside on the conveyor. The system may be provided with a guide (e.g. a rail) located above the carriages for stability and/or guiding the carriages on the conveyor. Each carriage may hold between <NUM> and <NUM> trays, in particular between <NUM> and <NUM> trays, more particularly approximately <NUM> trays. Each carriage may be between <NUM> and <NUM> tall, in particular between <NUM> and <NUM>, more particularly approximately <NUM> tall (e.g. <NUM> tall).

Each carriage may comprise a support frame for holding the tray(s). The support frame may comprise a substantially cuboidal, cylindrical, or any other shaped frame portion, and at least one tray supporting member disposed on the cylindrical frame portion per hydroculture growing tray to be carried on the support frame.

The support frame may be between approximately <NUM> and <NUM> in width, in particular between approximately <NUM> and <NUM> in width, more particularly approximately <NUM> in width. The support frame may have an approximately square footprint, but may alternatively be rectangular. The support frame may be between approximately <NUM> and <NUM> in height, for instance, between approximately <NUM> and <NUM> in height, in particular between approximately <NUM> and <NUM> in height, more particularly approximately <NUM> in height.

The support frame may comprise more than one tray supporting member per hydroculture growing tray to be carried on the support frame. In this way, each tray may be supported in a stable position.

The support frame and/or the frame portion may be rotationally symmetric about the substantially vertical axis, in use.

The support frame and/or the frame portion may have <NUM>-fold rotational symmetry about a substantially vertical axis, in use.

The support frame may be configured to carry more than one hydroculture growing tray thereon.

The support frame may be configured to carry at least one stack of hydroculture growing trays.

The support frame may be configured to carry a first hydroculture growing tray (or stack of hydroculture growing trays) on a first side of the support frame and a second (stack of) hydroculture growing tray(s) on a second side of the support frame. For instance, the support frame may be configured to carry <NUM>, <NUM>, <NUM> or <NUM> stacks of hydroculture growing trays.

Each stack of trays may comprise between approximately <NUM> and <NUM> trays, in particular between approximately <NUM> and <NUM> trays, more particularly <NUM> trays.

Each tray in a stack of trays may be spaced from each adjacent tray by between <NUM> and <NUM>, in particular <NUM> and <NUM>, more particularly approximately <NUM>.

Each tray may have a surface area available for growing plants of between <NUM> square meters and <NUM> square meters, in particular between <NUM> square meters and <NUM> square meter, more particularly approximately <NUM> square meters. The trays may be rectangular, or may alternatively be square, trapezoidal, or any other appropriate shape.

Each hydroculture growing tray may comprise a tray base having a substantially horizontal base portion and a perimeter wall. In this way, the hydroculture growing tray may be configured to hold water therein.

Each hydroculture growing tray may comprise a tray lid, the tray lid provided with at least one hole therein. The hole may be an access hole, which may be for allowing fluid, water and/or nutrients to pass into the tray. There may be only one access hole. Alternatively or additionally, the at least one hole may be a plant hole configured to hold a single plant to be grown by means of hydroculture, or any comparative method. Specifically, the plant hole may be for receiving a stem of a plant therethrough. There may be a single plant hole or a plurality of plant holes; for instance, between <NUM> and <NUM> holes, in particular between <NUM> and <NUM> holes, more particularly between <NUM> and <NUM> holes. Each plant hole may be configured to hold a single plant or a plurality of plants. Alternatively or additionally, each plant hole may be configured to hold a punnet of plants. In this way, the layout of plant holes may be chosen to suit a particular plant type. The plant hole may be of any shape. For instance, the plant hole may be shaped to accommodate a particular plant. The plant hole may be shaped to facilitate insertion or removal of a plant. The hole may be drilled or cut out. The hole may be a slot, it may be round, it may be square, or it may be any other shape.

The tray may be substantially rectangular in from; however, in preferred embodiments, the tray may be substantially trapezoidal in form. Other shapes for the tray are contemplated.

The tray base may comprise an exit hole configured to allow fluid to exit the tray. In this way, stale water can be removed from the tray.

A drain may be provided to convey water from the exit hole away from the tray for recycling, reuse and/or disposal. The drain may comprise a downpipe, for instance, formed as part of the carriage, in particular located centrally on the carriage, collecting water from each exit hole from each respective tray and conveying it away. In some alternative arrangements, the drain may comprise a plurality of channels, for instance one per tray, one per adjacent pair of trays or one per stack of trays. Such a drain may be located on a watering station, such that a carriage moves into position at the watering station such that water may be fed into and collected from each tray, before the carriage is moved on.

Optionally, the tray may further comprise a tube disposed with its axis substantially vertically within the exit hole such that fluid may only exit the tray when a fluid level within the tray is above some predefined height. In this way, plants to be grown by means of hydroculture within the tray may be maintained with a sufficient fluid supply. The tray may further comprise a grommet and/or washer disposed within the exit hole, configured to grip the tube. In this way, fluid may be prevented from unintentionally leaking from the tray. The axial position of the tube within the exit hole may be variable such that the predefined height above which fluid may exit the tray through the tube is variable. Alternatively or additionally, the tray may comprise a valve configured to allow water to reach a certain level before draining.

The trays may be configured to allow irrigation water and/or nutrient supply to be distributed to the plant roots intermittently and drain away. For instance, the trays may have a directional water distribution channel(s) formed within the trays, and may have individual drain connections, which may be attached to the carriages. The directional water distribution channel(s) may comprise a pattern of ridges to aid water and nutrient dispersal around tray and plant roots before draining away. The tray may allow for complete drainage of tray in-between waterings.

The present system may provide for example a fourfold increase in the usable growing area, or perhaps higher such as an increase of at least <NUM>, <NUM> or specifically <NUM> times. That is, for every <NUM> square meter of greenhouse available for growing area in a single layer system, the present system is able to operate with an equivalent of approximately <NUM> square meters of the floor area by extending growing area into the vertical space.

The conveyor is a floor-mounted/ground conveyor or conveying track. In this way, the carriages may be mounted upon the conveyor (rather than being suspended therefrom), such that an optimal amount of growing light may reach the plants without being obscured by an aerial conveyor track.

Each carriage may be removably replaceable on the conveyor. For instance, each carriage may be interchangeable with each other carriage. In this way, carriages may be removed for servicing (or some other purpose), and replacement carriages may be inserted.

The plurality of carriages may be arranged in a first order on the conveyor, and the plurality of carriages may be re-orderable on the conveyor into a second order. In this way, the carriages may be reordered to optimise growing conditions for the plants thereon.

The soilless plant growing system comprises a growing room in which the conveyor, carriages and trays are located, wherein the growing room may comprise light-transmissible windows, which may be composed of polycarbonate, glass, tinted glass and/or other light-transmissible material, for instance over the range of <NUM> to <NUM> nanometres.

The windows may be configured to diffuse incoming light. For instance, the windows may be translucent, but for instance not transparent. In this way, more light is available for photosynthesis without solar gain found in standard glasshouses which require the use of shade screens when irradiation from sun is high to prevent scorching of leaves and build-up of heat. The polycarbonate may be clear twinwall polycarbonate having a thickness of approximately <NUM>.

The growing room may comprise an air supply system, for instance an HVAC system. The air supply system may comprise a controller for varying air supply in response to one or more sensed variables, as discussed below.

The soilless plant growing system may further comprise lighting disposed adjacent to the conveyor, and configured to be stationary with respect thereto, such that each carriage passes the lighting as the carriage passes around the closed loop. For instance, the trays may face outwards and may pass under (e.g. led) lights on one, both or either side of the track. In this way, lighting (for instance to supplement natural light) may be easily installed and maintained. The lighting may be a plurality of LED lights. Maximising natural available light in addition to LED lights exposes plants to wider range of wavelengths of light which can impact on plant quality and physiological characteristics. A sensor may monitor (e.g. continuously) light levels and adjust as specified, thereby reducing energy use. The lighting may be configured to emit light substantially predominantly over the <NUM> to <NUM> nanometre range. The lighting may be provided at each level; that is, substantially above each tray in a stack on a carriage, for instance with trays passing underneath as they move along the conveyor. The movement evens out exposure to light within the tray and avoids heat build up or 'egde effect' observed in stationary systems.

The soilless plant growing system comprises at least one watering station configured to irrigate the plants on each carriage as the carriage is passed adjacent to the watering station. In particular, fresh water may be provided to the plants at the watering station. In this way, plumbing and watering systems may be minimised. The watering station may be configured to provide water supplemented with nutrients to the plants, such as plant food, but may alternatively/additionally be configured to supply fresh water if required. The watering system may be configured to spray the plants with aerosolised water (e.g. as a fine mist), and/or to simulate rain by spraying the plants with drops/droplets of water, and/or to provide a flow of water directly into the tray for the plants to draw up from the tray. However, in preferred embodiments, the watering station may be configured to ensure that the plants leaves remain dry during watering, to limit the risk of mould and decay, and avoids blocking transpiration. The nutrient levels at the watering/irrigation station may be continually monitored and/or adjusted according to plant requirements. This process is sometimes known as fertigation. A controller may be provided to control the action of the watering station, for instance in response to some sensed environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, temperature and/or humidity) and/or plant attributes (e.g. height, leaf size, leaf colour and/or overall colour).

The nutrient levels, pH of irrigation water, etc. may be monitored continuously, continually and/or intermittently, and may be adjustable throughout the crop cycle, with option to provide each carriage with different irrigation and nutrient solution depending on crop type and stage of growth. The irrigation delivery and water and nutrient management may be fully automated and monitored to feedback to the database. Irrigation may be adjusted by an operator as required; in particular, the operator may add supplements to improve plant heath, crop quality and/or nutritional value of the crop.

Irrigation stops may be pre-selected via a control system and database which may record the location and contents of each carriage, including for instance crop batch, varietal information, sowing date, harvest date and any other information that may be desire, include information related to nutrient delivery, temperature, humidity and lighting throughout the growing cycle. The controller / control system and database enables complete traceability from sowing to customer for each batch of crop product. Each carriage, tray and/or plant may be identifiable via radio-frequency identification, such that their respective locations may be tracked; however, other monitoring/tracking systems are also envisaged. Control of the system may allow for automated loading/unloading from the conveyor in response to tracking of the carriages/trays/plants.

The watering station is configured to collect water run-off from the plants. In this way, water may be recycled for further use, if for example excess water is provided to the plants, and/or fresh water is provided to the plants in order to displace water contained within the trays.

The watering station is configured to purify water run-off collected from the plants. The watering station is configured to mechanically purify (e.g. filter), chemically purify, and/or use any other purification method (e.g. using UV light and/or living organisms). In this way, water run-off may be reused. Water recycled may be treated to remove microbial growth and/or salt build up. Stored water may be maintained by continuous aeration and circulation through filters.

The watering station(s) may comprise irrigation nozzles which deliver water and nutrients to each tray, flooding the plant roots before draining away. The watering station may have a separate line for flushing with disinfectant and draining of such, to prevent build up of biofilms, unlike conventional irrigation systems which may have extensive runs of pipes and drains to each location. Each carriage/tray may be supplied with a specified (dynamically controllable) volume of fluid/nutrient at each pass. Irrigation frequency and volume is specific to the stage of growth or individual plant requirements for each carriage/tray.

The clean room is the growing room. In this way, the plants grown by means of hydroculture therein may be ready for consumption upon harvesting, without the need for subsequent washing, cleaning and/or sterilising.

The clean room maybe held at an air pressure above ambient pressure such that air flow out of the clean room is at a speed of at least <NUM> meters per second, in particular at least <NUM> meters per second, more particularly at least <NUM> meter per second. The clean room maybe held at an air pressure at least <NUM> Pascals above ambient pressure, in particular at least <NUM> Pascals, more particularly at least <NUM>, <NUM> or <NUM> Pascals. External ambient atmospheric pressure may be continuously monitored, and internal clean room air pressure may be adjusted in response thereto. In this context, ambient air pressure may be an air pressure measured outside the clean room, which may be in the external atmosphere; however, conceivably it could be in an adjacent room such as an air lock room, itself held at a pressure above the external atmospheric pressure.

The air supply may be recirculated through high-efficiency particulate air (HEPA) and/or ultra-low particulate air (ULPA) filters to remove internally generated contaminants. The filters may be configured to remove particles of dust, bacteria and/or fungal spores. The filters may be configured to be efficient for removal of particles larger than <NUM> micrometers and/or <NUM> micrometer. The filters may comprise a pre-filter and a primary filter. The pre-filter may be configured to be efficient for removal of particles larger than <NUM> micrometers (e.g. EN <NUM> G4) and the primary filter may be configured to be efficient for removal of particles larger than <NUM> micrometer (e.g. EN <NUM> F9).

The system may be provided with a sensor for determining air quality and may comprise a controller for taking steps to return air quality to within a predetermined range in response to the sensor determining that the air quality is outside the predetermined range. The sensor may be configured to sense one or more environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, particulate levels, temperature and/or humidity). The controller may be configured to increase air recirculation, for increasing passage of air through the filter(s), thereby reducing particular concentration levels. Alternatively, the controller may be configured to increase/decrease temperature, humidity, oxygen and/or carbon dioxide levels, etc..

The clean room may be provided with an airlock and/or an air shower for entry and/or exit of people.

The clean room may be classified as ISO <NUM> to <NUM> on the ISO <NUM>-<NUM> cleanroom standard.

The soilless plant growing system further comprises an automated carriage apparatus for removing and/or inserting a carriage from and/or onto the conveyor, respectively. The automated carriage apparatus is in the form of a spur line such that points are switched to allow one carriage to be moved/rolled/slid off the closed loop. In such embodiments, one carriage may be inserted and/or moved/rolled/slid onto the closed loop at the same time as another carriage is removed and/or moved/rolled/slid off the closed loop, for instance to produce a one-on-one-off system. In particular, the conveyor may comprise the closed loop and a spur line. The spur line may be connected to the closed loop at one point only. The spur line may be an open line such that carriages removed from the closed loop must retrace their path to be inserted back onto the closed loop. Alternatively or additionally, the spur line may comprise a loop such that carriages move in substantially only one direction on the loop. The spur line may be connected to the closed loop at more than one point, such that carriages move in substantially only one direction on the spur line. The spur line may comprise any suitable form of spur conveyor similar or different to the conveyor, which may for instance be configured and/or powered by any means discussed above or following.

Additionally, the automated carriage apparatus may take the form of a crane or other lifting system for removing the carriage from the conveyor.

A cleaning station is provided adjacent to the spur line for cleaning the carriages.

The soilless plant growing system further comprises an automated tray apparatus for removing and/or inserting a tray from and/or onto the carriages, respectively. In this way, planting and harvesting may be achieved at a single location, or at least a reduced number of locations, to enable economy of scale. The automated tray apparatus may comprise an automated tray removal apparatus and/or an automated tray insertion apparatus.

The automated tray apparatus may be located in a loading/unloading room. The loading/unloading room may comprise a clean room in a manner similar to the growing room. Alternatively or additionally, the loading/unloading room may be located in the clean room environment of the growing room. Movement between the loading/unloading room and the growing room may comprise moving through a decontamination region, air curtain and/or airlock, or similar, or alternatively, may comprise moving through a conventional non-airlock type portal, configured such that environmental conditions may be maintained at substantially different levels.

An automated tray conveyor may be provided for removing trays from the loading/unloading room and/or automated tray apparatus. The tray conveyor may move trays thus unloaded through a decontamination region and/or airlock, or similar.

The automated carriage apparatus may be configured/arranged to convey carriages from the conveyor to the automated tray apparatus. The automated tray apparatus may be located adjacent to the spur line and/or any other form of automated carriage apparatus. The automated tray apparatus may be located in the growing room.

A tray cleaning station may be provided adjacent to the automated tray apparatus, for cleaning the carriages.

In particular, automation minimises the need for persons to enter a clean room, and therefore improves cleanliness and minimises energy use.

The soilless plant growing system may further comprise at least one sensor configured to determine the maturity of plants present in a tray. The sensor may be configured to sense one or more environmental conditions (e.g. light, air quality, for instance oxygen and/or carbon dioxide levels, water levels, pH, electrical conductivity and/or microbiology profile, temperature and/or humidity) and/or plant attributes (e.g. height, leaf size, leaf colour and/or overall colour). The sensor could comprise CCTV, optionally in combination with automatic identification software to determine growth characteristics of plants.

For instance, the sensor may sense a height of the plants growing on a tray, such that in response to a specific height and/or threshold height being reached, the system may be configured to determine that the plants are ready to harvest. Similarly, if a height of the plants on the tray does not reach a predetermined threshold in a given period, the system may be configured to determine that the plants require additional light, water and/or other nutrients. Such a height sensor may comprise a camera and a height scale arranged such that the plants are moved between the camera and the height scale such that an operator can view images from the camera and determine the height of the plants.

A light sensor may be provided on each tray, on each carriage, or located at fixed locations around the conveyor.

Each carriage may be configured to be rotatable about a vertical axis while on the conveyor. For instance, the portion of the carriage holding the trays (e.g. the support frame) may be rotatable with respect to the portion of the carriage in contact with the conveyor. In this way each carriage may be rotated to make best use of available light.

The system may further comprise a rotating station (or a plurality thereof) located adjacent to the conveyor, for rotating a selected one of the carriages as it passes. The rotation mechanism may comprise an arm arranged to contact the support frame of each carriage as the conveyor moves the carriage past the arm. The arm may be a hook. Alternatively, the rotation mechanism may comprise a motor and an engagement means that may be provided on the carriage, on the conveyor and/or adjacent the conveyor. The rotation mechanism may be configured to rotate the support frame through an angle of up to approximately <NUM> degrees, in particular approximately <NUM> degrees, or alternatively approximately <NUM> degrees relative to the conveyor.

In alternative embodiments, each carriage may comprise, for example, a motor for rotating the carriage on demand.

A propagation room may be provided, which may be adjacent to the growing room, and may be provided with misting irrigation and/or grow on benches that may be configured to ebb and flow water, optionally containing nutrients provided to base of trays (sub irrigation). The propagation room may be a separate room that may be climate controlled and/or may be a clean room.

The propagation room may enable early growth of plants grown in plugs or on a mat. Propagation trays may be seeded by an automated process. Seed and grow media may be sanitised and pre-treated before use to enable clean and pathogen free production. Plants may be spaced during propagation before transfer to biohall/carriages at final spacing. The propagation area may have series of wheeled trolleys carrying propagation or biohall trays over <NUM>-<NUM> levels. Where mats are used for production of smaller plants, the mats may be suspended over a plastic-formed (e.g. reusable) tray insert which allows space for root development and aeration of the root zone. The propagation room may comprise a plurality of rooms, for instance a germination area (e.g. maintained at high humidity) and a grow-on area (e.g. with separate climate).

The propagation room may be linked to the growing room by a corridor which may also be used for loading and/or unloading plants, harvesting and moving cut product. The corridor may include at least one (e.g. only one, or a series) of belt conveyor(s) to transport trays to and from a loader and/or the automated tray apparatus.

The growing room may comprise a crop handling area therein. However, in preferred arrangements, a crop handling area is provided adjacent to the growing room. The crop handling area may comprise a harvesting area and/or a packing area. The automated carriage apparatus (e.g. spur line) is arranged to move carriages between the growing room and the crop handling area. The automated tray apparatus may be located within the crop handling area. Alternatively, the automated carriage apparatus may be located in the growing room.

The crop handling area comprises a further clean room. In particular, the harvest area and/or the packing area may form part of the clean room, or may comprise a further clean room(s).

Movement between the growing room and the crop handling area and/or the harvest area, and/or between the harvest area and the packing area may comprise moving through a decontamination region, air curtain and/or airlock, or similar, or alternatively, may comprise moving through a conventional non-airlock type portal, configured such that environmental conditions may be maintained at substantially different levels.

The growing room is held at a first predetermined set environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, particulate levels, light/illumination level, temperature and/or humidity). The crop handling area is held at a second predetermined set of environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, particulate levels, light/illumination level, temperature and/or humidity) that are different from the first predetermined set of environmental conditions. In particular, the harvest area may be held at a second predetermined set of environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, particulate levels, light/illumination level, temperature and/or humidity) that may be different from the first predetermined set of environmental conditions, and/or the packing area may be held at a third predetermined set of environmental conditions (e.g. air quality, for instance oxygen and/or carbon dioxide levels, particulate levels, light/illumination level, temperature and/or humidity) that may be different from the first and/or second predetermined set of environmental conditions.

For example, the second predetermined set of environmental conditions may include a lower temperature, lower light level and/or higher humidity than those of the first predetermined set of environmental conditions. Similarly, the third predetermined set of environmental conditions may include a lower temperature, lower light level and/or higher humidity than those of the second predetermined set of environmental conditions. Specifically, the second and/or third predetermined set of environmental conditions may include a temperature of between <NUM> and <NUM> degrees centigrade, in particular between <NUM> and <NUM> degrees centigrade, more particularly between <NUM> and <NUM> degrees centigrade, for example approximately <NUM> degrees centigrade. The second predetermined set of environmental conditions include a light level of substantially zero. The third predetermined set of environmental conditions may include a light level of substantially zero.

The second and/or third predetermined set of environmental conditions may be varied and/or variable. In particular, the temperature may be lowered, the light level may be lowered and/or humidity the humidity may be raised gradually in response to plants being moved from the growing room into the crop handling area, the harvest area and/or the packing area, and/or the temperature may be lowered, the light level may be lowered and/or humidity the humidity may be raised gradually in response to plants being moved from the harvest area into the packing area. Specifically, the second and third environmental conditions may initially be substantially equal to the first environmental conditions.

The system may be constructed from stainless steel, food grade plastics material, etc..

According to a second aspect of the present invention, there is provided a method of growing a plant in the absence of soil according to claim <NUM>.

The exact amount of time and conditions required for growing plants depends on the plant variety in question; however, for the sake of example only, seedlings may be placed in a growing on area between approximately <NUM> and <NUM> days after germination, in particular, between approximately <NUM> and <NUM> days. The seedlings may be grown in the growing on area for between approximately <NUM> and <NUM> days, up to a maximum of <NUM> days. The growing on area need not necessarily be provided with natural light, but may be provided with natural light, and may also or alternatively be provided with artificial light. The seedlings may be transferred to the carriage from the growing on area, for instance once roots are developed sufficiently. The seedlings may be transferred to the carriage once they are mature, for instance after approximately <NUM>-<NUM> days after propagation. They may be transferred to a hydroculture growing tray whilst in the growing on area.

Plants may be placed in hydroculture growing trays. The hydroculture growing trays may be placed on the support frame of the carriage. The carriage may be exposed to sunlight between approximately <NUM> hours and approximately <NUM> hours per day. The carriage may be moved on the conveyor between approximately <NUM> hours and approximately <NUM> hours per day, in particular, between approximately <NUM> hours and approximately <NUM> hours per day, more particularly approximately <NUM> hours per day.

The location of the growing tray on the carriage may be changed at a frequency of between approximately <NUM> day and approximately <NUM> weeks, in particular between approximately <NUM> days and approximately <NUM> days, more particularly approximately <NUM> week. Crops, for instance leaves, may be harvested from the mature plants at a frequency of between approximately <NUM> days and approximately <NUM> days, in particular between approximately <NUM> days and approximately <NUM> days. More particularly, food, for instance leaves, may be harvested from the mature plants after approximately <NUM> days, <NUM> days and <NUM> days on the conveyor. Food, for instance leaves, may be harvested from the mature plants at most between approximately <NUM> and <NUM> times (e.g. lettuce may be single cut), in particular between <NUM> and <NUM> times (e.g. for leafy crops, such as watercress). The method may include at least one sacrificial harvest, being the final harvest, after which the plant may be disposed of. Between approximately <NUM> and <NUM> per cent of the plants may be harvested each week.

Grow media, seeds and nutrients may be sanitised and may conform to strict bio control practices. Such items entering the clean area may be passed through a sanitising area prior to introduction into the clean area.

The system is ideally suited to cultivation of fast-growing, small-sized, leafy plants and flowers, in particular herbs, salad and brassicas, for instance watercress.

It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein.

Similarly, it is to be noticed that the term "connected", used in the description, should not be interpreted as being restricted to direct connections only. Thus, the scope of the expression "a device A connected to a device B" should not be limited to devices or systems wherein an output of device A is directly connected to an input of device B. It means that there exists a path between an output of A and an input of B which may be a path including other devices or means. "Connected" may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other but yet still co-operate or interact with each other. For instance, wireless connectivity is contemplated.

Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or aspects. Furthermore, the particular features, structures or characteristics of any embodiment or aspect of the invention may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments or aspects.

Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art.

In the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The use of the term "at least one" may mean only one in certain circumstances.

The principles of the invention will now be described by a detailed description of at least one drawing relating to exemplary features of the invention. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept or technical teaching of the invention, the invention being limited only by the terms of the appended claims.

<FIG> is a perspective view of a carriage for use in a soilless plant growing system. The carriage comprises a frame <NUM> vertically projecting upwards from a stand <NUM> and configured to be rotatably connected to the stand <NUM>, such that the frame <NUM> may be rotated about a vertical axis with respect to the stand <NUM>. The stand is provided with a conveyor engagement mechanism <NUM> that may be in the form of wheels for engaging a track of the conveyor.

The frame <NUM> is provided with a plurality of tray supports (not shown) for holding two vertical stacks of trays <NUM> thereon, each stack comprising ten trays <NUM>. Each tray <NUM> includes a lid having an array of holes <NUM> therethrough, for holding plants to be grown by means of hydroculture therein. The trays may comprise approximately one hundred holes each, but may alternatively comprise other numbers of holes, for instance between three holes and five hundred holes, in particular between five and three hundred, more particularly between fifty and one-hundred-and-fifty. The trays <NUM> in each stack are arranged to be spaced from one another vertically be a common distance; however, differing distances or variable distances (for instance by having movable and/or removable tray supports) are also envisaged.

In an alternative arrangement, the trays may not be provided with lids with holes, but may be provided with a mat (e.g. fleece, synthetic fleece, wool, hessian, hemp, coir, coconut fibre, mineral wool or other forms of mat). The mat may be flexible, and therefore the mat may be provided on a rigid grid/lattice on the tray, to support the mat above the tray base.

<FIG> is a schematic view of closed-loop path <NUM> of a conveyor in a growing room <NUM>. The path <NUM> is of a substantially serpentine form having portions that zig-zag or return parallel/antiparallel to one another. The path <NUM> may comprise a spur <NUM> along which carriages may be diverted, so that they may be taken to a loading/unloading area <NUM> (which may be separate from the growing room <NUM> in that it may be held under atmospheric conditions conducive to harvesting plants (e.g. cooler than the growing room), and/or conducive to propagating plants (i.e. warmer than the growing room, for growing-on). Alternatively, the loading/unloading area <NUM> may be within the growing room <NUM>. The invention may comprise more than one spur <NUM>, or even a secondary spur from the spur <NUM>, for instance one leading to a propagation room and one leading to a harvesting room.

<FIG> is a schematic view of a lighting arrangement for use with the carriage of <FIG>. The lighting arrangement is shown on one side of the carriage only, for instance where the carriage is located adjacent to a side of the growing room directly illuminated by sunlight; however, arrangements are considered in which lighting is provided on both sides, for instance in portions of the growing room that are not adjacent to the side of the growing room directly illuminated by sunlight. LED lights <NUM> are provided immediately beneath an upper tray <NUM> to illuminate a tray <NUM> below. The lights <NUM> may be provided on a line/wire running substantially parallel to the conveyor, such that trays <NUM> from multiple carriages may be illuminated by a single line of lights <NUM>, and may pass unhindered along the conveyor. Each line of lights <NUM> may be supported by upright posts <NUM> or similar arrangements spaced along the line, and power to the lights <NUM> may be provided by a power cable running up from ground level, for instance up one of the posts <NUM>. The lights may be located substantially entirely along the path of the conveyor, except where they may interfere with other operations, such as movement means, watering stations, loading/unloading points, sensors, etc..

<FIG> is a perspective view of a watering station for use with the carriage of <FIG>. The watering station comprises a support frame <NUM>, which in some optional arrangements includes a retention mechanism <NUM> for holding the carriage (in particular the frame <NUM>) in the watering station. Running up the support frame <NUM> are water supply pipes <NUM> (one for each stack of trays <NUM>), having water feed outlets <NUM> arranged for each tray <NUM> of the stack.

Water may be fed into each tray through one of the holes <NUM>, and/or a bespoke water feed hole. Excess water from each tray <NUM> may leave that tray and be collected by a drain mechanism <NUM>, for possibly disposal and/or reuse. The drain mechanism <NUM> may comprise a series of funnels, each disposed beneath a respective tray <NUM>.

<FIG> is a perspective view of a base of a tray <NUM> without its lid. The tray <NUM> includes upward projections <NUM> from the base for supporting a middle portion of the lid thereon, and also a peripheral lip <NUM> for supporting a periphery of the lid thereon. The lower surface of the tray <NUM> includes a recessed arrangement of interconnected channels <NUM> for retaining water therein, such that roots of plants contained within the tray may extend into the water. The tray may be configured such that the holes in the tray lid are located above the channels <NUM>. A tray overflow <NUM> is provided in the tray, separate from the channels <NUM> such that if excess water is introduced into the tray, such that the channels <NUM> overflow, it may exit the tray <NUM> via the overflow <NUM>. In particular, when water is introduced at the watering station, it is envisaged that excess water be provided intentionally in order to, at least partially, displace existing water from the channels <NUM> in favour of the newly introduced water. The overflow <NUM> may be located such that water exiting the tray is collected by funnels of the drain mechanism <NUM>.

<FIG> is a sequence of views showing the mechanism for unloading trays from a carriage.

In (a), a carriage loaded with trays <NUM> on a frame <NUM> is shown on a spur <NUM> of the conveyor. An unloading mechanism <NUM> is shown spaced from the carriage.

In (b), the unloading mechanism <NUM> is moved into engagement position with the carriage such that each unloading support <NUM> on the unloading frame <NUM> is located (immediately) below a respective tray <NUM>.

In (c), the unloading supports <NUM> are raised to lift the trays <NUM> off the frame <NUM> (in particular off the tray supports <NUM>). This may be achieved by the tray supports <NUM> being horizontally offset from the unloading supports <NUM> with respect to the frame <NUM>.

In (d), the unloading mechanism <NUM>, now loaded with trays <NUM>, is moved out of the engagement position with the carriage.

In alternative arrangements, it may be the carriage that is moved up/down, or the carriage on the spur that is moved into/out of the engagement position, rather than the unloading mechanism <NUM>.

The carriage and/or the unloading mechanism <NUM> may subsequently be rotated in order to remove the trays <NUM> from the stack on the opposing side of the carriage.

A similar operation for loading trays onto the carriage is also envisaged, for example operating in reverse to the sequence laid out above. Loading/unloading may take place on the closed loop of the conveyor <NUM> instead of the spur <NUM>, in certain arrangements.

The trays <NUM> may be brought down by mechanical means to ground level where they are fed onto a further conveyor (e.g. a roller belt conveyor) to be moved to harvesting operation. During harvesting, the trays pass through a cutting line such that the cut product is conveyed to a packing line. The trays may be removed from the system for sanitising and/or replanting, or for crops with multiple cuts (i.e. harvesting at several points during an individual plants growth) the trays may be replaced back onto a carriage or the same carriage.

Claim 1:
A soilless plant growing system, comprising:
a conveyor for moving plants around a closed loop (<NUM>), wherein the conveyor is a floor-mounted conveyor located in a growing room that is held at a first predetermined set of environmental conditions;
the growing room being a clean room (<NUM>) in which the conveyor is located, the clean room (<NUM>) provided with a filtered air supply and held at a pressure above ambient atmospheric pressure;
a plurality of carriages configured to be mounted on the conveyor for movement thereon;
an automated carriage apparatus to remove a carriage from the conveyor and/or insert a carriage onto the conveyor, wherein the automated carriage apparatus is in the form of a spur line with switchable points to move a carriage of the plurality of carriages off the conveyor and move it to a crop handling area that comprises a further clean room, wherein the crop handling area is held at a second predetermined set of environmental conditions that are different from the first predetermined set of environmental conditions, wherein the second predetermined set of environmental conditions include a light level of substantially zero, and wherein a cleaning station is provided adjacent to the spur line for cleaning the carriages;
at least one tray (<NUM>) configured to be received on each of the plurality of carriages, each tray (<NUM>) configured for growing at least one plant in the absence of soil;
at least one watering station configured to irrigate the plants on each carriage as the carriage is passed adjacent to the watering station, wherein the watering station is configured to collect water run-off from the plants and to purify water run-off collected from the plants by using filtering and another purification method of chemical purification, using UV light and/or living organisms; and
an automated tray apparatus (<NUM>) to remove and/or insert a tray from and/or onto carriages of the plurality of carriages.