AU2012254950A1 - Continuous growing and harvesting method and apparatus - Google Patents

Abstract

A method and apparatus for continuous growing and harvesting of crops including a continuous conveyor belt means adapted as a growing surface as well as a crop transport 5 mechanism, wherein in operation, seed or pre-germinated seed is sown by direct delivery to the continuously moving belt from hoppers to form a mat by the intertwining of root growth, or as individual plants and wherein the matured crop mat or plants are harvested while a fresh crop is being sown at the same time in a continuous process. - 17- C-44 Coo oCI 0N

Description

STANDARD PATENT APPLICATION CONTINUOUS GROWING AND HARVESTING METHOD AND APPARATUS FIELD OF TH E INVENTION This invention relates to agricultural, horticultural and nursery industries, in particular but not 5 exclusively to a continuous crop or weed growing and harvesting method and apparatus. BACKGROUND OF THE INVENTION The germination and growing of mat type crops is known. Most prior art systems involve the 10 germination and rooting of crops in trays or specialised growing receptacles. This is typically known as batch processing which is time consuming, labour intensive and requires chemical intervention to ensure sterility, maturation and quality control. This is due to the need to remove the crop mat from the growing trays, sterilising, preparing and seeding the trays for a fresh crop. In addition, most prior art systems are either hydroponic or require a growing 15 substrate such as soil or an artificial equivalent. In addition, while batch processing attempts to simulate a continuous growing method, it is not a truly continuous growing system which requires little or no human intervention. As a consequence, crop mats produced by these prior art methods involve a good deal of horticultural expertise and expense. 20 OBJECT OF THE INVENTION It is the object of the present invention to provide a novel and innovative continuous growing method and apparatus typically for weed or crop mat plants which requires little or no human intervention or to provide the public with a useful alternative. 25 STATEMENT OF INVENTION In one aspect therefore, the invention resides in a continuous growing and harvesting apparatus comprising in combination: - 1continuous conveyor belt means adapted as a growing surface and crop transport mechanism, overhead hopper means adapted to sow as required or continually deliver crop seed 5 directly to the belt surface; liquid nutrient delivery means to provide liquid nutrition to the seed bed on the belt; crop harvesting means whereby the crop mat continuously produced can be harvested and processed, 10 wherein in operation, seed or pre-germinated seed is sown by direct delivery to the continuously moving belt from the hoppers to form a continuous mat by the intertwining of root or stem growth, and wherein a matured crop mat is transported to the harvesting means while a new 15 crop is being sown at the same time in a continuous process. In another aspect, the invention resides in a method of continuously growing and harvesting a crop comprising the steps of: 20 (a) delivering crop seed directly on to a continuously moving conveyor belt adapted as a growing surface and crop transport mechanism; (b) providing liquid nutrition to the seed on the belt; (c) producing a continuous crop mat by the intertwining of root or stem growth; 25 (d) harvesting the crop at the end of a growing cycle while a new crop is being sown at the same time in a continuous process. 30 In another aspect, the invention resides in a continuous growing and harvesting apparatus comprising in combination: -2continuous conveyor belt means adapted as a growing surface and crop transport mechanism; the conveyor belt having a surface configuration comprising a multiplicity of 5 indentations or receptacles as seed germination cells; overhead hopper means adapted to sow as required or continually deliver crop seed to the receptacles or cells; 10 liquid nutrient delivery means to provide liquid nutrition to the seed; crop harvesting means whereby plants growing in the cells can be harvested and processed, 15 wherein in operation, seed or pre-germinated seed is sown by direct delivery to the continuously moving belt from the hoppers and wherein the plants growing in the cells are transported to the harvesting means while a new crop is being sown at the same time in a continuous process. 20 In another aspect, the invention resides in a method of continuously growing and harvesting a crop comprising the steps of: (a) delivering crop seed directly on to continuously moving conveyor belt adapted 25 as a growing surface and crop transport mechanism; the conveyor belt having a surface configuration comprising a multiplicity of indentations or receptacles as seed germination cells; (b) providing liquid nutrition to the seed in the receptacles of the belt; 30 (c) producing a crop of plants growing in each cell, and (d) harvesting the plants at the end of a growing cycle while a new crop is being sown at the same time in a continuous process. -3- In another aspect, the invention resides in a continuous growing and harvesting apparatus comprising in combination: 5 continuous conveyor belt means adapted as a crop transport mechanism; growing medium delivery apparatus adapted to deliver a growing medium overlay to the surface of the belt: overhead hopper means adapted to sow as required or continually deliver crop seed directly to the growing medium; 10 liquid nutrient delivery means to provide liquid nutrition to the seed bed on the growing medium; crop harvesting means whereby the crop mat produced can be harvested and processed, 15 wherein in operation, seed or pre-germinated seed is sown by direct delivery to the growing medium on the continuously moving belt from the hoppers to form a mat by the intertwining of root or stem growth, and wherein a matured crop mat on the growing medium is transported 20 to the harvesting means while a new crop is being sown at the same time in a continuous process. In another aspect, the invention resides in a method of continuously growing and harvesting a crop comprising the steps of: 25 (a) delivering crop seed directly on to continuously moving conveyor belt with a growing medium overlay; (b) providing liquid nutrition to the seed on the growing medium on the belt; 30 (c) producing a crop mat by the intertwining of root or stem growth; -4- (d) harvesting the crop at the end of a growing cycle while a new crop is being sown at the same time in a continuous process. Preferably, where the belt is configured to have indentations or growing cells, the indentations 5 are between 1 mm to 5 mm deep for plants harvested as a crop mat. For larger crops, where plants are not harvested as a mat, the cells are deeper and are in the form of receptacles. 10 Preferably, the growing medium can be paper, coir, or any medium in sheet form. Preferably the growing medium has a wicking capability wherein the liquid nutrient is absorbed and released to the crop seed. 15 Preferably the growing medium delivery means is a roll of the growing medium that is continuously delivered in sheet form to the surface of the conveyor belt at the same speed as the belt. Preferably, the liquid nutrient delivery means is an overhead spray means, however can be 20 located below the crop mat as it is transferred to a harvesting platform associated with the harvesting means. Preferably, the liquid nutrient is devoid of or only has trace amounts of carbon so as to encourage the growing crop to sequester carbon from the air. 25 Preferably, there is liquid collection means adapted to collect any nutrient solution runoff from the belt and the apparatus. Preferably, the belt has a gradient to facilitate nutrient runoff. In the alternative the apparatus 30 can be mounted on a sloping floor to achieve the same purpose. Preferably, the liquid collection means is tray, located from under the end of the belt and the harvesting means. -5- The collected liquid nutrient runoff is preferably used for animal consumption. In the alternative, the runoff can be recycled for reuse as a nutrient solution possibly with a booster quantity of fertiliser or trace elements to restore the nutritional quality of the solution. 5 Preferably, the conveyor belt has side walls to confine the liquid nutrient solution to the crop. Suitably, and depending on the type of crop, the speed of the belt is in the order of between 5 cm. and 20 cm. per hour. 10 More preferably, the belt speed ideally 11 cm. per hour. For example, for lettuce crops which are ideally harvested within three days, the belt speed may be increased to between 5 to 10 cm. per hour. 15 Preferably, the harvesting means comprises a platform at the end of the belt wherein the crop mat is pushed on and cut into strips. Preferably, the harvesting means includes blade means such as a guillotine device, however other devices such as a circular saw adapted to travel to and fro as it cuts the strips may also be 20 used. The strips can then be processed by a belt, screw or other conveyor which disentangles and breaks up the root bed to form stockfeed. Preferably, for larger crops, the harvesting means comprises a device having multiple combs or forks specially adapted to pull individual plants out of each cell. 25 In a preferred embodiment, there can also be included a powered rotary fork device comprising a roller member having a plurality of fingers or tines to drag or control the speed of the crop mat as it approaches the harvesting means wherein the rotational speed of the rotary fork is 30 matched to that of the belt to ensure a smooth passage of the maturing crop mat on the apparatus. -6- Preferably, there is also belt sterilising or disinfecting means comprising a receptacle or spray means to deliver an antibacterial or antibiotic solution to the belt continuously throughout the growing cycle. 5 In another example, where a crop mat is produced, there can be an additional conveyor belt apparatus adapted to receive a crop mat transferred from the continuous growing and harvesting apparatus hereinbefore described; the belt of the additional conveyor belt apparatus configured to include a plurality of spaced holes or perforations through which air and liquid nutrient can be provided to the crop mat. 10 In yet another aspect the invention resides in any crop continuously grown and harvested by any of the apparatus or methods hereinbefore described. -7- BRIEF DESCRIPTION OF THE DRAWINGS In order for the invention to be better understood reference will now be made to the accompanying drawings, wherein; 5 Figure 1 shows a plan view of a preferred apparatus according to the invention. Figure 2 shows a side view of a tiered or stacked arrangement of multiple units of the apparatus of Figure 1. Figures 3A and 3B show plan and elevation views of a preferred belt with receptacles or cells. 10 Figure 4 shows a preferred example of a growing medium delivery system of the invention. Figures 5A and 5B show diagrammatic side and plan representations of the additional conveyor belt apparatus. DETAILED DESCRIPTION OF THE DRAWINGS Referring now to Figure 1 there is shown a preferred apparatus according to the invention. The 15 conveyor belt 10 has side walls 12, 14 to contain the liquid nutrient used to feed the crop. Crop seed is delivered to or sown directly on the belt surface via overhead hoppers 16, 18, 20. The seed delivery of the hoppers can be varied according to the belt speed to ensure a uniform crop mat is produced. On leaving the hoppers, the seeds are sprayed with liquid nutrient by the liquid nutrient delivery means in the form of overhead sprayers (not shown). The belt is 20 partially shown to reveal the structure supporting the belt. The structure preferably comprises a chassis 13 inclusive of longitudinal rail members 15, 17, 19 over which the belt is supported and driven by at least one of the belt rollers 21, 23. This is to ensure that the belt provides a relatively uniform planar or flat surface on which the crop mat is produced. There can also be spray means (not shown) located beneath the harvesting platform 22 wherein nutrient solution 25 can sprayed in an upwards direction to feed the crop root mat. Also shown is the harvesting means comprising a platform 22 on which the matured crop mat is pushed wherein it is cut into strips by circular saw or guillotine blade 24. The strips are the processed into stockfeed by the belt conveyor 26 which breaks up the strips. -8- Figure 2 shows a side view of a number of units 30, 40, 50 of the invention in a tiered or stacked arrangement. In this view the continuously moving conveyor belts 32, 42, 52 are driven by at least one of the pairs of rollers 34, 36; 44, 46; 54, 56 supported by chassis 38, 48, 58. There are also shown smaller supporting rollers which help to control and maintain belt tension. Also 5 shown is the liquid collection means in the form of trays 39, 49, 59 underneath the end rollers 36, 46, 56 immediately before the harvesting platforms 31, 41, 51. As previously discussed, the liquid nutrient runoff collect in the trays may be used for animal consumption. In the alternative when water conservation is a priority, the nutrient runoff may 10 be recycled wherein a booster of fertiliser may be added to the collected liquid for reuse in growing a new crop mat on the apparatus. It will be obvious that in the last case, there will have to be a nutrient recycling means associated with the liquid collection means which will include ancillary valves, pumps and associated plumbing (all not shown). 15 There is also shown troughs 33, 43, 53 containing disinfectant or sterilizing solution to ensure disease is not spread to new seed as the belt moves around. Figures 3A and 3B show plan and elevation views of a conveyor belt 60 configured to have growing receptacles or cells eg. 62,64,66. Crop seed delivered to each cell by overhead hoppers 20 (not shown) are sprayed with liquid nutrient. As previously mentioned, where crops are harvested in the form of a crop mat, the indentations comprising the growing cells are shallow to allow the intertwining of root and stem growth. For larger crops, the cells are deeper and the plants are harvested preferably by a device (not shown) having multiple combs or forks adapted to pull the plants without damage out of the individual cells. 25 Figure 4 shows a preferred growing medium delivery apparatus. The growing medium is preferably paper, cardboard, coir or other fibrous matrix sheet material delivered from a roller 74 to overlay the continuous conveyor belt 76 supported between rollers 78, 80. Crop seed delivered to the growing medium overlay by the overhead hoppers (not shown) is sprayed with 30 liquid nutrient. The wicking action of the medium absorbs the liquid nutrient which is in turn taken up by the seed crop. The wet surface of the growing medium also serves to keep the loose seeds in place on the moving belt. As the crop mat matures, it is harvested along with the growing medium. - 9- Figures 5A and 5B show diagrammatic side and plan representations of the additional conveyor belt apparatus. 90 Where a crop mat is produced (not shown), there can be an additional conveyor belt apparatus adapted to receive a crop mat transferred from the continuous growing 5 and harvesting apparatus hereinbefore described. The belt 92 of the additional conveyor belt apparatus is configured to include a plurality of spaced holes eg. 94, 96, 98 or perforations through which air and liquid nutrient can be provided to the crop mat from beneath the belt 92. 10 VARIATIONS It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth. 15 In the specification the terms "comprising" and "containing" shall be understood to have a broad meaning similar to the term "including" and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the terms 20 "comprising" and "containing" such as "comprise", "comprises", "contain" and "contains". - 10-

Claims (29)

1. A continuous growing and harvesting apparatus comprising in combination: S continuous conveyor belt means adapted as a growing surface and crop transport mechanism, overhead hopper means adapted to sow as required or continually deliver crop seed directly to the belt surface; 10 liquid nutrient delivery means to provide liquid nutrition to the seed bed on the belt; crop harvesting means whereby the crop mat continuously produced can be harvested and processed, 15 wherein in operation, seed or pre-germinated seed is sown by direct delivery to the continuously moving belt from the hoppers to form a continuous mat by the intertwining of root or stem growth, and wherein a matured crop mat is transported to the harvesting means while a new crop is being sown at the same time in a continuous process. 20

2. A continuous growing and harvesting apparatus comprising in combination: continuous conveyor belt means adapted as a growing surface and crop transport mechanism; 25 the conveyor belt having a surface configuration comprising a multiplicity of indentations or receptacles as seed germination cells; overhead hopper means adapted to sow as required or continually deliver crop seed to the receptacles or cells; 30 liquid nutrient delivery means to provide liquid nutrition to the seed; - 11 - crop harvesting means whereby plants growing in the cells can be harvested and processed, wherein in operation, 5 seed or pre-germinated seed is sown by direct delivery to the continuously moving belt from the hoppers and wherein the plants in the cells are transported to the harvesting means while a new crop is being sown at the same time in a continuous process.

3. A continuous growing and harvesting apparatus comprising in combination: 10 continuous conveyor belt means adapted as a crop transport mechanism, growing medium delivery apparatus adapted to deliver a growing medium sheet overlay to the surface of the belt: overhead hopper means adapted to sow as required or continually deliver crop seed 15 directly on the growing medium: liquid nutrient delivery means to provide liquid nutrition to the seed bed on the growing medium; crop harvesting means whereby the crop mat continuously produced can be harvested and processed, 20 wherein in operation, seed or pre-germinated seed is sown by direct delivery to the growing medium on the continuously moving belt from the hoppers to form a continuous mat by the intertwining of root or stem growth, and wherein a matured crop mat is transported to 25 the harvesting means while a new crop is being sown at the same time on the growing medium in a continuous process.

4. The apparatus and method of Claim 3 wherein the growing medium is paper, coir, or any 30 medium in sheet form.

5. The apparatus of Claim 4 wherein the growing medium has a wicking capability wherein the liquid nutrient is absorbed and released to the crop seed. - 12-

6. The apparatus of Claim 3 or Claim 4 wherein the growing medium delivery means is a roll of the growing medium that is continuously delivered in sheet form to the surface of the conveyor belt at the same speed as the belt. 5

7. The apparatus of any of the above claims wherein the liquid nutrient delivery means is an overhead spray means located below the crop mat as it is transferred to a harvesting platform associated with the harvesting means. 10

8. The apparatus of any of the above claims wherein the liquid nutrient is devoid of or only has trace amounts of carbon so as to encourage the growing crop to sequester carbon from the air.

9. The apparatus of any of the above claims wherein there is liquid collection means adapted to collect any nutrient solution runoff from the belt and the apparatus. 15

10. The apparatus of any of the above claims wherein the belt has a gradient to facilitate nutrient runoff or the apparatus is mounted on a sloping floor to achieve the same purpose.

11. The apparatus of any of the above claims wherein the liquid collection means is a tray 20 located under the end of the belt and the harvesting means.

12. The apparatus of any of the above claims wherein the collected liquid nutrient runoff used for animal consumption. 25

13. The apparatus of any of the above claims wherein the runoff is recycled for reuse as a nutrient solution with a booster quantity of fertiliser or trace elements to restore the nutritional quality of the solution.

14. The apparatus of any of the above claims wherein the conveyor belt has side walls to confine 30 the liquid nutrient solution to the crop.

15. The apparatus of any of the above claims wherein the speed of the belt is in the order of between 5 cm. and 20 cm. per hour. - 13-

16. The apparatus of any of the above claims wherein the harvesting means comprises a platform at the end of the belt wherein the crop mat is pushed on and cut into strips. 5

17. The apparatus of any of the above claims wherein the harvesting means includes a guillotine blade to cut the crop mat into strips.

18. The apparatus of any of the above claims wherein the harvesting means includes a circular saw adapted to travel to and fro to cut the crop mat into strips. 10

19. The apparatus of Claim 17 or 18 wherein the strips are processed by a screw or belt conveyor which disentangles and breaks up the root bed to form stockfeed.

20. The apparatus of Claim 2 wherein the harvesting means includes multiple the combs or forks 15 specially adapted to pull individual plants out of each cell.

21. The apparatus of any of the above claims wherein there is included a powered rotary fork device comprising a roller member having a plurality of fingers or tines to drag or control the speed of the crop mat as it approaches the harvesting means wherein the rotational speed of 20 the rotary fork is matched to that of the belt to ensure a smooth passage of the maturing crop mat on the apparatus.

22. The apparatus of any of the above claims wherein there is belt sterilising or disinfecting means comprising a receptacle or spray means to deliver an antibacterial or antibiotic solution 25 to the belt continuously throughout the growing cycle.

23. The apparatus of any of the above claims wherein where a crop mat is produced, there is additional conveyor belt apparatus adapted to receive the crop mat transferred from the continuous growing and harvesting apparatus hereinbefore claimed and described; the belt of 30 the additional conveyor belt apparatus configured to include a plurality of spaced holes or perforations through which air and liquid nutrient can be provided to the crop mat. - 14-

24. A method of continuously growing and harvesting a crop comprising the steps of: (a) delivering crop seed directly on to a continuously moving conveyor belt adapted as a growing surface and crop transport mechanism; 5 (b) providing liquid nutrition to the seed on the belt; (c) producing a continuous crop mat by the intertwining of root or stem growth; (d) harvesting the crop at the end of a growing cycle while a new crop is being sown 10 at the same time in a continuous process.

25. A method of continuously growing and harvesting a crop comprising the steps of: 15 (a) delivering crop seed directly on to continuously moving conveyor belt adapted as a growing surface and crop transport mechanism; the conveyor belt having a surface configuration comprising a multiplicity of indentations or receptacles as seed germination cells; 20 (b) providing liquid nutrition to the seed in the cells of the belt; (c) producing a crop of plants growing in each cell; (d) harvesting the plants at the end of a growing cycle while a new crop is being sown at the same time in a continuous process. 25

26. A method of continuously growing and harvesting a crop comprising the steps of: (a) delivering crop seed directly on to continuously moving conveyor belt adapted as a growing surface as well as a crop transport mechanism; the belt having a growing medium overlay; 30 (b) providing liquid nutrition to the seed on the growing medium overlay on the belt; (c) producing a continuous crop mat by the intertwining of root or stem growth; (d) harvesting the crop at the end of a growing cycle while a new crop is being sown at the same time in a continuous process. -15-

27. The apparatus of Claim 2 wherein the cells are between 1 mm and 5 mm deep.

28. The apparatus of Claim 2 wherein the cells are more than 5 mm deep. 5

29. A crop grown and harvested by the apparatus or methods of any one of the above claims. - 16 -