DK179595B1

DK179595B1 - Process for line production of plant growth medium bags and pots

Info

Publication number: DK179595B1
Application number: DKPA201700414A
Authority: DK
Inventors: Peter Bilde Hansen Lars
Original assignee: Ellepot A/S
Priority date: 2017-07-14
Filing date: 2017-07-14
Publication date: 2019-02-25
Also published as: DK201700414A1; WO2019011742A1

Abstract

The present invention relates to a process for line production of plant growth medium bags comprising the steps of: a) continuously folding the free end of a continuous length of water and air permeable sheet material, preferably supplied on a reel, into a tube around and beyond a free end of a growth medium feeding tube; b) forming a first sealing in the tube by engaging and flattening the opposed walls of the open end of the tube, and advancing the continuous length of water and air permeable sheet material a predefined distance; c) through the free end of the growth medium feeding tube, filling the tube with a measured amount of growth medium; d) forming a second sealing in the tube at a position above the growth medium by engaging and flattening the opposed walls of the open end of the tube to form a first growth medium bag, or a compartment in a first growth medium bag with multiple compartments, and advancing the continuous length of water and air permeable sheet material a predefined distance; e) optionally, repeating the steps c)-d) to form a series of interconnected growth medium bags; and f) separating one or a group of interconnected growth medium bags from the series of interconnected growth medium bags.

Description

Process for line production of plant growth medium bags and pots

Technical field of the invention

The present invention relates to aids to produce plants, and specifically to aids to produce orchids.

Background of the invention

Today, orchids, particularly Phalaenopsis (known as moth orchid), are one of the most important flower products for the markets around the world. Most cultivated orchids are native to the tropics. In their natural habitat, they attach themselves to the bark of trees, or to the surface of other plants. Their thick, white roots are specially adapted to absorb moisture and dissolved nutrients. Orchids roots, and eventually the entire plant, will die if they do not get air, and this is the reason that orchids do not grow in soil (with the exception of a few terrestrial varieties). The orchid potting media should be open, with exceptionally good drainage, yet capable of holding sufficient moisture to support the plant's needs. Orchids are therefore often grown in bark mixes. The most reliable method of seed production of orchids is asymbiotic germination, or flasking. This method involves growing the seeds in a nutrient solution, which provides the necessary nutrients for the growing plants. The nutrient solution is mixed into agar to provide mechanical support for the seedlings. After one to two years, the seedlings will normally be large enough to survive outside the flask. The seedlings are removed from the flask, all the agar solution washed from the plants and then potted into pots where they continue to grow. For the first few weeks, the tiny plants are kept moist and humid while they acclimatise to life outside the flask. The seedlings will then take another 2 to 10 years or more, depending on the species, before they are large enough to flower, most common species taking around 2 or 3 years. The process step of potting the plants is very time consuming, and there exist a need to reduce the complexity of this step, while providing a solution where the seedlings can continue to be mechanically supported.

US3739522 discloses a cell system for use in horticulture comprising a belt of sheet material, such as plastic, folded in half longitudinally and having its two layers sealed along lines transverse to and spaced apart along the belt. The sheet forms a series of spaced web portions in which the layers are contiguous, and an alternating series of cells each suitable for receiving the root system of a mature plant. Cover means for the mouths of the cells may comprise a cover strip separate from the belt, or edge portions of the belt may be folded over the mouths. The seals in the web portions may be discontinuous and localized to allow water and nutrient to flow between the cells; or unsealed edge portions of the webs may form a liquid conduit between cells.

Summary of the invention

It is an object of the present invention to provide aids for reducing the complexity of the potting process of orchids seedlings.

The inventor of the present invention has developed a growth medium bag that can be used to wrap around an orchid seedling, such that it is mechanically supported, and may fit into a pot tray. The production of such a growth medium bag requires a new and specialized production process for large scale production. Furthermore, this production process has proven useful for other growth medium pot products for use in hydroponic growth of pot plants, such as herbs. Today, most of the greenhouses applying hydroponic growth of herbs utilize injection moulded plastic pots. This is very problematic, as there is a dramatic increase of plastic waste in general in the world. Furthermore, when the herbs are harvested, the plastic pots are seldom separated from the root and growth medium, and both parts are therefore not recycled. Hence, it is also an object of the present invention to provide an alternative growth medium pot to replace the environmentally unfriendly injection moulded plastic pots. Furthermore, it is an object to provide machinery for their production.

A first aspect relates to a process for line production of plant growth medium bags comprising the steps of:

a) continuously folding the free end of a continuous length of water and air permeable sheet material, preferably supplied on a reel, into a tube around and beyond a free end of a growth medium feeding tube;

b) forming a first sealing in the tube by engaging and flattening the opposed walls of the open end of the tube, and advancing the continuous length of water and air permeable sheet material a predefined distance;

c) through the free end of the growth medium feeding tube, filling the tube with a measured amount of growth medium;

d) forming a second sealing in the tube at a position above the growth medium by engaging and flattening the opposed walls of the open end of the tube to form a first growth medium bag, or a compartment in a first growth medium bag with multiple compartments, and advancing the continuous length of water and air permeable sheet material a predefined distance;

e) optionally, repeating the steps c)-d) to form a series of interconnected growth medium bags; and

f) separating one or a group of interconnected growth medium bags from the series of interconnected growth medium bags.

The second sealing of a growth medium bag may be a first sealing in a neighbouring growth medium bag after initiation of the process, i.e. after changing a reel or folded stack of continuous length of water and air permeable sheet material.

In the present context, the term “plant growth medium” should be broadly interpreted, and includes fertilizer, peat moss, fir bark, dried fern roots, sphagnum moss, rock wool, perlite, cork nuggets, stones, coconut fiber, lava rock, compost, or a blend that combines several of these materials.

By using a water and air permeable sheet material, preferably biodegradable, woven or nonwoven, there is no need for the environmentally unfriendly injection moulded plastic pots. Rather, the water and air permeable sheet material may be recycled together with the plant roots and growth medium in a composting facility. The sheet material must be water and air permeable in order for the produced plant pot to be able to absorb water and dissolved nutrients.

The term “biodegradable” as used herein describes the chemical dissolution of materials by bacteria or other biological means.

As used herein, the term “nonwoven sheet material” means a sheet material that has a structure of individual fibers or threads, which are interlaid, but not in an identifiable repeating manner. Nonwoven sheet materials may be formed by a variety of processes such as, for example, meltblowing processes, spunbonding processes, coforming processes, airlaying processes, wetlaying processes, and hydroentangling.

The fibers used for the water and air permeable sheet material are preferably biodegradable, which can be natural or synthetic fibers, e.g. cellulosic fibers, protein fibers or synthetic polymer fibers. Natural fibers, preferably recycled, can comprise pulped or shredded cellulose fibers, such as wood pulp, shredded wood, shredded paper (tissue, newsprint and the like), straw, cotton fiber, composted vegetation, fibrous sphagnum moss, peat moss, shredded stalks including shredded corn stalks and shredded pine straw (including needles, twigs, cones and small branches). Shredded vegetation is preferably dry before shredding. Protein fibers can e.g. be hair or gelatin. Biodegradable synthetic fibers can comprise reconstituted cellulose fibers, such as rayon fibers, vinyl polymer fibers, such as fibrous polyvinyl alcohol, poly lactic acid, and polyamide fibers.

The term “cellulosic fibers” as used herein describes fibers made from an organic compound derived primarily from plants such as trees.

The term “wood pulp fibers” as used herein describes a type of cellulosic fiber made from a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulosic fiber from plants such as trees or cotton.

The term “regenerated/reconstituted cellulosic fibers” as used herein describes a type of cellulosic fiber made from wood pulp using a solvent fiber spinning process. The process involves dissolving wood pulp in a solvent, and spinning the resultant spinning solution into fibers.

In one or more embodiments, the biodegradable and water and air permeable sheet material consist of spunlaced fibers without fiber binding materials. The term spunlaced as used herein refers to a structure of individual fibers or threads, which are physically entangled, without thermal bonding. Physical entanglement may be achieved using a water entanglement process, or alternatively, a needling process or a combination of both processes. The spunlaced fibers provide the strength to the water and air permeable sheet without the need for a binder, also, and very importantly for the present use, when the water and air permeable sheet is wet.

In order for the water and air permeable sheet material to be sealable, at least some of the fibers should preferably be made from, or coated with, a thermoplastic material. Alternatively, the water permeable sheet material could be coated with a hotmelt composition. Another method for sealing the tube may be to emboss the sheet parts together.

In one or more embodiments, the water permeable sheet material is heat sealable.

The water and air permeable sheet material must obviously be advanced during the continuous process. Different means may be used, such as a pair of jaws configured to move in the water and air permeable sheet material advancement direction during their engagement with the tube. The pair of jaws may be welding jaws configured to make the sealing.

In one or more embodiments, the sealings are made by flattening the tube between two welding jaws, and wherein the continuous length of water and air permeable sheet material is advanced by moving the two welding jaws, when engaged with the tube, in the water and air permeable sheet material advancement direction.

In one or more embodiments, the separation step is performed by dividing a sealing into two sealings by cutting (mechanical cut or heat cut) longitudinally therethrough.

In one or more embodiments, a part of the growth medium bag is removed prior to or during the separation step by cutting, to form a growth medium pot.

In one or more embodiments, the separation step is performed by dividing the second sealing into two sealings, a second and a first sealing, by cutting longitudinally therethrough. In this way, the second sealing for a first tubular chamber is prepared simultaneously with a first sealing for the following second tubular chamber.

In one or more embodiments, a second sealing for a first tubular chamber is prepared simultaneously with a first sealing for the following second tubular chamber, and wherein the separation step is performed by cutting between said second and first sealing.

In one or more embodiments, the tube is sealed along its length, e.g. by a lap sealing. The sealing is preferably made on the tube part when it passes over the growth medium feeding tube. Thereby, a part of the free end of the growth medium feeding tube serves as a part of the sealing means. In one or more embodiments, a part of the free end of the growth medium feeding tube comprises a protrusion adapted for receiving a welding jaw.

In one or more embodiments, the growth medium feeding tube is connected to a growth medium delivering unit comprising:

- a storage container adapted for holding growth medium, and with an outlet in the bottom wall;

- a stirrer configured to maintain the growth medium homogeneous in the storage container; and

- an open-ended dosing chamber configured to move between a first position and a second position; wherein the first open end connects to the outlet of the storage container in the first position, and wherein the second open end connects to the inlet of the growth medium feeding tube in the second position.

- an open-ended dosing chamber configured to move between a first position and a second position; wherein the first open end connects to the outlet of the storage container in the first position, and wherein the second open end connects to the inlet of the growth medium feeding tube in the second position, while the first open end disconnects from outlet of the storage container, thereby removing a dosage of growth medium from the storage container, through the open-ended dosing chamber, and into the growth medium feeding tube.

The growth medium delivering unit with a dosing chamber is a new way of thinking within the field of paper pots, where the growth medium is normally delivered into a cylindrical paper tube as a continuous mass (see e.g. WO1992003914). Such a configuration is not possible, when producing a plant bag or pot according to the present invention. In order to provide space for making the sealings, the growth medium must be provided into the cavity of the tube in doses. This dosage of growth medium may be delivered e.g. by suction or blow means. Therefore, it is important that the water permeable sheet material must also be air permeable, as the air blown into the tube together with the dosage of growth medium must leave the tube through the walls of the tube. Similarly, when the dosage is sucked into the tube, a low pressure (e.g. vacuum) must be generated within a part of the tube by removing air from the tube lumen.

In one or more embodiments, the open-ended dosing chamber is configured as a block with a channel extending therethrough, and wherein the first open end of the channel connects to the outlet of the storage container in the first position, and wherein the second open end of the channel connects to the inlet of the growth medium feeding tube in the second position.

In one or more embodiments, the block is slidingly engaged with the bottom wall of the of the storage container.

In one or more embodiments, the open-ended dosing chamber is slidingly engaged with bottom wall of the of the storage container.

In one or more embodiments, the stirrer is configured to change rotation direction each 2-10 dosing operations. This configuration is to avoid demixing of the growth medium.

In one or more embodiments, the stirrer paddle blade/head is configured as one or more cylindrical rods extending radially away from the stirrer shaft. This configuration is to avoid demixing of the growth medium.

A second aspect relates to a growth medium bag or pot obtainable by the process according to the present invention.

A third aspect relates to the use of a growth medium bag according to the present invention for cultivating plant seedlings, such as onion plant seedlings, and orchid plant seedlings.

The dimensions of the growth medium bags are preferably longer than their width, the length being within the range of 30-200 mm, and the length being within the range of 40-400 mm. For orchid seedlings, the width should preferably be within the range of 30-80 mm, and the length within the range of 60-160 mm.

A fourth aspect relates to an apparatus for use in the process according to the present invention, the apparatus comprising:

- a stirrer configured to maintain the growth medium homogeneous in the storage container;

- an open-ended dosing chamber configured to move between a first position and a second position; wherein the first open end connects to the outlet of the storage container in the first position, and wherein the second open end connects to an inlet of a growth medium feeding tube in the second position, while the first open end disconnects from outlet of the storage container, thereby removing a dosage of growth medium from the storage container, through the open-ended dosing chamber, and into the growth medium feeding tube;

- means adapted for continuously folding the free end of a continuous length of water and air permeable sheet material, preferably supplied on a reel, into a tube around the growth medium feeding tube; and

- a suction chamber positioned around and beyond the free end of the growth medium feeding tube, and adapted to be in a) an open first configuration and b) in a closed second configuration; wherein when in the closed second configuration the suction chamber encloses the free end of the growth medium feeding tube and the water and air permeable sheet material tube formed around it, and engages and flattens the opposed walls of the water and air permeable sheet material tube at a predefined distance downstream from the free end of the growth medium feeding tube; and subsequently removes air out of the chamber, such that a dosage of growth medium in the dosing chamber and/or in the growth medium feeding tube, is transported through the growth medium feeding tube and into the water and air permeable sheet material tube within said suction chamber.

In one or more embodiments, the apparatus further comprises:

- a first means adapted for forming a first sealing in the tube by engaging and flattening the opposed walls of the open end of the tube, and advancing the continuous length of water and air permeable sheet material a predefined distance; and

- a second means adapted for forming a second sealing in the tube at a position above the growth medium by engaging and flattening the opposed walls of the open end of the tube to form a first growth medium bag, or a compartment in a first growth medium bag with multiple compartments, and advancing the continuous length of water and air permeable sheet material a predefined distance. The first and the second means may be the same.

In one or more embodiments, the first and/or the second sealing means may be integrated into the lower part of the suction chamber.

In one or more embodiments, the apparatus comprises a cutting means adapted for separating the formed plant growth bag from the continuous length of water permeable sheet material.

In one or more embodiments, the means adapted for forming a first and a second sealing are positioned on each side of a slot adapted for receiving the cutting means adapted for separating the formed growth medium bag from the continuous length of water and air permeable sheet material.

In one or more embodiments, the apparatus further comprises a piston configured to move through the first and second open ends of the open-ended dosing chamber when the open-ended dosing chamber is in the second position.

As used in the specification and the appended claims, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from about or approximately one particular value and/or to about or approximately another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another embodiment.

Brief description of the figures

Figure 1 shows an apparatus for use in the process in accordance with various embodiments of the invention;

Figure 2 shows a part of the apparatus members in accordance with various embodiments of the invention;

Figure 3 shows a sealing means in accordance with various embodiments of the invention;

Figure 4 shows a cutting means in accordance with various embodiments of the invention;

Figure 5 shows a growth medium storage container relative to an open-ended dosing chamber in accordance with various embodiments of the invention; and

Figure 6 shows a growth medium bag in accordance with various embodiments of the invention.

Detailed description of the invention

Figure 1 shows an apparatus 100 for line production of plant growth medium bags. The apparatus 100 comprises folding means 200, sealing means 300, a growth medium feeding tube 400, cutting means 500, a growth medium storage container 600, a dosing chamber 700 (not visible, see Figure 5), and a suction chamber 800.

The folding means 200 is adapted for continuously folding the free end of a continuous length of water and air permeable sheet material 10, preferably supplied on a reel 20, into a tube 12 around the growth medium feeding tube 400.

The sealing means 300 is adapted for:

- forming a first sealing in the tube 12 by engaging and flattening the opposed walls of the open end of the tube, and advancing the continuous length of water and air permeable sheet material 10 a predefined distance; and

- forming a second sealing in the tube at a position above the growth medium by engaging and flattening the opposed walls of the open end of the tube 12 to form a first growth medium bag 30, or a compartment 32 in a growth medium bag 30 with multiple compartments 32, and advancing the continuous length of water and air permeable sheet material 10 a predefined distance (arrow 14 indicates a predefined distance relative to the second sealing). The first and the second sealing means 300 are the same. The second sealing 34 of a growth medium bag 30 may be a first sealing in a neighbouring growth medium bag 30. The function of the sealing means 300 is better seen in Figure 3.

In between the first sealing operation and the second sealing operation, a dosage of growth medium is transported to the lumen of the growth medium bag or compartment being formed. In the disclosed apparatus 100 a stirrer is configured to maintain the growth medium homogeneous in the storage container 600. An openended dosing chamber 700 is configured to move between a first position and a second position (better seen in Figure 5). The first open end 720 connects to the outlet 610 of the storage container 600 in the first position, and wherein the second open end connects to an inlet (not shown) of a growth medium feeding tube 400 in the second position, while the first open end 720 disconnects from outlet 610 of the storage container 600, thereby removing a dosage of growth medium from the storage container 600, at least partly through the open-ended dosing chamber 700, and at least partly into the growth medium feeding tube 400.

A stirrer paddle blade/head 740 is configured as two cylindrical rods extending radially away from the stirrer shaft. This configuration is to avoid demixing of the growth medium.

A suction chamber 800 (better seen in Figure 2) is positioned around and beyond the free end 410 of the growth medium feeding tube 400, and adapted to be in a) an open first configuration (as seen in Figure 2) and b) in a closed second configuration. In the closed second configuration, the suction chamber 800 encloses the free end 410 of the growth medium feeding tube 400, and the water and air permeable sheet material tube formed around it. Furthermore, it engages and flattens the opposed walls of the water and air permeable sheet material tube at a predefined distance (arrow 14 indicates a predefined distance relative to the second sealing) downstream from the free end 410 of the growth medium feeding tube 400; and subsequently removes air out of the chamber, such that a dosage of growth medium in the dosing chamber 700 and/or in the growth medium feeding tube 400, is transported through the growth medium feeding tube 400 and into the water and air permeable sheet material tube within said suction chamber 800.

A cutting means 500 is adapted for separating the formed plant growth bag from the continuous length of water permeable sheet material with a cutting blade 510 cutting through a sealing between two neighbouring growth bags.

In Figure 2, seaIing means 900 is configured for sealing the tube along its length, here a lap sealing. The sealing is made on the tube part when it passes over the growth medium feeding tube. Thereby, a part of the free end of the growth medium feeding tube serves as a part of the sealing means 900.

An example of a growth medium bag produced by the process of the present invention is shown in Figure 6. The growth medium bag 30 is made from a single sheet of water and air permeable sheet material, and comprising a plurality of (two) compartments 32, each compartment 32 filled with a mass or plug of growth medium. Each compartment 32 is separated from a neighbouring compartment 32 by a sealing 34 formed in the sheet material. The dimensions of the growth medium bags are preferably longer than their width, the length being within the range of 30200 mm, and the length being within the range of 40-400 mm. For orchid seedlings, 5 the width should preferably be within the range of 30-80 mm, and the length within the range of 60-160 mm. As seen from Figure 4, the cutting means may in one or more embodiments be configured to vary the sequence of compartments in neighbouring growth medium bags in a line of produced growth medium bags by cutting in sealings of varying distance from one another.

References

Water and air permeable sheet material

Tube

Arrow indicating a predefined distance

Reel

Growth medium bag

Compartment

Sealing

100 Apparatus

200 Folding means

300 Sealing means

400 Growth medium feeding tube

410 Free end of growth medium feeding tube

500 Cutting means

510 Cutting blade

600 Growth medium storage container

610 Outlet

700 Dosing chamber

710 Pneumatic/hydraulic cylinder

720 First open end

740 Stirrer paddle blade/head

800 Suction chamber

900 Sealing means

Claims

Patent claims

A method for line production of plant growing medium bags comprising the steps of:

a) continuously folding the free end of a continuous length of water and air permeable sheet material, preferably supplied on a spool, into a tube around and beyond a free end of a feed tube of a culture medium;

b) forming a first seal in the pipe by engaging and flattening the opposite walls of the open end of the pipe and advancing the continuous length of water and air permeable sheet material a predetermined distance;

c) filling the tube with a measured amount of culture medium through the free end of the culture medium feed tube;

d) forming a second seal in the tube in a position above the culture medium by engaging and flattening the opposite walls of the open end of the tube to form a first culture medium bag or a space in a first culture medium bag having several compartments and carrying the continuous length of water and air permeable sheet material a predetermined distance forward;

e) optionally repeating steps c) -d) to form a series of interconnected culture medium bags; and

f) separating one or a group of interconnected culture medium bags from the row of interconnected culture medium bags.

The method of claim 1, wherein the seals are formed by flattening the tube between two welding jaws, and wherein the continuous length of water and air permeable sheet material is advanced by moving the two welding jaws as they engage the tube in the water. and direction of air permeability of sheet material.

A method according to any one of claims 1-2, wherein the separation step is performed by dividing a seal into two seals by cutting (mechanical cutting or heat cutting) longitudinally therethrough.

A method according to any one of claims 1-3, wherein a portion of the culture medium bag is removed by cutting before or during the separation step to form a culture medium pot.

A method according to any one of claims 1-4, wherein the feed tube of the culture medium is connected to a unit for supplying culture medium comprising:

a storage container adapted to store culture medium and with an outlet in the bottom wall;

a stirrer configured to keep the culture medium homogeneous in the storage container; and

an open-end dosing chamber configured to switch between a first position and a second position; wherein the first open end is connected to the outlet of the storage container in the first position, and wherein the second open end is connected to an inlet of a feed tube of a culture medium in the second position, while the first open end is disconnected from the outlet of the storage container, thereby removing a dose of culture medium from the storage container, through the open-ended dosing chamber and into the feeding tube of the culture medium.

Cultivation medium bag or pot obtainable by the method according to any one of claims 1-5.

Use of a culture medium bag according to claim 6 for growing seedlings.

An apparatus (100) for use in the method of any one of claims 1-6, said apparatus comprising:

- a storage container (600) adapted to store culture medium and with an outlet (610) in the bottom wall;

a stirrer configured to keep the culture medium homogeneous in the storage container;

an open end dosing chamber (700) configured to switch between a first position and a second position; wherein the first open end (720) is connected to the outlet (610) of the storage container (600) in the first position, and wherein the second open end is connected to an inlet of the feed tube (400) of a culture medium in the second position, while the first open end (720) is disconnected from outlet (610) in the storage container (600), whereby a dose of culture medium is removed from the storage container (600), through the open-ended dosing chamber (700) and into the feed tube (400) of the culture medium.

means (200) adapted to continuously fold the free end of a continuous length of water and air permeable sheet material (10), preferably supplied on a spool (20), into a tube (12) around the feed tube (400) of the culture medium; and

a suction chamber (800) arranged around and beyond the free end of the feed tube of the culture medium and adapted to be in a) an open first configuration, and

b) in a closed second configuration; wherein the suction chamber (800), when in the closed second configuration, encloses the free end (410) of the feed tube (400) of the culture medium and the water and air permeable sheet material tube formed around it and engages and flattens the opposite walls of the water and air-permeable sheet material tubes in a predetermined distance (14) downstream of the free end (410) of the culture tube feed tube (400); and subsequently removing air from the chamber so that a dose of culture medium in the dosing chamber (700) and / or in the feed tube (400) of the culture medium is transported through the feed tube (400) of the culture medium and into the water and air permeable sheet material tube inside said suction chamber (800) .

The apparatus (100) of claim 8, further comprising:

a first means (300) adapted to form a first seal in the pipe (12) by engaging and flattening the opposite walls of the open end of the pipe and passing the continuous length of water and air permeable sheet material (10); predetermined distance forward; and

second means (300) adapted to form a second seal in the tube (12) in a position above the culture medium by engaging and flattening the opposite walls of the open end of the tube to form a first culture medium bag or space in a first multi-compartment culture medium bag and advance the continuous length of water and air permeable sheet material (10) a predetermined distance.

The apparatus (100) of claim 9, wherein the first and / or second sealant (300) is integrated into the lower portion of the suction chamber (800).