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Hydroponic lettuce production and minimally processed lettuce

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 290 May, 2015 Agric Eng Int: CIGR Journal Open access at http://www.cigrjournal.org Special issue 2015

Hydroponic lettuce production and minimally processed lettuce

Ricardo Oliano de Carvalho1, Luís Carlos Nunes Weymar Jr1,
Charles Baldi Zanovello1, Maria Laura Gomes Silva da Luz2, Gizele Ingrid Gadotti2,
Carlos Alberto Silveira da Luz2, Mário Conill Gomes2*
(1. Agricultural Engineering student,Federal University of Pelotas, RS, Brazil;
2. Professor-Engineering Center, Federal University of Pelotas, RS, Brazil)

Abstract: People’s concern about their health and well-being is increasing. As a result, the greenery appears as an
important food and agricultural areas need to be efficiently used. In this context, there are concerns about the environment,
which is another important factor, as it has to ensure sustainability. It was due to these demands the use of hydroponics which
appears as an alternative to be implemented for soil conservation and preservation of water resources. The objective of this
work was to project a system for producing hydroponic lettuce and analyses its technical and economic feasibility, aiming to
supply snack bars of Pelotas, RS, Brazil, with a minimally processed product (washed and cut lettuce).A study of the snack
bars market was conducted. The snack bars were classified as small, medium, and large. From these data, the equipment
was chosen to achieve the necessary unit operations to produce hydroponic lettuce and lettuce minimally processed. The mass
balance studies and layout were also done. The study of economical indexes to establish the viability or otherwise of the
project was done. These indexes were: NPV (Net Present Value), IRR (Internal Rate of Return) and payback. The analysis
was performed in a planning of 10 years and considering a MRA (Minimum Rate Attractiveness) of 11.6% per year. Three
scenarios for the project were studied. Scenario 1: a greenhouse with a maximum capacity of 59,400 heads of lettuce per year,
predicting a time of learning to achieve maximum production in the seventh month. Scenario 2: two greenhouses, considering
to be sold 70% of production in the first year, 85% in the second year and all production only in the third year. Scenario 3:
three greenhouses, considering that all production will be sold only in the fourth year.
Technically, the project proved to be feasible by allowing producing large amount of lettuce in a small area, in a minimally
processed hydroponic system, generating a practical and sanitary product. Because the greenhouse is a relatively large
investment, and the compaction of the countertops, decreased the necessary inner space, allowing eliminating wasted space in
the production area.The project proved to be unfeasible with only one greenhouse, but two or three greenhouses showed to be
feasible. However, when deployed, the project with two greenhouses in the first year, and three greenhouses in the first two
years, will need an investment of capital to withstand the years without profitability.

Keywords: marketing, leaf vegetable, packaging

Citation: Carvalho, R. O. D., L. C. N. Weymar Jr, C. B. Zanovello, M. L. G. S. D. Luz, G. I. Gadotti, C. A. S. D. Luz, and M.
C. Gomes. 2015. Hydroponic lettuce production and minimally processed lettuce. Agric Eng Int: CIGR Journal, Special
issue 2015: 18th World Congress of CIGR: 290-293.

do not increase at the same rate. The agricultural areas

1 Introduction 1

need tobe efficiently used. In this context, there are

People’s concern about their health and well-being is concerns about the environment, which is another
increasing. As a result, the greenery appears as an important factor, as it has to ensure sustainability. It was
important food. Moreover, population growth is due to these demands the use of hydroponics which
increasing rapidly and consequently there is an increase appears as an alternative to be implemented for soil
in food consumption, but the areas for agricultural crops conservation and preservation of water resources.
According to Resh (1997), hydroponics is an
Received date: 2014-10-31 Accepted date: 2014-12-06
*Corresponding author: Ricardo Oliano de Carvalho, alternative technique in which the soil is replaced by an
Department of Agricultural Engineering, Federal University of aqueous solution containing only mineral elements
Pelotas, Brazil. Email: ricardo.oliano@gmail.com.
May, 2015 Agric Eng Int: CIGR Journal Open access at http://www.cigrjournal.org Special issue 2015 291

required to vegetables. Furlani (1998) said that plants The objective of this work was to project a system for
grow in cultivation channels through which nutrient producing hydroponic lettuce and analyze its technical
solution circulates intermittently at defined intervals and and economic feasibility, aiming to supply snack bars of
controlled by a timer, by their own profiles for the Pelotas, with a minimally processed product (washed and
hydroponic cultivation system. cut lettuce).
Lettuce (Lactuca sativa L.) is the vegetable used in
2 Material and methods
larger scale in hydroponics, called NFT (Nutrient Film
Technique) or technique of laminar flow of nutrients. The production system of hydroponic lettuce and

This is in agreement with Ohse et al. (2001), that minimal processing are projected to be in an area of

comment hydroponics is easy adaptation system, which 11x284m, 1.600m from downtown Pelotas, leading by a

has shown high performance and reductions in cycle couple and an employee.

compared to growing in soil. A study of the snack bars market was conducted in

In 2012, it was produced of lettuce and chicory more Fragata subdivision of Pelotas/RS, due to the proximity

than 24,946Mton and 223,487Hg/ha of yield in the world. of the production place. The snack bars were classified as

The production share were 57.1% Asia, 24% Americas, small, medium, and large, because there is great variation

16.8% Europe, 1.3% Africa and 0.9% Oceania. Main in consumption among them.

producers were China, USA, Spain and Italy. Main An analysis of competitor was also conducted to

countries delivering were Belgium-Luxembourg, Kuwait, assess the risks of the enterprise.

Congo, Austria and USA (FAOSTAT, 2014). From these data, the equipment was chosen to achieve

In USA, a small number of firms are responsible for the necessary unit operations to produce hydroponic

growing, processing and transporting lettuce to retail lettuce and lettuce minimally processed. The mass

outlets. Today, almost all head lettuce is field packed for balance studies and layout were also done.

bulk sale or for transporting to a salad processing plant. The study of economical indexes to establish the

Estimates suggest that about one fourth of all iceberg viability or otherwise of the project was done. These

lettuce is now destined for processing into packaged indexes were: NPV (Net Present Value), IRR (Internal

salads (ERS 2006) Rate of Return) and payback, according to Buarque (1991)

Lettuce is the leaf vegetable most consumed in Brazil, and Casarotto (2009). The analysis was performed in a

and is considered the basis for salads. According to Cenci planning of 10 years and considering a MRA (Minimum

(2011) and ERS (2006), it is practicality because lettuce Rate Attractiveness) of 11.6% per year.

demands minimal processing operations. Basically, it is Three scenarios for the project were studied. Scenario

necessary to subject the vegetable to a few physical 1: a greenhouse with a maximum capacity of 59,400

changes, such as washing and cutting greenery, making it heads of lettuce per year, predicting a time of learning to

ready for consumption or preparation. achieve maximum production in the seventh month.

The industry of fresh-cut fruits and vegetables is Scenario 2: two greenhouses, considering to be sold 70%

constantly growing due to consumers demand. of production in the first year, 85% in the second year and

Techniques for maintaining quality and inhibiting all production only in the third year. Scenario 3: three

undesired microbial growth are demanded in all the steps greenhouses, considering that all production will be sold

of the production and distribution chain (ALLENDE; only in the fourth year.

TOMÁS-BARBERÁ; GIL, 2006). 3 Results and discussion

 292 May, 2015 Hydroponic lettuce production and minimally processed lettuce Special issue 2015

By studying the market it was established that the sowing or cutting up the first pair of leaves; 2) seedling
weekly demand of lettuce of snack bars in Fragata production II, when the seedlings are transplanted to
subdivision was 1,290 heads of lettuce to supply. Thus, it hydroponic profiles, including between the first pair of
was found that there are six small snack bars, ten medium, leaves until the fifth leaf. After this point, the lettuce
and seven large bars, with an average consumption of 15, enters the final stage of growth, around four weeks, when
50 and 100 heads of lettuce per week, respectively. the plants will be harvested.
Whereas losses are around 30%, a production of 1,500 Subsequently, harvesting and washing lettuce occurs.
heads of lettuce per week is required. The portion of the The processing will be made in two ways: Model 1:
production not sold in snack bars will be marketed as lettuce will be packed for delivery in big boxes to the
hydroponic product packaged for retail. snack bars; Model 2: lettuce will be harvested, packed
The study determined that the greenhouses will be and shipped to the market.
built in wood, the pampeana type, with 8x70 The main competitors of this project are the markets
meters.From the data obtained, the flowchart/mass of the region. They supply the stores with lettuce today.
balance from production to marketing seedlings of Other competitor is the rural producer, who offers the
lettucewas made (Figure 1). same service. Other competitors are the local market and
To optimize the inner space in the greenhouse, a retailers in the northern region of the city. However, as
system of trails that allow the benches to slide and be the demand is low and the product cannot be stored, it
compacted, opening the corridors for people who will makes buying lettuce too costly in these establishments.
transplant or harvest lettuce, was designed. The purchase prices of the head of lettuce in the snack
The production of seedlings was divided into two bars were averaged: in the regional market US$ 0.45;
stages: 1) production of seedlings I, held in phenolic foam directly from the farmer US$ 0.22; in the local market
lasting around seven to 10 days, comprising between and retailers US$ 0.34.

Figure 1Flowchart and mass balance from production of marketing hydroponic lettuce
 293 May, 2015 Agric Eng Int: CIGR Journal Open access at http://www.cigrjournal.org Special issue 2015

This market needs regularity both in delivery and in The project proved to be unfeasible with only one
quality. For this, contracts will be signed to ensure buyers greenhouse, but two or three greenhouses showed to be
of a regular supply of the product. If there is any problem feasible. However, when deployed, the project with two
with the production, to ensure delivery, lettuces will be greenhouses in the first year, and three greenhouses in the
purchased from another region to meet the demand. first two years, will need an investment of capital to
Budgets and revenue forecasting can assemble cash withstand the years without profitability.
flow and the economical indexes were analyzed, as It is recommended to study whether the project would
shown in Table 1. become more attractive with the production of other crops
such as tomato, zucchini, among other hydroponics.
Table 1 Economical indexes of the scenarios studied
Index Scenario 1 Scenario 2 Scenario 3 References
NPV, R$ -76,893.29 34,746.52 55,814.46 Allende, A.,F.A.Tomas-Barbera,M.I.GIL. Trends in Food
IRR, % - 24,25 24,48 Science & Technology 17 (2006) 513–519.
Payback, - Buarque, C. 1991.Avaliação econômica de projetos: uma
5 5
years apresentação didática. 6.ed. Rio de Janeiro: Campus,
124p.
Casarotto, F. N. 2009.Elaboração de projetos empresariais:
Scenario 1 proved to be unfeasible. Scenario 2 showed
análise estratégica, estudo de viabilidade e plano de
loss in the first year and then the amount invested begins
negócio. São Paulo: Atlas, 236p.
to return, already having an IRR of around twice the Cenci, S.A.2011.Processamento mínimo de frutas e hortaliças:
MRA, which wasconsidered 11.6%.Scenario 3 is very tecnologia, qualidade e sistemas de embalagem. Rio e
Janeiro: Embrapa Agroindústria de Alimentos/MAPA,
similar to Scenario 2, but this scenario has financial loss
144p.
over the first two years, meaning the company would
ERS – Economic Research Service. 2006.Iceberg
have to have capital to support two years without profits, Lettuce:Vegetables and Melons Outlook, USDA –
but after this period has no return on investment from the United States Department of Agriculture,
FAOSTAT. 2014. Lettuce and chicory production. Available in:
fifth year.
http://faostat3.fao.org/. (accessed, 4. Dec. 2014).
4 Conclusions Furlani, P.R. 1998.Instruções para o cultivo de hortaliças de folhas
pela técnica de hidroponia - NFT.Campinas: Instituto
Technically, the project proved to be feasible by Agronômico, 30p. (IAC, Boletim Técnico, 168).
allowing producing large amount of lettuce in a small Ohse, S.,D.Dourado-Neto, P. A.Manfron, and O. S.SANTOS.

area, in a minimally processed hydroponic system, 2001. Qualidade de cultivares de alface produzidos em
hidroponia. Scientia Agrícola, Piracicaba, 58(1):
generating a practical and sanitary product.
181-185.
Because the greenhouse is a relatively large RESH, H. M. 1997. Cultivos hidropônicos: nuevas técnicas de
investment, the compaction of the countertops, decreased producción. 4.ed. Madrid: EdicionesMundi-Prensa, 509p.

the necessaryinner space, allowing eliminating wasted

space in the production area.

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