Benching Production Surface – 8 Keys we should care

The choice of an indoor/greenhouse benching system, or “production surface“, is influenced by many variables. Traditionally, decisions were driven by labor concerns (e.g., bending and reaching), cost, and ease of movement within the structure. These factors remain important, but advances in production technologies, especially irrigation and fertilization methods, have introduced additional considerations when selecting a production surface. These surfaces can be raised or located on the indoor/greenhouse floor. Key aspects to consider when choosing a production surface for crops include:

Production Surface Height

The height of the production surface significantly impacts worker comfort and efficiency. If the surface is too low, workers must bend excessively, leading to fatigue and potential health issues. Conversely, a surface that is too high can make it difficult to reach and manage plant materials. Typically, raised surfaces are set at a height of 3 to 3½ feet. Floor-based systems (e.g., gravel or flood floors) eliminate height concerns but still require workers to bend to reach plants. In some setups, crops may be elevated higher than 3 to 3½ feet to optimize space usage, such as hanging baskets above head height or gutters for strawberries at shoulder height.

In addition to worker comfort, the height of the production surface can impact the microenvironment around the plants. Raised benches can improve air circulation around the plants and help maintain a more uniform temperature and humidity level. This can be particularly important in preventing diseases and promoting healthy plant growth. Furthermore, elevated surfaces can facilitate better light distribution, ensuring that all parts of the plant receive adequate illumination.

Production Surface Width

The width of a raised production surface is primarily dictated by the need for worker access to plant materials. If workers can access both sides of the bench, a width of 4-5 feet is recommended. For access from one side only, the width should not exceed 2.5 feet. For floor-based systems, aisle spacing depends on whether plants need to be accessed during their growth cycle. If frequent access is required for tasks like pinching or handling, aisles must be adequately spaced. For plants that are automatically irrigated and handled only at harvest, aisles can be minimized or eliminated.

In addition to worker access, the width of the production surface can influence the efficiency of automated systems. For example, boom irrigation systems or automated harvesting equipment must be able to move freely and operate effectively across the entire width of the bench. Therefore, ensuring compatibility with these systems is crucial for maximizing operational efficiency.

Air and Drainage Spaces in Production Surfaces

Raised benches with open surfaces allow for water drainage and improved air circulation, preventing uneven drying and wet spots that can lead to disease. Ebb-and-flow benches, which use plastic flood trays, manage water through built-in channels for drainage and air circulation. Floor-based surfaces often use gravel for drainage or may be grooved concrete to direct water away.

Proper drainage is essential for maintaining plant health and preventing root diseases caused by standing water. Additionally, adequate air circulation around the root zone helps in oxygen exchange, which is vital for root respiration and overall plant vigor. Systems designed with air and drainage considerations ensure that plants receive consistent moisture levels, reducing the risk of over- or under-watering.

Strength

Raised benches must support the weight of plants, containers, and wet soil, which can be substantial. Both the bench surface and its support structure need to handle these loads. Floor-based surfaces must support plant weight without settling, and they may also need to support equipment or vehicles.

The structural integrity of the bench is critical for preventing collapses or damage that could disrupt production. Materials like expanded metal or high-density plastic are often used for their strength and durability. The support structures, whether metal frames or reinforced legs, must be designed to distribute weight evenly and maintain stability under heavy loads.

Cost

Production surfaces involve initial costs for purchase, assembly, and maintenance. The true cost includes the lifespan and potential production cost savings, such as reduced labor, irrigation, and fertilizer expenses. Efficient space usage is also crucial for minimizing production costs and maximizing profits. Maximizing usable growing area within an indoor/greenhouse helps lower the per-square-foot cost of production.

Investing in higher-quality, more durable production surfaces can lead to long-term savings by reducing the frequency of replacements and repairs. Additionally, advanced systems like ebb-and-flow benches can decrease labor costs by automating irrigation and fertilization processes. Analyzing the cost-benefit ratio of different production surfaces is essential for making informed decisions that enhance profitability.

Compatibility with Irrigation Methods

Production surfaces must be compatible with irrigation systems, both current and future. Systems like ebb-and-flow benches integrate irrigation, reducing labor costs. Bench design must also match irrigation booms or other methods.

Ensuring that the production surface can accommodate various irrigation methods provides flexibility and adaptability. This compatibility allows for the integration of new technologies as they become available, ensuring that the production system remains efficient and up-to-date. Whether using drip irrigation, overhead sprinklers, or capillary mats, the production surface must support the effective delivery of water and nutrients to the plants.

Support Requirement

The type of support system required depends on the load and the material of the production surface. Rigid materials like expanded metal need minimal support, while flexible materials like wire mesh require extensive support. Rolling benches and Dutch tray systems need elaborate supports for mobility under heavy loads.

Choosing the appropriate support system is crucial for maintaining the structural integrity and functionality of the production surface. The support system should be designed to handle dynamic loads, such as the movement of plants, equipment, and workers. Ensuring that the supports are robust and well-distributed helps prevent sagging, warping, or failure over time.

Adaptability to New Technology

As technology evolves, production surfaces may need to adapt. Flexible systems that can accommodate new technologies will allow growers to integrate advancements without needing to replace their existing setup.

Production surfaces that are adaptable to new technology offer long-term benefits by allowing growers to continuously improve their operations. This adaptability can include features like adjustable heights, modular designs, and compatibility with various automation systems. By investing in versatile production surfaces, growers can ensure that their facilities remain cutting-edge and capable of incorporating the latest innovations in horticulture.

By considering these factors, growers can select the most suitable production surfaces for their indoor/greenhouse setups, ensuring efficiency, worker comfort, and adaptability to future technological advancements. This holistic approach to choosing production surfaces can significantly enhance productivity, reduce costs, and improve the overall quality of crop production.

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