Development and performance evaluation of semi-automatic nursery grow bag filling machine

Abstract

Preparation of media is a critical operation in horticultural nurseries. Manual media filling in polybags is labour-intensive, time-consuming, and inefficient. To address these challenges, a semi-automatic nursery grow bag filling machine was designed and developed for small-scale horticultural nurseries. The machine comprises a hopper, rotating magazine, cups, outlet pipe, electric motor, and safety guard, powered by a 1 HP single-phase motor. Media such as cocopeat, vermicompost, and their mixture are fed through the hopper, with filled bags collected at the outlet. Performance evaluation was conducted using Design Expert 10 software to study the effect of operational parameters, including motor speed (6, 8, 10 rpm) and moisture content (10–50%), on output parameters. Results showed that 6 rpm provided the highest productivity and consistent bag weight. Vermicompost, with 10–20% moisture content, delivered optimal performance, while higher speeds and moisture levels reduced efficiency. Vermicompost consistently outperformed cocopeat and its mixture with cocopeat, which showed sensitivity to increased speed and moisture. The findings align with prior research on media characteristics and their influence on horticultural practices. Chemical and physical properties of cocopeat mixtures significantly impact plant growth, supporting observations on the moisture sensitivity of cocopeat (Awang et al. (2009)). Mason and Evans (2018) highlighted challenges in manual bag filling and the importance of mechanization in improving nursery operations, emphasizing the practical benefits of semi-automation. The role of optimized media in container-based horticulture, underscoring vermicompost’s superior performance (Colombo et al. (2016)). For best results, operating the machine at 6 rpm with 10–20% moisture content using pure vermicompost is recommended. High moisture levels (30% and above), particularly for cocopeat, should be avoided to ensure efficient performance. These recommendations are consistent with broader studies on mechanized nursery practices and potting media optimization (Selvan et al., 2015; Sujitha and Shanmugasundaram, 2017).