HHP's 10K HPA Build Thread!

Atomizer

Well-Known Member
The high cost would outweigh any savings for most growers.

A typical lettuce nute solution made up from raw chems costs around $0.024/gallon (excl the water), so if the grower wastes 1gpd from each of his 150 chambers equipped with stainless manifolds (compared to 2gpd waste for pvc) he`ll still be losing 54,750 gallons of nutes per year. Thats $1314/yr down the drain (literally)
If he recoups the cost of the (150) stainless manifolds from the nute savings gained by fitting them..it will take him a little under 150 years.
 

oxanaca

Well-Known Member
i think its crazy your worried about the sightly higher cost of the netafims and you have a $1300 manifold
 

indrhrvest

New Member
If he recoups the cost of the (150) stainless manifolds from the nute savings gained by fitting them..it will take him a little under 150 years.
I did design build for clean rooms, process systems (chip etching) etc.. for many years. Nozzles will need to be replaced. Lines will need to be cleaned etc.. You are not factoring in labor, maintainence etc.. If you use pushlock fittings, over time they will start to leak. Plastic threads will strip. It's much easier to undue a few bolts and have the entire manifold come out for servicing. The manifold will last as long as the system. The savings would be in labor reduced and reliability.

A typical lettuce nute solution made up from raw chems costs around $0.024/gallon (excl the water), so if the grower wastes 1gpd from each of his 150 chambers equipped with stainless manifolds (compared to 2gpd waste for pvc) he`ll still be losing 54,750 gallons of nutes per year. Thats $1314/yr down the drain (literally)
You seem to be forgetting, I mentioned our manifolds have very small holes drilled into them where the bungs are placed. This very small diameter hole will allow the 3/8 manifold to maintain pressure and distribute more evenly allowing us to run a much shorter cycle. So yes, nutes will be saved, but labor is what eats into operating costs.. not nutes.

The manifold wouldn't cost $1,300 each in a large installation anyway, it would be closer to half that because of leveraged manufacturing. $1,300 is the price for retail. Our system would function very much on par with Agrihouse's, is only $700 more and is 4 times the size. So the system is still cheaper per square foot and you get a nice stainless manifold instead of a bunch of pushlock fittings and hose that would be a maintainence nightmare.

IMG_8409.jpg
 

Atomizer

Well-Known Member
You seem to be forgetting, I mentioned our manifolds have very small holes drilled into them where the bungs are placed. This very small diameter hole will allow the 3/8 manifold to maintain pressure and distribute more evenly allowing us to run a much shorter cycle.
A manifold with small holes between the pipe and the nozzles is going to transform the performance compared to just screwing the same nozzles directly into the pipe?

The nozzles represent the greatest resistance to flow in the manifold (ie they have the smallest holes). So unless your new holes are physically smaller than the orifice in the nozzles, you need a plan B ;)
 

indrhrvest

New Member
So unless your new holes are physically smaller than the orifice in the nozzles, you need a plan B ;)
Volume in the TEE throat, full bore branches and line turbulence due to fitting seams do have an effect. When we are talking about 1 second cycles, something as simple as removing line resistance will have an impact on performance. Water follows the least path of resistance. Having a smooth bore manifold is always going to function superior to a line with a bunch of fittings creating line turbulence. Fluid dynamics are a big part of engineering mechanical systems.

And no.. the orifice isn't the greatest resistance. The greatest resistance comes from line turbulence created by varying bore sizes. Each pushlock fitting TEE will create line turbulence due to the uneven bore size. The resistance that's been elminated by removing 60 push lock TEE's will have a tremondous effect and increase laminar flow. This is all fluid dynamics 101.

 

Atomizer

Well-Known Member
But you dont have a tee`s you have nozzle mounts welded to the tube and holes drilled in thin walled tube that behave like the orifice in a nozzle (because they have almost no depth). The flow in the manifold will be turbulant regardless of whether you use push fittings or straight tube (hint: Reynolds Number)
If you used tee`s and laminar flow in the calculations you may want to take another look at the math as both turbulant flow and the thin section holes will require a different set of equations. If i have time i`ll work through the math for both, i`ll have to assume the pipe id, length, hole size etc but it`ll make a change from the usual accumulator, nozzle stuff. Best have a bottle of aspirin close by if simple flow calculations make your head hurt, because these will give you a migrane ;)
 

indrhrvest

New Member
Best have a bottle of aspirin close by if simple flow calculations make your head hurt, because these will give you a migrane ;)
The majority of turbulence will be within the bung and isolated. We've elminated most of the line turbulence by removing the fittings. That allows the main line to charge faster which was the entire point. To be honest, I don't need math to know removing 8 fittings per line (16 bore changes) with varying bore sizes will increase laminar flow.
 

Atomizer

Well-Known Member
If you`d said "removing 8 fittings will make it less turbulant" that would be accurate. You cant increase laminar flow if there`s none to begin with.
If the stainless is 8mm id with a flowrate equivalent to 30 tefens, the reynolds number is 4771, so it`ll be turbulant even without any fittings.
 

indrhrvest

New Member
If you`d said "removing 8 fittings will make it less turbulant" that would be accurate. You cant increase laminar flow if there`s none to begin with.
If the stainless is 8mm id with a flowrate equivalent to 30 tefens, the reynolds number is 4771, so it`ll be turbulant even without any fittings.
As opposed to what the reynolds number would be if factoring in 16 bore changes. There's no point making this complicated. I get it.. your fish will always be bigger.
 

Mike Young

Well-Known Member
Please keep arguing! I think both of you have knowledge that is useful to those of us who don't know the in's & out's of fluid dynamics. Very interesting stuff!
 

Atomizer

Well-Known Member
Hey Mike, its not an argument, just a discussion on the merits of a $1300 stainless manifold :)

You are not factoring in labor, maintainence etc.. If you use pushlock fittings, over time they will start to leak. Plastic threads will strip. It's much easier to undue a few bolts and have the entire manifold come out for servicing.
I`ve never had a JG fitting leak, you must have got a dodgy batch or used some cheap foreign copies :)
I can change all the nozzles out in my 16ft x 2ft (56cuft) chamber inside a minute, they push into the mounts so there`s no threads to strip. I reckon unscrewing/replacing 60 nozzles could take a good 15-30 minutes and you`d still have the manifold to put back in.

Given that you could build an insulated 8x4 chamber, complete with two AA nozzles, solenoids, 422 timer and a brand spanking new bambi compressor for slightly less than the cost of the manifold...it will need to deliver a monumental boost in performance ;)
 

Jimmy Luffnan

Well-Known Member
I don't think there is an argument here ^^
Atomizer needs no introduction to his expertise and experience in HP applications and Indrhrvest is obviously very passionate about HP and creating a professional product that he has spent alot of R&D time on to achieve.

No matter what you try to create in this world, if you truly want to create the best, then objective scrutiny is a must.
Both parties know many things about HP, but there is no one authoritative.

Math is Math, but the proof is always in the pudding ;)

Cheers Jimmy.
 

indrhrvest

New Member
Please keep arguing! I think both of you have knowledge that is useful to those of us who don't know the in's & out's of fluid dynamics. Very interesting stuff!
I think the that both of us are just looking at this from two different perspectives in terms of material construction. I have plenty of experience in maintaing mechanical systems in commercial applications so I know the reliability of certain products having used them.

Hey Mike, its not an argument, just a discussion on the merits of a $1300 stainless manifold :)
Again, you keep focusing on one cost, our system is still cheaper per square foot than the next HPA commercial system. That is all that matters. Having a stainless manifold gives us a selling point over the competition.

I`ve never had a JG fitting leak, you must have got a dodgy batch or used some cheap foreign copies :)
You are also not operating in a commercial setting with careless employees.

I can change all the nozzles out in my 16ft x 2ft (56cuft) chamber inside a minute, they push into the mounts so there`s no threads to strip. I reckon unscrewing/replacing 60 nozzles could take a good 15-30 minutes and you`d still have the manifold to put back in.
In commercial setting you'd have trays stacked 3-4 high, with only maybe 15 inches of space between racks depending on the product being grown. Imagine being hunkered over with only 15 inches of overhead trying to maintainece 20 trays in a 200 tray operation unscrewing one nozzle at a time. In our system you undue 4 bolts accessible from the outside and the whole manifold lifts out..

Given that you could build an insulated 8x4 chamber, complete with two AA nozzles, solenoids, 422 timer and a brand spanking new bambi compressor for slightly less than the cost of the manifold...it will need to deliver a monumental boost in performance ;)
A compressor? We already know compressed air would kill margins. We ruled out compressed air in the first months of our R&D. (I have 2HP oil-less medical grade compressor with driers for sale if anyone wants it) AAA is not even in the equation for us, it makes no sense from a COG's point of view. The energy required would be enourmous for an AAA operation. Our system is designed for building intergrated agriculture, why would you need insulation in a climate controlled room? I assure you, the cheap homemade chambers DIY'er build would not stand up to the rigors of commercial use. You could drop our trays of a two story building and nothing would happen, they are almost 3/8 thick seamless HPDE. Unless you are gluing HDPE sheets together, whatever material you are using would create a scum build up nightmare. You also must use HDPE for food grade applications. The stuff you get at Home Depot to build a aerochamber would never pass FDA approval for use in a food production facility.

I don't think there is an argument here ^^
Atomizer needs no introduction to his expertise and experience in HP applications and Indrhrvest is obviously very passionate about HP and creating a professional product that he has spent alot of R&D time on to achieve.
We are building a commercial system.. not a hobby system. I think applying what works for a hobbyist to commercial operations isn't taking into account the lifespan of the equipment or the regulatory issues on food production facilities such as FDA approved materials, NEMA housings for electrical etc... Just because a hobbyist can build a bckyard system cheaper, doesn't mean a commercial developer about to drop $1M in to a vertical farm is going to want to use a homemade design. Having our systems use better quality components allows us to offer warranty's. Atomizer, try installing your design into a commercial operation and watch as you fail regulatory inspection. There is a reason commercial hydro systems are made from HDPE and not ABS.. and certainly not foam board from Home Depot.

Math is Math, but the proof is always in the pudding
I've seen the results posted by HPA hobbyists in the many forums.. I'm not at all worried about the quality of our pudding. With no prior experience in horticulture, growing lettuce to 150 grams in 28 days from seed our first time out beats Cornell's 35 days.. We are more than satisfied..
 

Atomizer

Well-Known Member
Were looking at it from different perpectives. Mine is no compromise HPA and yours is to find a happy medium for large scale commercial that is maintained by unskilled employee`s. You liken your system to Agrihouse`s, which is also similar to Pod Racer`s approach and both are considered less than optimal. If it fits your bill thats great, but it doesnt push any boundaries because its a form of aero has been around for decades. Anyone with an accumulator based HPA with the emphasis on control will know there is a big difference.

For a typical grower on this forum, FDA approval is not a requirement, minimal nute consumption is more of a factor as they are usually shop bought. Noise probably tops the list for most, closely followed by immunity to power outages.
Considering your standalone 8x4 system may cost $3000 or more, it doesnt tick any boxes for the HPA hobbyist. There`s not too many commercial scale lettuce/basil growers on here to ask their opinion ;)
 

indrhrvest

New Member
There`s not too many commercial scale lettuce/basil growers on here to ask their opinion ;)
We are just using lettuce and basil as test applications because its an easy test subject. The system was designed for applications such as growing Nocotiana Benthamiana for manufacturing recombinant protiens used in cancer treatments, commercial medical cannanbis and other high value plant species. Don't assume we did all this just to grow lettuce.

Gen two testing starting soon :)

 

Atomizer

Well-Known Member
Lettuce prices would need to be at an all-time high :)
A high light/fast growing test subject would make a better yardstick as cannabis will need 3x more light than lettuce.
 

indrhrvest

New Member
Lettuce prices would need to be at an all-time high :)
A high light/fast growing test subject would make a better yardstick as cannabis will need 3x more light than lettuce.
Just started testing the new system. The new manifold made a tremendous difference. We still have that spitting you can't stand, but that's due to a slight crown of water sitting on top of the nozzle since we point our nozzles up, not down. I had to order a more advanced timer because even at 1 second we are now pushing .05 gallons. We did add a few more nozzles as well for better coverage. I think we can reduce cycle times down to just .3 seconds now. That should get us to around 5.7 gallons per day, or about 1.5 gallons per plant every 30 days. That's more than a 50% reduction in water usage and we added 15 more nozzles..
 

Atomizer

Well-Known Member
Pointing the tefens up will also prevent the manifold from draining after each misting. 60 nozzles to get the coverage seems like a lot, i guess the cone diameter isnt reaching its maximum potential before running into the underside of the lid. On the plus side, your 2ft deep chambers might need a few less nozzles ;) I find 12 horizontal nozzles is more than enough for full coverage of a 16x2 chamber.
 

hammer21

Well-Known Member
My 2 cents don't do a hpa because it will fail root ball gets to big and to thick for any mist to get to the center then you will get root rot. No way around it things will go good for 45-60 days and you have created a monster meaning root ball. With that big of grow go with a low pressure system use a iwaki 70 rzt pump with cheap plastic sprayers with 0.40 tips it will run a few hundred nozzles and you will be more happy. You Never ever want fuzzy roots. Bottom line root ball gets to large and center gets no mist=rot. Invest in some 3 way valves and do a recirculating system meaning pump runs 24-7 back to tank then activate solenoids to spray. Good luck....
 

oxanaca

Well-Known Member
My 2 cents don't do a hpa because it will fail root ball gets to big and to thick for any mist to get to the center then you will get root rot. No way around it things will go good for 45-60 days and you have created a monster meaning root ball. With that big of grow go with a low pressure system use a iwaki 70 rzt pump with cheap plastic sprayers with 0.40 tips it will run a few hundred nozzles and you will be more happy. You Never ever want fuzzy roots. Bottom line root ball gets to large and center gets no mist=rot. Invest in some 3 way valves and do a recirculating system meaning pump runs 24-7 back to tank then activate solenoids to spray. Good luck....
have you ever ran small plants ie. 4 plants per square foot
 
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