Hydroponic Foam Case Study

Manufacturing a custom reticulated foam for hydroponics to meet the specific needs of an agricultural organization.

Background

When an organic sustainable farm located in Kansas needed a custom foam for its hydroponic applications, they turned to the experts at H-O Products. The team was searching for a repeatable solution ideal for its hydroponic systems – which grow plants without soil, using only water and nutrients.

The farm collaborates with schools, military and community organizations to bring agricultural resources to communities where access to nutritious, fresh and locally grown foods may be limited.

With customized 40’ x 8’ shipping containers, each featuring 256 polyurethane vertical towers, the farm produces an estimated 1,000 heads of lettuce per week, as well as basil and other hearty greens. One container holds approximately 2,500 plants at any given time.

As the company projects significant increase in the use of its sustainable farming systems, the hydroponic foam solution would need to be scalable for future high volume runs while maintaining an affordable price point.

Challenges

The best growing medium for hydroponic processes depends on the specific plants being grown, the hydroponic system being used, and personal preferences of the grower. While sand or gravel could be appropriate in some applications, given the customer’s unique vertical growers, they were searching for a material that could meet specific requirements, including:

1. Moisture resistant while supporting plant roots in a vertical state. Traditional growing options, such as soil, are not ideal for vertical hydroponic systems because they are too heavy and do not drain well. The farm needed a growing medium that was lightweight, porous, and able to retain moisture without becoming waterlogged.
2. An FDA grade foam to help ensure the safety of their food products. FDA grade foams are generally recognized as safe by the FDA for use in food production, and are resistant to bacteria and other microorganisms, helping to prevent the spread of disease in hydroponic systems.
3. A custom hydroponic foam that would meet the size specifications of the vertical channels.
4. A durable, reusable product that could be sliced, allowing the farmer to insert seeds and maintain plants during the growing stage. 
5. A solution that could be scaled quickly, responding to high volume production needs at a reasonable price.

Solutions and Results

After consultation and collaboration with the farm’s Founder and Chief of Engineering to understand their unique requirements, the H-O Products team viewed hydroponic foam options, ideal porosities, technical requirements, and biocompatibility.

The H-O development team also considered various coatings that could foster optimal plant growth, such as:

• antimicrobial coating to prevent disease
• UV-resistant coating to protect from ultraviolet light
• fire retardant coating to make foam less flammable in commercial conditions

After internal testing of material options, as well as a review of material converting requirements and costs, the H-O Products team then presented 2-3 prototypes to the customer for testing.

After analyzing several samples with varying porosities for a month, the customer indicated that the prototype made of reticulated polyether polyurethane foam with 20 PPI best met its needs, as its high number of pores allowed for ideal aeration of plant roots, while also providing strong root support.

Choosing a reticulated foam with optimal PPI (pores per inch) is critical in hydroponic applications, as it directly influences the balance between water retention, air circulation, and support for plant roots. In the customer’s testing, 20 PPI foam retained water well, but also drained appropriately, helping to prevent roots from becoming oversaturated or dried out. 20 PPI hydroponic foam is also extremely durable and can withstand repeated use making it a good choice for hydroponic growers.

H-O Products ultimately produced a product that could be cut to exact size specifications and quickly manufactured for an initial short volume production run. The team also developed a scalable process to accommodate up to 10x the growth in the near future.

From prototype to production, H-O Products process engineering and process capabilities helped the farm meet its needs on time and on budget. Our team looks forward to contributing to the productivity of this growing sustainable farming community for years to come.

Over 60 Years of Expertise in Custom Engineered Foam, Tapes and Gaskets

If you need guidance on selection of foam for hydroponic applications, require assistance with custom options, or need technical advice on substrate materials, the team at H-O Products is here to help. Contact us today and let’s talk about your hydroponic foam specifications.

About H-O Products

Our engineered products – including foam, rubber, polymeric and composite tapes, pads and gaskets – offering reliable sealing, cushioning, mounting and assembly in harsh environments, while minimizing downtime and maintenance costs. From prototype through final product, our customers can be confident in performance, reliability, and the continued support of our expert team. Learn more about H-O Products and how we can give your company a competitive edge in today’s global marketplace.