Periodic Reporting for period 2 - PROTECTOR (Improving resource efficiency through a protective film for hose reel irrigation)
Reporting period: 2019-08-01 to 2020-12-31
PROTECTOR is a market-creating technology that provides improving levels of performance in hose reel irrigation at progressively lower cost. The competitive advantages that farmers get will boost the manufacturing of these products.
PROTECTOR is a patented, simple and totally new device which decrease the friction among hose and ground thus eliminating the problems and limitations described, making HRI more efficient, competitive and sustainable.
PROTECTOR allows the use of thinner hoses (note that the cost of a 1,000 m long hose Ø 135 mm may be around 10,500 €, while a hose of the same length and external diameter but the thinnest version costs around 6,500 €) and lighter tractors (which are cheaper and more manageable) and makes it possible to use longer hoses too. In consequence, it reduces the high energy consumption used for pumping the water and for positioning the hose and allows sprinklers work at more adequate pressure.
PROTECTOR makes agricultural practices more environmentally sustainable: water is used more efficiently, energy consumption and associated GHG emissions are reduced and less plastic is used. Environmental sustainability and climate change are nowadays among the most important challenges of the humankind and many EU policies promote the development and use of technologies that help to address these issues.
The general objective of the project is to develop a fully marketable version of PROTECTOR.
PROTECTOR is a patented, simple and totally new device which decrease the friction among hose and ground thus eliminating the problems and limitations described, making HRI more efficient, competitive and sustainable.
PROTECTOR allows the use of thinner hoses (note that the cost of a 1,000 m long hose Ø 135 mm may be around 10,500 €, while a hose of the same length and external diameter but the thinnest version costs around 6,500 €) and lighter tractors (which are cheaper and more manageable) and makes it possible to use longer hoses too. In consequence, it reduces the high energy consumption used for pumping the water and for positioning the hose and allows sprinklers work at more adequate pressure.
PROTECTOR makes agricultural practices more environmentally sustainable: water is used more efficiently, energy consumption and associated GHG emissions are reduced and less plastic is used. Environmental sustainability and climate change are nowadays among the most important challenges of the humankind and many EU policies promote the development and use of technologies that help to address these issues.
The general objective of the project is to develop a fully marketable version of PROTECTOR.
Technical work
- Selection of the better protective tapes
- Definitively excluded auxiliary drives by hydraulic (oil) and hydraulic (water) systems - too many problems related to adjustment depending on the pressure of the sprinkler, which must remain the one set by the operator;
- The need to put a roller before the unrolling phase of the sheet;
- Need to lift the tube and consequently raise the roll reel-picking axis to avoid the crops and facilitate the recovery phase of the sheet;
- The need to create a kind of labyrinth so that the tape does not fold
- Modification of the friction so that the tape and the rewinding system are coordinated
- Modification of the unwinding of the sheet so that the tube does not come out when the machine is unwound
- Need to lighten the weight of the protector
- Creation and implementation of a new design in order to lighten the structure and make it less subject to jolts and repercussions of crops
- Addition of sensors that allow the protective sheet to adjust the rolling direction independently
Dissemination and commercialisation work
- EIMA 2018
- AGRITECHNICA 2019
- FRUITLOGISTICA
- Specialized magazines
- Social media
- Brochure
- Reached potential customers (call, mail ecc)
- Visit to potential customers
- Selection of the better protective tapes
- Definitively excluded auxiliary drives by hydraulic (oil) and hydraulic (water) systems - too many problems related to adjustment depending on the pressure of the sprinkler, which must remain the one set by the operator;
- The need to put a roller before the unrolling phase of the sheet;
- Need to lift the tube and consequently raise the roll reel-picking axis to avoid the crops and facilitate the recovery phase of the sheet;
- The need to create a kind of labyrinth so that the tape does not fold
- Modification of the friction so that the tape and the rewinding system are coordinated
- Modification of the unwinding of the sheet so that the tube does not come out when the machine is unwound
- Need to lighten the weight of the protector
- Creation and implementation of a new design in order to lighten the structure and make it less subject to jolts and repercussions of crops
- Addition of sensors that allow the protective sheet to adjust the rolling direction independently
Dissemination and commercialisation work
- EIMA 2018
- AGRITECHNICA 2019
- FRUITLOGISTICA
- Specialized magazines
- Social media
- Brochure
- Reached potential customers (call, mail ecc)
- Visit to potential customers
Find the best plastic tape:
Considerable advantages in hose reel irrigation: fuel savings of 20%, reduction of hose weight and cost of 50% and 65%, respectively, and reduction of 25% in operation costs)
Select the automation system:
100% full and robust automation system that synchronize with almost every HRIs.
Reach full industrialization by 2020:
Average production cost that keep PROTECTOR prices below 5 % of the hose reel irrigation system without compromising the business viability.
Reduction of operational costs:
With PROTECTOR, friction reduces by 90% and weight of the hose is consistently reduced too. This decreases the efforts needed to pull the hose and the water head loss, thus consuming less fuel.
Fuel savings: 22% in pumping water and 40% in unrolling and rolling the hose.
Increase machinery lifespan:
PROTECTOR will protect the hose from abrasion, extending its useful life. Also, it will prevent from the hose breakage or the machinery overturn when the hose gets stuck on wet, rainy or muddy grounds.
20% reduction of GHG emission at the end of the economic life of the irrigator.
Avoid the soil compaction caused by heavy tractors:
PROTECTOR allows for the use of lighter hoses so that tractors used to pull them can be less powerful and hence lighter and cheaper
Increase irrigation efficiency:
The lower friction allows to thinner hoses, increasing the internal diameter and being able to carry a higher quantity of water.
Double hose lifespan (20 years instead of 10)
Increase irrigation accuracy:
With PROTECTOR, the rewinding of the hose is faster and without problems related to hose sticking. It allows for a more homogeneous and accurate irrigation of the crop.
Fewer failures & breakages (estimated savings 5 - 10%).
Considerable advantages in hose reel irrigation: fuel savings of 20%, reduction of hose weight and cost of 50% and 65%, respectively, and reduction of 25% in operation costs)
Select the automation system:
100% full and robust automation system that synchronize with almost every HRIs.
Reach full industrialization by 2020:
Average production cost that keep PROTECTOR prices below 5 % of the hose reel irrigation system without compromising the business viability.
Reduction of operational costs:
With PROTECTOR, friction reduces by 90% and weight of the hose is consistently reduced too. This decreases the efforts needed to pull the hose and the water head loss, thus consuming less fuel.
Fuel savings: 22% in pumping water and 40% in unrolling and rolling the hose.
Increase machinery lifespan:
PROTECTOR will protect the hose from abrasion, extending its useful life. Also, it will prevent from the hose breakage or the machinery overturn when the hose gets stuck on wet, rainy or muddy grounds.
20% reduction of GHG emission at the end of the economic life of the irrigator.
Avoid the soil compaction caused by heavy tractors:
PROTECTOR allows for the use of lighter hoses so that tractors used to pull them can be less powerful and hence lighter and cheaper
Increase irrigation efficiency:
The lower friction allows to thinner hoses, increasing the internal diameter and being able to carry a higher quantity of water.
Double hose lifespan (20 years instead of 10)
Increase irrigation accuracy:
With PROTECTOR, the rewinding of the hose is faster and without problems related to hose sticking. It allows for a more homogeneous and accurate irrigation of the crop.
Fewer failures & breakages (estimated savings 5 - 10%).