Aquaponics Factory
We supply Aquaponics Factory (the entire indoor aquaponics farming system) to urban farmer for producing food fish and vegetables.
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Aquaponics Factory created a “union agricultural productions between plants and fish” that would also generate more value from the land than hydroponic vertical farms, open field fish farming or other agricultural production alone. In conventional aquaponics, the aquaculture effluent is diverted through plant beds and not released to the environment, while at the same time the nutrients for the plants are supplied from a sustainable, cost-effective and non-chemical source. This integration removes some of the unsustainable factors of running aquaculture and hydroponic systems independently.
The concept that energy demanding is also boosted by the decreasing cost of solar panels in recent years, combined with population growth that requires new solutions for both food production and energy generation.
Researchers have reaffirmed that Aquaponics Factory will bring tremendous water saving, attained ultra productivity, sustainable and renewable energy concepts could reduce the payback period for Aquaponics Factory project to less than seven years. Other vertical farming generally need 15 years or more on payback period. This is farmer of the future, a modern and innovative solution to food security that is climate-resilient and could be deployed rapidly in any location, from buildings to underground. It include following 6 modules A) Product Specification of Aquaponics Factory Shown in above A1) Dimension: Indoor floor area 1,500 m2, working height 6m A2) Annual Production Capacity:62.8Ton salad green (=449,000 head of Lettuce) +10.1Ton prawn(=72,000 pcs of GRP) or 58.6 Ton fishes(=117,200 pcs of tilapia. Sufficient to meet the nutrients need of 1,200 people whole year round
A3) Package include- Project-related software on harvest, farm ERP & filtration system- food fish/shrimp pond @ 20 ton capacity each- 140 no. of acrylic Fish/ shrimp rearing tanks @ 0.65 ton capacity each- 30 Green walls with total 48,600 grow pots - 2 set Aquaculture RAS System- 2 set climate cell for plant automated seeding & grown up harvest- 1 set water quality sampling system, breeding system- AI Grow LED lights - 3 unit industrial autonomous Robot MIR250 for operation of plant grow and fish culture- 1 set Auto feeding system- Piping and installation- M & E facilities- 1 set Food Processing line- 1 set of waste conversion line Further detail as follow:
Researchers have reaffirmed that Aquaponics Factory will bring tremendous water saving, attained ultra productivity, sustainable and renewable energy concepts could reduce the payback period for Aquaponics Factory project to less than seven years. Other vertical farming generally need 15 years or more on payback period. This is farmer of the future, a modern and innovative solution to food security that is climate-resilient and could be deployed rapidly in any location, from buildings to underground. It include following 6 modules A) Product Specification of Aquaponics Factory Shown in above A1) Dimension: Indoor floor area 1,500 m2, working height 6m A2) Annual Production Capacity:62.8Ton salad green (=449,000 head of Lettuce) +10.1Ton prawn(=72,000 pcs of GRP) or 58.6 Ton fishes(=117,200 pcs of tilapia. Sufficient to meet the nutrients need of 1,200 people whole year round
A3) Package include- Project-related software on harvest, farm ERP & filtration system- food fish/shrimp pond @ 20 ton capacity each- 140 no. of acrylic Fish/ shrimp rearing tanks @ 0.65 ton capacity each- 30 Green walls with total 48,600 grow pots - 2 set Aquaculture RAS System- 2 set climate cell for plant automated seeding & grown up harvest- 1 set water quality sampling system, breeding system- AI Grow LED lights - 3 unit industrial autonomous Robot MIR250 for operation of plant grow and fish culture- 1 set Auto feeding system- Piping and installation- M & E facilities- 1 set Food Processing line- 1 set of waste conversion line Further detail as follow:
B1) Aquaponics-RAS Module
At Tankmaker.com, we made fish happy beside take pride in everything we produce.
This is made possible through Aquaponics assisted RAS (the recirculating aquaculture system (RAS) with aquaponics assisted setup); it is a new type of RAS from the aquaculture model, through a series of water exchnage between plants- fish-plants and so forth as treatment units, the wastewater produced in the aquaculture pond is treated and recycled again with zero waste and low cost.
The standard RAS is to integrate the advanced technologies in the fields of environmental engineering, civil engineering, modern biology, electronic information, and other disciplines, so as to remove the harmful pollutants such as residual bait feces, ammonia nitrogen (tan), nitrate-nitrogen (NO2 — N) and so on. Hovever, this is an expensive approach that are not sustainable due to the need of manual waste and nitrate removal. Aquaponics assisted RAS not only solve the problem of the low utilization rate of water resources, but also provide stable, reliable, comfortable, and high-quality living environment for breeding organisms, and provide favorable conditions for high-density breeding. It also provide ample space, adequately bright and soothy environment to made fish happy! Fishes will eat more when they are happy, plant will grow faster; Aquaponics Factory will be productive! The simulated yields revealed that vertical farming could produce at least 1000 ±40 tons per hectare of food fishes per year, which is 50 times more than the current farming average.
The standard RAS is to integrate the advanced technologies in the fields of environmental engineering, civil engineering, modern biology, electronic information, and other disciplines, so as to remove the harmful pollutants such as residual bait feces, ammonia nitrogen (tan), nitrate-nitrogen (NO2 — N) and so on. Hovever, this is an expensive approach that are not sustainable due to the need of manual waste and nitrate removal. Aquaponics assisted RAS not only solve the problem of the low utilization rate of water resources, but also provide stable, reliable, comfortable, and high-quality living environment for breeding organisms, and provide favorable conditions for high-density breeding. It also provide ample space, adequately bright and soothy environment to made fish happy! Fishes will eat more when they are happy, plant will grow faster; Aquaponics Factory will be productive! The simulated yields revealed that vertical farming could produce at least 1000 ±40 tons per hectare of food fishes per year, which is 50 times more than the current farming average.
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The multi-tier RAS is a sustainable form of aquaculture in aquaponic setup. It is beneficial to fish health and resulted in ultra high productivity - it produced up to 80 kg of food fish per m3 water
- it consumed 300L of water for 1 kg of fish production (more than 2000 L was needed in standard RAS or up to 60,000 L needed in conventional aquaculture pond)
- it is in Multi-tier setup within the same floor of building to maximize production yield of up to 4 times- Starting with introduce fingerling fish (40~50 grams each) to the highest tier of fish tank- The fishes will be transferred to next lower lever through the same water once it grow bigger; it will further transfer to next lower level upon further grow etc- All day feeding to promote grow & maintain water quality- Fish are housed in transparent acrylic tank that all round see through; this enable ease of fish health & system monitoring and provide a soothing environment for the fish (reduce stress and disease).
Above picture shown was the Aquaponics Assisted RAS System in place with following Industrial grade machinery1. Radial Flow Settler 2. Pure Oxygen Machine 3. Oxygen cone - 4. Drum Micro filtration Machine 5. Thermostat Chiller Machine6. Protein Separator 7. RAS Circulating Pump8. Ultraviolet Sterilizer
B2) Green Wall Module
Media-Based Systems, IN STACKABLE VERTICAL wall is the crops growing system used in Aquaponics Factory; it make optimal use of space to grow exotic crops such as lettuce, spinach, basil, kale and parsley, spices, herbs, tomatoes and cucumbers.
The crops adopts vertical soil-less cultivation technology, providing crops with good production conditions such as light, temperature, water, air, and fertilizer under intelligent LED supplementary lighting from artificial light sources.
The green wall technology enable output of Aquaponics Factory as living crops and meaning it is sold with the roots still attached. The living crops is with the head on, so that in itself is a big difference from lifeless crops like the cut and packed salad green. It is more nutritious and it lasts longer.
Aquaponics green wall technology enable the system self sufficient for crops without introducing external A, B or C nutrients /fertilizer. The veggie green wall growing ‘towers’ fed nitrate rich nitrients in the form of both liquid and mist, aeroponically from the system, which is applied directly to the LECA media of plants. The LECA media contains millions of beneficial bacteria that allow beneficial microbes colonize on and around plant roots. The allows biofiltration and improves fertilizing nutrient intake.
In general,
Pesticide use: indoor farming = no bugs. no bugs = no pesticide.
Fertilizer use: no loss due to runoff, and majority came from fish waste = near zero needed (self sufficient)
Water consumption: closed grow rooms = evaporation is both minimal and contained with RAS system = minimun is added
Carbon footprint - directlly proportion to distribution: food can be produced adjacent to high consumption areas, rather than in the middle of nowhere. this prevent the potential for a great deal of infrastructure supporting rural farms = near zero
The field study from project done as well as simulated yields revealed that vertical farming on vegie leafy could produce up to 1000 MT per hectare per year, which is up to 390 times more than the current oot door soil farming.
The Vertical Green Walls are
- using 95% less water through vertical casacading flow that will increase effective area by more than 13.5 times (as the water flow from pots to pots, vertically that stake up of 50 pots per column are possible)
- CEA, require no insecticide or fertilizer- enhancing grow, where no soil, sunlight or direct water is needed
- incorporating full Spectrum LED grow light (mimic sunlight for plant growth and aesthetically pleasing presentation of plants to human eyes; old generation plants light in pink and blue hues are history)
- ensuring zero CO2 input or emission out of farm (through the use of mobile Growth LED; it is operated in 24 hours for plants for oxygen - carbon dioxide exchange)
- reducing the harvest cycle (e.g. Lettuc from 70 days to 25 days, rice from 120 days to 75days)
- facilitating nutrient / fertiziler intake to be 80% less.
- reducing electrical energy usage, up to be 80% less (electrical energy used was found to be less than 700kWh/m2 in Aquaponics Factory and it was 3,500kWh/m2 for other hydroponics Vertical farm)
Aquaponics Factory leverages on the abundant light and heat resources resources form the sun in tropical areas, implementing measures such as multi-layer vertical soil-less cultivation and artificial light source control etc.
The tech reduces the rice's growth cycle by around 40 percent compared to rice cultivated in traditional field; the tech also reduce the costs of energy by 80%
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B3) AI and Predictive Analytics (Virtual Grow Module)
There was hardly success for commercialize aquaponics in the past due to low yield & lack of expertise; first grow success is almost impossible based on pre-assumption on certain set of faming parameters due to millions of design & parameters for aquaponics.
The Virtual Grow Module is another Tankmaker’s proprietary technology based on predictive low-code software approach. It is an important part of process to be perform prior to farming to achieve First Grow Success; it is similar to Moldflow simulation that mandately done prior to injection mold making.
It contain optimization strategy that simulate various possible design with respect to the optimized goal. It will predict harvest time, grow rate, compatibility of fish & plant pairing, energy usage, machine life, equipment efficiency, MTTF etc and more of a necessity. Based on software inputs, the Aquaponics system irrigates and maintains temperature, humidity, pH, water conductivity, air temperature, humidity, dissolved oxygen, water flow rate and all other parameters to provide an ideal environment suitable for both fish and plant growth.
The approach is based on scientific solution with real-time data capturing capabilities through iot devices and correlate the desire result as per optimized simulation to enable early intervention to maximize productivity and avoid production disruptions. Aquaponics Factory has the answer for a platform that works with the existing hydroponic setups while delivering
- Minimize unplanned downtime for mismatch grow
- Maximize productivity
- Avoid process failure that occur due to trial and error
- Increase equipment uptime and reduce maintenance costs
No code/low code has been around for a long times, but the market has caught fire recently due to an increase in applicable use cases and a ton of innovation in the capabilities of these new low-code/no-code platforms, specifically around their ease of use and integration into company’s system.
Together with the Green Wall & RAS, the First grow Success program transform the Aquaponics digitally into modular form, enabling knowledge based working that are 10 times more populous than technical workers and transforming the agricultural sector through technology-driven solutions.
This has the potential to save significant time and money and to enable end-to-end digital experiences of vertical farm, achieve First Grow Success!
Completely shift the farmer focus into making farming profitable instead of trial and error.
Predictive Maintenance: Integrate AI-driven analytics to predict maintenance needs for both the robotics fleet and environmental systems. For example, if sensors detect recurring anomalies, the system can alert one to potential mechanical issues.Optimized Harvesting and Plant Growth Forecasting: AI models can use collected data to forecast optimal harvesting times, yield predictions, or maintenance schedules. This allows the fleet and EMS to preemptively allocate resources, maximizing productivity.
This unified approach to managing the aquaponics factory should give one a seamless, data-driven operation that minimizes manual intervention, improves efficiency, and maximizes output. Absolutely, AI is an excellent solution for managing complex, data-intensive environments like an aquaponics system. Since there are many interdependent parameters—such as water quality, nutrient levels, temperature, and lighting—AI can help by modeling and optimizing these variables to improve first grow success. Here’s how AI to be applied effectively to ensure success from the start:1. Data Collection and Parameter MonitoringSensors: Use IoT sensors to continuously gather data on parameters like pH, temperature, humidity, dissolved oxygen, and light intensity. The more data collected, the better the AI model will be at predicting optimal conditions.Real-Time Data Feed: Set up a real-time data pipeline from your sensors to the AI model, enabling it to constantly learn and adjust its predictions.
2. AI-Driven OptimizationPredictive Modeling: Use machine learning to create predictive models based on historical and real-time data. These models can help understand how each parameter impacts plant growth and fish health, making it easier to find the ideal balance for each.Multi-Variable Optimization: AI algorithms can analyze how different variables interact, optimizing for the best overall conditions rather than just isolated factors. For example, it can determine how the pH level needs to adjust when temperature fluctuates to maintain nutrient uptake efficiency.
3. Automated Adjustments via Reinforcement LearningReinforcement Learning (RL): RL algorithms can test different parameter configurations in a controlled simulation environment to find the best approach for maintaining growth conditions. RL can suggest or even automate adjustments based on real-time data, adapting as conditions shift.Self-Adjusting Systems: Integrate AI with your control systems so it can automatically adjust parameters like nutrient levels, light intensity, or water flow in response to current conditions.
4. AI for Early Issue DetectionAdnomaly Detection: AI can analyze data trends to detect anomalies, such as pH or oxygen level fluctuations, that may signal upcoming issues. Early alerts allow you to proactively address problems before they impact growth.Health Predictions: Based on historical data, AI can help predict plant or fish health issues, flagging potential nutrient deficiencies or water quality issues.
5. Simulation for First Grow SuccessDigital Twin Modeling: Create a “digital twin” of the aquaponics system—a virtual replica that simulates the interactions between fish, plants, and environmental conditions. This model allows one to run simulations to test different conditions without affecting the actual grow. One can use the digital twin to experiment with various setups to find the best initial configuration.Scenario Testing: AI can simulate different scenarios (e.g., high humidity, low light) to identify ideal conditions for the first grow, enabling one to make informed decisions for system setup.
6. Feedback Loop for Continuous LearningAdaptive Learning: As the first grow progresses, AI can refine its models based on new data, gradually improving accuracy and efficiency. This feedback loop helps improve outcomes over time.Human-AI Collaboration: To ensure flexibility, AI should suggest optimal adjustments, but human operators can have final control. This way, any adjustments can also feed back into the AI, training it further.Implementing AI in this way would give you a data-backed approach to optimize and stabilize the first grow with greater confidence.
This unified approach to managing the aquaponics factory should give one a seamless, data-driven operation that minimizes manual intervention, improves efficiency, and maximizes output. Absolutely, AI is an excellent solution for managing complex, data-intensive environments like an aquaponics system. Since there are many interdependent parameters—such as water quality, nutrient levels, temperature, and lighting—AI can help by modeling and optimizing these variables to improve first grow success. Here’s how AI to be applied effectively to ensure success from the start:1. Data Collection and Parameter MonitoringSensors: Use IoT sensors to continuously gather data on parameters like pH, temperature, humidity, dissolved oxygen, and light intensity. The more data collected, the better the AI model will be at predicting optimal conditions.Real-Time Data Feed: Set up a real-time data pipeline from your sensors to the AI model, enabling it to constantly learn and adjust its predictions.
2. AI-Driven OptimizationPredictive Modeling: Use machine learning to create predictive models based on historical and real-time data. These models can help understand how each parameter impacts plant growth and fish health, making it easier to find the ideal balance for each.Multi-Variable Optimization: AI algorithms can analyze how different variables interact, optimizing for the best overall conditions rather than just isolated factors. For example, it can determine how the pH level needs to adjust when temperature fluctuates to maintain nutrient uptake efficiency.
3. Automated Adjustments via Reinforcement LearningReinforcement Learning (RL): RL algorithms can test different parameter configurations in a controlled simulation environment to find the best approach for maintaining growth conditions. RL can suggest or even automate adjustments based on real-time data, adapting as conditions shift.Self-Adjusting Systems: Integrate AI with your control systems so it can automatically adjust parameters like nutrient levels, light intensity, or water flow in response to current conditions.
4. AI for Early Issue DetectionAdnomaly Detection: AI can analyze data trends to detect anomalies, such as pH or oxygen level fluctuations, that may signal upcoming issues. Early alerts allow you to proactively address problems before they impact growth.Health Predictions: Based on historical data, AI can help predict plant or fish health issues, flagging potential nutrient deficiencies or water quality issues.
5. Simulation for First Grow SuccessDigital Twin Modeling: Create a “digital twin” of the aquaponics system—a virtual replica that simulates the interactions between fish, plants, and environmental conditions. This model allows one to run simulations to test different conditions without affecting the actual grow. One can use the digital twin to experiment with various setups to find the best initial configuration.Scenario Testing: AI can simulate different scenarios (e.g., high humidity, low light) to identify ideal conditions for the first grow, enabling one to make informed decisions for system setup.
6. Feedback Loop for Continuous LearningAdaptive Learning: As the first grow progresses, AI can refine its models based on new data, gradually improving accuracy and efficiency. This feedback loop helps improve outcomes over time.Human-AI Collaboration: To ensure flexibility, AI should suggest optimal adjustments, but human operators can have final control. This way, any adjustments can also feed back into the AI, training it further.Implementing AI in this way would give you a data-backed approach to optimize and stabilize the first grow with greater confidence.
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B4) Robotic Module
Robotic Operation is the indispensable tools in Aquaponics Factory as it focus on integrating advanced technology and automation to enhance produce quality, taste and production efficiency.
The MiR250 autonomous robot make routine operations even more efficient. It is well-suited for transporting supplies or harvested produce, performing consistent monitoring rounds, or even delivering items between sections, especially in large-scale setups like the factory.
1. Routine Monitoring and MaintenanceSensor Readings Collection: Equip the MiR250 with sensors or connect it to the main control dashboard, so it can check key parameters like temperature, humidity, or CO2 levels in each zone.Water Quality Sampling: With minor customization, the robot could perform water sampling for quality checks, collecting data from multiple points throughout the system.
2. Material Transport and Inventory ManagementTransport of Nutrients and Supplies: Use the MiR250 to move fish feed, nutrients, or maintenance supplies to different zones, reducing the need for human intervention and minimizing contamination risks.Harvest Transport: The MiR250 can efficiently move harvested crops from plant beds to storage or packing areas, preserving productivity and maintaining hygiene.
3. Routine Tasks AutomationCleaning and Waste Collection: The robot could be programmed to collect waste materials or manage compostable plant waste and fish solids.Routine Inspection and Alerts: Set up the MiR250 for regular inspection rounds, programmed to alert operators if anything seems out of range or requires intervention.
4. MiR Fleet Software Integration with Control SystemsMiR Fleet is a robust software platform specifically designed for coordinating MiR robots. It manages task assignments, prioritizes jobs, and prevents collision by tracking the robots' positions in real-time.Features:Task Allocation: Dynamically allocates tasks based on robot availability and priority, ensuring efficient use of the fleet.Traffic Management: Controls routes to prevent bottlenecks, allowing two or more robots to navigate without interruptions.Zone Control: Sets restricted or priority zones to keep high-traffic areas clear.
5. Centralized Integration with an Industrial Automation SystemA high-level system, such as a Manufacturing Execution System (MES) or Warehouse Management System (WMS), can be used to integrate the fleet management system with the rest of your aquaponics factory's operations.
Integration Options:Task Scheduling and Optimization: The MES or WMS can work in tandem with MiR Fleet to prioritize tasks based on production needs, automating workflows from harvest to packing.Data Sharing: Centralized data integration allows the fleet system to sync with water quality, environmental sensors, and inventory data, providing a unified interface for monitoring and control.
1. Routine Monitoring and MaintenanceSensor Readings Collection: Equip the MiR250 with sensors or connect it to the main control dashboard, so it can check key parameters like temperature, humidity, or CO2 levels in each zone.Water Quality Sampling: With minor customization, the robot could perform water sampling for quality checks, collecting data from multiple points throughout the system.
2. Material Transport and Inventory ManagementTransport of Nutrients and Supplies: Use the MiR250 to move fish feed, nutrients, or maintenance supplies to different zones, reducing the need for human intervention and minimizing contamination risks.Harvest Transport: The MiR250 can efficiently move harvested crops from plant beds to storage or packing areas, preserving productivity and maintaining hygiene.
3. Routine Tasks AutomationCleaning and Waste Collection: The robot could be programmed to collect waste materials or manage compostable plant waste and fish solids.Routine Inspection and Alerts: Set up the MiR250 for regular inspection rounds, programmed to alert operators if anything seems out of range or requires intervention.
4. MiR Fleet Software Integration with Control SystemsMiR Fleet is a robust software platform specifically designed for coordinating MiR robots. It manages task assignments, prioritizes jobs, and prevents collision by tracking the robots' positions in real-time.Features:Task Allocation: Dynamically allocates tasks based on robot availability and priority, ensuring efficient use of the fleet.Traffic Management: Controls routes to prevent bottlenecks, allowing two or more robots to navigate without interruptions.Zone Control: Sets restricted or priority zones to keep high-traffic areas clear.
5. Centralized Integration with an Industrial Automation SystemA high-level system, such as a Manufacturing Execution System (MES) or Warehouse Management System (WMS), can be used to integrate the fleet management system with the rest of your aquaponics factory's operations.
Integration Options:Task Scheduling and Optimization: The MES or WMS can work in tandem with MiR Fleet to prioritize tasks based on production needs, automating workflows from harvest to packing.Data Sharing: Centralized data integration allows the fleet system to sync with water quality, environmental sensors, and inventory data, providing a unified interface for monitoring and control.
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B5) Fish / Shrimp Module
Consists of array acrylic tank with hiding shelters for Giant River Prawn
B6) Giant Pond Tank
Consists of various custom made FRP tank of 5,000 gallons each.
The Vertical RAS Module is in modular form, can be deployed easily. It employ rectangular acrylic tank to achieve multi-level setup in the single storey of building for space saving and ease of monitoring. It also provides ample space, adequately bright and soothy environment to made fish happy! Fishes will eat more when they are happy, plant will grow faster; Aquaponics Factory will be productive!The simulated yields revealed that vertical farming could produce at least 1000 ±40 tons per hectare of food fishes per year, which is 50 times more than the current farming average.
All enquiries are welcome, please write to sales@tankmaker.comTankmaker.com is owned by Elite Tea Pte Ltd and Tankmaker LLP in Singapore and all rights reserved for Elite Tea Pte Ltd