Cutting Grow Wool....any ideas out there?

[Kiwi Phil]

I have been working hard to get the 'Chain Store' I supply, to maintain my sales, and possibly consider a 2nd product from me that:
1. they may find more profitable,
2. suit a different buyer...sold in a different section of the Supermarket
3. but will run in different packageing, name (no association to my existing product)

The National Boss rang me today saying he wanted me to proceed with samples, and if they were as good as my existing product, they would be 'in'.

The catch is, I will grow this product in Grow Wool....not a black pot (that I am currently using to meet a different demand.)
Here is the difference

Black pot on the left that I currently use.....grow wool on the right....being the new product.

I have a problem with Grow Wool, and this is where I am seeking comment from those with a background in this or similar or engineering fields.

Grow Wool is a material widely used in insulation (ceiling, walls etc), but they also make it in slim-sheets or cubes, for plant propagation

I can buy either slim-sheets, or pre-formed cubes.

I need the cubes, but they are 2x more expensive (ie 3c) than me cutting up a slim-sheets myself, so I need a means of being able to cut the slim-sheets into cubes myself very quickly.

I know lettuce growers do just that, but they won't tell me what sort of set-up they built to cut the thin sheets....that's ok....I can't fault people for keeping their inventions secret.....I will just have to work it out for myself.

I need these thin-sheets to be cut in to 1.5inch square cubes.
I will put 110 cubes into a black plastic tray
I will use about 60 trays per week to start with
So I need to be able to cut and place over 6,000 cubes into trays in around an hour...

Here is a photo of a half sheet of pre-formed cubes.
This is what I need after i have cut a slim-sheet.
How do I do it??

Any comments will be greatly appreciated.

Cheers
Phillip

 

[tashasdaddy]

Re: Cutting Grow Wool....any ideas out there?

make a big vegamatic chopper, would a hot wire system work, criss cross pattern, the way they cut styrofoam.

 

[Vlad D Impeller]

Re: Cutting Grow Wool....any ideas out there?

Sorry Phil, my limited knowledge in such matters would not be helpful with your process design. The leaves on that plant sure does resemble Basil, don't it ?

 

[gonfishn]

Re: Cutting Grow Wool....any ideas out there?

I don't know if this fits but in the Mattress Industry they using putting wool as a filler instead of the traditional foam. It also so puts a hefty price on the product.
i have seen queen sets for $2500.00. It does feel great versus foam and even memory foam. They are calling it the green bed. All natural from the cover down.

Now as i read this i am sure this means nothing but another post count..lol

 

[tommays]

Re: Cutting Grow Wool....any ideas out there?

Phil

You really need 6000 and hour at 100 per minute that would push even are automated machines

 

[jaxnjil]

Re: Cutting Grow Wool....any ideas out there?

phil; maybe a stamp press but the cost for the press and die would place it out of reach

 

[Tim Frank]

Re: Cutting Grow Wool....any ideas out there?

Black pot on the left that I currently use.....grow wool on the right....being the new product.


Grow Wool is a material widely used in insulation (ceiling, walls etc), but they also make it in slim-sheets or cubes, for plant propagation

I need the cubes, but they are 2x more expensive (ie 3c) than me cutting up a slim-sheets myself, so I need a means of being able to cut the slim-sheets into cubes myself very quickly.

I know lettuce growers do just that, but they won't tell me what sort of set-up they built to cut the thin sheets....that's ok....I can't fault people for keeping their inventions secret.....I will just have to work it out for myself.

I need these thin-sheets to be cut in to 1.5inch square cubes.
I will put 110 cubes into a black plastic tray
I will use about 60 trays per week to start with
So I need to be able to cut and place over 6,000 cubes into trays in around an hour...

Here is a photo of a half sheet of pre-formed cubes.
This is what I need after i have cut a slim-sheet.
How do I do it??

Any comments will be greatly appreciated.

Cheers
Phillip

If I am understanding the info you provided, the incremental cost to you of buying the cubes preformed vs buying the sheets and cutting it yourself is a factor of two, which on the 3 cent cost is an extra 1.5 cents. Based on your weekly starting requirement of 6000 that is a savings of just $90-.
Intuitively there is not much automation that you can develop and operate that would be justified on a return of $90- per week.
If I were you I would grimace and pay the 3 cents per, or go back to the lettuce growers and ask what price they would sell the cubes to you. Whatever system they developed and are using, if they increase their volume on that production, their costs go down also; they might offer them to you at 2.5 cents.

 

[SS MAYFLOAT]

Re: Cutting Grow Wool....any ideas out there?

Have you checked out the Grodan (brand name) cubes? You might be able to get a bulk discount if you deal directly with them. They are suppose to be ready to drop in and grow. No ph adjusting or rinsing. I was thinking about trying some this spring to get my starts going.

I think you would need to have a customized table saw made up with multiple blades in order to cut the sheets into strips. Then turn the strips 90* and recut to make your cubes. However without an automatic feed system, it would be dangerous to operate.

 

[JB]

Re: Cutting Grow Wool....any ideas out there?

Hmmmmm. What, exactly, is Growool? What material?

How thick are the "thin" sheets, ie: how many layers of the "sheet" are needed to make the cube?

Is it a box that you can't think outside of? For example, could you go hydroponic instead of using a more or less solid medium? My Boston lettuce is grown hydroponically and delivered complete with root system. It stays "fresh" in my fridge for weeks with the roots still in water.

 

[SuzukiChopper]

Re: Cutting Grow Wool....any ideas out there?

I'll be thinking about this some but the few questions I do have is what do you use now to cut those blocks? Is that stuff resilient enough for a chopping action or is slicing better? Does it compress like home insulation would?

My initial thoughts is that if it compresses like home insulation and then will return back to its initial thickness, then you can compress multiple sheets at a time with a jig. The jig I have in my mind has two parts... one for a lengthwise cut and then one for the widthwise cuts. The jig would be setup to give you your sizes and allow for a large knife to pass through. Compress say 5 sheets together, make the two lengthwise cuts... then toss down the jig for the width cuts.

Better yet, if the sheets can be chopped rather then sliced you could so something similar to a paper cutter (http://www.nationalartcraft.com/images/sub-1522-02.jpg) but have multiple knives one direction and 2 knives going lengthwise. Doesn't have to be a pretty setup but might be an option.

I'm just typing while I'm thinking.

 

[SS MAYFLOAT]

Re: Cutting Grow Wool....any ideas out there?

Anyone ever get flowers that have that green styrofoam like stuff that is saturated with water? The green stuff's brand name is Grodan. It comes in 1.5X1.5X1.5 and on up into 6"X6" cubes. It also come in sheets from 1.5" to 6" thick in various widths and lengths. It is used instead of soil. Cleaner, free of disease, fungus, and easy to control. Rock wool is spun into a cotton candy type threads and then compressed into sheets or cubes.

 

[Kiwi Phil]

Re: Cutting Grow Wool....any ideas out there?

As I understand it SS, the Grodan product is made of Stone wool, which I 'think' is also called Rock wool here, and the process you mentioned above is same for making both.
We don't have a distributor here for the Grodan name in propagation blocks....that's why I am going the Grow wool way.
They are darned good products.

After the above suggestions and questions....I am working on them and will get back.

Cheers
Phillip

 

[mthieme]

Re: Cutting Grow Wool....any ideas out there?

A building product that doubles as fertilizer ???
Gotta contemplate that one for a bit.
Sorry, just thinking out load.

 

[Kiwi Phil]

Re: Cutting Grow Wool....any ideas out there?

I have been thru all your posts (many times), and cut and pasted your suggestions and ideas.
Also spent a few hours on the phone. No one is giving anything away, so it is not going to be so easy.

Tim Franks post hit me hard between the eyes.

If I am understanding the info you provided, the incremental cost to you of buying the cubes preformed vs buying the sheets and cutting it yourself is a factor of two, which on the 3 cent cost is an extra 1.5 cents. Based on your weekly starting requirement of 6000 that is a savings of just $90-.
Intuitively there is not much automation that you can develop and operate that would be justified on a return of $90- per week.
If I were you I would grimace and pay the 3 cents per, or go back to the lettuce growers and ask what price they would sell the cubes to you. Whatever system they developed and are using, if they increase their volume on that production, their costs go down also; they might offer them to you at 2.5 cents.

Went over my costings again (factored in everything), and the difference is actually 4.1 cents saving, and at the moment it makes good sense to just pay it, as for every increased $100,000 turnover, it equates to $4,100, and as this increased turnover is on top of the existing turnover, which meets all the farm overheads already, it is a stupid idea.
I won't discount the idea of cutting them myself completely....things may change.....but I have decided for the moment i am going to buy the pre-cut cubes and just plonk them in the trays as i need them....sweet and easy.

Thanks everybody....I suffer from tunnel vision here by myself.....good to get others opinions and views.

Cheers
Phillip

 

[tashasdaddy]

Re: Cutting Grow Wool....any ideas out there?

best of luck with the venture.