Ankit Bhatnagar, Consultant at Shubhavni Smartfarms (OPC) Pvt. Ltd. in Mainpuri, Uttar Pradesh, explains how farmers can now use modern technology to grow saffron beyond Kashmir while maintaining its quality. By using the aeroponic method, saffron is grown under controlled conditions without soil. Water is also not used, making it a completely soil-free way of farming.
Our firm is recognised by DPIIT and listed under Startup India AgriTech Startups. We are working on changing the way Saffron is traditionally cultivated to a technology-based method with controlled conditions. There are many challenges a saffron grower faces while following the traditional method of saffron farming. Based on our understanding, we have developed methods that can help farmers overcome the constraints to get better yields even in smaller areas. As far as saffron is concerned, there is a huge gap between demand and supply. We want to narrow down that gap and make our country self-reliant in saffron production. We are also encouraging other saffron growers who are trying to grow saffron indoors or in the fields of Kashmir.
One will come across many hurdles and challenges in the saffron industry. The main challenge is meeting the demand as the supply is quite low in India. We are way behind in saffron production. In Kashmir, also, the cultivation is very low, with only areas like Pampore and Kishtwar leading the cultivation. Saffron grows well in suitable geographical and climatic conditions. So even in Kashmir, it is not grown in most of the areas. The next challenge is the quality, as many people doubt the top quality of the product. Since the demand and supply gap is quite high, and also the price, the saffron available in the market is either lower grade or adulterated. So, we mostly depend on Iran and Afghanistan to meet our domestic demand. The saffron we get is either Irani or Afghan saffron, apart from Kashmiri saffron. The third challenge is land availability. Researchers have found that the cultivable land in Kashmir is reducing at a fast pace due to various reasons, which again affects saffron cultivation. Yet another major issue is the soil-borne diseases in traditional saffron cultivation, leading to the use of pesticides. All these factors affect the saffron cultivation greatly. In indoor farming, the main challenge was determining and maintaining the right conditions. Next, we have to ensure that access is restricted to others to prevent dust, insects, or animals from entering. When we do saffron cultivation indoors, we can see the saffron bulbs, and in case of any infection, we can treat it easily, unlike the traditional method, where it is hard to notice until the bud comes out from the ground. The risk of any fungal attack is less. Monitoring and understanding are the main requirements.
There are solutions to the challenges faced by the saffron cultivators. We have started using technology and modern farming techniques to promote saffron cultivation in other states also. We have to ensure that the quality of the saffron is not compromised when we use technology. Aeroponic saffron cultivation is an ideal solution for this problem. Aeroponic cultivation means we do not use any substrate or medium. It is soil-free without any water. We place the saffron bulbs under controlled conditions by way of providing the necessary mist and humidity. It is done in a vertical setting at a high level. We will create a cold room with the necessary infrastructure. We only maintain the climatic conditions, with the right amount of humidity by way of mist, control the carbon dioxide, fresh air levels, and sufficient light. We use IoT-enabled sensors so that we can control them from our smartphones or laptops.
Controlled saffron farming
This method has a specific requirement for infrastructure. Saffron is cultivated mainly in cold weather, and we need to create such conditions when we grow saffron indoors. We have to create a Kesar cold room, which is a multi-purpose room, used as a cold storage, with chillers for maintaining the temperature. We install puff panels on the walls and ceiling for insulation purposes. The puff panels are of uniform density, placed between GI sheets, and act as insulators. When we do in places like UP, which experience extreme heat. These puff panels help in maintaining the temperature. We also need humidifiers to maintain the correct level of humidity in the room. There is no soil used or water sprayed on the saffron bulbs. We use sensors and controllers to maintain the temperature, humidity, light, and carbon dioxide content. These are the primary requirements in the Kesar cold room. We need racks as the cultivation is done in a vertical form to save space. It can be any type of rack (GI pipes or Slotted angle). We should not use plastic trays to maintain the humidity. Bulbs are placed on the wooden trays inside the Cold room. We need to give space at the bottom of the trays to allow airflow. We can use LED lights to control the intensity of light as we need to create an environment similar to that in Kashmir. We need dimmers when we use LED lights. The most important requirement is the Bulbs. We must procure bulbs from Kashmir, especially from Pampore, as they are of good quality after interacting with the farmers there to know about saffron bulbs. We should use RO water for the humidifier to prevent scaling inside the humidifier. We also require some land space to put the saffron bulbs in the soil after harvest is done, since it is a one-time purchase. These bulbs multiply by about 30-40% per year. So, bulb multiplication is very important. After about 3 weeks of placing the bulb, we can see a small white bud coming out, and any bulb weighing more than 8 grams has the potential to flower in the same year.
We need to take care of the bulb procurement from Kashmir and transport the same to our location. We need to use jute bags, which are breathable and prevent any damage to the bulbs. We have to do aeration for two to three days in an open warehouse, not exposed to direct sunlight, but in a well-ventilated place. This will remove the excess moisture from the bulbs. Then there is another process called silvering, which is to remove the extra layers from the bulb. Fungal treatment is needed if any bulb is affected. We can use neem oil and place it back, but it should be done only for the affected bulbs. Then we should place the bulbs in a controlled environment. The bulbs will get acclimatised and start sprouting. We have to keep monitoring the climatic conditions and adjust according to the requirements and stages. After about 3 to 4 months, some heavier bulbs start flowering, followed by the smaller ones. Then we need to harvest the flowers and the threads from them and dry all the parts separately. We may find yellow strands, and three strands should be dried separately in a well-ventilated room and not under sunlight. Then, we can pack them in air-tight containers to improve the shelf life. We can pack them in small jars upon receiving orders. After this, we need to prepare the soil to plant the saffron bulbs for propagation and get more bulbs ready for the next cycle.
Indoor farming benefits
The main benefits include an increase in supply to meet the demand. It also provides employment for women from rural areas, as this kind of work suits women better. When we use the technology, saffron can be cultivated anywhere in India, as we can control the temperature and other conditions, and climatic conditions in the area won’t affect the indoor cultivation of saffron. The cold room can be reused as a cold storage room, to prevent food wastage, and to get additional income. By following vertical farming, we also save arable land and water. We do not use any pesticides. Also, we can prevent soil-borne diseases as we do not use soil, protect the crop from contaminations, natural calamities such as excess rain, floods, or animals, and ensure the quantity and quality are both good.
Saffron farming economics
Open cultivation is not feasible in the Rest of India, as the climatic conditions are different from Kashmir. If we opt for a controlled environment, we can do it in smaller areas, which will be a commercially viable investment. From a 500 sq. ft room, we can expect profit from the third or fourth year. The amount spent initially for the cold room, other infrastructures, and Bulb procurement is a one-time investment. If we want to look at exporting the produce, we can do it after 3 years.
We spent about Rs 27 lakhs for a 560 sq. ft area. We approached Blue Star, which is a reputed cold room manufacturer. We could have spent less by approaching a local vendor, but we preferred quality structure. The combined cost was about Rs. 27 lakhs, which included bulbs, other facilities, and a cold room. We also bought 2000 kgs of bulbs, racks, trays, and other things, and from the second year, there was no major expense. We just have to take care of the electricity, labour, marketing, and packaging costs, mainly operational expenses. From the second year onwards, I do not expect an expenditure of more than Rs. 2.5-3 lakhs as operational cost for saffron farming.
Soil-free saffron growth
We should buy the Bulbs directly from the farmers. We approached farmers and bought the bulbs directly from them. We can also learn a lot from them about how Saffron is grown using traditional farming techniques, and work on creating a model to use that information to grow it under controlled conditions. Subsidies are available for cold room construction in almost all states. We have to check with the concerned office about the subsidy in the region. We can also contact the horticulture department on how to apply for the subsidy. It can be done anywhere in India, unlike the traditional method, which has restrictions. This method requires very little arable land and water compared to traditional farming. The results of the crop grown under controlled environments are excellent as optimal conditions are provided, no pesticides are used, it's protected from excess rain or natural calamities, etc. Climatic conditions are replicated, and a protected environment is provided for the plants.
Environmental conditions vary. When we plant the bulbs in the room, it is different, and when the sprouting starts, the conditions have to be modified. The temperatures have to be reduced when winter sets in. We can use LED lights along with dimmers to reduce the intensity of light. We can modify the exposure to light using dimmers for the plants. We do not use any substrate for this method. The saffron bulbs are placed on wooden trays. So we do not use any cocopeat. When we plant the bulbs in the open space for propagation, we need to create proper soil suitable for the process. The soil has to be a mixture of clay, river sand, cow dung, vermicompost, and no pesticides. We use a humidifier to create mist when bulbs are in a controlled environment. The humidifier will convert the water into a form of mist to create the humidity. There is no direct spraying of water inside the controlled environment. This method is soil-free and involves no water spraying. We will use sensors and controllers as the plants emit carbon dioxide, and the levels should be maintained, along with circulating fresh air. The sensors and controllers take care of the same. Dampers control the levels of carbon dioxide and fresh air. All of these tasks related to controlled climatic conditions can be achieved by automation. The saffron bulbs should be placed inside the controlled environment, and we can expect the harvest by mid-November.
Bulb care practices
It is only when we see any fungal attack on the bulbs, we need to take them out, treat them with neem oil, and place them in a different tray. When we move them to soil, we need to ensure that the soil is good and healthy and not use any pesticides. To maintain the health of the soil, we need to use cow manure, which also helps during the propagation phase of saffron bulbs. There is no specific pest management for a controlled environment, as it is all done inside. We need to be careful about the access by others to the area. We do not run any training programs or batches.
The speaker concludes, saying, “ This is the initiative of my mother, Shubha Bhatnagar. To help rural women, she wanted to do mushroom and saffron cultivation. As she found this challenging, she took over saffron cultivation. We have 22 women working with us, and when there is no saffron farming, they are engaged in the usage of cold storage. I am from an engineering background and take care of all technical aspects in the firm. We have automated most of the operations by deploying enabled Sensors and Controllers, and they can be managed from a smartphone.”
Contact details
Ankit Bhatnagar
Consultant, Shubhavni SmartFarms (OPC) Pvt Ltd, Mainpuri, UP
Mobile: 82184 44545
Email: ankit.bhatnagar05@gmail.com
www.shubhavni.com
Our firm is recognised by DPIIT and listed under Startup India AgriTech Startups. We are working on changing the way Saffron is traditionally cultivated to a technology-based method with controlled conditions. There are many challenges a saffron grower faces while following the traditional method of saffron farming. Based on our understanding, we have developed methods that can help farmers overcome the constraints to get better yields even in smaller areas. As far as saffron is concerned, there is a huge gap between demand and supply. We want to narrow down that gap and make our country self-reliant in saffron production. We are also encouraging other saffron growers who are trying to grow saffron indoors or in the fields of Kashmir.
One will come across many hurdles and challenges in the saffron industry. The main challenge is meeting the demand as the supply is quite low in India. We are way behind in saffron production. In Kashmir, also, the cultivation is very low, with only areas like Pampore and Kishtwar leading the cultivation. Saffron grows well in suitable geographical and climatic conditions. So even in Kashmir, it is not grown in most of the areas. The next challenge is the quality, as many people doubt the top quality of the product. Since the demand and supply gap is quite high, and also the price, the saffron available in the market is either lower grade or adulterated. So, we mostly depend on Iran and Afghanistan to meet our domestic demand. The saffron we get is either Irani or Afghan saffron, apart from Kashmiri saffron. The third challenge is land availability. Researchers have found that the cultivable land in Kashmir is reducing at a fast pace due to various reasons, which again affects saffron cultivation. Yet another major issue is the soil-borne diseases in traditional saffron cultivation, leading to the use of pesticides. All these factors affect the saffron cultivation greatly. In indoor farming, the main challenge was determining and maintaining the right conditions. Next, we have to ensure that access is restricted to others to prevent dust, insects, or animals from entering. When we do saffron cultivation indoors, we can see the saffron bulbs, and in case of any infection, we can treat it easily, unlike the traditional method, where it is hard to notice until the bud comes out from the ground. The risk of any fungal attack is less. Monitoring and understanding are the main requirements.
There are solutions to the challenges faced by the saffron cultivators. We have started using technology and modern farming techniques to promote saffron cultivation in other states also. We have to ensure that the quality of the saffron is not compromised when we use technology. Aeroponic saffron cultivation is an ideal solution for this problem. Aeroponic cultivation means we do not use any substrate or medium. It is soil-free without any water. We place the saffron bulbs under controlled conditions by way of providing the necessary mist and humidity. It is done in a vertical setting at a high level. We will create a cold room with the necessary infrastructure. We only maintain the climatic conditions, with the right amount of humidity by way of mist, control the carbon dioxide, fresh air levels, and sufficient light. We use IoT-enabled sensors so that we can control them from our smartphones or laptops.
Controlled saffron farming
This method has a specific requirement for infrastructure. Saffron is cultivated mainly in cold weather, and we need to create such conditions when we grow saffron indoors. We have to create a Kesar cold room, which is a multi-purpose room, used as a cold storage, with chillers for maintaining the temperature. We install puff panels on the walls and ceiling for insulation purposes. The puff panels are of uniform density, placed between GI sheets, and act as insulators. When we do in places like UP, which experience extreme heat. These puff panels help in maintaining the temperature. We also need humidifiers to maintain the correct level of humidity in the room. There is no soil used or water sprayed on the saffron bulbs. We use sensors and controllers to maintain the temperature, humidity, light, and carbon dioxide content. These are the primary requirements in the Kesar cold room. We need racks as the cultivation is done in a vertical form to save space. It can be any type of rack (GI pipes or Slotted angle). We should not use plastic trays to maintain the humidity. Bulbs are placed on the wooden trays inside the Cold room. We need to give space at the bottom of the trays to allow airflow. We can use LED lights to control the intensity of light as we need to create an environment similar to that in Kashmir. We need dimmers when we use LED lights. The most important requirement is the Bulbs. We must procure bulbs from Kashmir, especially from Pampore, as they are of good quality after interacting with the farmers there to know about saffron bulbs. We should use RO water for the humidifier to prevent scaling inside the humidifier. We also require some land space to put the saffron bulbs in the soil after harvest is done, since it is a one-time purchase. These bulbs multiply by about 30-40% per year. So, bulb multiplication is very important. After about 3 weeks of placing the bulb, we can see a small white bud coming out, and any bulb weighing more than 8 grams has the potential to flower in the same year.
We need to take care of the bulb procurement from Kashmir and transport the same to our location. We need to use jute bags, which are breathable and prevent any damage to the bulbs. We have to do aeration for two to three days in an open warehouse, not exposed to direct sunlight, but in a well-ventilated place. This will remove the excess moisture from the bulbs. Then there is another process called silvering, which is to remove the extra layers from the bulb. Fungal treatment is needed if any bulb is affected. We can use neem oil and place it back, but it should be done only for the affected bulbs. Then we should place the bulbs in a controlled environment. The bulbs will get acclimatised and start sprouting. We have to keep monitoring the climatic conditions and adjust according to the requirements and stages. After about 3 to 4 months, some heavier bulbs start flowering, followed by the smaller ones. Then we need to harvest the flowers and the threads from them and dry all the parts separately. We may find yellow strands, and three strands should be dried separately in a well-ventilated room and not under sunlight. Then, we can pack them in air-tight containers to improve the shelf life. We can pack them in small jars upon receiving orders. After this, we need to prepare the soil to plant the saffron bulbs for propagation and get more bulbs ready for the next cycle.
Indoor farming benefits
The main benefits include an increase in supply to meet the demand. It also provides employment for women from rural areas, as this kind of work suits women better. When we use the technology, saffron can be cultivated anywhere in India, as we can control the temperature and other conditions, and climatic conditions in the area won’t affect the indoor cultivation of saffron. The cold room can be reused as a cold storage room, to prevent food wastage, and to get additional income. By following vertical farming, we also save arable land and water. We do not use any pesticides. Also, we can prevent soil-borne diseases as we do not use soil, protect the crop from contaminations, natural calamities such as excess rain, floods, or animals, and ensure the quantity and quality are both good.
Saffron farming economics
Open cultivation is not feasible in the Rest of India, as the climatic conditions are different from Kashmir. If we opt for a controlled environment, we can do it in smaller areas, which will be a commercially viable investment. From a 500 sq. ft room, we can expect profit from the third or fourth year. The amount spent initially for the cold room, other infrastructures, and Bulb procurement is a one-time investment. If we want to look at exporting the produce, we can do it after 3 years.
We spent about Rs 27 lakhs for a 560 sq. ft area. We approached Blue Star, which is a reputed cold room manufacturer. We could have spent less by approaching a local vendor, but we preferred quality structure. The combined cost was about Rs. 27 lakhs, which included bulbs, other facilities, and a cold room. We also bought 2000 kgs of bulbs, racks, trays, and other things, and from the second year, there was no major expense. We just have to take care of the electricity, labour, marketing, and packaging costs, mainly operational expenses. From the second year onwards, I do not expect an expenditure of more than Rs. 2.5-3 lakhs as operational cost for saffron farming.
Soil-free saffron growth
We should buy the Bulbs directly from the farmers. We approached farmers and bought the bulbs directly from them. We can also learn a lot from them about how Saffron is grown using traditional farming techniques, and work on creating a model to use that information to grow it under controlled conditions. Subsidies are available for cold room construction in almost all states. We have to check with the concerned office about the subsidy in the region. We can also contact the horticulture department on how to apply for the subsidy. It can be done anywhere in India, unlike the traditional method, which has restrictions. This method requires very little arable land and water compared to traditional farming. The results of the crop grown under controlled environments are excellent as optimal conditions are provided, no pesticides are used, it's protected from excess rain or natural calamities, etc. Climatic conditions are replicated, and a protected environment is provided for the plants.
Environmental conditions vary. When we plant the bulbs in the room, it is different, and when the sprouting starts, the conditions have to be modified. The temperatures have to be reduced when winter sets in. We can use LED lights along with dimmers to reduce the intensity of light. We can modify the exposure to light using dimmers for the plants. We do not use any substrate for this method. The saffron bulbs are placed on wooden trays. So we do not use any cocopeat. When we plant the bulbs in the open space for propagation, we need to create proper soil suitable for the process. The soil has to be a mixture of clay, river sand, cow dung, vermicompost, and no pesticides. We use a humidifier to create mist when bulbs are in a controlled environment. The humidifier will convert the water into a form of mist to create the humidity. There is no direct spraying of water inside the controlled environment. This method is soil-free and involves no water spraying. We will use sensors and controllers as the plants emit carbon dioxide, and the levels should be maintained, along with circulating fresh air. The sensors and controllers take care of the same. Dampers control the levels of carbon dioxide and fresh air. All of these tasks related to controlled climatic conditions can be achieved by automation. The saffron bulbs should be placed inside the controlled environment, and we can expect the harvest by mid-November.
Bulb care practices
It is only when we see any fungal attack on the bulbs, we need to take them out, treat them with neem oil, and place them in a different tray. When we move them to soil, we need to ensure that the soil is good and healthy and not use any pesticides. To maintain the health of the soil, we need to use cow manure, which also helps during the propagation phase of saffron bulbs. There is no specific pest management for a controlled environment, as it is all done inside. We need to be careful about the access by others to the area. We do not run any training programs or batches.
The speaker concludes, saying, “ This is the initiative of my mother, Shubha Bhatnagar. To help rural women, she wanted to do mushroom and saffron cultivation. As she found this challenging, she took over saffron cultivation. We have 22 women working with us, and when there is no saffron farming, they are engaged in the usage of cold storage. I am from an engineering background and take care of all technical aspects in the firm. We have automated most of the operations by deploying enabled Sensors and Controllers, and they can be managed from a smartphone.”
Contact details
Ankit Bhatnagar
Consultant, Shubhavni SmartFarms (OPC) Pvt Ltd, Mainpuri, UP
Mobile: 82184 44545
Email: ankit.bhatnagar05@gmail.com
www.shubhavni.com