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Submitted by:
Avihai Ilan, Workafes Woldetsadik
September 2011
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Contents
I. Introduction . 3
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I. Introduction
Propagation of plants is a fundamental occupation of mankind. Civilization may have
started with ancient man learned to plant and grow kinds of plants which fulfilled
nutritional needs for himself and his animals. From the great diversity and variation in
plant life he has been able to select kinds of plants particularly useful to his welfare.
Besides, it requires knowledge of plant growth and structure. This may be said to be
science of propagation. The propagator can obtain some of this information by
working with the plants themselves, but it should be implemented, if possible with
formal courses or on hands training.
Though the basics of theoretical and practical knowledge propagation of any plant is
vital in production of improved planting materials and ensuring successful agriculture,
there is a need of information regarding facilities and pre-conditions important to run
successful plant propagation business of any type .
In recent times, Ethiopia is engaged in transferring the agriculture sector, specially the
fruit and vegetable sector to better productivity and quality with expansion of supply
of improved planting materials mainly to the small holder farmers. But the size of the
support is very much limited and is far less against the demand of the country.
Therefore, the increased engagement of public & private sector and NGOs in
production and supply of improved horticulture plants has a paramount of importance
in bringing a paradigm shift to enhance production and productivity and met the GTP
objectives.
Accordingly, to attract more and more public and private investment in horticulture
plants propagation activity, it is found vital and actual to provide first hand
information about design, techniques, investment, input suppliers etc- pre-
conditions to establish new Fruit Nursery and Tissue Culture Laboratories and run
successful and feasible plant propagation agri-business.
In general, this book provides information concerning the fundamental principles and
procedures involved in fruit nursery and tissue culture plant propagation laboratories
and serves as a manual that describes useful techniques, facilities (material and
financial), investment for propagating important fruit plants. These two types of plant
propagation are considered separately and placed consecutively for the sake of easing
the understanding of the users.
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II. Propagation via plant tissue culture opportunity for Ethiopia
1. Background
Plant tissue culture (TC), cultivation of plants under aseptic and artificial conditions,
is an important tool for mass vegetative propagation of plants. The advantages of this
method are controlled environment and controlled development of the plants that
enable very rapid multiplication rate. Another advantage is the clean conditions for
plant development that produce micro-plants free of many pests and diseases. The
small size of the propagated plants saves nursery space and plant transport costs. The
main disadvantage of TC plants is their high production costs. This difficulty limits
the number of plant species in commercial TC propagation. Nevertheless, the leading
method for mass vegetative propagation of several plant species is plant tissue culture.
Among these plants is banana and ornamentals (philodendron, dieffenbachia,
anthurium, syngonium, ferns and others). In other plant species propagation by TC is
followed by field or nursery vegetative propagation to achieve plants that are free of
many pest and disease at a reasonable price. This type of propagation is used for
sugar cane, potato, strawberry and other species.
The demand in Ethiopia for plants that can (and should) be propagated by TC is large.
For example, the area of banana fields in Ethiopia is about 40,000 Hectare.
Accordingly, the number of banana plants in Ethiopia can be estimated as 80 millions.
Under favorable conditions we can assume the renewal of plantation every five years.
Consequently, the annual banana planting in Ethiopia can be estimated as 16 million
plants. The current micro-propagation capacity in Ethiopia is about 3 millions plants
per annum. This is based on one medium commercial TC lab (MIT Mekele) and
several small research TC laboratories that recently began mass production by TC.
Following the requirements for new plant tissue culture laboratory will be described
including the lab and acclimatization facility design, equipment and human resources.
Production process and production planning will be discussed as well as micro-
propagation costs and ways for their reduction.
2. Design of TC laboratory
Tissue culture plants are grown under low intensity artificial light (mostly cool white
fluorescent lamps). Consequently, their photosynthetic system is only minimally
active and the supply of photosynthesis products like sugars is essential for their rapid
growth and propagation. TC media that is rich in minerals and sugars creates good
conditions for microbes that can multiply faster than plant and take over the plant
cultures unless aseptic conditions are maintained. Maintaining aseptic conditions is
therefore a key factor in TC lab design.
The acclimatization facility is a protected cultivation area that can provide low light
intensity and high humidity that are required at early stage of acclimatization as well
as protection from pests. The recommended acclimatization facility is a tunnel topped
with polyethylene sheet with side walls made of insect proof net and polyethylene
rolled screens. The facility should be equipped with fog/mist application system.
b. Dish washing
The equipment needed for dishwashing room is two big sinks and taps, perforated
shelves for vessels' drying and storage cabinets for the washed vessels. Additionally,
a source of deionized water is recommended.
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c. Chemical storage
This room should contain cabinets to store the chemicals. Desiccator is recommended
for storage of hygroscopic materials.
d. Growth room
The equipment needed in growth room is racks and shelves equipped with fluorescent
lamps (cool white is recommended), timer for automatic control of the lamps and AC
with sufficient capacity to maintain 18-30 degrees at the room as per the need of
relevant crop and with the capacity to overcome heat emission by all the room's
fluorescent lamps. An automatic switch for stopping the room's light when AC fails
is recommended.
e. Transfer room
This room should contain clean benches, tables with blower and HEPA filter that
create aseptic work environment. Equipment for plant transfer includes scalpels and
forceps. Glass bead sterilizers are recommended for transfer tools sterilization.
Alternatively Bunzen gas burners may be used. The operators dressing include: hats,
face masks, latex gloves, gowns or over-wholes and shoes.
f. Acclimatization tunnel
The acclimatization tunnels should contain tap and sink, gown hangers and shoe
disinfection trays at the entrance room. The tunnel should include tables and
irrigation system (foggers, mist, micro sprinklers) with control panel, water tank and
irrigation tank. The tables should be made of galvanized metal and carry the
acclimatization celled trays.
4. Investment
4.1 Low cost laboratory equipment
Savings should be made on the most expensive devices: Autoclaves can be replaced
by pressure cookers (electric or gas operated), "do it yourself approached may be
applied for clean bench and glass bead sterilizers. Expensive particle counter can be
replaced by simple colony counts on microbes' enrichment media. Expensive culture
vessels such as Magenta jars could be replaced with locally available autoclavable
glasses, like marmalade jars, etc.
4.2 Low cost acclimatization facility
Simple self made construction that maintain the following conditions: detached from
soil, protected from insects, control of light intensity and humidity. Example:
construction of small acclimatization facility with eucalyptus bars skeleton and
polyethylene sheet. Expensive humidity tents can be replaced by red cheese cloth that
reduce light intensity and maintain high humidity.
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Table 1: Investment: low cost vs. high cost (USD)
5. Human resources
The micro-propagation company personnel should include:
Lab manager at least BSc Biology degree. Previous TC experienced is
recommended.
Media preparation laborant (chemist).
Transfer room operators
Growth room supervisors
Other lab personnel
Acclimatization nursery foreman previous nursery experience is preferred.
Acclimatization personnel
Beside of the roles specified above other lab and nursery attendants will be trained for
their tasks by the lab and nursery foremen.
6. Operation planning
The annual production plan is prepared according to the amount of plants ordered or
expected to be ordered from the laboratory. The multiplication factor (MF) assumed
and the productivity is depending on the propagated crop. If there is no previous
experience with the crop variety the planning may be based on other varieties of the
same genus or other plants from the same botanical family. The calculation starts
from the end, i.e. from the needed monthly supply and go back all the way to the
explant stage (subculture 1).
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Table 2: example of annual production plan for 1M plants per annum (linear
production is assumed).
Subcult Productiv MF Month
# plant/day 1 2 3 4 5 6 7 8
1 explant 200 0.5 7692 7692 7692 7692 7692 7692 7692 7692
2 500 1 3846 3846 3846 3846 3846 3846 3846 3846
3 1000 2 3846 3846 3846 3846 3846 3846 3846 3846
4 1000 2 7692 7692 7692 7692 7692 7692 7692 7692
5 1000 2 15385 15385 15385 15385 15385 15385 15385 15385
6 1000 2 30769 30769 30769 30769 30769 30769 30769 30769
7 rooting 1000 1.3 61538 61538 61538 61538 61538 61538 61538 61538
Final 700 80000 80000 80000 80000 80000 80000 80000 80000
Labor - TR 165 165 165 165 165 165 165 165
Shelf sqm/plant 0.0006 78 78 78 78 78 78 78 78
Based on the annual production plan, the needed amount of labor in transfer room and
accordingly in other lab compartments can be estimated as well as the shelf area
required in the laboratory's growth rooms. Consequently, the annual plant production
provides the background for design of new laboratory or expansion of existing one.
7. Operation cost
7.1 Operation cost: labor saving solutions
The following measures can reduce labor costs. Increasing proportion of
meristematic tissues vs. other tissues may allow arbitrary and swift separation of the
TC propagules. However, Mechanized separation is currently available for only a few
plants like ferns. Some separation of propagules can be achieved by agitation in
liquid culture. Operators transfer efficiency with most plants should reach 1500
units/day or more. Adequate training and QC are required to achieve it. Direct
transfer of small plants without roots from rooting stage to acclimatization will
increase planting productivity at the acclimatization stage.
7.2 Operation cost: energy saving solutions
Energy saving in tissue culture laboratory can be achieved by the following: Large
transparent windows at the growth rooms will reduce the need for illumination,
vessels with plantlets at stage III may be kept in the greenhouse instead of their
growth at the growth room.
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III. Modern fruit tree nursery as opportunity for investment
1. Background
Ethiopia enjoys various growth conditions that support optimal cultivation of many
fruit trees. Currently only a small proportion of this potential is used. In several fruit
species the current practice of cultivating un-grafted seedlings creates large variability
and mostly poor fruit quality, shelf life, taste, etc. Several fruit species are devastated
by pests and diseases and adaptation of resistant rootstocks and varieties is badly
needed. The above situation opens an opportunity for fruit plant propagator to
provide significant amount of quality plants.
2.2 Avocado
The current area of avocado plantations in Ethiopia is 5,067 Ha (FAO-Stat, 2009).
Avocado cultivation in Ethiopia is characterized by insufficient number of trees per
Ha, cultivation of mostly seedlings with great variability, low quality, low yields and
no rootstocks. The demand for uniform quality varieties is clear. Rootstocks are
required to address biotic (for example avocado root rot) and a-biotic (for example:
soil and water salinity) stress. The potential need of avocado plants to replace the
current plantations is 280X5000 = 1.4M plants (without expansion of cultivated area).
Consequently, the immediate potential for nursery sales (assuming plant price of USD
1.5) is USD 2.1M. The demand for quality avocado plants is expected to increase
once fruits export will begin.
2.3 Citrus
The current area of citrus cultivation in Ethiopia includes: 754 Ha lemons, 2440 Ha
orange (FAO-Stat, 2009). No data for other citrus varieties is available. The total
citrus cultivation area may reach 3500 Ha. The existing plantations are characterized
by insufficient number of plants per Ha. Unlike avocado and mango citrus growers
are growing mostly grafted plants. The main problem of current citrus cultivation is
the fast spread of pests and disease and especially Pharmaularia angolensis that
devastate plantations in several regions. Introduction of resistant or tolerant varieties
can create large potential for nursery propagation.
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Development of relevant activities: quality plant propagation, packing houses, cold
storage, export services, processing, etc. can further increase the demand for fruit
trees and the potential for nurseries' sales.
3.3 Fertigation
Fertigation, the supply of water and fertilizers can be done in three major ways:
water cans, micro-sprinklers and drip. Drip is the most adequate for the plants but
it is expensive and difficult to maintain. Micro-sprinklers are somewhat less
expensive and their maintenance is simple. Supply of water on the plant's canopy
is less favorable. Large plants may disturb water supply to the roots. That can be
overcome with back-up house with shower head. Water can irrigation is the
cheapest in investment but labor intensive.
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3.5 Seedlings in poly-bags (pre/post grafting)
The seedlings transferred from the germination beds or sleeves are planted in
poly-bags. Poly-bags are stationed on raised beds. The recommended bed size is
1.2m wide and 20-40 cm high (depending on the likelihood of flood). The
distance recommended between the beds is 80 cm. each bed can harbor 4 rows of
poly-bags. Rootstock becomes ready for grafting at pencil size diameter. When
grafting avocado or mango leave a few leaves under the grafting point. Selection
of scions: size, woodiness, situation (not flowering, budding), disinfecting of
scions is a must. The scion should be grafted a short time after its collection.
Adaptation of grafts at the cold season takes longer time. Every grafted plant
should be tagged with the name of the variety using hard plastic tags, preferably
different colors to different varieties. Whenever a known rootstock is used it
should be mentioned on the plant's tag. Hardening of plants before their shipment
to the planting site can be done by transfer to Open nursery and reduced
irrigation.
POLY-
BAGS
Poly-begs Nursery
NURSERY
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R
4.2 Site preparation
The first step of nursery construction is site preparation. This will include:
clearing, plowing, leveling and bed preparation. The estimated cost of this stage
is USD 2000 for a 0.5 Ha nursery (50,000 plants capacity).
4.3 Shading
Simple shading can be prepared by eucalyptus sticks skeleton and shade cover of
dry grass. The cost for an area of 0.5 Ha (50,000 plants capacity) will be less than
USD 5,000. A construction of a net house with metal skeleton of poles and wires
and HDPE shade net may cost USD 30,000 for an area of 0.5 Ha.
4.4 Fertigation
Simple irrigation can be done with water cans. If micro-sprinkler fertigation is
selected (including: reservoir, dam, pump, head control, fertilizer tanks, pipes and
sprinklers and hose with shower head backup) the cost will be about USD 20,000.
6. Financial analysis
Operation costs at nursery with capacity of 50,000 plants may be:
Labor costs USD 8450 (51%)
Other operation costs USD 8,100 (49%)
TOTAL OPERATION COSTS USD 16,550
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Table 2: Financial analysis of a simple nursery.
The nursery rate of success (plant survival) is mainly dependent on grafting quality.
Other reasons for plant mortality: timing of transfer from seed beds to poly-bags. We
can expect increased success rate at more expensive nursery facilities. However, the
additional income may not justify the larger investment. The main factors for nursery
success: good nursery facility, good soil prep, grafted plants (high grafting success
rate), marketing
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7. Benefits to plant buyers
The cost of avocado plant to the farmer is ETB 20-25 (about USD 1.5). Annual costs
of cultivation are marginal: compost preparation, plant design (pruning). Yield of
100-200 Kg per tree (full yield from the fifth year) gives the farmer annual income of
ETB 300-600. Following the introduction of international varieties and
commencement of export the fruit price and benefit to the grower will increase
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IV. Ethiopian suppliers of tissue culture inputs
1. Introduction
Plant tissue culture requires various inputs for laboratory design, construction,
equipment, vessels and disposables as well as acclimatization facilities construction,
equipment and supplies. This chapter provides partial lists of suppliers. The readers
are requested to note additional input suppliers from their knowledge.
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Fasil: 0911-611846
AA Bottle & Glass Manager: Gobane
Factory 0911-229795
Old Ambo Rd
Afro German Tesfaye Koji. Diagnostics rep. Lab chemicals
Chemicals Est. PLC 011-0550200, 0911-888096 Lab equipment
(off Twedros sqwar) [email protected]
Pharma SC Markos Hildebrandt Lab chemicals
(Churchill Rd. off Tel: 011-1550207 Lab equipment
Twedros sqware, Fax: 011-1552799
above Lion's [email protected]
pharmacy)
Neyo Biomedical Eng. Nega kebede Lab equipment
Engineering (near Tel: 011-8501607
T/Haimanot square) Mob: 0911-246320
AA [email protected]
Hanover general Mob; 0911-128042 Lab supplies
business PLC
Addis Ababa
JIJE Laboglass Tel.011 372 0701 Lab glassware
Fax011 372 0700
Enterprise
Mobile091 166 2491
(near Mauritania St.)
E-Mail
Kalwin Multi Tel.: 011 155 2622 Lab supplies
Supply Plc 14084 Fax: 011 155 0793
Addis Ababa
Tesema Aba Kamaw
st (between Gaston
Guez sq and Gola
Sefer/zambia St.)
Micron Intl. Trading Tel: 011-551 43 34 Lab equipment and
house PLC (near Mob: 0911-63 36 23 supplies
Mexico square) Fax: 011-551 14 93
email: [email protected]
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Company Contact Services
Axum Greenline Trading Tel: 011-6183087 Greenhouse, irrigation,
Plc. Mulugeta 0911-416651 repairs
Netafim Girmai 0911-135315 Greenhouse, irrigation,
John Deere Water Itna 0921-607303 Greenhouse, irrigation
(formerly: Plastro) Agent:
Gedeb Engineering Plc.
IRRI Al-Tal Gerard 0911-412946 Greenhouse, irrigation
Mesfin Metal Works Mesfin 0911532523 Metal works for
greenhouses (tables)
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V. Ethiopian suppliers of nursery equipment
2. Nursery supplies
Company Contact Services
Axum Trading Plc. (near Mulugeta 0911-416651 Chemicals
yodo Abissinia, off
Bolemadenalem)
Agri Sher (near yodo Tel: 011-6631578 Chemicals
Abissinia, off Fax: 011-6631300
Bolemadenalem) Nardos Zeleke 0911-
054680
Oxford Polyethylene Tel: 011-6636521 Poly-bags, grafting bags,
Industries Plc. (near Bole Suresh 0911-456926 colored plastic for tags
madenalem & ring road
junction)
Ethiopia Plastic Factory Tel: +251 1 51-2666 Poly-bags
Postal Address: P O Box Fax: +251 1 51-7890
2340 Addis Ababa
Excel plastics 011-629219799 Celled trays?
AA,Gerji-ELPAJakros [email protected]
Rd.
Upper Awash State Farm 0221-122707 Citrus seeds
Addis off. (Saris-Abo
church) 011-4424999
Tsegaye 0911-201190
Girma 0912-170738
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