Manuel Moussa

Exact Irrigation System: Saving > 60% Water through Energy Chains and Monitoring

Dercks Gartenbau irrigates potted plants in open fields at an industrial scale using an exact irrigation system that delivers water and fertilizer directly into the center of each pot. The starting point was recurring waterlogging, rising water and fertilizer consumption, and the need to use cultivation areas more efficiently. Key challenges included a travel distance of more than 200 meters, reliable supply of media and data in outdoor operation, obstacles along the travel path, cost pressure, and the requirement to avoid unplanned downtime. Technically, the irrigation system is supplied via an igus energy chain instead of dragging hoses across the field. Sensor technology (smart plastics) monitors push and pull forces for condition monitoring and serves as the basis for predictive maintenance. The solution combines energy chains, media lines, and condition monitoring sensors connected to monitoring and notification systems. The results are measurable: 60–70% water savings (down to roughly one third of previous consumption), reduced fertilizer runoff into groundwater, approximately 50% lower energy costs, and 9–10% improved land utilization. For IT and OT decision-makers, this use case demonstrates how IoT-based monitoring secures mechanical systems, enables predictable maintenance, and measurably reduces operating costs and environmental impact.