Potentials for cost reduction in a new model of commercial micropropagation

A commercial micropropagation facility, using semi-solid medium in jam bottles as culture containers and a conventional growthroom (with filtration of the air condition system and artificial lighting), was adapted to a new system which uses proprietary liquid medium, improved handling methods to speed up inoculations in polybags and biologically clean stock cultures. Diffused sunlight in the greenhouse is used as light source for the multiplication and rooting of cultures. The temperature of the greenhouse was only controlled by fan-and pad cooling when exceeding 37°C in the afternoons of hot days, allowing ambient temperature of the greenhouse as sufficient control for the cultures. A representative comparison from the daily commercial production records of both the systems was conducted. In the new system, number of propagules produced per workstation per day increased 5 times, and rate of multiplication of propagules per culture in a multiplication cycle increased 3.5 times. Thus, net improvement of performance of the new system is product of these, i.e. 17 times. This is without infusion of automation and with simultaneous reduction in capital costs, running costs as well as interest cost. Further, losses from contamination and during hardening stage is also reduced in the new system. Cost data has been presented on a comparative basis to avoid disclosing commercially sensitive absolute figures. Use of natural light and ambient temperature for culture incubation achieved about a 75% reduction in capital cost as well as in the cost of electricity. Production of cultures per worker, on account of new proprietary handling methods, was 70% more in the new model, a factor relevant to developed economies as this feature can be utilized in their present systems too, whether rest of the features of new system are adapted or not. Potential reduction, extrapolated from actually achieved results, in cost of production is 92 – 98% in Indian context and is estimated to offer about 55–87% for developed countries, depending upon efficiency of hardening. Thus this model is relevant to developing as well as developed countries. Further scope exists in improvement in cost reduction in tropical and semi-tropical climate. In temperate climate, scope is lesser for cost reduction, but the same may yet be practically worthwhile when compared to costs in conventional model. Over and above the advantages mentioned above, sturdiness and survival of plants in hardening was better in plants coming from new system.