---
title: Why and How to Improve Nursery Potting Production Efficiency?
description: This article tells you why to Improve Nursery Potting Production Efficiency & how to enhance the efficiency. A lot of insightful questions are listed.
image: https://www.cmac.com.au/hubfs/improving-nursery-potting.jpg
---

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# Blog

## [Why and How to Improve Nursery Potting Production Efficiency?](https://www.cmac.com.au/blog/why-how-to-improve-nursery-potting-production-efficiency)

Posted by [Aaron Chen](https://www.cmac.com.au/blog/author/aaron--chen) on 30/06/2019

![improving-nursery-potting](https://www.cmac.com.au/hs-fs/hubfs/improving-nursery-potting.jpg?width=190&name=improving-nursery-potting.jpg)

As a nursery owner or manager, increasing profit margin for the business is always a main concern. The plant nursery is a labour intensive industry with over 70% of the nursery operation cost is a labour cost. [In order to improve your nursery profit margin, you need to minimise the labour cost](https://www.cmac.com.au/blog/how-to-choose-potting-machine-improve-nursery-potting-efficiency).

The Horticultural Research and Development Corporation (HRDC) conducted [a research amongst 52 nurseries in Australia (NSW, QLD,VIC) in 2000](https://www.cmac.com.au/hubfs/docs/HAL_logistics.pdf).

| Number of nurseries participating in the research   |  |  |  |  |
| --- | --- | --- | --- | --- |
|   | Small (1-5 staff) | Medium (6-15 staff) | Large (over 15 staff) | Total |
| QLD | 5 | 4 | 8 | 17 |
| NSW | 8 | 8 | 7 | 23 |
| VIC | 4 | 4 | 4 | 12 |
| Total | 17 | 16 | 19 | 52 |

| Number of pots investigate in each of pot size |  |  |  |  |  |  |  |
| --- | --- | --- | --- | --- | --- | --- | --- |
| Pot Size | 100mm | 125mm | 130mm | 140mml | 150mm | 1750mm | 200mm |
| Number of pots | 15680 | 11750 | 1960 | 56820 | 7830 | 9800 | 41150 |

The research found that **65-85%** of excessive potting labour costs come from the inefficient organisation of potting procedures, the use of inappropriate potting system and equipment and poor materials handling methods.

The research result also indicated that many nurseries in Australia can reduce potting labour costs and increase profit margins by improving the efficiency of their potting production systems.  

In order to find out how to improve nursery potting efficiency, we have to look into the potting systems and find out how to evaluate the potting efficiency.

## **What is the potting system in a Nursery?**

The nursery potting production system can be divided into:

1. Hand potting
2. Machine potting

Hand potting is the process where potting staff manually fill pots by hands using equipment such as a [standard bench](https://www.cmac.com.au/nursery-equipment/manual-potting-equipment/potting-benches), [modified bench](https://www.cmac.com.au/nursery-equipment/manual-potting-equipment/potting-bench-and-hopper), [mobile bench systems](https://www.cmac.com.au/nursery-equipment/trailers/potting-trailer), [tables](https://www.cmac.com.au/nursery-equipment/other/rotating-table),[purpose built potting stations](https://www.cmac.com.au/nursery-equipment/manual-potting-equipment/potting-station) and [utilising trailer deck tops](https://www.cmac.com.au/nursery-equipment/trailers). Hand potting has a high physical demand on nursery workers. It can cause potting staff to fatigue over time and affect the production rate.

 

 Compared with hand potting, machine potting is a more efficient method for the potting practice in a nursery. If a potting machine is well designed, it should have ergonomic working height which ensures that workers’ comfort levels are high.

 

Staff normally perform better due to the speed setting on the potting machine and constant media flow. [Some potting machines also have a dibbling functionality](https://www.cmac.com.au/nursery-equipment/potting-machines/comet-potting-machines). Although it is common that nurseries buy potting media which has already been mixed with fertiliser, sometimes the process of dibbling media is necessary and should be adopted to promote plant nutritional.

The dibbling process includes getting the fertiliser into a hopper, forming a hole in the potting media for the fertiliser, inserting the fertiliser as a measured amount and covering the fertiliser.

 

## **Evaluating your potting efficiency**

Objectively evaluating the efficiency of a production system is difficult, researchers from HRDC came up with an evaluation system to identify specific areas nurseries can potentially increase their profit margin by reducing potting labour costs.

Potting production efficiency in a nursery is affected by issues such as:

### **1. Worker Related Issues** 

- The levels of worker health and safety  
- The level of workers’ comfort
- The skill levels of workers (The technique of potting etc)
- The allocation of tasks to potting staff

### **2. Organisation and Potting procedures ** 

- The location of the potting area relative to the growing area 
- The elimination of non productive time in potting production
- The quality of information coming from management to potting staff
- The handling of potting inputs and potting outputs

### **3. Improvements to potting system**

- The proper potting system to the type and number of plants being potted
- The operating speed of the potting machine 

### **Below is a document with some questions for the nursery manager to give an indication of whether:**

- your potting labour costs are higher than necessary
- there is a possibility to further reduce labour costs
- your nursery should investigate the potting efficiency problems in more details

[Click here](https://www.cmac.com.au/hubfs/docs/Rapid_diagnosis_on_potting_production_efficiency.pdf) for the list of questions from HRDC research paper **OR** read the questions below.

 

![Rapid-diagnosis-on-potting-production-efficiency_001](https://www.cmac.com.au/hubfs/images/Blog-Pictures/Rapid-diagnosis-on-potting-production-efficiency_001.jpg)

## **![Rapid-diagnosis-on-potting-production-efficiency_002](https://www.cmac.com.au/hubfs/images/Blog-Pictures/Rapid-diagnosis-on-potting-production-efficiency_002.jpg)![Rapid-diagnosis-on-potting-production-efficiency_003](https://www.cmac.com.au/hs-fs/hubfs/images/Blog-Pictures/Rapid-diagnosis-on-potting-production-efficiency_003.jpg?width=508&name=Rapid-diagnosis-on-potting-production-efficiency_003.jpg)![Rapid-diagnosis-on-potting-production-efficiency_004](https://www.cmac.com.au/hs-fs/hubfs/images/Blog-Pictures/Rapid-diagnosis-on-potting-production-efficiency_004.jpg?width=511&name=Rapid-diagnosis-on-potting-production-efficiency_004.jpg)![Rapid-diagnosis-on-potting-production-efficiency_005](https://www.cmac.com.au/hs-fs/hubfs/images/Blog-Pictures/Rapid-diagnosis-on-potting-production-efficiency_005.jpg?width=499&name=Rapid-diagnosis-on-potting-production-efficiency_005.jpg)**

## **How to improve nursery potting efficiency?**

The recommendations below are given by the The Horticultural Research and Development Corporation (HRDC) after conducting the research amongst 35 participating nurseries in Australia:

### **1. Worker Issues**

- Always try to have worker health and safety policies in place and have warning labels on the potting machine to avoid risk of accidents.
- Purchase potting benching with ergonomic working height and try to use a machine to eliminate repetitive and tedious manual work to ensure workers’ comfort
- Train staff and help them work efficiently with less non-productive hours
- Allocate tasks to workers according to their motivation and abilities in performing different potting tasks
- Rotate workers tasks to prevent repetitive and boring tasks that could lead to injuries

### **2. Organisation and Potting procedures**

- Hand potting is generally more suitable for nurseries when: **(1)** During the potting season, the daily quantity of potted plants is about 1,000 or less, and/or **(2)** Average batch sizes of plants requiring different treatments, procedures, pot sizes, pot colours, or of plant types that are in clearly different categories of potting difficulty, is below approx. 300.
- Use [a potting machine that is specially designed to cope with different size pots](https://www.cmac.com.au/nursery-equipment/potting-machines/comet-potting-machines) when hand potting volumes are uneconomical for the nursery.
- Use conveyor, trailers and trolley/barrows to improve transport efficiency for the handling of potted plants which is one of the most time consuming tasks in production nursery.
- Communicate clearly with potters before potting starts to avoid wasted materials, time and efforts
- Analyse tasks collaborated by different workers before potting, during potting and after potting to reduce non-productive time

### **3. Improvements to potting system**

- Figure out the amount of total potting labour cost on cents per pot
- Find out problems in potting systems, bottlenecks, procedures and worker issues
- Work out the cost and benefit of potential improvements ie. purchase a potting machine to speed up the potting process, or have a different potting machine more suited for the lower or higher volumes, or have a hand potting station available for the lower volumes, bigger pots or for potting up. Reduce a bottle neck by getting more nursery trailers or adding extra decks to your existing trailers.
- Indentify which type of potting equipment ([semi-automatic](https://www.cmac.com.au/nursery-equipment/potting-machines/comet-potting-machines) or fully-automatic) is best to suit your nursery according to the quantities of plant material being potted and the required different treatments, procedures, pot sizes, pot colours and plant types required during the potting season – refer to the hand potting above
- Introduce the most beneficial changes to get a quick return on investment (ROI)
- Re-evaluate the new potting system

## **In Conclusion**

Due to the high labour cost in many nursery businesses, it is important to constantly evaluate the potting efficiency and try to improve it through the different aspects of worker related issues, organisation and potting procedure as well as the improvement to potting equipment.

The general recommendation given above by HRDC is to raise awareness on how to increase the average daily number of plants to be potted, which have similar treatment, potting procedures, pot sizes and colour.  If nursery managers don’t have enough time to investigate or don’t have the capability to identify and solve the potting efficiency problems, contracting a [production system consultant](https://www.cmac.com.au/blog/86-questions-before-purchasing-potting-machine-production-efficiency) is a good alternative solution.

[![Alternatively, click here for the solution! Learn how COMET could triple your nursery potting production efficiency](https://no-cache.hubspot.com/cta/default/320163/4feff3f9-65ad-4b9b-a6f1-318d02e26a3a.png)](https://cta-redirect.hubspot.com/cta/redirect/320163/4feff3f9-65ad-4b9b-a6f1-318d02e26a3a)

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## Problems we have solved for customers[Read Testimonials](https://www.cmac.com.au/about-us/testimonials)

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\*\[Owner\]\* An industrial laundry system service company needed repairs and redesign done to their tooling. C-Mac made changes to the tooling to make access and ease of use to decrease service down times.

\*\[Service Manager\]\* An industrial fan service company had a failure of a major shopping centre air conditioning fan/ blower. C-Mac repaired the unit within a 24hr turn around for minimum downtime.

\*\[Owner/Manager\]\* A major food manufacturer specializing in tomato sauce had a filling machine breakdown. The machine was brought to C-Mac and repaired in 24hrs for minimum downtime of the production line costing $5,000 per hour.

\*\[RAAF - Warrant Officer\]\* Airfield support staff required a portable sandbagging frame and requested a design, prototype and trials at no cost. There was nothing suitable on the market i.e. made in Australia. "Sandbagging Frames":materials-handling/1-bagging-equipment#silt-bagging-frame are now on the national procurement data base and some probably overseas at different war zones.

\*\[Mechanical Design Engineer\]\* An automotive transmission design customer needed help with designing an automatic transmission gear prototype. We suggested and engineered a more cost effective and practical way for the mass production stage.

\*\[Nursery Manager\]\* At an exhibition saw our self tracking nursery trailers and indicated he had a costly issue transporting large (heavy) pots containing advanced trees. Existing method was a bobcat. C-Mac designed and quoted for the manufacture of a Self Tracking “Low Loader”. His comment on the first day of using "Low Loader trailer":nursery-equipment/7-trailers/#low-loader-self-tracking-trailer “Can now move 100 litre pots with trees, 150 metres in 1 hr and not get a sore back”.

\*\[Purchasing Officer\]\* A mining design and machining company needed help with machining components urgently as they were too busy to keep up with the demand. C-Mac machined the components so the deadline could be met.

\*\[General Manager\]\* Customer had to submit a proposal and compete against other countries for the manufacturing facility. C-Mac submitted drawings to show there was space in existing plant to install the new process and to comply with all Australian OH&S Standards. Working together with customer to submit proposal to the Head Office overseas WON the contract. Project was a success meeting 6month lead time and budget.

\*\[Nursery Owner\]\* Needed a specific Potting & Mixing machine. for his yuccas nursery, but the problem was it was no longer manufactured. From his description and specifications our engineers designed and modelled in 3D software his requirements. "Potting Machine":nursery-equipment/3-potting-machines/ was manufactured and fully tested with potting media in our workshop, video was then sent to customer who was very pleased with the results. Machine disassembled and freighted interstate and installed.

\*\[Maintenance Engineer\]\* An industrial hydraulic fitting manufacturer had problems with gear and shaft breakages with their machinery. They also had problems repairing and maintaining. C-Mac offered to repair and maintain their machinery on-site instead of having to permanently employ fitters.

## Information

- [About](https://www.cmac.com.au/about-us/our-history)
- [Careers](https://www.cmac.com.au/employment)
- [Blog](https://www.cmac.com.au/blog)
- [Contact Us](https://www.cmac.com.au/contact)

## [Locate Us](https://www.cmac.com.au/contact)

21/64 Drummond St   
South Windsor NSW 2756

Phone: (02) 9631 6000  
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Copyright 1966-2022 @ C-Mac Industries Pty Ltd<http://www.KungfuMarketing.com.au>

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