Composite films: results of large-scale tests

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INTRODUCTION

Greenhouses are becoming a key area of future agricultural development. Their role in increasing crop yields, improving product quality and reducing costs is steadily growing. This is especially noticeable in countries with a developed agricultural sector, such as Uzbekistan, Russia, the Republic of Belarus, China, Germany and other countries, where greenhouses already play an important role in ensuring food security and sustainable development. Let us consider, for example, the trends and achievements of China, as one of such countries. A number of our publications [2–4; 21] present the results of studies of composite films based on functional ceramics and polyethylene. These materials have unique properties that combine strength, durability and the ability to integrate functional properties, such as temperature stabilization, both in cold and hot weather, reducing water consumption by 4–6 times, accelerating plant growth and development, protecting them from diseases, increasing crop yields by 30–100%, etc. The use of composite films in agriculture opens up new opportunities for year-round crop production. These innovative materials have high light transmittance, resistance to ultraviolet rays, mechanical damage and chemical influences. Due to this, plants can develop in conditions close to optimal, regardless of the season.

Composite films help to create a stable microclimate inside greenhouses and hothouses, which allows to sig-nificantly reduce crop losses due to unfavorable weather conditions. They maintain optimal temperature and humidity, providing plants with comfortable conditions for growth and development. This is especially important in regions with a cold climate, where growing many crops without greenhouses is impossible.

In addition, composite films help to increase the yield and quality of products. They prevent the penetration of pests and diseases, and protect plants from mechanical damage. This allows to reduce the costs of chemicals and other plant protection products, which has a positive effect on the environmental situation.

The production of agricultural crops under composite films also helps to improve the environmental situation. Reducing the use of chemical crop protection products and reducing crop losses due to more stable growing conditions help conserve natural resources and reduce the negative impact on the environment. The use of such films plays an important role in reducing the amount of plastic waste. This is due to the features of pulsed IR radiation generated by functional ceramics. Due to this radiation, the strength of the films increases over time. This occurs due to the elongation of polymer molecules, cross-linking of radicals and chain fragments formed during destruction. As a result, the rate of radical recombination prevails over the rate of their formation, which helps stabilize the film structure and increase its durability. Under such films, plants develop faster and more actively, which contributes to more efficient absorption of carbon dioxide and oxygen production. This is especially important in the context of climate change and increasing concentrations of green-house gases in the atmosphere.

The use of such films not only helps reduce the amount of plastic waste, but also helps improve the environmental situation, reducing the level of carbon dioxide and increasing the concentration of oxygen in the air. Thus, the use of composite films in agriculture is a promising area that allows not only to increase crop yields and product quality, but also to make a significant contribution to environmental protection. We have currently conducted large-scale tests of composite films together with the Chinese company Shanghai Daodun Technology Co., Ltd. These tests included an assessment of the mechanical properties of the films, their resistance to external influences, as well as testing of functional characteristics. We sought to identify the potential advantages and disadvantages of such materials in real operating conditions.

In cooperation with Shanghai Daodun Technology Co., Ltd., we also explored the possibilities of optimizing the composition and structure of composite films to improve their performance characteristics. This included selecting the optimal proportions of components, developing new methods for synthesis and processing materials. As a result, we were able to increase the strength, durability and functionality of the films, making them more competitive in the market.

We present the results of tests and studies of composite films for greenhouses in China, presented by Chinese partners.

CURRENT TRENDS AND ACHIEVEMENTS

As of 2022, the area of greenhouses in China reached an impressive 193 million hectares, equivalent to 16,410 square kilometers. This indicates the large-scale implementation of greenhouse farming and its importance to the country’s economy. Greenhouses allow you to create optimal conditions for growing various crops, including vegetables, fruits and flowers, which is especially important in the context of climate change and shrinking fertile land. Future Forecasts

By 2030, the eco-greenhouse market is expected to exceed RMB 50 billion. This growth will be driven by a compound annual growth rate (CAGR) of 10%, demonstrating the high investment attractiveness and potential of this industry. Eco-greenhouses that use renewable energy and modern technology are becoming increasingly popular due to their ability to minimize environmental impact and ensure sustainable pro-duction.

KEY TRENDS

1. Intelligent. The introduction of automated control systems such as sensors, irrigation systems, and climate control allows for the optimization of growing conditions and increased production efficiency.
2. Scaling. Increasing the size of greenhouses and creating giant greenhouses helps reduce production costs and increase production volumes.
3. Concentration of production chains. The integration of various stages of production, from cultivation to processing and packaging, helps improve efficiency and reduce logistics costs.
4. Development of vertical farms. Vertical farms using multi-tiered structures can significantly increase crop yields in a limited area. This is especially true for densely populated regions and countries with limited land resources.
5. Use of innovative materials. Modern greenhouses are made of durable and long-lasting materials such as polycarbonate, which ensures their high stability and long service life.
6. Energy efficiency. The introduction of energy-saving technologies such as solar panels and heat recovery systems can reduce energy costs and make greenhouse farming more environmentally friendly.

ADVANTAGES OF GREENHOUSE FARMING

• Control of growing conditions. Greenhouses allow you to create ideal conditions for plant growth, including temperature, humidity, lighting and soil composition.
• Increased yield. Modern technologies and growing methods allow you to get higher yields per unit area.
• Reducing costs. Optimization of processes and the use of energy-saving technologies help reduce production costs and make it more cost-effective.
• Improved product quality. Controlling growing conditions allows for higher quality products, which is especially important for export.

Thus, greenhouses play a key role in modern agriculture, ensuring sustainable development and increasing production efficiency. The introduction of innovative technologies and growing methods can significantly increase yields, reduce costs and improve product quality. Future forecasts indicate significant growth in the eco-greenhouse market, which confirms their importance and potential.

Nanocomposite film is an innovative material that converts solar energy into radiation with a specific spectrum. It improves plant photosynthesis, increasing density, accelerating ripening and increasing yield.

The film also has a cooling effect, reducing the temperature by up to 9 °С. This is especially important in drought, heat and extreme weather conditions.

In addition, the film increases plant resistance to stress, pests and diseases. It is durable, easy to install and cost-effective.

Nanocomposite film is a solution for increasing agricultural efficiency, protecting crops and reducing costs.

The concentration of carbon dioxide (CO₂) in the atmosphere is an important factor for plant growth and ecosystem development. In normal air, its level is about 400 parts per million (ppm). However, in greenhouses, especially when using ceramic infrared films, the concentration of CO₂ can be increased to 1000 ppm and higher. This significantly accelerates photosynthesis, improves the absorption of nutrients and promotes more active plant growth.

The ecological cycle in greenhouses with infrared films includes the utilization of carbon dioxide from the atmosphere. The films transmit infrared radiation, which plants use for photosynthesis, while retaining heat. As a result, greenhouses become ground absorbers of CO₂, processing emissions from power plants and other sources of greenhouse gases. This helps to reduce the level of carbon dioxide in the atmosphere and form a unique ecosystem of the green cycle.

The agrotechnical advantages of greenhouses with infrared films are numerous. Firstly, such greenhouses significantly reduce water consumption by 50% due to more efficient use of moisture and reduced evaporation. Secondly, infrared films create favorable conditions for plant growth, which reduces the risk of diseases and pests. Thirdly, the high content of CO₂ in the air helps to improve the quality of vegetables, making them denser, juicier and richer in vitamins.

These greenhouses are also ideal for growing premium organic produce. The absence of chemical fertilizers and pesticides, as well as control over growing conditions, allow you to get environmentally friendly and healthy products.

Composite films have great potential for use in windows of buildings and vehicles. They effectively regulate the indoor temperature, providing heat in winter and coolness in summer. This allows you to significantly reduce energy costs and reduce emissions of harmful substances, such as chlorine gas.

In addition, composite films have antimicrobial properties. In closed spaces where people are, they are able to destroy up to 100% of viruses, bacteria and flu viruses. This makes them an important element in creating a healthy and safe environment.

The development of transparent self-adhesive films opens up new prospects for their application in various industries. In the automotive industry, they can be used to create more comfortable and energy-efficient cars. In residential and non-residential premises, composite films help stabilize the temperature, providing an optimal microclimate. They also help disinfect the air, which is especially important in conditions of increased morbidity.

The use of such films increases the cost-effectiveness and environmental friendliness of the operation of buildings and vehicles. This makes them an ideal solution for the modern world, where concern for health and the environment is becoming increasingly im-portant.

PROMOTING NANOCOMPOSITE FILM TECHNOLOGY, BUILDING LARGE-SCALE GREENHOUSES, AND LEADING THE DEVELOPMENT OF GREEN ORGANIC AGRICULTURE

The company actively promotes innovative technologies, including nanocomposite films, to improve growing conditions for crops. These films have unique properties such as high transparency, UV protection, moisture retention, and temperature regulation.

Building large-scale greenhouses using nanocomposite films can significantly improve yields and product quality, while reducing resource costs. The company also focuses on developing green organic agriculture by introducing environmentally friendly methods and technologies. This includes the use of biofertilizers, composting, eliminating chemical pesticides and herbicides, and developing sustainable agricultural technologies.

As a result, the company becomes a leader in organic agriculture, offering high-quality products and solutions that meet modern environmental standards.

CROSS-BORDER INTEGRATION, DEVELOPING A SERIES OF NEW INFRARED NANOMATERIAL TECHNOLOGIES AND CREATING APPLICATION SCENARIOS TO BUILD A LEADING GLOBAL COMPANY IN THE FIELD OF SMART AGRICULTURE

In order to achieve global leadership in agriculture, the company actively engages in cross-border integration, cooperating with international partners and sharing advanced technologies. Particular attention is paid to the development of new nanomaterials that can effectively absorb and emit infrared radiation.

These technologies are applied in various aspects of agriculture, including greenhouse heating systems, humidity and temperature control, and plant health monitoring. Application scenarios of nanomaterials are developed based on the specifics of different regions and climatic conditions.

As a result, the company becomes a leading global company in the field of smart agriculture, providing comprehensive solutions to improve the efficiency and sustainability of agricultural production.

INTERNATIONAL COOPERATION, INTEGRATION OF NEW TECHNOLOGIES FROM DIFFERENT COUNTRIES, EXCHANGE AND COOPERATION, TRADE AND LOGISTICS, BRAND BUILDING AND BECOMING AN INFLUENTIAL WORLD-CLASS COMPANY THAT PROMOTES THE DEVELOPMENT OF MODERN AGRICULTURE

International cooperation plays a key role in the company’s strategy. It actively integrates new tech-nologies from different countries, participating in research, development and exchange of experience. This allows the company to keep abreast of the latest achievements and implement them in its activities.

Cooperation with international partners also promotes the development of trade and logistics, ensuring a stable supply of products and materials. Forming the company’s brand as an influential and reliable world-class organization is an important aspect of its strategy. This is achieved through active promotion in international markets, participation in exhibitions and conferences, as well as through the creation of a positive image of the company.

As a result, the company becomes an influential player on the world stage, promoting the development of modern agriculture and offering innovative solutions to improve its efficiency and sustainability.

DEVELOPMENT OF COMPOSITE FILMS FOR GROWING PLANTS AND MICROALGAE

Innovative composite films have been created for growing plants and microalgae, especially in conditions unfavorable for agriculture. Such films can be used in the Aral Sea zone, where the environmental situation requires effective solutions for restoring natural resources.

Studies have shown that composite films can effectively stabilize temperature. In hot weather, they reduce the temperature by 8.3–10 °С, and in subzero temperatures (for example, –17 °С) they increase it by 21°. This makes them ideal for protecting plants from extreme weather conditions (App. 1).

Composite films based on innovative technologies (ITE) are also being studied for use in various industries. They can be used to create energy-efficient buildings, greenhouses, as well as in the automotive industry to improve thermal insulation and reduce the weight of vehicles.

SCALING UP THE PRODUCTION OF CERAMICS BASED ON ITE AND TESTING

A technology has been developed for scaling up the production of ceramics based on innovative technologies (ITE). This allows for a significant increase in production volumes and a reduction in the cost of production, making it available for widespread use.

Composite films have been successfully tested at the Agricultural Academy of China and with DaoDun Technology. As a result, a joint production agreement was signed, which indicates high potential and trust in the technology.

The results of tests in China showed a significant improvement in conditions for growing plants:

• Temperature reduction in hot weather by 8.3–10 °С;
• Temperature increase at negative values (for example, –17 °С) by 21°.
• Increase in yield and plant development by 30–50%.

Composite films have also been successfully tested in Germany, Greece, Belarus, Kazakhstan and Russia. This confirms their versatility and effectiveness in various climatic conditions.

The possibility of creating self-adhesive films is being actively developed together with 3M. This will open up new prospects for the use of films in construction, automotive engineering and other industries.

DURABILITY OF COMPOSITE FILMS

One of the key advantages of composite films is their durability. The mechanism of radical growth of the polymer chain significantly exceeds the mechanism of destruction, which leads to an increase in the strength and elasticity of the material over time. This radically solves the problem of plastic waste, since the films can be used repeatedly and do not require frequent replacement.

The durability of the films and their ability to self-heal significantly reduces the burden on the environment. They not only protect plants from adverse conditions, but also help reduce the amount of plastic waste, which is especially important in the context of a growing environmental problem.

CONCLUSION

The developed composite films are an innovative solution for agriculture, construction and other industries. Their ability to stabilize temperature, durability and environmental safety make them a promising material for use in various conditions. Successful tests and the conclusion of joint production agreements indicate the high potential of the technology and its demand at the international level.

Based on the results obtained, we plan to continue working on improving the properties of composite films and their use in various industries, as well as expanding the geography of their distribution. At present, joint tests have been agreed upon, with the subsequent introduction of such composites with Russia, the Republic of Belarus, Germany, Cameroon, Kazakhstan, Kyrgyzstan and other countries.

About the authors

Rustam Kh. Rakhimov

Author for correspondence.
Email: rustam-shsul@yandex.com
ORCID iD: 0000-0001-6964-9260
SPIN-code: 3026-2619

Dr. Sci. (Eng.); Head, Laboratory No. 1

References

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