Abstract

This case study evaluates the impact of the DCON Ag Air Smart Irrigation System on a 9-acre mango farm. It compares traditional, semi-automated, and fully automated irrigation methods to analyze improvements in water usage, fertilizer efficiency, labor reduction, and crop yield.

The results show significant savings in resources along with better crop quality and higher productivity, demonstrating the effectiveness of smart irrigation in modern farming.

Project Overview

This case study evaluates the impact of implementing DCON Ag Air Smart Irrigation System on a 9-acre farm by comparing traditional, semi-automated, and fully automated irrigation methods.

Objectives

• Optimize water usage
• Improve fertilizer efficiency
• Reduce labor dependency
• Enhance crop yield & quality
• Increase overall farm profitability

Farm Details

Location	Erode
Total Area	9 Acres
Crop	Mango
Irrigation Type	Drip Irrigation
Technology Used	DCON Ag Air Controller

Authors

Experimental Methodology

The total land was divided into 3 equal zones (3 acres each) to compare different irrigation methods.

Zone 1: Traditional Method

Irrigation (Manual Scheduling)

In this zone, irrigation was carried out manually based on the farmer’s experience and visual observation of soil conditions. The irrigation schedule varied weekly depending on weather and field requirements, leading to inconsistent watering patterns. Typically, irrigation was performed 2 to 3 times per week, with each session lasting between 2 to 3 hours.

Week	Irrigation Days	Duration
Week 1	Mon, Thu, Sat	2 hrs
Week 2	Tue, Fri	2 hrs
Week 3	Mon, Wed, Sat	2.5 hrs
Week 4	Tue, Thu, Sun	2–2.5 hrs
Week 5	Mon, Fri	2 hrs
Week 6	Wed, Sat, Sun	2.5 hrs
Week 7	Mon, Thu	2 hrs
Week 8	Tue, Fri, Sun	2–2.5 hrs

Water Usage (Approximate)

Water usage was not measured precisely and depended on estimation. The average water consumption per irrigation ranged between 25,000 to 32,000 liters for 3 acres. Weekly water usage varied from 60,000 to 95,000 liters, indicating a lack of control and efficiency.

Week	Frequency	Water / Irrigation	Total Weekly Water
Week 1	3 Days	25,000 – 28,000	75,000 – 84,000
Week 2	2 Days	26,000 – 29,000	52,000 – 58,000
Week 3	3 Days	29,000 – 32,000	87,000 – 96,000
Week 4	3 Days	25,000 – 30,000	75,000 – 90,000
Week 5	2 Days	23,000 – 26,000	46,000 – 52,000
Week 6	3 Days	27,000 – 32,000	81,000 – 96,000
Week 7	2 Days	25,000 – 28,000	50,000 – 56,000
Week 8	3 Days	26,000 – 30,000	78,000 – 90,000

Fertilizer Usage (Manual Application)

Fertilizers were applied manually without precise calculation. The quantity and timing were based on farmer judgment, often resulting in overuse or underuse.

Week	Application	Type	Qty (Kg)	Weekly Cost (₹)
Week 1	Once	Urea / Complex	45 – 50	1,125 – 1,750
Week 2	Once	Urea / DAP	40 – 45	1,200 – 1,800
Week 3	Twice	Urea / Potash	50 – 60	1,750 – 2,700
Week 4	Once	Complex mix	45 – 55	1,350 – 2,200
Week 5	Once	Urea	35 – 40	875 – 1,200
Week 6	Twice	Urea / DAP	50 – 60	1,500 – 2,400
Week 7	Once	Complex mix	40 – 50	1,200 – 2,000
Week 8	Once	Urea / Potash	45 – 55	1,350 – 2,475

Labor Usage

All operations were manual, requiring 2 to 3 workers. Labor costs ranged between ₹3,500 and ₹7,500 per week.

Week	Workers	Days	Hours	Weekly Cost (₹)
Week 1	2	3	18–24	4,800
Week 2	2	2	12	3,200
Week 3	3	3	36–45	7,200
Week 4	2	3	18–24	4,800
Week 5	2	2	12	3,200
Week 6	3	3	36–45	7,200
Week 7	2	2	12	3,200
Week 8	2–3	3	18–36	4,800 – 7,200

Challenges:

• Overwatering / under-watering
• Fertilizer wastage
• Inconsistent crop growth

Zone 2: Semi-Automated System

Irrigation (Automated Scheduling)

In this zone, irrigation was controlled using automated timers and basic controllers with predefined schedules, ensuring consistent water application compared to manual methods. Fertigation was still manual but required less effort due to improved irrigation control. Daily operations took approximately 30 minutes, improving efficiency.

Water Usage (Controlled)

Water usage was regulated through automation. Weekly consumption ranged between 50,000 and 75,000 liters for 3 acres.

Week	Frequency	Water / Irrigation	Total Weekly Water
Week 1	3 Days	20,000 – 24,000	60,000 – 72,000
Week 2	2 Days	22,000 – 25,000	44,000 – 50,000
Week 3	3 Days	24,000 – 28,000	72,000 – 84,000
Week 4	3 Days	21,000 – 26,000	63,000 – 78,000
Week 5	2 Days	20,000 – 23,000	40,000 – 46,000
Week 6	3 Days	23,000 – 27,000	69,000 – 81,000
Week 7	2 Days	21,000 – 24,000	42,000 – 48,000
Week 8	3 Days	22,000 – 26,000	66,000 – 78,000

Fertilizer Usage (Manual with Monitoring)

Fertilizer application remained manual but was better planned, reducing wastage. Weekly costs ranged from ₹1,000 to ₹2,200.

Week	Application	Type	Qty (Kg)	Weekly Cost (₹)
Week 1	Once	Urea / Complex	40 – 45	1,000 – 1,575
Week 2	Once	Urea / DAP	35 – 40	1,050 – 1,600
Week 3	Twice	Urea / Potash	45 – 55	1,575 – 2,475
Week 4	Once	Complex mix	40 – 50	1,200 – 2,000
Week 5	Once	Urea	30 – 35	750 – 1,050
Week 6	Twice	Urea / DAP	45 – 55	1,350 – 2,200
Week 7	Once	Complex mix	35 – 45	1,050 – 1,800
Week 8	Once	Urea / Potash	40 – 50	1,200 – 2,250

Labor Usage

Labor requirements reduced to 1–2 workers. Weekly costs ranged from ₹2,500 to ₹5,000.

Week	Workers	Hours	Weekly Cost
Week 1	2	12–16	3,200
Week 2	2	12	3,200
Week 3	2	24–30	4,800
Week 4	2	12–16	3,200
Week 5	1–2	10–12	2,400 – 3,200
Week 6	2	24–30	4,800
Week 7	1–2	10–12	2,400 – 3,200
Week 8	2	12–24	3,200 – 4,800

Overall Observation:

Improved water management and reduced labor dependency, but lacked fertigation precision.

• Better water control
• Reduced labor
• More consistent irrigation

Zone 3: DCON Ag Air (Full Automation)

Irrigation (Smart Automation)

Fully automated irrigation based on real-time soil moisture data. Water and nutrients were applied only when required, ensuring optimal crop growth and minimal wastage.

Water Usage (Optimized)

Weekly usage ranged between 35,000 and 55,000 liters for 3 acres.

Week	Frequency	Water / Irrigation	Total Weekly
Week 1	2–3 Days	15,000 – 18,000	30,000 – 45,000
Week 2	2 Days	16,000 – 19,000	32,000 – 38,000
Week 3	3 Days	18,000 – 20,000	54,000 – 60,000
Week 4	2–3 Days	15,000 – 19,000	30,000 – 57,000
Week 5	2 Days	14,000 – 17,000	28,000 – 34,000
Week 6	3 Days	17,000 – 20,000	51,000 – 60,000
Week 7	2 Days	15,000 – 18,000	30,000 – 36,000
Week 8	2–3 Days	16,000 – 19,000	32,000 – 57,000

Fertilizer Usage (Automated Fertigation)

Fertilizers were applied automatically with precise dosing, reducing wastage. Weekly cost ranged from ₹800 to ₹1,800.

Labor Usage

Minimal labor required due to automation. Weekly cost ranged from ₹1,500 to ₹3,000.

• Precision farming
• Minimal human error
• Complete remote control

Final Comparison: Traditional vs Semi-Automated vs Fully Automated

1. Water Usage Comparison (3 Acres – Weekly Average)

Parameter	Traditional	Semi-Automated	DCON Ag Air
Weekly Water Usage	60,000 – 95,000 L	50,000 – 75,000 L	35,000 – 55,000 L
Water Control	Low	Moderate	High (Precise)
Water Savings	—	~15–25%	~40–50%

Insight: DCON Ag Air achieves the highest water efficiency by reducing wastage through real-time control.

2. Fertilizer Usage & Cost (8 Weeks Total)

Parameter	Traditional	Semi-Automated	DCON Ag Air
Weekly Cost	₹1,200 – ₹2,800	₹1,200 – ₹2,800	₹800 – ₹1,800
Total Cost (8 Weeks)	₹11,000 – ₹19,000	₹11,000 – ₹19,000	₹6,500 – ₹12,000
Application Method	Manual	Manual (Monitored)	Automated (Precision)
Efficiency	Low	Low	High

Insight: Automated fertigation reduces fertilizer wastage by ~30–40% and improves nutrient absorption.

3. Labor Usage & Cost (8 Weeks Total)

Parameter	Traditional	Semi-Automated	DCON Ag Air
Workers Required	2–3	1–2	1
Weekly Cost	₹7,500	₹5,500	₹3,000
Total Cost (8 Weeks)	₹60,000	₹44,000	₹24,000
Effort Required	High	Medium	Very Low

Insight: Full automation reduces labor dependency by up to 60–70%.

4. Irrigation Efficiency

Parameter	Traditional	Semi-Automated	DCON Ag Air
Scheduling	Manual	Flow & Volume Based	Sensor + Smart Control
Consistency	Low	High	High
Human Error	High	Minimal	Minimal
Monitoring Time	High	~30 mins/day	~30 mins/day (Remote)

5. Crop Performance

Parameter	Traditional	Semi-Automated	DCON Ag Air
Crop Growth	Uneven	Improved	Uniform & Healthy
Yield Quality	Inconsistent	Better	High Quality
Productivity	Moderate	Good	Maximum

Overall Benefits Summary

The transition from traditional to fully automated irrigation demonstrates a clear improvement in efficiency, control, and profitability. The DCON Ag Air system delivers superior performance across all key agricultural parameters, making it a reliable solution for sustainable and precision farming.

Key Parameter	Traditional	Semi-Automated	DCON Ag Air
Water Efficiency	Low	Moderate	High (Optimized)
Fertilizer Efficiency	Low	Moderate	High (Precision)
Labor Requirement	High	Moderate	Low
Automation Level	None	Partial	Full
Operational Control	Manual	Scheduled	Smart & Remote
Human Error Risk	High	Moderate	Minimal
Crop Consistency	Inconsistent	Improved	Uniform & Healthy
Overall Profitability	Low	Moderate	High

Return on Investment (ROI) Analysis

The DCON Ag Air Smart Irrigation System provides strong financial benefits by reducing water usage, fertilizer consumption, and labor costs while improving yield quality and productivity.

Cost Component	Traditional	Semi-Automated	Full Automation
Water Usage Cost Impact	High	Medium	Low
Fertilizer Cost	₹11,000 – ₹19,000	₹8,000 – ₹15,000	₹6,500 – ₹12,000
Labor Cost	₹32,000 – ₹42,000	₹20,000 – ₹30,000	₹12,000 – ₹20,000