Automation makes leek cultivation future-proof

Find out how Indurra and Siemens are giving hydro leek cultivation and the future of leek growing a major boost with benefits for growers, consumers and the climate.

The very first hydro leeks were in Belgian supermarkets by October 2025: leeks grown in a water basin, rather than in the ground. REO and Inagro developed the concept, with Indurra and Hydromasters providing smart automation using Siemens technology. The result? An exceptionally efficient, scalable and sustainable leek crop.

Leek cultivation under pressure

Leeks have been the stronghold of (West) Flemish vegetable cultivation for decades, accounting for 3,650 hectares and a solid economic value. However, stricter environmental regulations, more extreme weather conditions and an ever increasing shortage of skilled workers are putting pressure on cultivation. Over recent years, a quarter of professional leek growers have disappeared from the field.

In order to secure the future of leek cultivation, fruit and vegetable cooperative REO and Inagro, the West Flanders research centre for agriculture and horticulture, set out to find an alternative. In 2015, they started performing trials on hydroponics, where leeks grow on floating supports in a basin with circulating nutrient water. After several years of exploratory research and testing in a pilot plant at Inagro, REO and Inagro decided that growing hydro leeks could be both profitable and sustainable.

Scalable and viable thanks to automation

In order to also make the setup scalable and future-proof, they decided to automate the cultivation process and harvesting. “Harvesting leeks is very labour-intensive and physically demanding work,” says Patrick Heughebaert, managing director at machine manufacturer Indurra based in Ypres. “It is becoming increasingly difficult to find (seasonal) workers and labour costs are high. The answer is robotisation. And we have plenty of experience in this area at Indurra.

”Indurra has been building smart automation solutions for over 25 years, integrating robots from Stäubli and others to make production processes smoother, more efficient and reliable. from a pizza robot, a flexpicker for tacos and a robotic cell for cheese manipulation to a customised installation to harvest chicory: Indurra’s has impressive credentials in the food sector.

“When I took the helm in 1997, Indurra was still part of Pidy, a world leader in dough products,” Patrick explains. “In 2008, we set out on our own, but still with Pidy as a major customer. Due to these roots in the food sector and our location in the Westhoek, agriculture, horticulture and food still account for 80% of our turnover.”

Optimal growing conditions, smooth harvest

Thanks in part to this experience, Indurra won REO and Inagro’s competition to develop a harvesting robot for hydro leeks. Besides, the carriers for the leek crops also come from Indurra’s quiver. In order to fully automate the process, the engineers from Ypres also built a loading and unloading station.

Johan Sinaeve, who came on board with Indurra to develop the carriers, explains: “The leek plants grow in small tubes attached to carriers. We developed a customised automated hydroponic system that allows the carriers to slide into the basin and out again.”

“As hydroponics is done in the open, we had to take into account highly variable water levels between summer and winter. The hydrocomputer with integrated sensors controls water and nutrient dosing. By meticulously controlling water and nutrients, we can continuously respond to changing conditions and, by doing so, optimise growth.”

Smart control with Siemens

Behind the scenes, the entire installation runs using Siemens technology. Indurra designed, programmed, tested and managed the control of the carriers, the harvesting robot as well as the loading and unloading station in TIA Portal. “Since all components speak the same language, data, movements and sensors flow seamlessly together,” Johan says.

“By now we are so familiar with all the Siemens technology that we don’t realise how advanced everything is,” Patrick adds. “Using SIMIT and PLC Sim Advanced, for example, we were able to virtually test the whole system even before a single component was built. This drastically reduced the development time and significantly reduced stress levels during actual delivery.”

About Indurra

Indurra (formerly Dewilde Engineering) is a company based in Ypres with decades of experience in robotics, industrial repairs and automation. The company has 45 employees, including 15 engineers. Hydromasters is a spin-off from Indurra.

We are so familiar with Siemens technology that we often forget how advanced it is. And how reliable! We just assume that everything will still be running in 20 years.

Patrick Heughebaert, Managing Director, Indurra

Ease of use, insight and optimisation

For the operator, everything is brought together in one clear platform. The user can monitor, control and adjust the entire installation live via the WinCC Unified interface on an industrial Siemens IPC.

MDC – Machine Data Collection – provides valuable insights in this regard. All operational data is automatically collected, analysed and logged: from energy consumption and motor performance to cycle times, water levels and sensor values. This allows growers to permanently adjust and continue to optimise the system. The modern, intuitive interface provides beautiful graphs, automatic alarms and comprehensive diagnostics functions.

“Deviations or error messages are immediately visible,” says Johan. “Everyone can follow live what is happening in the system. If something goes wrong, an immediate notification and analysis is provided. Things that used to take hours of searching are now solved in seconds."

If something goes wrong, an immediate notification and analysis is provided. Things that used to take hours of searching are now solved in seconds.

Johan Sinaeve, Managing Director, Hydromasters

Siemens and Indurra: a long-standing partnership

The cooperation between Indurra and Siemens goes back many years. Indurra is an official OEM partner and works closely with the Siemens Industry Academy (SIA).“Our engineers regularly attend training courses at SIA to stay up-to-date with the latest technology,” says Patrick. “We also like to give interns or masters students the same opportunity. This exchange of knowledge with Siemens is incredibly important for us. This is how we keep our finger on the pulse, which keeps our capacity to innovate sharp.”“When it comes to innovation, I believe in only one concept: cooperation,” Patrick adds. “We work very closely with Siemens. We are rather proud of our title of OEM partner. You don’t win that trust overnight.”

From SIA, we deliberately take on a social role, as a bridge between academia and industry. This is how we support our partners in the war for talent.

Thomas Vermeir, Account Manager, Siemens

Hydro leeks set sustainable standard

During the summer of 2025, the first Flemish hydro leek grew in a test basin with a grower based in Ypres. The benefits for both growers and the environment are spectacular.

“As the leeks grow in optimal conditions, there are fewer diseases and pests,” Patrick says. “Growers therefore also need fewer pesticides. The quality is also more consistent. The white stalks are even longer. And because the leeks are free of sand particles, they are particularly interesting for export.”

Johan highlights efficiency gains: “The leeks grow faster, allowing for several growing rounds per year. And the yield is higher because the plants are closer together. Over one hectare of hydroponics, the system produces as many leeks as over seven hectares of open field.”

Hydro leeks also make cultivation more sustainable. The circular system has a neutral water balance: no irrigation, no water loss and no leaching of fertilisers. Meanwhile, tests are even being conducted using drones to apply pesticides even more precisely.

With Hydromasters, Johan is now aiming to further industrialise and market the technology. Indurra and Hydromasters, with the support of Siemens, are therefore setting new sustainable standards in high-tech agriculture.