Kerala brothers build one of India’s largest hydroponic lettuce farms; export to Dubai and Qatar

In the hills of Kerala's Wayanad, two brothers are pioneering one of India’s largest commercial lettuce farms, but without soil. Brothers P J Sukhdev and P J Jyothibasu grow premium lettuce varieties using deep water culture (DWC), a method in which plant roots are suspended continuously in oxygenated, nutrient-rich water.

The duo established the Wayanad Exotic Fruit Farmers Producers Company, under which they built the polyhouse hydroponic farm, driven by a futuristic vision. 

“We started this in mid-2023 after years of research and planning. We chose lettuce because it is not commonly cultivated here, and there’s a strong demand in the overseas market,” Sukhdev tells 30Stades. 

“Wayanad is home to us, but more than that, the climate is suitable. Our consultants also backed the idea," he adds. Their venture, nestled on a hillside in Puthuppally, Wayanad, is now one of the largest commercial hydroponic lettuce farms in the country and the first of its kind in Kerala.

India is the world's third-largest commercial producer of lettuce after China and the USA.  

Hydroponic farming is a soilless cultivation method in which plants grow in water enriched with essential nutrients. The roots have direct access to nutrients, eliminating the inefficiencies of traditional soil farming.

How do they do it?

“So, hydroponic farming is a method where you grow plants without soil. Instead of planting them in the ground, you grow them in water mixed with all the essential nutrients. It allows for faster growth, more control, and a lot less water consumption,” Sukhdev explains.

Also Read: This farmer conserves 350 types of native vegetable and fruit seeds; sells across India 

What sets their farm apart from other hydroponic ventures in India is the use of DWC.

“It’s like the roots are floating in a perfect stew of nutrients. This method is ideal for leafy greens like lettuce. It’s clean, efficient, and works well in polyhouse setups where light, humidity, and temperature can be controlled," he says.

"Moreover, there’s a dosing pump that helps us manage it precisely," Sukhdev adds.

Moving uphill

The brothers’ 5,000 sq ft polyhouse farm is built on a sloping hillside, without levelling the land. The setup consists of 32 HDPE tanks, arranged at different levels. These tanks are filled with eight inches of nutrient-rich solution, with gravity ensuring a gentle flow from one tank to the next. On the surface of each tank, thermocol sheets float with holes carved out for seedlings. The roots remain submerged in the nutrient mix, while oxygen is supplied through built-in aeration systems in every tank.

Also Read: Five MBAs who quit jobs and became successful vegetable farmers 

“It’s a fully controlled ecosystem. Because it’s a closed setup, pest issues are low and there’s very little water wastage,” he adds.

The brothers source the seeds from Holland and they are sown in oasis cubes. In about five days, once the first two leaves appear, they are moved to a nursery.

At 15 days, they’re transferred to the thermocol rafts on the tanks. After 45 to 50 days, depending on the weather, they are harvested, Sukhdev explains.

Production and marketing 

The farm produces three types of lettuce. Lollo Bionda is crisp, light green, and ideal for sandwiches and burgers, while Lollo Rossa has red-tinged, frilly leaves with a strong flavour. The Red Oakleaf is buttery and slightly sweet. 

Beyond lettuce, they’ve started growing small batches of other exotic vegetables, like cherry tomatoes (red and yellow wine-ripened varieties), and herbs including rosemary, basil, and Italian basil. They’re also testing strawberries and mulberries.

Each week, around 500 kg of lettuce is harvested. Within India, the produce is shipped to cities in Kerala -- Kochi, Calicut, and Trivandrum.  The rest is exported to Dubai and Qatar.

“In Dubai, we supply wholesalers who handle the local distribution. We fly out one shipment per week. The lettuce is used in salads, sandwiches, and gourmet dishes. In India, the lettuce is supplied to retail chains like Lulu and Nesto, apart from burger joints, hotels, and supermarkets," he says.

"Priced at around Rs 300 per kg, the lettuce appeals to health-conscious consumers looking for premium quality," Sukhdev shares.

Also Read: How this Kerala man built Rs 2 crore business by exporting organic vegetables to Dubai

Diversification and learning from Dubai

Jyothibasu, Sukhdev's brother, is a trained chef. He had earlier experimented with hydroponics in Dubai on a smaller scale. However, high production costs and space limitations led the brothers to bring the idea back home. 

“Dubai was our testing ground. We realised the cost was too high for scaling, so we moved to Wayanad. It gave us more flexibility and room to grow. Now, we hope to expand our sales to territories beyond Dubai," Sukhdev says.

While hydroponics is the core, the brothers are also focusing on exotic fruit farming. They’ve begun with rambutan, avocado, and mangosteen, grown on nearby plots. Through their Farmer Producer Company, they also source high-quality fruits from other farmers and distribute them under a unified label.

Challenges: Power and Freight

Despite their success, challenges remain, primarily power costs and air freight charges. “Power is a big cost. A subsidy or support from the government would help. Freight is another issue -- lettuce is lightweight but takes up more volume. So our 2.5 kg pack is often charged as 5 kg cargo,” Sukhdev explains.

Still, the returns are promising. The brothers received an agri-infra loan of Rs 1.58 crore, with total investment pegged at Rs 4.5 crore. They are currently in the break-even phase, but confident of high profitability soon.

The future

Sukhdev is especially proud of the quality response. “In recent feedback, when our product is placed alongside lettuce from places like Ooty, consumers consistently choose ours. The taste is better, and people trust us for health benefits and zero pesticides,” he adds. 

“We’re also working towards using organic manure. The rise in health consciousness is another big driver. People now care about the origin of their food. That’s a huge advantage for us,” he shares. 

With 13 staff, a controlled supply chain, a growing export presence, and diversification in progress, the Wayanad-based duo is not just farming. They are future-proofing agriculture. 

“We’re confident. The demand for good food is growing, and hydroponics is the way forward. It is simple; we can achieve what typically requires an acre of land in traditional farming using significantly less space with hydroponics. This experiment is just the beginning for us. I am sure our success will pave the way for the future,” Sukhdev signs off. 

(Chandhini R is a Kerala-based journalist specialising in human interest, entertainment, and art and culture stories)

Also Read: This couple earns Rs 8 lakh per acre from organic turmeric farming; products reach Germany, Australia and the US

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