No losses start with the tray

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PRODUCT NEWS

Emiel te Walvaart, Monday 15 June 2026

222 sec

Waalstek and Modiform jointly developed a tree tray that perfectly matches an automated cutting process

At cutting specialist Waalstek in Huissen, everything revolves around uniformity, reliability and efficiency. Large volumes require a flawless process, from starting material and substrate to the tray in which the cuttings root. Together with Modiform, Waalstek developed a 160-cell tree tray that has been operating trouble-free for ten years. 'No losses are the first gain,' says Peter Gerrits of Waalstek.

Peter Gerrits (Waalstek) and Evert van Tol (Modiform) with the 160-cell tree tray

In professional cutting production, the tray is much more than a plastic carrier. The right tray helps determine rooting performance, uniformity and compatibility with automated systems. At Waalstek in Huissen, this is part of daily practice. The company produces hedge plant cuttings for major European customers. Its assortment consists of seventeen species, including Euonymus, Ligustrum and still large quantities of Buxus.

'We work almost exclusively for large customers,' says Peter Gerrits. 'Our strength lies in large volumes and consistent quality. Everything we do must be reliable and scalable.'

Growing with common sense

Waalstek was founded in 1996 and has grown over the past thirty years into a European player with three locations. 'We have grown through common sense,' says Gerrits. 'We continuously look for improvements, but only add new products if we can produce them in large volumes.' This pragmatic approach applies not only to the plant material, but also to the tools used in the production process.

Waalstek came into contact with Modiform when the company was first established. 'Through mutual contacts we ended up with Modiform. The cooperation was pleasant and they were able to supply exactly the trays we needed.' Waalstek has worked for years with two tray types: the 2565 Tree Tray 104 and a 160-cell tray. About ten years ago, the latter underwent a major redevelopment.

New 160-cell tray

Existing 160-cell trays from other suppliers did not meet expectations. 'They were too flimsy or broke too quickly,' says Gerrits. 'And as soon as a tray is damaged, it no longer runs properly through our customers' planting robots.' That is why Modiform developed the 2583 Tree Tray 160. 'We produced trial trays and tested them in our destacking robot. After a few minor adjustments, we had a tray that does exactly what we want.'

According to Gerrits, the tray stands out because of its sturdiness and wide folded rim. 'When the tray is fully filled with cuttings, substrate and water, it remains perfectly balanced. Other trays collapse when you lift them. Then the cuttings touch each other and get pulled loose when you set the tray down again.' This immediately results in damage and losses. 'We operate with virtually no losses. No losses are the first gain.' According to the grower from Huissen, this directly translates into a lower cost price. 'You have fewer losses to absorb and can keep prices competitive for the customer.'

'When the 160-cell tray is fully filled with cuttings, substrate and water, it remains perfectly balanced'

Retaining heat

A notable feature of the tray is the absence of additional ventilation holes in the upper rim. 'That was a deliberate choice. The black tray absorbs heat whenever the sun shines, even in winter. We want to retain that heat.' According to Gerrits, this creates a more stable climate around the cuttings and supports rooting, making year-round production possible.

Standardly two cuttings per cell in the 160-cell tray

The cell depth was also carefully optimised. 'We want enough growing medium in each cell so the cutting can root properly and is less likely to dry out.' This also benefits the customer. 'The grower needs to irrigate less often and receives a cutting that establishes more vigorously.'

A good cutting depends on the choices made at the start of the process. Gerrits: 'The tray and the potting mix are the foundation. Together with Jiffy, we optimised the substrate. And the quality of the unrooted cutting must also be top-notch.'

A solid foundation saves labour and reduces the need for crop protection products. 'If you keep the starting material healthy, you have already won 90 percent of the crop protection battle.' Waalstek limits itself to foliar feeding. 'We deliberately supply a slightly leaner cutting. As a result, the plant starts searching for roots more quickly after potting. Within seven days you can already see clear root growth.'

Two cuttings per cell

Waalstek deliberately follows its own approach. In the 160-cell tray, two cuttings are standardly inserted per cell, regardless of the variety. In the 104-cell tray, three cuttings are placed per cell. 'This allows us to produce a heavier cutting for larger pot sizes. We do things slightly differently to distinguish ourselves.'

Another important detail is the tray base with small feet. 'This keeps the drainage hole clear of the ground. You do not want roots growing out of the tray and attaching themselves to the mat or cultivation floor.' The airflow beneath the tray naturally stops root growth at the bottom of the cell. 'This keeps the root system compact and easy to handle.'

125,000 trays per year

Waalstek processes approximately 125,000 Modiform trays annually. Almost all trays are returned to the factory after use for recycling. 'That fits well with our vision,' says Gerrits. 'If materials can be reused, the entire chain benefits.'

Customisation in propagation

Since April, Evert van Tol has been the new propagation account manager at Modiform. Van Tol has worked at Modiform since mid-2024 as an account manager for the pots and transport trays business unit. Originally trained as a landscaper, he has built up many years of experience in the green sector. 'The great thing about propagation is that it is truly customised,' says Van Tol. 'You work together with the customer to determine the requirements and then develop the optimal tray based on those needs.'

According to him, the collaboration with Waalstek demonstrates Modiform's approach. 'By testing intensively and continuously fine-tuning, you arrive at a product that functions flawlessly for many years.'

Tray in focus: 2565 Tree Tray 104

In addition to the 2583 Tree Tray 160, Waalstek also uses the 2565 Tree Tray 104. This tray is suitable for loose substrate, paper plugs and anti-weed topping. Thanks to its tray base with integrated feet, it offers good root guidance and can be used on a variety of cultivation floors. Van Tol sees increasing demand for paper plugs. 'More and more specialised companies are filling our trays with paper plugs. Waalstek deliberately chooses to fill the trays with substrate itself.'

2583 TREE TRAY 160

Small component, major impact

The tray may seem like a minor detail in the overall cultivation process, but at Waalstek it proves its value every day. By jointly developing a customised tray with Modiform, the company succeeded in eliminating losses and further optimising the process. Gerrits summarises it simply: 'If the foundation is right, the rest almost follows automatically.'

This article was previously published on 15 June 2026 on the Boom in Business website.

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