Little Leaf Farms Raises $90M to Grow Its Greenhouse Network

by Jennifer Marston

Image from: Little Leaf Farms

Massachusetts-based Little Leaf Farms has raised $90 million in a debt and equity financing round to expand its network of hydroponic greenhouses on the East Coast. The round was led by Equilibrium Capital as well as founding investors Bill Helman and Pilot House Associates. Bank of America also participated.

Little Leaf Farms says the capital is “earmarked” to build new greenhouse sites along the East Coast, where its lettuce is currently available in about 2,500 stores. 

The company already operates one 10-acre greenhouse in Devins, Massachusetts. Its facility grows leafy greens using hydroponics and a mixture of sunlight supplemented by LED-powered grow lights. Rainwater captured from the facility’s roof provides most of the water used on the farm. 

According to a press release, Little Leaf Farms has doubled its retail sales to $38 million since 2019. And last year, the company bought180 acres of land in Pennsylvania on which to build an additional facility. Still another greenhouse, slated for North Carolina, will serve the Southeast region of the U.S. 

Little Leaf Farms joins the likes of Revol Greens, Gotham Greens, AppHarvest, and others in bringing local(ish) greens to a greater percentage of the population. These facilities generally pack and ship their greens on the day of or day after harvesting, and only supply retailers within a certain radius. Little Leaf Farms, for example, currently servers only parts of Massachusetts, Pennsylvania, New York, and New Jersey. 

The list of regions the company serves will no doubt lengthen as the company builds up its greenhouse network in the coming months.

Fifth Season Takes Vertical Farming to a Whole New Level

Image from: Pittsburgh Post-Gazzette

Fifth Season’s verdant baby spinach screams farm fresh even though it’s grown nowhere near traditional farmland. The sweet and slightly crunchy greens are grown in a Braddock warehouse on racks stacked 30 feet high. Located just a stone’s throw from U.S. Steel’s Mon Valley Works Edgar Thomson Plant, it is urban farming at its core.

What makes the vertical farming operation especially unique is that it is automated and robots call the shots. About 40 to 60 machines are involved in every step of the life of the spinach and other leafy greens, from planting the seed to providing nutrients to the final packing.

Fifth Season does employ local “farm workers” to assist the robots in seeding, harvesting, packaging, quality assurance and control using computer software, but there is no human touch involved through it all.

“The first time someone ever touches the spinach leaf with a finger is when the package is opened,” says Grant Vandenbussche, chief category officer.

Co-founded by brothers Austin and Brac Webb and Austin Lawrence, Fifth Season started a year ago. Within months it was rolling out its baby spinach, leafy greens and salad kits.

“We wanted a name that represents what we are doing,” says Austin Webb, 32, who also is the CEO. “It is a call to the fact we have created an entirely new season. It is 24/7, 365 with the technology we have built.”

None of them planned to become modern farmers, says the Carnegie Mellon University grad, but they turned to vertical farming because it was an efficient, economically sustainable way to solve land and water woes.

Image from: thespoon.tech

‘Fields’ of Greens

Fifth Season grows an equivalent production of 200 acres in 25,000 square feet of grow space. Its “fields” are stacked on top of one another in vertical shelves. When you add up all that surface area of grow space, it is more like 126,000 square feet.

“We also quickly turn crops at the farm,” Mr. Vandenbussche says.

While spinach takes about 40 days to grow outdoors and can be harvested only twice during its peak season, it takes the crop only three or four weeks to grow in the controlled environment and is harvested 19 times. Once the plants are harvested, a new cycle of reseeding begins with fresh media, seeds and nutrients.

“That’s why we get so much more productivity,” he says. “We are immediately reseeding our ‘land.’”

This controlled environment yields quality produce because it is always peak season at Fifth Season, says Chris Cerveny, who heads the Grow R&D division. Greens are grown in the same conditions year-round, getting the exact amount of nutrients and water they need. Because pests and airborne toxins also are kept at bay, crops can be produced without pesticides.

All that TLC comes through in the slightly curled baby spinach, which is sweet and not grassy. The leaf doesn’t wilt or get slimy or lose its slight crunch even after two weeks of refrigeration.

A lot of thought was given even for the curl, which gives the spinach a stronger volume, making it look full and bountiful. The curl also makes the spinach more forkable unlike its flat-leaf counterpart that is hard to stab on a plate.

Other leafy greens such as kale, mustard, Chinese cabbage, green tatsoi and purple pac choi are featured in two blends — Bridge City and Three Rivers. Fifth Season plans to roll out its Romaine lettuce in spring.

The greens also are found in four types of salad kits — Sweet Grains (blended greens, quinoa, chickpeas, corn, feta and poppy seed dressing), Crunchy Sesame (blended greens, farro, sesame sticks, dried cranberries and ginger-mandarin dressing), Toasted Tuscan (spinach, lentils, sun-dried tomatoes, bagel chips and vinaigrette), and Spiced Southwest (blended greens, black beans, pepitas, cotija cheese, corn-salsa sticks and chipotle ranch dressing) — which are available online and in Giant Eagle stores. A fifth salad kit is in the works and is being called “a shakeup of one of the most classic salads.”

While machines are a big part of what Fifth Season does, it seeks to keep human connection alive. It recently launched a recipe blog for those who have an appetite for cooking and writing, The Green Room is devoted to cataloging personal memories, dream meals and recipes via short stories.

Fifth Season also has partnered with the Penguins and is providing greens for the team’s pregame meals for the 2020-21 season.

“We want people in Pittsburgh to be able to eat the exact same delicious blend of greens that Sidney Crosby and company are eating,” Mr. Webb says. “We want people to know that there’s a new way to grow food and to eat and experience it.”

Image from: Next Pittsburgh

It’s All Under Control

Everything from seeding to packaging is done in four rooms. The process starts in the seeding and processing room, where seeds and growing media are placed inside black planter-like boxes called inserts. Each has a unique code that’s traced by a software system. The inserts go on white trays that pass through a photo station, feeding information to the computer system, and then glide into the bio dome.

There are two rooms in the bio dome, each with a grow space of 12,500 square feet. They’re lit up with a pinkish-purplish glow from high-efficiency LED light bulbs that mimic the different seasons of the year.

“They are positioned over the plants at different heights depending on stage of growth,” Mr. Cerveny says. “This is partly how we can provide consistently ideal growing conditions.”

As the plants grow, they are moved by a robot to optimize their growth cycle. Full-grown crops are transferred to the harvesting room by another robot.

“Harvesting is where it becomes like a Willy Wonka factory,” Mr. Vandenbussche says.

Long rows of trays filled with tiny plants are sent on a conveyor system to a station where workers inspect them for quality with surgical tools. After inspection, the plants are harvested by a robot and then immediately ride up a tall conveyor to be packaged and sealed in a 34- to 36-degree room so they remain fresh.

“Every crop we grow gets evaluated for maximum flavor, volume, crunch and color,” he says.

The plants’ intense, dark color is controlled by LED light bulbs, which are dialed up or down to get the correct hue. Although they never see the sun, the greens don’t get into a funk as humans might.

“What humans see in terms of light and how chlorophyll responds during photosynthesis are two different things,” Mr. Cerveny says. “Plants really only need red and blue light to grow effectively. We include some additional colors to help bring out other quality aspects of our crops, but providing the full sunlight spectrum is effectively a waste of energy, especially indoors.

“To the human eye, it looks like the plants live in a land of purple and pink lights, but they are perfectly happy there.”

Even though the environment is controlled and the software system is constantly updated, no two plants are exactly the same. Some fight for light more than others. Some might fail the quality control test and end up in a compost waste facility if their flavor is off or their color is not right.

“That is what is so amazing. We have more control than any other farmer, and yet we have limitations. Every seed is different,” Mr. Vandenbussche says. “They are plants. They are real living organisms.”

Ensuring Singapore's Food Security Despite the Odds

Image from: Reuters

As with most issues that impact national security in Singapore, it often seems that the odds are stacked against us.  Food security — access to safe and nutritious food — is a challenge on several fronts. 

Singapore is a small city-state with limited resources, with only 1 per cent of land available for food production, and over 90 per cent of food is imported from an increasingly disrupted world. The Covid-19 pandemic has further amplified the gravity of safeguarding food security.  The city-state has been proactively planning for long-term food security through the Singapore Food Agency’s (SFA) strategy of “three food baskets” — diversifying food sources, growing locally and growing overseas.  This approach has served the Republic well in securing a supply of safe food.

DIVERSIFIED SOURCING IS KEY

Singapore’s food importers leverage the nation’s connectivity and the global free trade environment to import from multiple sources in about 170 countries and regions worldwide.  Should there be a disruption to any one source, importers are able to tap alternative food sources and ensure supply remains stable. Lockdown measures brought about by Covid-19 underscored Singapore’s vulnerabilities to supply disruptions in food. 

It was not by luck that the Republic’s food supply remained stable and market shelves continued to be promptly restocked — it was the result of a deliberate whole-of-government strategy to diversify food sources. To keep the nation’’s diversified food supply lines intact amid the Covid-19 global pandemic, SFA worked closely with the Ministry of Trade and Industry and Enterprise Singapore (ESG) to monitor Singapore’s food supply situation. Together with the Ministry of Foreign Affairs, these economic agencies worked with like-minded countries to maintain open trade links.

LOCAL PRODUCTION AN IMPORTANT BUFFER

SFA drives innovation in local farms with the ambitious goal of producing 30 per cent of Singapore’s nutritional needs by 2030 as part of our “30 by 30” plan.  To meet this goal, we need a holistic and long-term approach to space-planning, boosting agri-food technology and developing local agri-specialists. To facilitate and support the establishment of high-technology and productive farms in Singapore, SFA tenders out land based on qualitative criteria such as production capability, production track record, relevant experience and qualifications, innovation and sustainability.

In addition, a masterplan for the greater Lim Chu Kang (LCK) region, spanning about 390ha of land, will be undertaken in consultation with stakeholders over the next two to three years.  The redeveloped LCK agri-food cluster will produce more than three times its current food production.

Building on the above efforts to grow Singapore’s high-tech agri-tech sector, SFA will continue to partner with the Economic Development Board and ESG to attract best-in-class global agri-tech companies, as well as to nurture promising homegrown agri-tech companies into local champions and help them to expand overseas.

EXPLORING ALTERNATIVE, UNDERUTILISED SPACES

Urban food solutions are expected to play a key role in global food security.  While there are progressive enterprises operating out of farmlands and industrial estates, some agricultural game-changers are also taking root in unconventional areas — indoors, on rooftops and in underutilised spaces.

SFA worked with the Singapore Land Authority to introduce an urban farm at the former Henderson Secondary School site, which was transformed into Singapore’s first integrated space comprising an urban farm, childcare centre and nursing home within a state property.  The farm space within the site was awarded in May 2019 to social enterprise City Sprouts, and it has become a vibrant destination for the young and old to learn about urban farming and enjoy a relaxing day out.

Citiponics, the first commercial farm located on a multi-storey car park in a residential neighbourhood, harvested its first yield of vegetables in April 2019.  In September 2020, another nine sites atop multi-storey car parks were awarded for urban farming. 

The successful bidders included proposals for hydroponic and vertical farming systems with a variety of innovative features, such as the Internet of Things (IoT), blockchain technology and automated climate control.  These sites have the potential to collectively produce around 1,600 tonnes of vegetables annually.

Image from: Ciitiponics

TAPPING TECH

The Agriculture Productivity Fund (APF) supports local farms in their capability development and drive towards higher productivity.  Through APF, SFA co-funds the adoption of farming systems to better control environmental variables, test-bed technologies and boost production capabilities. Between October 2014 and September 2020, a total of almost S$42 million has been committed to 115 farms.

The Covid-19 pandemic presented greater impetus to speed up local food production capacities. In September 2020, SFA awarded S$39.4 million to nine companies under the 30x30 Express Grant to quickly ramp up food-farm outputs over the next six months to two years. With advanced robotic and digital systems increasingly being used in farming, Singapore’s vegetables farmers have also become innovative agri-engineers and specialists in their own right.

With support from the 30x30 Express Grant, urban farming engineering solutions firm Indoor Farm Factory Innovation will set up an indoor vegetable farm with a vertical integration growth system up to 8m in height in a fully controlled and pesticide-free environment.  The farm will leverage artificial intelligence farming systems integrated with IoT monitoring, dosing irrigation and an advanced environmental control system to achieve optimum growing conditions all year round.

Seng Choon, a chicken egg farm that has been in business for more than 30 years, has also proved itself a modernist in its operations.  The company uses a computer that scans eggs to ascertain if they are clean; while feeding systems, temperature controls and waste cleaning systems have been automated with SFA’s support. Singapore’s efforts at ensuring food security would not be complete without support from consumers.  To boost recognition of local produce among consumers, SFA brought the industry and public together to create a new “SG Fresh Produce” logo. 

Farmers have been using this emblem on their packaging since August 2020. A website was also launched to provide a trove of information on locally farmed food. While the Covid-19 pandemic has led to import restrictions, it also helped to accelerate support for local produce. With public support for local farmers and other key measures, Singapore can beat the odds in ensuring food security in this ever-evolving, ever-disrupted world.

Federal Grant Bolsters Higher Education In AgTech

Growers have indicated the need for highly skilled workforce is becoming more urgent as technology restructures the future of farming.

Today’s blog notes a bright spot amongst many past reports of reduced government-backed financial support in research & development (R&D) and education programs that aim to improve living conditions, reduce environmental impact, and manage the growing population’s resources via technology.

Cornell University has reported that the US Department of Agriculture (USDA), through its National Institute of Food and Agriculture (NIFA), has endowed the university’s College of Agriculture and Life Sciences’ School of Integrative Plant Science with a $496,000 grant. The federal funding will be used to develop new controlled environment agriculture (CEA) training programs for a skilled workforce that is sorely needed.

Cornell’s associate professor of horticulture Neil Mattson, well-known to us as the keynote speaker at our 2019 HortiCann Light + Tech conference, will collaborate with Cornell Small Farms program director Anu Rangarajan, Ohio State University’s Agricultural Technical Institute, and SUNY Broome Community College to create a technical training certificate in CEA production. The partners also expect to develop a two-year associate’s degree program for students at these institutions and other community colleges to provide solid education in CEA.

Mattson said in the Cornell Chronicle, “Growers consistently state that finding well-trained personnel to operate their facilities is among the largest barriers to expansion.”

Why do we need this educational support? The global population is growing, and supply needs to ramp up to deliver healthy foods to all economic strata. Many food crops are currently unavailable close to home for many, which places a burden on transportation and increases carbon footprint, as well as impacting shelf life. CEA can bring many food-growing resources closer to consumers, especially in urban areas or regions that would prove inhospitable to sensitive crops in a traditional farming operation.

CEA gives growers the means to apply physical systems of growth media, environmental controls, horticultural lighting, and water supply systems along with evidence-backed research in pest management, food safety processes, light customization, and more to produce food sources in a manner designed to balance economic viability, food demand, and sustainability.

Technologies available to modern CEA growers would naturally require a more advanced skillset. Indeed, said Rangarajan, “Our efforts have laid the groundwork for what I hope will be a dynamic training program that will build the workforce and elevate the industry as a whole.”

It’s an exciting time in the horticultural and agricultural space, and learning opportunities abound. Bookmark our HortiCann Light + Tech conference homepage for updates on our upcoming October program, now virtual for 2020. Moving beyond horticultural lighting fundamentals, the program will also delve into agribusiness and the return on investment in advanced systems and controls, AgTech systems integration, and topics related to legalized cannabis growing operations.

Photo credit: Image by iamereri via Pixabay; used under free license for commercial or non-commercial purposes.

Author: Carrie Meadows | LEDsMagazine | Jul 10, 2020