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Vertical Farms Hold Promise For Local, Sustainable Produce
Vertical farming uses controlled environmental agriculture techniques, like hydroponics or aquaponics, to grow crops in vertically stacked rows with 90% less water than traditional soil-based farming
Technique Uses Small Footprint,
Less Water To Provide Year-Round Crops
Beth Edwards
June 30, 2021
A former grocery store or an empty strip mall might not be the first images that come to mind when thinking of places to grow food. But around Indiana, many of these spaces are being turned into vertical farms to help alleviate farmland shortages and greenhouse gas emissions linked to traditional farming practices.
Vertical farming uses controlled environmental agriculture techniques, like hydroponics or aquaponics, to grow crops in vertically stacked rows with 90% less water than traditional soil-based farming. It also uses 75-90% less land than traditional farms and is able to be conducted in industrial areas. It allows the grower to have total control over the grow cycle of the crop.
Courtesy of Green Sense Farms
The technique allows for year-round income for farmers and fresh, healthy, local produce for consumers regardless of climate.
With the world’s population expected to grow to 9.7 billion people by 2050, agricultural production will need to increase by 70%. Vertical farming offers an alternative to scarce farmland and to traditional farming techniques, which cause 22% of the world's greenhouse gas emissions.
A controlled environment
Krishna Nemali, assistant professor of controlled agriculture at Purdue University, said controlled environmental agriculture is driven by both plant science and engineering, with the purpose of growing crops in managed environments year-round.
In Indiana, farmers can do little outdoors between fall and spring because of low light levels and temperatures, he said.
“But with controlled environmental agriculture, you can produce year-round because you artificially manage the ideal environmental conditions for plants,” he said.
The farmer controls the lighting, temperature, nutrients, water and sometimes even carbon dioxide, but needs to understand plant science to know what is best for the plant being grown, as well as the engineering behind how best to deliver those resources without waste.
Professor Krishna Nemali at a workshop held by Purdue Extension to show participants how researchers use hydroponics to grow crops. Photo by Tom Campbell
“Our research shows that we use about one-third of the water used to grow the same crop in the same acreage outdoors. That’s because we recycle the water; we don’t just add water on top of the plants. In controlled environmental agriculture, the water is recirculated and is delivered to plants in a closed-loop system, where there is no runoff or leaching,” said Nemali.
While such systems do require a large amount of energy use, Nemali said research has enabled farmers to optimize energy use and lower consumption.
But there are limits to what can be grown using these methods.
“Because your investment is high, your return should also be high in order to make profits. There is a technology piece and usually, there is high-intensity cultivation that happens; therefore, growers want to grow high-value crops like vegetables and those that have direct impact to consumers,” said Nemali.
The time for harvesting the vegetables is more condensed as well. For instance, it will take about a month to grow leafy greens, around six to eight weeks for tomatoes and eight weeks for strawberries, instead of an entire season like in traditional farming.
The industry is growing rapidly and creating new jobs in many urban areas because it doesn’t require soil to produce fresh produce.
“A grower can purchase an old warehouse, let’s say 10,000 square feet or a quarter of an acre. But then they can grow 10 or 11 levels vertically, and in doing so, that’s a quarter of an acre times 10. So they are actually producing crops that would normally require two-and-a-half acres of land on this quarter of an acre simply by going vertically,” said Nemali.
Nemali said there is a huge amount of interest in vertical farming in Indiana. Indiana currently imports around 95% of its vegetables from outside the state. That means there is potential for large profits in vertical growing.
For example, USDA estimates that each person in the US consumes around 11-13 pounds of lettuce each year, which would roughly equal a salad each week. Nemali estimates Hoosiers consume about $60 million in lettuce each year, but Indiana farmers grow only a fraction of that amount.
Courtesy of Green Sense Farms
“We probably won’t produce $1 million worth of lettuce this year. So there’s a huge demand for local production,” Nemali said. “I’m just giving you one crop; imagine all those vegetables we are importing from outside. If it’s grown locally, that money stays with our growers and our farmers, and that will improve their livelihoods. That is why there is a huge interest in this industry.”
A pioneer in northwest Indiana
One company that has been a leader in the vertical farming industry for a while is Green Sense Farms in Portage.
Before he founded Green Sense, Robert Colangelo spent many years working on a wide variety of environmental issues, from research at Argonne National Laboratories to cleaning and repurposing brownfields. He said he was looking for something new when a friend approached him with an idea to start a vertical farm.
“I became very passionate about it, and I thought this would be a next great step in my environmental career, getting involved in agriculture,” he said.
He said he wished he had gotten involved in agriculture earlier in his career.
“We are not here to put field farms or greenhouses out of business,” he said. “I think as the population grows, we really have to look at what crops grow best outdoors and what crops grow best indoors and just rethink agriculture based on water and soil conservation. When we approach it that way, everyone feels comfortable with vertical farming.”
Robert Colangelo, head farmer of Green Sense Farms. Courtesy of Green Sense Farms
Green Sense began as an owner-operated farm. Colangelo grew leafy greens and herbs, which he mainly sold in the Chicago and Northwest Indiana markets. However, he now helps other companies or growers develop and build their farms.
Colangelo said while the business side of Green Sense was harder to learn than the growing itself. Knowing where to locate the farm and find the right talent, having the right operating procedures in place, and finding the right customer base took longer to learn, but now Green Sense helps others with exactly those issues.
It also designs farms specifically for the crop that the company or individual wants to grow, customizing growing techniques and economic data.
Vertical farming extends to other industries
Green Sense is currently working on several projects, including a casino in Las Vegas that would showcase a vertical farm in its restaurant so the diners could see the food they are eating. It has partnered with a company in Spain to offer combination greenhouses and vertical farms, and it also is considering a project that would turn old grain silos into a combination vertical farm, restaurant, and market.
“We’ve learned a lot about what doesn’t work, and we keep striving each day to figure out what works better,” said Colangelo.
Vertical farming isn’t limited to growing food. Green Sense has worked on projects for many different industries, including pharmaceutical companies, tree growing and many others that may seem surprising.
Colangelo believes the future of vertical farming will be highly automated.
“They will still require smart people to run them, but (with) a lot of the menial, repetitive tasks being done by machines. I think the future for farming is bright, and this is a great opportunity for young, smart people to get involved with,” he said.
Piper Halpin agrees. She worked with Colangelo for four years at Green Sense, starting out harvesting and seeding crops before becoming an operations manager. She now is involved in vertical farming in Boston.
“It’s exciting to be a part of and addicting because it is so technology forward, innovative and new,” she said. “Also, you don’t have to live in a rural area in order to be successful.”
Courtesy of Green Sense Farms
Colangelo and Halpin agree the technology aspect is attractive to younger people and helps to engage their interest in the field.
“It’s a great way to get young people reinvolved in agriculture,” Halpin said. “It’s been a cool bridge between old agriculture and new agriculture. I think it’s going to jumpstart a whole new interest level in ag that was kind of dying off before.”
Nemali said younger people are also interested because vertical farming is environmentally sustainable.
“They also see the importance of this industry in terms of feeding millions with fresh food, making sure it’s safe and done in a responsible way,” he said.
Nemali would like to see an increase in the variety of crops that can be grown in controlled environmental agriculture, technological improvements that lower energy consumption, and more university programs to train workers and researchers for these farms.
“This area is growing, and I want people to see, admire and provide support for it,” Nemali said.
Support from scientists, policymakers, marketers, and the government will enable a new workforce to develop the industry in the next 10 to 15 years
How Can Crop Production Data Advance The Controlled Environment Agriculture Industry?
The Controlled Environment Agriculture Open Data project aims to advance controlled environment research, machine learning, and artificial intelligence through the collection and dissemination of crop production data
The Controlled Environment Agriculture Open Data project aims to advance controlled environment research, machine learning, and artificial intelligence through the collection and dissemination of crop production data.
by By David Kuack
There is a considerable amount of data being generated by both private companies and university researchers when it comes to controlled environment crop production. This data is being generated for ornamentals, food crops, and cannabis. One of the questions about all this data is whether it is being used to its maximum potential to benefit the horticulture industry.
“Data has become a big topic in the horticulture industry with university researchers and private companies,” said Erico Mattos, executive director of the Greenhouse Lighting and Systems Engineering (GLASE) consortium. “People can identify with the challenges and opportunities with the amount of data that is being generated. However, we don’t yet have a centralized repository and a standard methodology for storage to allow us to explore and exploit this data.”
The formation of the Controlled Environment Agriculture Open Data (CEAOD) project aims to promote crop production data sharing from universities and private companies to accelerate CEA research.
Addressing the data proliferation
In 2018 during the North Central Extension & Research Activity–101 (NCERA-101) meeting members of this USDA-organized committee discussed what should be done with the extensive amount of data being generated by controlled environment researchers. Ohio State University professor Chieri Kubota proposed the formation of a sub-committee to address the need to develop guidelines for sharing data generated by controlled environment agriculture researchers.
“Dr. Kubota initiated the discussion about the need for a centralized platform to store data collected from controlled environment research,” Mattos said. “A task force was formed that included Chieri, Kale Harbick at USDA-ARS, Purdue University professor Yang Yang, Melanie Yelton at Plenty and myself. Since the task force was formed Ken Tran at Koidra and Timothy Shelford at Cornell University have also become members of the task force.
“We started discussing how we could make use of all this data. Researchers in the United States collect a huge amount of data. All of the environmental data such as temperature, relative humidity and carbon dioxide and light levels in controlled environment research is collected. There is also a biological set of data which includes plant biomass and fruit yield.”
Mattos said there is also a great deal of research data generated and collected by private companies that is not shared with the horticulture industry.
“With the advancement in sensors and environmental controls, the capability now exists that this data can be collected,” he said. “With the advancements in computing power, this data can be used to start new applications and new tools that haven’t been available before. However, in order to do this, we have to have access to a large amount of data. That’s why the task force thought it would be good to create a repository where researchers and private companies could share the data following a specific format. This data could then be used in the advancement of machine learning and artificial intelligence applications to optimize crop yields in commercial CEA operations.”
An increasing number of funding agencies and organizations, including USDA, are requiring researchers include information about their data management plans in their grant proposals.
Need for collecting and organizing data
Mattos said university researchers see the value in creating a centralized database.
“There are probably millions of data points when you consider how many researchers are doing research in the U.S.,” he said. “Historically these researchers have not been required to share their data. However, an increasing number of funding agencies and organizations, including USDA, are requiring that researchers share their data. If researchers apply for a grant from USDA, they are required to include information about their data management plans in their grant proposals.
“Researchers see the value of sharing this data, but this is not a common practice which involves allocating time and resources. This means someone on their research team would have to organize and share the data. There are probably millions of data points (big data) when you consider how many horticulture researchers there are in the U.S.”
Creating a central database
Based on the need for collecting and organizing the controlled environment research data that is being generated, the task force established the Controlled Environment Agriculture Open Data (CEAOD) project [https://ceaod.github.io/]. The project aims to promote data sharing to accelerate CEA research.
The CEAOD website provides guidelines on how to upload the data. The task force developed the guidelines, which include three sets of data that can be uploaded to the website.
“One set is environmental data, including environmental controlled parameters such as temperature, carbon dioxide, relative humidity, and ventilation,” he said. “These data points are usually collected automatically by sensors. Another set of data is biological data, which is usually collected by humans. These biomass production yield parameters include shoot and root biomass and plant height and weight. The final document is the metadata which are descriptions of the experimental setups and data sets. It is a file that explains the experiments. It describes how the experiments were done.
“There is a certain format that is recommended to be followed to upload the data on the CEAOD website. The step-by-step process is listed on the website. There are no restrictions on which crops the data can be submitted. Our goal is to establish a platform to host a large number of crop production data sets to allow for the development of machine learning and artificial intelligence algorithms aimed at improving crop production efficiency.”
Leading by example
This winter GLASE will have a student collecting and organizing environmental and biological research data.
“The data will be uploaded to the CEAOD database and we will be documenting these activities,” Mattos said. “We will create a guideline of recommendations. We also plan to work with researchers from other institutions to demonstrate how the data can be organized and uploaded to create awareness and how to use the database.
“We hope this initial GLASE contribution will incentivize other researchers to share their data and will facilitate the uploading process. Access to the CEAOD database is free. It is an open platform and anyone can contribute to the development of this database tool.”
Once research data is collected and available for dissemination, the equipment used to produce controlled environment crops will be able to optimize the environmental conditions for a wide variety of crops, including lettuce, tomatoes, and cannabis.
Benefits to the horticulture industry
Mattos said private companies would also benefit from the collection of data and creating a centralized database.
“These companies need more data because it would allow them to analyze the data to develop new products and identify new markets,” he said. “Unfortunately, many of these companies don’t want to share their data. They are very proprietary about their data. They see that collecting and analyzing this data can put them ahead of their competition.
“Many private companies see the need for more data and how it can be valuable but are unwilling to share their own data. But like in other industries there are early adopters. I believe there will be companies that step up and will share their data with the horticulture industry. Hopefully, industry people will be willing to contribute and work on this database as well.”
Mattos said one of the big applications with this project is related to machine learning and artificial intelligence.
“With these applications, large sets of data are needed in order to create baselines,” he said. “Using the data, machines can be taught. Currently, growers’ production knowledge and opinion are more accurate for growing crops than artificial intelligence predictions. Growers are still more reliable, but it is just a matter of time before the use of big data and artificial intelligence will be able to match the growers in regards to optimizing growth.
“We are trying to develop this platform between the growers and controlled environment researchers and the machine learning/data computer scientists. I’m not sure the controlled environment researchers have grasped the potential that is available. We are not using this technology. Establishing this platform, as we collect and disseminate the data, there is real potential to help the advancement of the horticulture industry.”
For more: Erico Mattos, Greenhouse Lighting and Systems Engineering (GLASE), (302) 290-1560; em796@cornell.edu.
More info on CEAOD
Want to learn more about the Controlled Environment Agriculture Open Data project? Then check out these two upcoming events.
Aug. 4, 2-3 p.m. EDT
GLASE webinar: Controlled Environment Agriculture Open Data project. Presented by Erico Mattos, executive director of GLASE, and Kenneth Tran, founder of Koidra LLC.
Aug. 13, 10:30 a.m.-12 p.m. EDT
American Society for Horticultural Science presentation: The Promise of Big Data and New Technologies in Controlled Environment Agriculture. Presented by Erico Mattos.
David Kuack is a freelance technical writer in Fort Worth, Texas; dkuack@gmail.com.