production Facility

Vertical

22k sq-ft 3-Level Vertical Farm (Type 3B)

Crop Cycle Overview

The hydroponic greenhouse system will accommodate a 12 week grow cycle with options for using vertical racks for increasing plant yields. Each system begins with 1 week of germination, followed by 4 weeks in veg stage and 8-9 weeks in flowering stage. The multi-stage arrangement allows maximum output per square foot by spacing plants as they grow. 

 

Estimated Pro-Forma Production Assumption Average yield per Plant: .25 lbs.
Average yield
per Week: 576 lbs.
Average yield per Month: 2,496 lbs.

Average yield per Year: 29,952 lbs.

Production Estimates

 

Germination/cutting stage:

Spacing: 6” center
Length: 1 week
Total plants in Cloning chamber: 252

 

Intermediate stage:

Spacing 12” center
Length: 4 weeks
Total plants per bay: 2,304 Number of bays: 4
Total plants in veg stage: 9,216

 

Finishing stage:

Spacing 12” center
Length: 8 weeks
Total plants per bay: 2,304
Number of bays: 8
Total plants in finishing stage: 18,432

Plants harvested: 2,304
(1-bay) every 5 days

 

Total plants harvested per year: 119,808

Average yield per Bay: 576 lbs.
Total Annual Yield: 29,953 lbs.
Total Weekly Yield: 576 lbs.

Total Annual Gross Income: $59,904,010

Total Annual Operating Expense: $4,492,950

Total Annual EBITDA: $55,411,060 

Growth Stages:

 

Watering System:

 

Water Storage:

  • Rainwater storage basin: 480,000 gallons

  • Treated Rainwater Day Tank: 15,000 gallons

  • Growing Pond: 1,270,000 gallons

  • Water to be treated: 100% basin and growing pond water

  • Treated water volume: Up to 57,600 gallons per day of rainwater basin water, or lesser amount of rainwater plus unspecified volume of dirty drain water. -720,000 gallons per day of Cultivation Pond water.

Treatment Flow Rates:

Rainwater Basin: 40gpm continuous recirculation rate

Cultivation Pond: 500 gpm continuous recirculation rate

Irrigation period: 24 hours per day

Type of fertilizers used: Non-organic

Type of growing media: No media
Available Electrical: 120/220/277/480V 3-phase. Selected voltages to be confirmed.

Expansion requirements: None

 

Treatment Process Flow Summary: 

Following is a step-by-step description of how your system will function. This “flow configuration” may be changed once we have confirmed final details.

Step 1: Hydroponic Aeration
A single aeration disk and set of small compressors (both included) will pump up to 20 million gallons per day of the rainwater basin, turning over your pond far more than 20 times per day. This keeps the basin clean and reduces demand for treatment.

Step 2: Hydroponic water pressurization and transfer
One constant speed pump (included) will pump water at 40 gpm continuously at 50psi from the basin to its dedicated treatment system for makeup water to the 15,000-gallon day tank. A 2 HP pump is supplied with a foot valve and required check valves.

Step 3: Pre-Treatment Filtration:
Basin water will first be directed through two 21” depth media filters filled with AgPlus media (included). These filters will remove particulates down to approximately 5 microns before in size before discharging into the tanks. This will remove the majority of particulate as well as some of potentially pathogenic microbes, keeping the tanks clean and reducing demand for the ozone system.

Step 4: Ozone Reaction and Treatment
Pre-Filtered water then flows through an 80-gallon pressurized Ozone Reaction Vessel (ORV) (included) where it is introduced to highly ozonated water from the Ozone Generation System. In the ORV organic contaminants are oxidized and residual ozone remains in the water to be carried to the storage tanks thus elevating the ORP and Dissolved Oxygen of the water in the storage tanks.

Step 5: Ozone Generation & Control

A side-stream of water is drawn from the incoming untreated water and circulated through the Ozone Generation System (included) where it is injected with a high concentration of ozone and then introduced back into the main stream of water flowing into the ORV (step 4). The Oxidation Reduction Potential

(ORP) (treatment level) is continuously monitored and controlled by an onboard touch-screen controller
that modulates the ozone output to maintain the desired ORP level in the water returning to the storage tank.

Step 6: Storage Tank Fill and Mixing
The high ORP/DO ozonated basin water is delivered to the 15,000-gallon main storage tank (not included) through a 2” manifold pipe inside on the bottom of the tank with four Mass Transfer Nozzles (included) to distribute the high ORP, high DO water from the treatment process uniformly through the tank volume. This assures that the water is efficiently mixed into the existing water and is done so under pressure to maintain the dissolved ozone and dissolved oxygen as the water is introduced to the tanks. This is an important step in maintaining the ozone and dissolved oxygen in solution as both degrade, the ozone very quickly and the dissolved oxygen over a longer period.

Step 7: Storage Tank Recirculation and Re-Treatment
Once the storage tank is full, it will be allowed a controlled overflow. The overflow will return to the rainwater basin to pre-treat that water. A set of automated electric ball valves (included) will also allow the overflow to be directed back to the inlet of the 40-gpm pump to be reprocessed continuously. This step may be employed during drought conditions or heavy rainfall that has allowed polluted water to enter the basin and increased the disinfection demand. These valves are controlled by controller onboard the Ozone Generation System skid. The recirculation treatment process allows establishment of the highest quality, safest water with high dissolved oxygen levels.

Step 8: Cultivation Hydroponic Refill
A 2” solenoid valve (included) will open and allow gravity refill of the Cultivation Pond from the 15,000- gallon fresh water storage tank. This water can be introduced anywhere in the pond that the plumbing is convenient.

Step 9: Cultivation Hydroponic Water Repressurization and Recirculation
A single 30HP pump (included) (or alternatively a pair of 15HP pumps) will draw 500 gpm from a suction manifold extending the entire 460’ length of the pond. This water will be pressurized to 58 lbs. This pump will recirculate water 24 hr./day.

Step 10: Pre-Treatment Cultivation Hydroponic Water Filtration
The flow from the pump(s) will then flow through an array of four 48” depth media filters. These filters will remove particulates down to approximately 5 microns before ozonation.

Step 11: Ozone Reaction and Treatment
Pre-Filtered water then flows through a 460-gallon pressurized Ozone Reaction Vessel (ORV) (included) where it is introduced to highly ozonated water from the Ozone Generation System. In the ORV organic contaminants are oxidized and residual ozone remains in the water to be carried to the storage tanks thus elevating the ORP and Dissolved Oxygen of the water in the storage tanks.

Step 12: Ozone Generation & Control

A side-stream of water is drawn from the incoming untreated water and circulated through the Ozone Generation System (included) where it is injected with a high concentration of ozone and then introduced back into the main stream of water flowing into the ORV (step 4). The Oxidation Reduction Potential (ORP) (treatment level) is continuously monitored and controlled by an onboard touch-screen controller that modulates the ozone output to maintain the desired ORP level in the water returning to the storage tank. Dissolved Oxygen is also continuously monitored on this skid

Step 13: Nutrient Injection
A side stream of treated water will now flow through an injection loop where the E.C. and pH sensors (included) will continuously monitor, and an electronic controller (included) will control the pulsing rate of the fertilizer and acid injection heads (included) to maintain the desired E.C. and pH setpoints.

Step 14: Cultivation Hydroponic Pressurized Distribution
Treated and fertilized water will not be reintroduced into the pond at a pressure of approximately 30 psi evenly distributed through 72 individual Mazzei Mass Transfer Nozzles (MTNs) (included). A manifold will run down the 460’ length of the pond (PVC not included). At each of the 12 “bays”, a branch will tee off of the main manifold and feed 41.7 gpm of flow through 3 paired sets of MTNs spaced evenly down the length of the bay. This will assure that the fresh oxygenated water will be uniformly distributed and pushed down to the opposite end of the bay, in the same direction as the crop flow, to where it will be drawn out again and retreated. 

Irrigation & Installation

Treatment System #1 is designed to adequately aerate the rainwater storage basin to maintain good dissolved oxygen levels to reduce algae and other growth.

Treatment System #2 will then purify 25,000 gallons per day of that rainwater for use as the primary source water for the facilities irrigation and maintain the 15,000-gallon storage tank free of algae and biofilm accumulation. Additionally, with the addition of some simple plumbing, there is capacity to alternately batch-treat several thousand gallons per day of irrigation runoff water stored in runoff capture pond, potentially allowing this to be a zero runoff facility.

Treatment System #3 is designed to continuously recirculate, filter and treat the approximately 1,270,000 gallons of nutrient rich water in main growing pond. This system will reduce water borne pathogen to levels that present no threat of disease to the crops. ORP levels will be elevated to provide residual oxidation capacity for biofilm reduction the pond and piping systems. A substantial residual benefit of the oxidation process with ozone is the elevation of Dissolved Oxygen levels in irrigation water to improve oxygen delivered to plants, which has been demonstrated to improve plant health and production yields.

This dosing levels in this system assume that the rainwater basin is aerated with a micro-diffusion aeration system that will actively “turn-over” the source pond a minimum of 20 full turns per day to prevent establishment of a thermocline and a sludge accumulation in the basin bottom, and to maintain uniform temperature and dissolved oxygen levels in the basin.

Treatment System #4 is designed to inject automatically a single stock solution fertilizer and sulfur dilution stock solution, based on flow rate, E.C. set point and pH set point, and to maintain stable E.C. and pH levels in the cultivation pond.

Seedling Rack Irrigation System is designed to deliver irrigation water to 15 seedling racks with each seedling rack containing twelve shelves of eight 4’x4’ “flood” type trays with overflow drains. Each tray will have a capacity of 16 liters per hour of maximum irrigation. Each of the 15 racks will be controlled as a separate irrigation zone.

Training and Support

 

We understand the importance of training and support programs for successful greenhouse operation and have developed several training and support packages to cover your needs.

To get the most out of the training, we offer continued online service and support customized to fit your needs. Options includes assistance with mechanical and structure components as well as plant, water and computer issues. Additionally, users have access to personalized quarterly reports that address potential problem areas and provide industry updates.

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Initial training will be provided for site personnel and greenhouse owner will be provided written operations manual.
 

Below are some of the key topics to be covered:

  • Irrigation strategy

  • Nutrient strategy

  • Integrated pest management

  • Planting and harvesting

  • Plant health

  • Food safety procedures

  • Maintenance scheduling

  • Maintenance procedures

Service Package includes:

  • Telephone support

  • Site diagnostic service

  • Irrigation strategy

  • Nutrient strategy

  • Interpretation of Water analysis

  • Seed selection

  • Plant growth analysis

  • Crop steering

  • IT Coordination

  • Seasonal light and weather analysis

  • New technology updates

  • Yield tracking database 

  • Twitter

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