Grantee Research Project Results
Final Report: Sustainable Year-Round Food Production in Cold Climates
EPA Grant Number: SU834321Title: Sustainable Year-Round Food Production in Cold Climates
Investigators: Powers, Susan E. , Gonyer, Daegan A.J. , Howley, Bridget , Ludovici, Eric , Bentley, Ethan , Darocha, James , Buel, Kyle , Shaddak, Laura , Jacobs, Nathan , Gilbraith, Nathan , Carnahan, Quinn , Doyle, Ryan , Bonnell, Sean
Institution: Clarkson University
EPA Project Officer: Page, Angela
Phase: I
Project Period: August 15, 2009 through August 14, 2010
Project Amount: $10,000
RFA: P3 Awards: A National Student Design Competition for Sustainability Focusing on People, Prosperity and the Planet (2009) RFA Text | Recipients Lists
Research Category: P3 Challenge Area - Sustainable and Healthy Communities , Pollution Prevention/Sustainable Development , P3 Challenge Area - Air Quality , P3 Awards , Sustainable and Healthy Communities
Objective:
Our goal is to create a Controlled Environment High Rise Farm (CEHRF) in order to maintain the supply of fresh organic produce across a 50-mile radius in a cold climate. The CEHRF (Controlled Environment High-Rise Farm) is a new organic farming model based on recent innovations in the respective areas of crop growth, artificial lighting and HVAC efficiency. The use of high-tech plant growth and lighting components within this food production system will greatly reduce water (by 90 %), nutrient (by 60%), land, and transportation energy requirements. The fresh produce industry will undergo drastic changes as the price of oil and transportation continues to rise in the coming years. There will be a point where the cost savings of growing produce in warm climates and distributing them around the country will be offset by the cost of transporting those products to the end consumer.
Fresh produce is something that consumers have come to expect year round for a reasonable price. In addition to this, the movement towards organic produce has been growing at an increasing rate over the past decade. Demand for fresh organic produce as a whole has increased at 18% per year over the past 3 years (Industry Statistics and Projected Growth).
In order to capitalize on this market potential, a Clarkson student team has undertaken a series of steps to prepare for all of the aspects needed in order to bring this plan to fruition. The team has conducted an initial feasibility study to determine the parameters of an aeroponics growing system, the potential profitability of the idea, the environmental implications associated with the project, and the design requirements. Secondly, a team conducted growing experiments in a test facility that will mimic the conditions of the final CEHRF, allowing for the optimization of the growing process.
Summary/Accomplishments (Outputs/Outcomes):
People
With the recent economic problems, people are very concerned about jobs. A CEHRF system will generate reliable fulltime, year-round local employment. These positions include six harvesters per 50,000 ft2 (active), three technicians per 50,000 ft2 (active), and one operations manager. This is six hourly positions and four salaried positions with benefits for the scenario presented in this report. Not only are these full-time, year-round positions created, but also the workers are in a safer environment than their seasonal counterparts.
The quality of the produce reaching the local populace will be fresher and qualify for organic certification by nature of the system. With these considerations, the CEHRF model appears superior to current practices.
Planet
The CEHRF model at first glance appears worse compared to current practices with respect to greenhouse gas (GHG) emissions, mainly because energy use is so much higher. It is important to note that when coupled with waste heat and strictly green electricity, the reduction in fertilizer use and lack of need for large farming or transportation equipment results in much lower life cycle emissions than current practices where farms have access to similar conditions. The main cause of CEHRF life cycle emissions is the electricity generation. Utilization of the electric generation capabilities of landfill gas would be an ideal pairing for the CEHRF, because waste heat also would be produced. There currently is research in lighting ongoing (Bilkent University) that has developed a bulb capable of 300 lumens/watt (not yet commercially available). That is 2.5 times more efficient than the lamps currently used in the design, and would lower electrical needs by more than 50%. With proper restrictions imposed on location and design, the GHG emissions of CEHRFs can be comparable to current practices, and recent technological developments promise to loosen those restrictions.
Environmental impact is where the CEHRF clearly is the better method, due to the greatly reduced footprint, water use and nutrient use. A five-story 10,000 ft2 CEHRF will produce as much lettuce in a year as 55 acres of farmland [18] using 90% less water and 60% less nutrients. Land used for CEHRF farming would not become stressed over time due to nutrient depletion and erosion. Farmers already apply significant amounts of nutrients to supplement the overburdened soil in agricultural areas, causing soil stress and larger environmental consequences such as eutrophication of waterways. Erosion also is a major problem of traditional farming, which would be completely avoided. CEHR farming can occur on less/unproductive soil (e.g., desert) with no adverse effects on produce output or quality.
Prosperity
In order to meet these growing demands for produce, we have analyzed the initial feasibility of placing a CEHRF in Saratoga Springs, New York. With a current population in excess of 200,000 within a 20-mile radius, a CEHRF could sustain the growth of a large amount of produce with a relatively small distribution radius. Initial research has shown that the revenue for providing food for roughly 50,000 people could be upwards of $10MM per year. Total operating cost for this system is $740,000. The ROE and ROA are 0.20 and 0.19, respectively. The gross profit margin is 0.94 and initial debt ratio is 1.08 using a discount rate of 5%. A number of crop yield and environmental factors were catalogued and used to make projections on 10,000 ft2 modules, in a 50 ft (depth) by 200 ft (length) by 15 ft (height) arrangement. Length and depth were chosen to increase natural lighting exposure (southern wall) while maintaining a structurally sound footprint. The system is scaled to demand by adding modules.
A market survey was created and conducted in Potsdam, New York, to help determine the demand and test the survey for later use in Saratoga Springs. Initial results from this survey suggest that more than 90% of the population would prefer to buy local produce if possible, and more than 60% of people would be willing to pay $5.50/kg of lettuce.
Conclusions:
An initial result from the mathematical model suggests economic feasibility with net annual revenue of more than $2.5 million per year. Based on a 20-year expected lifetime of the operation with a replacement of pumps every 5 years and aeroponics equipment every 10 years, the CEHFR has a Net Present Value of -$3MM. This shows that the CEHRF has a high potential to be economically feasible.
Another important aspect of the CEHRF is local job creation and it is unlike traditional farming where employment mainly consists of unskilled labor. Based on the produce demand of the location, the CEHRF will employ three full-time salary workers as well as eight harvesters. These jobs will be created where the produce is consumed, helping to spur the local economy.
Proposed Phase II Objectives and Strategies:
Direct impacts from Phase II will be local fresh produce supplementing campus dining, as well as potentially the local food co-op. Potential impacts of the results of Phase II are the industrialization and localization of farming, not just in cold climates, but also in arid climates and one day even space stations. Crop losses due to climate change and weather events can be avoided. Forests will no longer need to be cleared for more farmland. Seepage of fertilizer to ground and surface water can be eliminated. The additional 3 billion people of 2050 will have food to eat and clean water to drink.
The results of the Phase I lab tests will be used to redesign the aeroponic units in a more economical and efficient manner. The engineering design will be used to build the pilot plant, and the rough full-scale design will be the basis for a comprehensive full-scale design to be completed in Phase II. The mathematical model of Phase I will be the basis for a mathematical design optimization program. The environmental impacts and business plan will be refined as the engineering design and mathematical model progress.
In order to achieve the above objectives in Phase II it is necessary to develop an investor-ready prospectus that can be presented to future investors and a detailed engineering design consisting of a blue print, layout view, rack design, and structural analysis. Also a mathematical model that optimizes the design of the CEHRF system is necessary. This model will allow us to customize our system based on the requirements of the target location. Also needed are energy and waste heat recovery research and a market analysis of Saratoga Springs, New York. Finally, using the research gathered during Phase II, Clarkson students will pursue the amount of capital required to launch a full-scale operation. The full-scale design will consist of 10,000 sf modules, pumps, aeroponic units, and an HVAC system. The size of the module was determined as it is the minimum size for a viable greenhouse. The pumps will provide water for the system and the HVAC will regulate temperature and ventilation. NASA developed the concept of aeroponics for crop production in space. Unlike terraponic, traditional, and hydroponic methods, aeroponics does not require a substrate, such as soil or nutrient solutions, in which to immerse the plant roots. Instead it supplies a high-pressure water and nutrient mix directly to the roots of the plants.
Journal Articles:
No journal articles submitted with this report: View all 6 publications for this projectSupplemental Keywords:
Contained Environment High Rise Green House, AeroponicsRelevant Websites:
P3 Phase II:
Sustainable Year-Round Food Production in Cold Climates | 2011 Progress Report | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.