GAIA’s first harvest

GAIA Project Australia recently celebrated a tremendous milestone in our commercial project, which is under development in Melbourne, Australia, the first complete harvest of lettuce grown in our Rejig Grow vertical farm testing facility, and the results were more significant than expected! 

Current vertical farms have an average lettuce size of 300 to 350 grams with a dimension of 200 mm. GAIA produced an average size of over 300 grams of lettuce with dimensions over 200 mm. This is without having the optimal breathing environment of feeding Carbon dioxide to the lettuce as our current test environment is in the open air, which consists of approx. 400ppm vs having HVAC (heating, ventilation, and air conditioning) combined with CO2 will provide 1400ppm. Once we add in our HVAC with CO2 (eta is October 2022), our lettuce production time will decrease to the standard 4-week grow cycle, and we anticipate the average weight and size of the lettuce will also increase. 

Our test environment was in a Footscray warehouse from May to July (winter season), with indoor temperatures averaging between 8 to 15 degrees. 

We had completed the construction of our first singular modular system which is three levels, the top two levels had our compact channel configuration for early to medium lifecycle of the lettuce and the bottom level was our extended channel configuration that allowed the full growth of later stage development of lettuce. Each channel supports up to 12 plants, and there are ten channels per level, providing a total output capacity of 360 lettuce per harvest cycle.

We have artificial LED lighting providing energy requirements and a closed circuit water supply with an automated nutrient and UV water Sterilization system. The lighting configuration of the compact two top levels enabled us to have 40% less energy requirement than the bottom level once extended, which shows our 40% energy saving compared to other vertical farms that don’t have bi-directional expanding modular channels. 

We grew a combination of Batavia lettuce & Red leaf lettuce and chose this lettuce because they are the hardest to grow on a farm. They are sensitive to conditions such as light, temperature, nutrients in the water, and insects causing damage. However, we know that if we can grow this type of lettuce successfully, then other forms of lettuce will be simple. 

Why do we need new ways of growing lettuce? 

The global population is estimated to reach 9 billion by 2050. As it is now, a significant percentage of the people will be living in continue to live in urban areas. This will likely require a 70% increase in agricultural productivity (Corvalan et al. 2005; Tilman et al. 2011).  

Furthermore, continued rural to urban migration is predicted to increase the need for urban landscapes and accelerate the loss of cultivated land surrounding towns and cities (Pandey and Seto 2015). The negative impact will be land degradation and loss of soil fertility. Due to land-use intensification and climate change, agricultural land is increasingly becoming a scarce resource (Foley et al. 2011; Lambin et al. 2013)  

Here in Australia, we have recently felt the effects of climate change which has brought on significant weather conditions affecting our lettuce production. For example, from April through till today, as I write this article, many parts of Queensland and New South Wales have been flooded from excess rain. Due to less optimal weather conditions, it’s been exceedingly difficult to grow lettuce in these areas, which has caused a shortage of lettuce and driven up the costs to consumers by up to 10 times regular prices. Even some fast-food chains such as KFC have had to change their menu and replace lettuce with other alternatives to combat this shortage. 

Lettuce crisis issues like this will continue as 98% of all the lettuce grown in Australia is grown on traditional farms in soil and are prone to fail when we have natural disasters or non-favourable weather conditions.  

In addition to this it is predicted we have an average of only 70 more harvest cycles left from soil-based farming as we are depleting the nutrients from our soils and once depleted it will be difficult if not impossible to grow vegetables in soil after this time. 

What’s the future for lettuce production? 

For Australia and many parts of the world, we need to continue our move away from traditional farming (growing vegetables in an unprotected environment and soil) and move to a CEA (Controlled Environment Agriculture) way such as vertical farming or advanced greenhouse. This new age way of agriculture is far more resilient to natural disasters, and unfavourable weather conditions as the plants are protected and provided with optimal growing conditions. 

However, CEA farming has its challenges, the 2019 Global CEA Census report conducted by Agritecture LLC and Autogrow, which surveyed 316 farmers from 50 countries, shows that only 45% of CEA greenhouses are profitable. This poor result was mainly due to operating costs. Here is a breakdown of the top 7 operational costs, with one being the highest and seven being the lowest.

  1. Labour
  2. Energy
  3. Cost of good (seed, nutrients, grow media)
  4. Rent
  5. Packaging
  6. Distribution / Transportation
  7. Water

How does GAIA improve profitability for CEA?

As we can see from our first harvest results, our numbers are looking impressive. If we can consistently produce 40% more yield of lettuce than current CEA farmers. This will increase the gross profit of each harvest cycle, bringing down the average cost per lettuce head as the quantity is greater. Additional to this  we can offer cost reductions for 4 of the top 7 operational cost challenges farmers have as per above.

  1. Labour: our future Rejig Channel system with have robotic arms to move the channels between levels and auto extend the channels our as the plant grows, this automation is predicted to significantly reduce labour hours.
  2. Energy: The use of compact channel configuration for 2/3 of the plant’s life cycle means we only need to supply lighting for the compact channel area as compared to existing farms that have set spacing where 2/3 of the plant life doesn’t need the space and therefore is wasted. This equates to a 40% reduction in energy consumption
  3. Nutrients: We require less nutrients as per the compact Channel configuration
  4. Water: We require less water as per the compact Channel configuration

Next steps for GAIA

Now that we have proven the GAIA Rejig Grow channel system works as expected, we are now looking to fast track the production cycle by building an enclosure with HVAC and CO2.  Once done we perform further testing and refinements and then begin building modules 2 & 3 which once completed will have the capacity to produce 10 tones of lettuce per year!

Keep an eye out on our social media platforms and website to see how we progress and get in touch with us if your interested in our solution.

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