Industrial Greenhouses

In Controlled Environment Agriculture

Industrial Greenhouses: Scaling Up for Maximum Yield in CEA Farming

Industrial greenhouses are becoming essential to modern food production as the global population rises and the demand for fresh produce increases. These large, high-tech structures—often referred to as the “factories” of the produce world—are central to Controlled Environment Agriculture (CEA). They are designed to maximize crop yields within limited space and time by utilizing advanced technology, automation, and precise climate control to enhance plant growth.

The integration of Moving Gutter Systems further boosts the efficiency of industrial greenhouses by optimizing space and resources, which supports high-yield production.

This article explores the technology and scale of industrial greenhouses, their crucial role in large-scale CEA farming, their sustainability benefits, and the challenges they encounter.

The Scale and Technology Behind Industrial Greenhouses

Industrial greenhouses are designed for large-scale food production, often covering several acres and using advanced automated systems. These high-tech greenhouses do more than just control the climate; they combine hydroponics, vertical farming, and data-driven technology to create the best conditions for growing a lot of crops efficiently.

At the heart of these operations are hydroponics and vertical farming. Hydroponics lets plants grow without soil by placing their roots in nutrient-rich water, which can save up to 90% more water than traditional soil farming. This method helps plants grow faster and produce more food in a smaller space. Vertical farming takes this efficiency a step further by stacking plants in layers, using vertical space to increase production. This is especially useful in urban areas where land is limited.

Moreover, Moving Gutter Systems can be added to different types of greenhouses to boost efficiency even more. These systems automatically adjust the spacing of crops as they grow, ensuring they get the right amount of light and nutrients. By combining hydroponics, vertical farming, and Moving Gutter Systems, industrial greenhouses offer a powerful way to meet the growing demand for fresh produce.

 

Automation in Seeding, Transplanting, and Harvesting

Automation plays a vital role in the efficient operation of large-scale industrial greenhouses, where precision is key. Automated seeding systems ensure that seeds are consistently placed, promoting uniform growth and reducing waste. As plants grow and require more space, automated transplanting systems move them to larger growing areas, which helps lower labor costs and maintain plant health.

A particularly innovative solution found in many industrial greenhouses is the Moving Gutter System, which further enhances operational efficiency by optimizing space and resource use.

 

High-Volume Production for a Growing Market

The primary focus of industrial greenhouses is high-volume production. These facilities cater to large distributors, grocery stores, and food processing companies that require consistent, year-round produce supply. By specializing in a select range of high-demand crops—often leafy greens, tomatoes, cucumbers, and herbs—industrial greenhouses can streamline operations and maximize efficiency.

High-yielding crops such as lettuce, basil, and microgreens are especially popular because they grow quickly and respond well to controlled environments. The controlled environment also helps eliminate the seasonality of traditional farming, allowing these industrial operations to produce consistently year-round. This is a huge advantage for major distributors and food processing companies, which benefit from a reliable supply chain that can meet consumer demand without being influenced by seasonal crop fluctuations.

Industrial Greenhouse
Industrial Greenhouse

Sustainability Benefits: Optimizing Resources and Minimizing Environmental Impact

One of the defining advantages of CEA farming through industrial greenhouses is sustainability. By optimizing resource use, industrial greenhouses significantly reduce the environmental footprint of food production compared to traditional farming. Water efficiency is a hallmark of CEA farming, particularly in hydroponic systems, such as our Moving Gutter System, where water is directly supplied to plant roots, with little to no waste. This method uses up to 90% less water than soil-based farming, a crucial benefit in regions where water scarcity is a pressing issue.

Energy efficiency is also prioritized within these controlled environments. Industrial greenhouses are increasingly powered by renewable energy sources, such as solar or wind, to mitigate the environmental impact of energy consumption. Many facilities employ LED lighting specifically designed for plants, which provides the necessary light spectrum for growth at a fraction of the energy cost of traditional lights.

Additionally, by situating greenhouses closer to consumer hubs, industrial CEA farming reduces food miles—the distance food travels from farm to table. This approach decreases transportation-related carbon emissions and ensures that produce is fresher upon arrival, minimizing food waste along the supply chain.

 

Challenges in Industrial Greenhouse CEA Farming

Despite the numerous advantages, industrial greenhouses encounter challenges that must be addressed to maximize their potential. One significant hurdle is the high initial investment cost. The advanced technology needed for large-scale automation, climate control, and lighting systems requires substantial financial resources. This can be a barrier for smaller companies or those without external funding, making it difficult to enter the industrial Controlled Environment Agriculture (CEA) market. However, there are financing options and government grants available that can help alleviate these costs.

Energy demands present another challenge, especially in colder climates where heating is necessary during winter months. While many facilities are now integrating renewable energy sources to offset these costs, the infrastructure to support these systems can add to the initial expenses. Nevertheless, advancements in energy-efficient technologies and practices can help lower overall energy consumption in the long run.

Additionally, the risk of crop disease in closed environments is a concern, as crops grown closely together can lead to the rapid spread of disease or pest outbreaks, threatening a large portion of the harvest. To manage these risks, industrial greenhouses implement strict biosecurity measures, biological pest control methods, and regular monitoring to detect and address any signs of disease early on. With the right strategies and technologies, these challenges can be effectively overcome, allowing industrial greenhouses to thrive and contribute significantly to sustainable food production.

NFT System
Basil is a great crop to grow in CEA systems

The Future of Industrial Greenhouses in CEA Farming

Industrial greenhouses are transforming the way we approach agriculture in urban and resource-scarce environments. As technology continues to advance, Controlled Environment Agriculture (CEA) through industrial greenhouses is expected to become even more efficient and accessible. Innovations in AI-driven climate control, disease management, and resource optimization will help reduce costs, making it easier for more companies to adopt this progressive approach. A key component of this evolution is the Moving Gutter System, which represents the future of farming by optimizing space and resource allocation, enhancing crop yield, and increasing operational efficiency.

These greenhouses not only redefine modern farming practices but also pave the way for a sustainable and resilient future in agriculture. CEA farming with industrial greenhouses offers a balanced model that prioritizes productivity while maintaining environmental responsibility, providing scalable solutions to meet the world’s growing food demands.

Reach out to us

At Viemose DGS we have more than 75 years of experience in navigating the indoor horticulture industry and we excel in establishing indoor farming systems.

Reach out to us to gain more information on how we can help you establish your CEA facilities.

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