controlled environment farming Archives - Hydroponic Container Farms and Mushroom Farms

Container Farm FAQs – Shedding Light on Emerging Farm Tech

Given that the container farm industry is still an emerging one, those who are just finding out about this food production technology understandably have a lot of questions. We decided to aggregate the most common questions we’ve heard over our nine-year history, including the basics. Happy reading and if we’ve missed anything, please let us know at info@farmboxfoods.com!

What can these farms grow?

In the vertical farm, primarily leafy greens, culinary herbs, peppers, small tomatoes, micro greens and edible flowers.

In the mushroom farm, a host of gourmet and functional mushrooms, from oysters and lion’s mane to chestnuts, reishi and king trumpets.

The Hydroponic Fodder Farm allows you to sprout a variety of cereal grains, and we’ve primarily tested and grown barley grass and wheatgrass.

Do I need to have to know a lot about plants (VHF), mushrooms (GMF) or fodder (HFF) before starting?

No, but it doesn’t hurt. Having a horticultural or mycological foundation helps you know what to look for when starting to grow on a mass scale. In addition to our online training (and on-site training at your location), we encourage container farm purchasers to research the plants or mushrooms they’re planning to grow. What environmental conditions do they like best? What are the optimal nutrient levels for the water? Are the root systems for these plants compatible with vertical farming using tubes? That being said, we pass along everything we learned during our research-and-development phase to our customers.

Since the farms are automated, does that mean they can run themselves?

A seedling table that uses sub-irrigation to water new plants.

No. Let’s start with this: the technology in FarmBox Foods-made container farms is really cool. Digital sensors and a simple-to-use interface help you balance water pH levels, monitor and adjust nutrient concentrations, set the watering schedule, and much more. But the farms require the human eye and the human touch. A Vertical Hydroponic Farm generally requires one person to work 15-20 hours per week.

Do you provide a farmer to run my container farm?

That’s our plan down the road, but for now it’s up to you to find someone with the time and dedication necessary to run a container farm year-round. We do train your farmer on site with all the skills to grow successfully.

How often can I harvest?

In the Vertical Hydroponic Farm, a staggered growing schedule allows you to harvest every week. In the Gourmet Mushroom Farm, you can harvest twice a week. The Hydroponic Fodder Farm requires daily harvesting.

What sort of power hookup do I need?

Jason Brown, VP of operations, setting environmental conditions using a grow-control screen.

Both farms require a 100 amp, 220VAC single-phase hookup. A main breaker disconnect is provided on each unit, which allows for overhead or underground termination.

What is the daily average energy consumption of each farm?

Vertical Hydroponic Farm: The average, total energy usage per day is 190 kWh. Peaks will be around 11 kWh. The bulk of this energy usage is for the grow lights which run at night. There is also a significant amount of usage for climate control.

Gourmet Mushroom Farm: The average total energy usage per day is 50-70 kWh. Peaks will be around 12 kWh. The bulk of this energy usage is for the sterilizer which runs 3-4 times weekly. Climate control is the other significant user of electricity.

Hydroponic Fodder Farm: The average total energy usage per day is around 60 kWh, depending on the climate in which the farm operates. Hotter locales require more A/C to keep the plants cool, whereas colder climates require more warmth.

How much water do the farms use?

Vertical Hydroponic Farm: Around 10-15 gallons per day on average. Additionally, the farm’s water tanks have to be refilled after flushing your nutrients (this occurs about every 8 weeks). The total volume of the two tanks is 130 gallons. Beyond what you need for growing, water is also required for cleaning.

Gourmet Mushroom Farm: Depending on how many substrate bags you produce weekly, the farm’s total water usage can be up to 100 gallons per week.

Hydroponic Fodder Farm: 450-500 gallons. This is still a 90 percent reduction when compared with irrigating pasture.

How is water treated in the farms?

VHF: The farm has integrated reverse osmosis systems. Water pH is also treated.

GMF: Water for the humidification system is run through a reverse osmosis system.

Do you offer troubleshooting services if I need them?

FarmBox Foods will never leave customers without a resource for help. In the first year of operation, our team helps diagnose and walk customers through rectifying any issues that may arise. We charge an hourly rate for support after that year is up.

Since you use upcycled shipping containers, should I expect them to be in rough shape?

The exterior of a Hydroponic Fodder Farm made by FarmBox Foods.

Part of our commitment to making this whole operation more eco-friendly is upcycling — or repurposing — existing shipping containers instead of expending time, energy, money and materials to build new ones. With that in mind, you should expect a few dings and scrapes on the outside of the container. However, these superficial blemishes can often be concealed with a good wrap or paint job (optional). The inside of the container will be pristine, and we will never build a farm inside any container that is not structurally up to the task.

Do you deliver your farms?

Absolute-ly. We have a partnership with Absolute Logistics, which has been in the business for nearly 30 years. They handle all transportation planning, including customs procedures, so there’s no need to arrange your own shipping with a separate company. The cost of shipping is included in your final price.

Is there a FarmBox Foods app?

Not yet. We’re in the process of developing an app that enables farmers to connect directly with their container farm.

Do you provide the seeds and seed plugs needed for my operation?

Yes. But you can also find your own seed and seed plug distributor if you’d like. We’re happy to provide recommendations.

What is the warranty on the farms?

Both farms come with a 1-year warranty that covers all parts and labor.

How often do you have to clean the tubes in the VHF?

Every other harvest, so every 2-3 months.

How much do they produce?

It all depends on what you’re growing, but we estimate 200 pounds of veggies per week.

What’s the lifespan of a container farm?

With proper maintenance, the farms can last up to 25-30 years.

Are there ongoing costs?

Operational costs vary depending on location. Water rates, electricity rates and delivery costs are among the variables. Reach out to us at info@farmboxfoods.com for a full packet of information.

Are there financing options for your container farms?

Yes. We have preferred financing partners to arrange financing, but talk to your sales rep to find out what loans and grants might be available.

Cows sharing barley fodder grown in a Hydroponic Fodder Farm.

What measures can I take to prevent water emitters and filters from clogging?

Emitters are going to clog. It’s almost assured. The emitters are easy to change and clean out for reuse. FarmBox Foods is working towards finding a solution that makes this less likely to happen. As for filters, in time they will clog but if good practices are in place, they should never impact the ability to function. Simple cleaning of the filters, on a schedule, will keep the filters operational.

What components will need periodic replacement?

VHF: Dehumidifier air filter quarterly; grow tubes don’t need to be replaced unless they break (this is very unlikely); LEDs every 5-10 years; reverse osmosis filters (frequency varies by filter and water supply quality, but they require yearly replacement on average).

GMF: Misting pump filters and oil quarterly; sterilizer heating elements quarterly; air conditioning filters yearly; LEDs every 5-10 years; UV-C bulb every 5-10 years.

What replacement items would you always keep on hand to keep the farms running smoothly?

VHF: Electric ball valves, liquid level sensors, emitters, backup relays

GMF: Sterilizer heating elements, air conditioning filters, filters and oil for the misting pump, backup humidifier and backup relays.

Can the seedling plugs and spent mushroom substrate be used for further plant growing practices once they are removed from the farms?

Yes, both items can be incorporated into compost. The spent mushroom substrate in particular is quite sought after for this purpose. It can also be simply incorporated into soil and will continue to grow mushrooms if properly managed.

Is the water in the VHF that is disposed of when cleaning the tanks usable for irrigation or flower bed watering? Can we reuse it somewhere else so it is not wasted?

Yes, but we recommend using this water for established plants, trees, shrubs, lawns only.

In the case of a loss of power, how will this affect the farms? How long would the farms survive without power?

VHF: During a blackout, the most adverse effect to the plants would be that they wouldn’t be watered by the grow control. In such a scenario, you could keep everything alive by watering manually. Realistically, 24-48 hours (with manual watering) is the longest time period that power could be out without plants starting to die.

GMF: Mushrooms are quite resistant to power outages — the worst outcome from an extended loss of power will be that mushrooms don’t receive the proper humidification. Mushrooms will last up to several days in imperfect environments but will revive pretty quickly once environmental conditions are re-established.

Can the lights be programmed and controlled per wall?

Yes, your Agrowtek system allows for control of individual light walls, as well as watering.

What is included with the purchase of each farm?

VHF: Seedling table; nutrient tanks; water tanks; probes for nutrients; reverse osmosis systems; LED lighting; air conditioning systems; circulation fans; computer and grow control software; ozone generation systems; grow walls; grow tubes; water heater; hand sink; water pumps; electrical panel; critical spares kit

GMF: Substrate mixing and bagging machine; sterilization devices; utility sink; air conditioning systems; grow control; circulation fans; lab table; HEPA flow cabinet; movable racking; UV-C lighting; LED lighting; misting pump; hot plate; refrigerator; water heater; electrical panel; critical spares kit.

Hydroponic Fodder Farm: Everything you need to grow successfully, no add-ons required. 42 trays, racking, hopper, plumbing, fans, dehumidifier and more.

What nutrients does the VHF use?

We recommend the following nutrients and additives:

General Hydroponics FloraMicro 2-1-6

General Hydroponics FloraGro 5-0-1

General Hydroponics pH Down/Up

Alchemist 34% Liquid Oxygen

See this link for nutrient information:

https://generalhydroponics.com/products/floraseries/

What produce prices can I expect in my area?

We are unfortunately not privy to the market costs of produce in any particular area around the world, but we can help you find this information and complete ROI sheets to assist you in determining the viability of your farm.

What is the warranty on the farms?

All farms come with a 1-year warranty that covers all parts and labor.

Can the farms operate in desert climates?

Yes, our farms are fully insulated and operate without any problem in extreme environments.

How do I connect my water source to the farm?

Chestnut mushrooms grown in a Gourmet Mushroom Farm.

We use a standard 3/4-inch garden hose connection for all farms. From there, water is piped inside and through each farm’s respective reverse osmosis systems.

How many movable walls are there in the VHF?

There are three grow walls and two light walls. Each wall is double sided to maximize space inside the farm.

Do the farms meet Canadian building code standards?

Yes, FarmBox Foods farms meet or exceed compliance requirements for ICL, IBC, NEC, UL(C), ETL, CSA.

Your Salad Took a Road Trip: The Surprising Numbers Behind America’s Food Transportation System

Take a look at the produce in your refrigerator.

That head of lettuce, carton of strawberries, or bunch of spinach likely traveled farther than many people do on vacation before landing in your shopping cart.

Our modern food system is incredibly efficient, allowing us to enjoy fresh fruits and vegetables year-round regardless of the season. But that convenience comes with a fascinating logistical story. Every day, millions of trucks, trains, ships and airplanes move food across the United States, consuming enormous amounts of fuel along the way.

The numbers don’t lie.

Just How Far Does Our Food Travel?

The concept of “food miles” measures the distance food travels from where it’s grown to where it’s eaten.

According to research compiled by the National Center for Appropriate Technology (NCAT), fresh produce in the United States travels an average of more than 1,500 miles before reaching consumers. Processed foods average over 1,300 miles.

Some crops travel even farther.

Researchers at the former Leopold Center for Sustainable Agriculture examined produce arriving at Chicago’s wholesale market and found:

Lettuce traveled over 2,000 miles
Broccoli traveled over 2,000 miles
Spinach traveled over 2,000 miles
Grapes traveled over 2,000 miles

The average distance for the 30 produce items studied was 1,518 miles.

Those numbers aren’t surprising when you consider that much of America’s produce comes from concentrated growing regions like California’s Central Valley, Arizona’s Yuma region, Florida and Mexico before being distributed nationwide.

The Trucking Industry Does the Heavy Lifting

While railroads and ships play important roles in moving agricultural commodities, trucks handle the vast majority of fresh food distribution.

Refrigerated trailers transport everything from lettuce and berries to milk and frozen foods while maintaining carefully controlled temperatures throughout the journey.

A typical semi-truck averages approximately 6 to 7 miles per gallon of diesel fuel, depending on terrain, weather, weight and aerodynamics. That means a truck hauling produce 1,500 miles will burn roughly 215 to 250 gallons of diesel on that trip alone.

Now multiply that by thousands of trucks delivering food across America every day, and the scale becomes staggering.

America’s Food Freight Adds Up Fast

Transportation is only one piece of the food system, but it’s a significant one.

According to NCAT, transportation accounts for approximately 14% of the total energy used within the U.S. food system.

Researchers from the University of Michigan also found that while food transportation is extensive, the production of food itself accounts for a larger share of overall greenhouse gas emissions. Transportation contributes roughly 11% of food-related greenhouse gas emissions, while the production phase accounts for about 83%.

In other words, growing food requires far more energy than moving it, but transportation still represents a meaningful opportunity for improving efficiency.

Every Mile Costs Money

Fuel is one of the largest operating expenses for trucking companies.

If diesel costs $3.75 per gallon and a truck averages 6.5 mpg, fuel alone costs roughly 58 cents per mile.

A 1,500-mile shipment therefore requires approximately $865 worth of diesel fuel, and that’s not counting driver wages, equipment maintenance, refrigeration systems, insurance, tires, depreciation and distribution centers

Those transportation costs are ultimately reflected in the price consumers pay at the grocery store.

Local Production Is Gaining Attention

None of this means long-distance transportation is inherently bad.

Large-scale agriculture often benefits from ideal climates, economies of scale and highly efficient logistics. In some cases, producing food in the best growing region and transporting it efficiently can actually have a smaller environmental footprint than producing it locally under less favorable conditions.

However, there are situations where producing food closer to where it’s consumed offers meaningful advantages.

Local production can reduce transportation costs, decrease fuel consumption, shorten supply chains, preserve freshness, reduce spoilage (and therefore food waste), and increase resilience when disruptions occur

This is especially true for highly perishable crops like leafy greens, herbs and specialty vegetables.

A Different Approach to Food Production

As weather events, labor shortages, and transportation costs continue to challenge traditional agriculture, many organizations are rethinking where food should be grown.

Controlled environment agriculture, including hydroponic container farms, allows fresh produce to be grown directly where it’s needed, whether that’s outside a grocery store, beside a restaurant, on a school campus, or at a military installation.

Instead of shipping lettuce 1,500 miles across the country, it’s possible to harvest it just a few hundred feet away from where it will be eaten.

That’s not about replacing traditional agriculture. America’s large farming regions will always play a vital role in feeding the country.

But shortening the distance between harvest and plate can reduce transportation costs, improve freshness, strengthen local food security and make communities less vulnerable to supply chain disruptions.

In a world where nearly every tomato, head of lettuce and package of herbs has its own transportation story, sometimes the shortest journey is the most valuable one.

Overcoming Current & Future Food Challenges Using Ingenuity & Tech

As we navigate our way into the future and the challenges that face us, controlled-climate container farming is gaining more traction, and for good reason.

It brings a level of precision and efficiency to agriculture that traditional methods have historically struggled to match. At its core, the approach involves growing crops inside repurposed shipping containers equipped with advanced environmental controls. Light, temperature, humidity and nutrient delivery are all carefully managed, creating an optimized environment where plants can thrive year-round. This consistency opens the door to a range of benefits that extend far beyond just growing food; it reshapes how and where food can be produced, and helps us all understand a little better where our food comes from.

Pre-insulated container farms can operate in almost any conditions.

One of the most significant advantages is probably the most obvious: resource conservation. Traditional agriculture is known to be water-intensive and often relies heavily on fertilizers and pesticides, some of which are in short supply with global supply chains are interrupted. In a controlled container system, water is typically recirculated through hydroponic or aeroponic setups, reducing usage by more than 90 percent compared to conventional outdoor farming. Nutrients are delivered directly to the plant roots in precise amounts, minimizing waste and runoff. Because the environment is sealed and monitored, pests are far less of a concern, which dramatically reduces or even eliminates the need for pesticides. The result is a cleaner, more efficient system that uses fewer inputs to produce high-quality crops.

Another key benefit is the lower barrier of entry for future farmers. Traditional farming often requires large plots of land, pricy equipment and years of experience to manage variables like weather and soil health. Container farming simplifies many of these challenges. With a relatively small footprint and a controlled environment, new growers can focus on learning plant production without being at the mercy of unpredictable outdoor conditions. Many systems are also equipped with user-friendly software that automates and monitors key processes, making it more accessible for people who may not come from an agricultural background. This democratization of farming has the potential to bring a new generation into food production, something we know we need given the rising average age of today’s farmers and ranchers.

Cherry tomatoes grown in a vertical hydroponic farm.

Predictability is another gamechanger. In outdoor farming, yields can vary widely due to weather events, pests and seasonal changes. Controlled-climate systems remove much of that uncertainty. Growers can produce consistent harvests week after week, regardless of what’s happening outside. This reliability is especially valuable for businesses and institutions that depend on steady supply, such as restaurants, grocery stores and schools. It also allows for better planning and forecasting, reducing the financial risks that often come with traditional farming.

Mobility is a unique and powerful feature of container farming in particular. Because these farms are built inside standard shipping containers, they can be transported to virtually any location. This means food production can happen closer to where it’s actually needed, whether that’s in urban food deserts, remote communities, disaster-stricken areas or even extreme environments where traditional agriculture isn’t feasible. Instead of shipping food across long distances, you can bring the farm directly to the consumer. This flexibility opens up entirely new possibilities for addressing food security challenges around the world.

Container farming plays a meaningful role in reducing supply chain demands and lowering the carbon footprint associated with food transportation. In the conventional system, produce often travels hundreds or even thousands of miles from farm to plate, requiring refrigeration, packaging and logistics infrastructure along the way. By growing food locally in controlled environments, many of these steps can be minimized or eliminated. Fresher produce reaches consumers faster, with less spoilage and fewer emissions tied to transport. Over time, this localized approach to agriculture can contribute to a more sustainable and resilient food system overall.

The future challenges mentioned earlier are conquerable, and human ingenuity in concert with more useful tech can help knock those obstacles aside one by one.