Season 2 | Episode 33: How Retrofitting and Rebates Can Transform Your Cannabis Facility

Season 2 | Episode 33: How Retrofitting and Rebates Can Transform Your Cannabis Facility

Episode 33_Landing Page

Summary:

Guest Speakers: Mitch Galton (Director of Business Development) and Brett Cherniack (VP of Sales) from Urban Gro, a company providing integrated design and engineering solutions for controlled environment agriculture (CEA) facilities.

Key Discussion Points:

Urban Grow’s Services:

Specializes in retrofitting existing facilities and energy-efficient solutions for cannabis cultivation and other CEA industries.

  • Offers architectural design, cultivation system integration, and equipment commissioning.
  • Retrofitting Cannabis Facilities:
    • Challenges include assessing existing infrastructure (power, water, and space layout), especially in transitioning non-cannabis buildings.
    • Planning is critical, focusing on utilities, space allocation, and goals before starting a project.
    • Importance of ensuring proper infrastructure (HVAC, lighting) before retrofitting.
      • Types of Retrofits:
        • Existing cannabis facilities needing upgrades versus non-cannabis facilities being converted.
        • Challenges with distressed assets, where companies failed, requiring complete overhauls.
        • Converting single-level facilities to multi-tiered systems to increase canopy space but requiring significant HVAC and lighting upgrades.
        • Building Selection for Retrofits:
        • Important to consider zoning, local regulations, utility availability, and city support when selecting a building for a retrofit.
        • Delays in power availability can derail timelines and budgets, sometimes taking up to 24 months to get proper utility infrastructure.
  • Energy Rebates:
    • Significant rebates available for upgrading lighting and HVAC systems, covering up to 100% of the costs in some cases.
    • Utilities have become more knowledgeable about cannabis cultivation and offer tailored energy efficiency programs.
    • Planning ahead for energy rebates can save a company substantial amounts, and waiting for rebate approvals (about 4 weeks) is strongly recommended before making purchases.
  • New Cannabis Markets:
    • Examples from new states like Alabama and Kentucky show the challenges of being the first to market, such as not having patients or customers yet.
    • Importance of scaling cultivation in phases to match market demand and avoid overbuilding.
    • Challenges in HVAC Rebates:
    • HVAC rebates are more complex to calculate compared to lighting due to constant system usage in cannabis cultivation.
    • Some states are developing more prescriptive rebate programs for dehumidifiers, a major part of HVAC systems in cultivation facilities.
  • Closing Thoughts:
    • Both Mitch and Brett emphasize the importance of detailed planning, especially when dealing with capital-intensive retrofits.
    • Urban Gro’s team has extensive experience in cannabis, helping cultivators make smart decisions regarding retrofits, new facilities, and energy rebates.

If you are a grower looking to optimize your cultivation facility or anyone looking to cultivate more in less space, then this is the show for you. Each week, join Host Michael Williamson as he travels across the country, to explore the world of vertical farming and the future of cannabis and food production through his conversations with leading industry operators, growers and executives who are demonstrating success and resilience as growers and cultivators. Each episode provides stories and key insights that will inspire and show you first-hand, how each of these companies have overcome challenges, and found their own path to success.

Get a FREE Grow Consultation

Season 2 | Episode 32: Engineering Excellence in CEA | Lessons from Mike Zartarian

Season 2 | Episode 32: Engineering Excellence in CEA | Lessons from Mike Zartarian

Episode 32

Summary:

In this episode of Cultivation Elevated, hosts Michael Williamson and Anders Peterson are joined by Mike Zartarian, an electrical and controlled environment agriculture design engineer and the principal at Zartarian Engineering and Precision AG. With over 20 years of experience as a design engineer and systems architect, Mike brings valuable insights into the complexities of indoor cultivation facilities.

 

  • Mike Zartarian’s Background:
    • Mike shares his journey from working as a design engineer to focusing on controlled environment agriculture, including his work in both indoor vegetable production and cannabis cultivation.
    • He co-founded Zartarian Engineering with Mike Siegel and has been instrumental in designing holistic cultivation facilities.
  • Challenges in Indoor Cultivation:
    • Mike discusses the unique challenges of designing and commissioning indoor cultivation facilities, emphasizing the importance of a holistic approach that considers the entire plant life support system.
    • He highlights the differences between growing cannabis and other crops like lettuce, noting that cannabis is particularly energy-dense and sensitive to environmental variables.
  • Commissioning and Tuning Cultivation Facilities:
    • The conversation delves into the critical process of commissioning a new facility, which involves ensuring that all systems operate as designed before plants are introduced. Mike stresses that skipping this step can lead to costly mistakes and crop loss.
    • He shares his approach to commissioning, which includes pre-operational testing, sensor placement, and gradually ramping up plant introduction to ensure optimal system performance.
  • Sensor Technology and Innovation:
    • Mike introduces the new canopy sensor array developed by Zartarian Engineering, which includes an IR sensor to measure leaf surface temperature—a critical factor in accurately calculating VPD (vapor pressure deficit) for cannabis crops.
    • The discussion covers the importance of accurate sensor placement and density, as well as the impact of leaf surface temperature on crop steering and environmental control.
  • Best Practices for Cultivation:
    • The episode concludes with practical advice for cultivation facility operators, including the need to balance optimization versus maximization in facility design, managing systems and teams effectively, and the importance of commissioning to ensure long-term success.
  • Conclusion:
    • Mike shares his deep expertise in CEA and indoor cultivation, offering listeners actionable insights into designing, commissioning, and optimizing indoor grow facilities. The hosts emphasize the value of Mike’s approach and suggest a potential follow-up episode to explore additional topics in more depth.

If you are a grower looking to optimize your cultivation facility or anyone looking to cultivate more in less space, then this is the show for you. Each week, join Host Michael Williamson as he travels across the country, to explore the world of vertical farming and the future of cannabis and food production through his conversations with leading industry operators, growers and executives who are demonstrating success and resilience as growers and cultivators. Each episode provides stories and key insights that will inspire and show you first-hand, how each of these companies have overcome challenges, and found their own path to success.

Get a FREE Grow Consultation

Cannabis Flower Room Using Drip-To-Drain Grow Trays

Effective Tray and Drainage Strategies for Vertical Grow Rooms

Effective Tray and Drainage Strategies for Vertical Grow Rooms

Cannabis Flower Room Using Drip-To-Drain Grow Trays

Water is fundamental to your cannabis cultivation business. It follows that proper drainage is crucial to prevent oversaturation and promote healthy plant growth. In cannabis cultivation, especially within vertical farming systems, the design and implementation of an effective drainage system can significantly impact overall productivity and plant health. 

Grow tray selection is integral to this process, as certain trays come equipped with grid systems to aid in proper drainage. Collaborating with a plumber skilled in vertical racking systems and grow rooms can make a substantial difference in determining the best approach for your facility.

Providing each plant with the right amount of water and nutrients is essential in any cannabis cultivation operation. In vertical farming, irrigation systems are typically automated, and a well-chosen drainage method will handle most runoff. However, the trays used should also play a role in preventing plant oversaturation. High-quality trays are designed to avoid issues like root rot or plant death due to excessive moisture. Trays with built-in or removable grid systems offer an effective solution for managing runoff, ensuring it reaches drains without causing damage to the plants.

Cannabis Grow Facility Using Multi-Tier Grow Racks with Airflow Solutions by Vertical Air SolutionsAs Michael Williamson, Director of Cultivation at Pipp Horticulture, explains, “Other trays on the market may yellow, crack, or break over time. We make sure everything we develop in-house is made for the long haul. [Our products] allow for seamless integration and maximize all of your footprint.”

Selecting the appropriate drainage system for your vertical farming setup can be challenging. Growers need to consider various factors, including water storage options, filtration systems, water sources, and irrigation strategies. What works for one facility may not be suitable for another, highlighting the importance of customizing your approach based on specific needs. 

For those uncertain about the design process, Pipp Horticulture offers professional recommendations and connections to local service providers. Various drainage systems are available, such as slotted drainage, ejector systems, and trough drainage, each offering unique benefits depending on the specific requirements of the cultivation environment.

Not Too Much, Not Too Little

Every crop needs water to develop, meaning growers must introduce an adequate draining system to capture runoff and prevent oversaturation. Tray selection also plays a critical role in this process, as some are fitted with grid systems to aid in proper drainage. Working with a plumber skilled in vertical racking systems and grow rooms can make a considerable difference when determining the best approach.

Tray Selection

Providing each plant with the perfect amount of water and nutrients is an essential operation of any cannabis facility. In vertical farming, this process is generally automated via some form of irrigation system. Your chosen drainage method will handle most runoff, but trays should also help protect plants from oversaturation. 

The best trays are designed to aid in preventing issues like root rot or plant death due to excessive moisture. Options with built-in or removable grid systems provide an outlet for runoff to reach drains effectively and freely.

Moreover, opt for durable grow trays built to withstand high humidity levels and hefty substrates. Growing media like Rockwool and Coco Coir can be heavy when fully saturated with solution, so girth is an important property to consider. 

Pipp Hort offers a range of grow trays expertly crafted with cannabis cultivators in mind. We recognize the need for reliability throughout the entire growth cycle, from seedling to flowering. 

As Williamson explains, “Other trays on the market may yellow, crack, or break over time. We make sure everything we develop in-house is made for the long haul… This isn’t our first rodeo–[our products] allow for seamless integration and maximize all of your footprint.”

Below are four Pipp tray options to consider:

  • Combination grow tray with optional HDPE inserts: These trays are made-to-order and optimized for Drip-to-Drain or Ebb-and-Flow systems. When desired, HDPE inserts can be installed to improve drainage. 
  • Drip-to-Drain Grow Tray with optional HDPE inserts: Akin to Combination trays, the Drip-to-Drain options are compatible with HDPE inserts for optimized drainage. Each tray features an aluminum base to prevent corrosion, while HDPE grids guard against pesky mold and mildew.
  • Airflow Grow Trays: This sectional tray was designed to eliminate airflow restrictions in a vertical farming system. Trays are perfect for Drip-to-Drain and suitable for any growing substrate, particularly Rockwool.
  • ABS Grow Tray: The ABS tray is Pipp’s lower-cost option constructed from durable plastic and equipped with built-in slopes. Like our other trays, the ABS provides UV stability alongside antimicrobial and antifungal properties.

Types of Drainage System

Selecting a drainage system may seem like a challenging feat. Growers must consider water storage options (e.g., tanks or reservoirs), filtration systems, water sources, and irrigation strategies. What works in one facility may not function appropriately in another, so remember this as you weigh different options.

Cultivators concerned about the design process can contact Pipp for a vetted professional recommendation. Our team has worked with countless experts, and we’re happy to connect you with a local service provider.

Below are examples of drainage systems for vertical farming systems:

  • Slotted drainage: Some vertical farms install drains perpendicularly below rack systems. Runoff simply empties into an on-site reservoir or tank for an easy drainage solution.
  • Ejector system: With this drainage system, water funnels into a catch before being ejected up and out into a reservoir.
  • Trough drainage: With this approach, excess water funnels into a trough via pipes attached to carriages before exiting into a reservoir.

Conclusion

Effective water management is the cornerstone of a successful vertical cannabis cultivation operation. Proper tray selection and drainage systems play a vital role in maintaining plant health and preventing issues such as root rot and oversaturation. By utilizing high-quality trays equipped with grid systems and partnering with experienced professionals, growers can ensure that their irrigation and drainage processes are optimized for maximum efficiency.

Pipp Horticulture’s range of grow trays and tailored drainage solutions provide cultivators with the tools needed to achieve reliable and consistent results. The durability and design of these trays help protect plants throughout their growth cycle, while the various drainage options available can be customized to meet the specific needs of each facility. 

Selecting the right drainage system involves considering several factors, including water storage, filtration, and irrigation strategies. It’s essential to choose a system that aligns with your facility’s unique requirements to ensure smooth operations and prevent potential water management issues. We offer expert guidance and connections to local service providers, helping growers navigate the complexities of the design process.

By focusing on the details of water management and collaborating with knowledgeable professionals, you can enhance plant health, improve productivity, and ensure the long-term sustainability of your cultivation operation.

Cannabis Growers Using Pipp Horticulture at Culta

Get a FREE Grow Consultation

Using Catwalk to Service Second Level of Cannabis Plants

Start With the End in Mind When Laying Out Your Mobile Racks

Start With the End in Mind When Laying Out Your Mobile Racks

Using Catwalk to Service Second Level of Cannabis Plants

When planning your vertical grow room layout, it’s essential to start with the end in mind. The foundation of a successful grow operation begins with choosing the right racking system, one that accommodates your current needs and anticipates future growth. 

Growers must account for several critical factors beforehand, including available space, compliance regulations, and long-term cultivation plans. Overlooking these elements can lead to significant challenges down the road, potentially disrupting your operations and impacting your bottom line.

Working with an experienced team of designers, technicians, and support professionals can help ensure that you make informed decisions and integrate your racking system seamlessly. 

As you develop your plans, room by room, you’ll encounter an array of variables that will help or hinder your aspirations. Understanding the best practices of grow room design and mobile racking capabilities will get you moving in the right direction.

Mobile Racking Decisions

Airflow System for Canna | VAS 2.0The first step in designing a vertical grow room layout is choosing a racking system. Growers must account for various factors beforehand, including available space, compliance regulations, and future cultivation plans. 

Forgetting about these critical considerations can ultimately lead to problems down the road. Our best advice is to always work alongside an experienced team of designers, techs, and support professionals to ensure proper decision-making and seamless integration.

Pipp Vertical Racking Systems are tailored to fit each unique facility. You can use our Room Generator Tool to create an interactive 3D floor plan based on your available canopy space. 

Here are just a few things to consider when integrating a vertical racking system:

Room Dimensions & Obstructions​

The size of your grow room (e.g., length, width, and ceiling height) dictates much of the racking system setup. By calculating the area of your space, your design team can recommend the ideal amount of aisles necessary for your production needs.

Equipment Width & Material​

Racks and grow trays house the heart of your business–your plants. Naturally, you want to ensure these structures are made with top-quality materials to protect your crops from pathogens, pests, and disease.

Pipp’s Vertical Grow Racking Sytems fitted with Mobile Carriages are crafted with cultivators in mind. Each stainless steel, UV-stable rack is covered with an antibacterial and antifungal coating to prevent the spread of plant-killers like mold and mildew. 

Another key consideration is aisle width. Growers should leave ample space for multiple teams to interact with plants simultaneously. Keeping aisles between 36 and 54 inches wide allows for tandem work while helping prevent accidents due to tight quarters.

Compliance​

Compliance laws can vary depending on the location of a facility. For example, some states like California must meet specific seismic regulations in preparation for unexpected earthquakes. In these cases, Pipp’s low-profile racking systems with optional anti-tip features offer an all-in-one solution. 

Regardless, any cultivator can benefit from implementing an anti-tip system. This simple addition can protect plants and employees from harm. In the words of Michael Williamson, Director of Cultivation at Pipp Horticulture, “I can always grow more plants, but I can’t grow more people. So, keeping your employees safe is priority number one.”

Space for Growth

Whether you have current expansion plans or simply exploring the idea, chalking out canopy space for increased yield capacities is a great investment. Doing so doesn’t need to be difficult, either!

Leaving room for growth can be as easy as adding another tier to your vertical racking system. If you need one level at the moment, implementing a second with wiring and HVAC in place means you can add the second level to your current rack setup whenever ready. 

Williamson explains, “When planned appropriately, you know if your electrical distribution is in place from the beginning, you may want to consider building a curb for future [equipment]… having all that prep means phase 2 is as simple as adding a second tier, installing lights and plugging it in.”

Now, a best practice when sizing a veg canopy is to allocate between 20 and 30% of your total flowering footprint to vegetative growth. Square footage may vary if facilities have a combined veg, mother, and clone room as opposed to separate spaces. 

Regardless, the ideal size for a racking system is 32-40 ft. in length and 10-15 ft. in height. Triple-tiered racks are typical, but facilities with smaller inventories may consider double-tiered solutions instead. Regardless, these dimensions set you up for success as you create a functional veg room layout (and they apply to flower rooms, as well).

Safety Measures

When designing a vertical racking system, always assess your space for existing and planned safety measures. Fire extinguishers, smoke detectors, sprinkler systems, fire escapes, and sanitation stations are just a few examples of necessary obstructions that can influence the layout of your grow room.

Cultivators should also train employees on properly using these safety precautions and operating racking systems. Education is key to protecting the well-being of your employees and crops. Pipp’s field experts are available to guide both you and your team as you adapt to new equipment.

In the words of Michael Williamson, Director of Cultivation at Pipp Horticulture, “I can always grow more plants, but I can’t grow more people. So, keeping your employees safe is priority number one.”

Get a FREE Grow Consultation