Mobile Vertical Farming

Retro-Commissioning for Cannabis Cultivation: Fixing Inefficiencies and Maximizing Facility Performance

If your cannabis facility wasn’t properly commissioned before startup, you’re not alone. 

Many growers rush to bring plants in, only to encounter inefficiencies, regulatory issues, and underwhelming yields. Fortunately, retro-commissioning (RCX) offers a structured way to assess and optimize facility systems, improving efficiency and profitability without requiring a complete overhaul.

Retro-commissioning is the process of evaluating, testing, and recalibrating existing facility systems to improve performance—whether they were never commissioned properly or have simply degraded over time. 

This article provides a comprehensive technical roadmap to optimize facility operations even if you’ve already moved the plants in.

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Cannabis Facility Commissioning Done Right: A Guide to Success

Cannabis Facility Commissioning Done Right: A Guide to Success

Starting a cannabis cultivation operation is no small feat. From intricate systems to regulatory hurdles, every decision in the early stages has lasting consequences.

Commissioning is the critical but often overlooked foundation for long-term success in cannabis cultivation facilities–one that safeguards efficiency, compliance, and profitability.

This is an important starting point in the lifespan of a building designed for cannabis cultivation. Commissioning your facility upfront ensures that all systems, such as HVAC, lighting, fertigation, and irrigation, are functional and operating as intended before plants are introduced.

This article will explore the importance of commissioning, the hidden costs of skipping this step, and practical strategies to integrate commissioning into your facility’s startup plan.

What Is Commissioning, and Why Is It Important?

Commissioning, often abbreviated as CX, is a structured process to verify that all critical systems in a cannabis facility—including environmental controls, fertigation, and HVAC—are installed and functioning optimally.

Essentially, did you get what you purchased, and does it work? Overlooking that fundamental question is a mistake. That question is broken down into a comprehensive sequence of testing and calibrating equipment, resolving potential issues, and gathering baseline data before any plants are introduced.

Why Is It Overlooked?

Despite its benefits, commissioning is often skipped due to cost and time pressures. 

Cost and time constraints are a common hurdle. We all understand this, but it’s important not to get hung up on those simplistic business blockers. Those pressures can lead cultivators to move plants into a facility before it’s truly ready for operational success.

Along those same lines, profit margins remain thin across the board. While this might push some early businesses to get plants out the door as quickly as possible, this feeling of urgency belies the necessary diligence required to set up an efficient facility. Get things done early, and you’ll encounter fewer problems later.

This is particularly common among new market entrants who may lack the expertise to fully understand the consequences of rushing the process. Instead of prioritizing commissioning, many cultivators focus on getting their operation up and running as quickly as possible. They often believe that an operational issue can be addressed as it arises.

Not so.

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The Hidden Costs of Skipping Commissioning

Skipping commissioning might save time initially, but the long-term consequences can be devastating. 

Here are some of the hidden costs:

1. Inefficiencies and Downtime

Cannabis facility commissioning is best done right out the gate. Think about it: It’s far more difficult to course-correct mid-flight. Set your trajectory correctly the first time, and you’ll reap the benefits of greater efficiencies during the many production cycles to come.

The startup phase often results in a learning curve where yields and or quality may not meet expectations during the first few harvests due to system and process inefficiencies. This is familiar to all growers. That startup phase is universal; it is the first operational phase of the facility once plants are brought in and cultivation begins.

But commission takes place before that phase–and can truly help mitigate future problems.It’s much easier to commission a facility with no plants in it, of course. Once the plants are in, the rooms rely on those systems to grow and live. It’s a living, breathing organism. The idea with commissioning is that the team will pressure-test everything and make sure that everything’s functioning so that when plants arrive, no one needs to worry about having something fail and having to bring a whole system down.

2. Reduced Yield and Quality

Cannabis plants are highly sensitive to environmental fluctuations. Poorly calibrated systems can lead to stunted growth, pest infestations, and reduced potency. 

Low yields and even crop loss: These issues are avoidable with proper commissioning.

 

3. Higher Operating Costs

Energy inefficiencies, labor inefficiencies, and unplanned maintenance can significantly increase operating costs. This proactive approach can save cultivators significant costs associated with downtime, rework, or losses due to suboptimal growing conditions.

4. Beyond Compliance

Meeting compliance requirements for certificates of occupancy is one thing–and an important one. But COs only cover so much in their legal mandates. 

A CO, while necessary for legal compliance, does not guarantee that the facility is fully ready for cannabis cultivation. A CO only confirms the facility is safe for occupational or occupancy according to the building codes. It does not verify that critical systems like HVAC, fertigation, lighting, and environmental controls are functioning and at optimal levels for plant health and yield.

Planning for Success: Steps in the Commissioning Process

Proper commissioning requires careful planning and execution. Here’s a simple roadmap:

1. Pre-Commissioning Planning

  • Involve all stakeholders, including engineers, contractors, and facility managers.
  • Develop a comprehensive checklist of systems to be tested.

2. Testing and Calibration

  • Perform functional tests on all major systems.
  • Create airflow and temperature maps to identify dead spots and microclimates.

3. Documentation and Handover

  • Gather baseline data for future optimization.
  • Train staff on system functionality and troubleshooting.

Retro-Commissioning: A Second Chance for Facility Optimization

For facilities that have already skipped commissioning, retro-commissioning (RCX) offers a second chance to get it right.

There are opportunities for you to fix some things that you probably have been beating your head against the wall for a while. Fear not.

Retro-commissioning seeks to improve how building equipment and systems function together. It can resolve issues that were overlooked during the design or construction phase or have developed over time.

Steps in Retro-Commissioning:

  • Conduct a comprehensive facility audit.
  • Test systems for accuracy and consistency, such as irrigation output.
  • Implement temporary fixes, like manual irrigation systems, while optimizing long-term solutions.

Building a Culture of Data-Driven Optimization

Commissioning is not a one-time effort. It sets the stage for ongoing optimization through data collection and analysis.

Use Baseline Data Effectively

Third-party commissioning involves hiring an independent external form, firm, or consultant to perform the commissioning process. A third-party firm provides an unbiased assessment with no vested interest in the project’s design, installation, or ongoing operations. The baseline data provided by a firm like that is incredibly valuable. 

Third-party commissioning firms provide detailed reports, they perform diagnostics and certifications, and they hold equipment manufacturers and installation teams accountable for any deficiencies. 

These design, review, and final commission reports can be extremely useful to set a baseline for how your systems are functioning at the beginning of your facility. That gives you a baseline so that over the life of your facility, you can determine if your equipment is losing performance or starting to malfunction.

Regularly Update SOPs

Standard operating procedures (SOPs) should evolve based on lessons learned from commissioning and retro-commissioning. 

Don’t leave SOPs on a shelf. Update them regularly and test their efficacy.

Engage Your Team

Encourage feedback from staff. This basic principle can help you avoid those hidden costs. It’s not just your cultivation team that will navigate the choppy waters of an uncommissioned facility. 

If you’re not going to commission your facility, your production schedules are going to be all over the place. While you’re integrating or repairing a new system, it can throw off all your timelines, leading to delays and causing challenges for your wholesale team or your retail team when they’re trying to predict how much crop is coming downstream.

Avoid that through commission. And double down on the feedback loop your team can provide.

Conclusion

Commissioning is a sequence of important steps to follow early in a cultivation business’s life. It is the foundation for long-term success in cannabis cultivation. 

Skipping this critical phase can lead to inefficiencies, regulatory issues, and financial losses. By prioritizing commissioning, operators can mitigate risks, optimize their systems, and position themselves for sustained success.

When you look at the useful life of these facilities, is two weeks really going to make or break your business plan? Proper commissioning pays dividends in the long run.

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Pipp Storage-5 (2) (1)

From Single-Tier to Multi-Tier: How Buckeye Relief Plans Ahead in Ohio’s Dynamic Cannabis Market

Ohio formally began adult-use cannabis sales on Aug. 6, 2024. Excitement from both the licensed business community and the consumer market was tremendous. Dispensary lines ran out the door across the state, conveying the surge of demand now making its way into the marketplace. 

This is a significant development for the state: The three dozen licensed medical cannabis cultivators were given the first shot to enter the adult-use space to jumpstart the market ahead of any future expansion in licensing. And with a medical cannabis patient base of around 175,000 (as of 2022), that surge in demand for adult-use cannabis will prompt a dramatic swing in supply.

How should a cultivation business prepare for this expanded customer base?

Buckeye Relief has been preparing since 2016 and planning for the growth of the Ohio market. They chose equipment providers that could provide scalable solutions that would adapt to their needs. They served the medical market with high-quality medicine and built a loyal following. They planned for scalability from day one, transitioning from a single-tier to a multi-tier cultivation facility in preparation for that demand surge. 

Today, they are poised and prepared to be a market leader in high-quality cannabis products across the state.

The Cannabis Market in Ohio

Ohio became the 24th state to legalize adult-use cannabis, and regulatory agencies across the U.S. have had an opportunity to craft rules that might inspire the state’s impending switch. Essentially, though, Ohio is simply expanding its existing medical cannabis infrastructure to the broader marketplace, with more changes expected in the coming years. 

As of the sales start date in early August, 12 of Ohio’s 36 medical cannabis cultivation businesses had received approval for adult-use operations. More of those medical businesses will undoubtedly come online in the adult-use market, but for now, that supply stream must support some 98 dispensaries across the state (again, with more to come in the future). 

Those licensed cultivation businesses include Buckeye Relief, a Level-I cultivation company based in Eastlake, Ohio. Matt Kispert, Vice President of Cultivation at Buckeye Relief, recently shared the company’s preparations for this moment—and the anticipated challenges and opportunities.

In the run-up to the actual start of sales, Kispert emphasized the importance of compliance and logistical planning as they gear up for adult-use sales. While future legislative changes are expected to have more significant impacts, the general idea in Ohio is simply to greenlight a new supply chain for adult-use sales alongside the existing stream of medical products and sales. Compliance is still everything in this

The Buckeye Buildout - Pipp Horticulture Mobile Vertical Grow Racks

business. 

“Our focus has been on our packaging line: getting everything organized so we can make sure there’s a full distinction between medical and adult-use products,” he said. Buckeye Relief has meticulously organized its packaging workflows to ensure clarity and compliance.

That self-auditing work is an ongoing process; Buckeye has been in business since 2017, and that history already includes a notable expansion to a second level of multi-tier canopy space to meet Ohio’s medical market demands early on. 

Optimization of their multitier cultivation facility has made them a market leader in operational efficiency. 

Early on, Buckeye Relief began searching for qualified solution providers that would set them up for long-term success. For racking, Buckeye Relief needed a system that would start as a single-tier design and be converted to multi-tier as the market matured and adult use was legalized. 

“This was a single-level grow for the first couple of years,” says Curtis Dadian, Director of Business Development for Pipp Horticulture. “However, because of the adaptability of the Pipp racking system, they were able to easily add that second level as they had planned and prepared for during the initial construction and at that time integrated VAS. They were also one of our six beta sites for the Elevate catwalk system and realized significant efficiency gains with that product. They use Elevate today, every day, and love it.”

LISTEN: A Recipe For Success From Ohio’s First Medical Cannabis Cultivator – Buckeye Relief

That scalable equipment met Buckeye’s needs from day one–and gave the business an easy on-ramp to expansion.

“We anticipated growth by looking at other states and positioned ourselves to add cultivation space quickly,” Kispert said. “It took us six weeks to double our production space for the medical market.” This foresight has positioned Buckeye Relief advantageously now as the market expands. As the team prepared for 2024 and the imminent start of adult-use sales, the facility was outfitted with everything they’d need to increase production quickly.

The key? Start slow and grow with the market.

When Ohio opened its doors for adult, use this past summer, Buckeye Relief was prepared with an efficient multi-tier cultivation space and state-of-the-art curing space. In addition, they were an early adopter of the Elevate decking system, which reduces labor and allows employees to complete plant management activities safely.

Genetics Are Key

So, what does that look like in 2024? 

One of the company’s key strategies for growing into this adult-use supply curve has been genetic selection. Kispert stressed the importance of evaluating and optimizing the strains they grow.

Some of the main factors impacting the performance of these cultivars are tier spacing, airflow, light intensity, fertigation, and environmental conditions, which optimize phenotypic expression.

“We’ve been reevaluating every strain, looking at performance metrics, and shifting toward varieties that yield better and are easier to grow,” Kispert said. “Those are the ones we’re shifting the weight in the rooms toward, and we have been doing that for the last year or so because we’re steering a barge. We can’t just suddenly grow all new [genetics] overnight. So, we’ve been changing our room balances in that direction for a while now just to naturally bring our production levels up through genetic selection alone.”

Optimizing phenotypic expression takes work. Getting the most from every cultivar by managing the primary cultivation inputs requires diligence, patience, and the right genetics. Many factors impact plant growth, but getting a few dialed in, like the tier spacing and airflow management, for a two-tier flower room can be a game changer for production.

Kispert pointed to a Super Boof cross that the team has been running for about eight months. In the last three weeks of production, he says, the plant grows to massive proportions. 

By choosing purpose-built mechanical solutions, collecting data, and continuously updating SOPs, the Buckeye team can maximize the potential of every cultivar it currently has and plans to release in the future.

Buckeye Relief has revamped its processing wing to further capitalize on that move, investing in new equipment and retraining staff to maximize efficiency and product quality. 

Maintaining quality and consistency amid market changes is paramount at a basic level. While acknowledging trends in cannabis cultivation, Kispert reiterated Buckeye Relief’s commitment to delivering reliable products. 

“Our mission statement has always been quality and consistency. We want to put out the best product, even if that means sticking with genetics that some might view as a little old,” he said. Kispert believes this approach will ensure repeat sales and build strong brand loyalty.

For Buckeye, it’s about more than chasing the next best thing. Instead, it spends time refining its systems and applications to provide a dependable, high-quality consumer experience for anyone who enjoys its products.

Cannabis Cultivation at Buckeye Relief

Future Growth

As Ohio’s cannabis market transitions, Buckeye Relief also focuses on the end consumer experience. Kispert discussed the role of dispensary workers in educating consumers about product quality beyond THC content–another hallmark of state markets switching from medical cannabis to adult-use sales. The consumer, broadly speaking, is on an education curve as that transition happens. 

“Hopefully, with adult use happening now, we’ll see more dispensary workers able to provide firsthand experience with the products and steer people toward things based on conversation, not just potency,” he said.

Looking ahead, Buckeye Relief is planning further expansions to accommodate the expected surge in demand. 

“We’re in the process of designing another expansion, but we won’t be turning the lights on until probably this time next year,” Kispert said. 

In the meantime, the company is streamlining its product offerings to ensure they can meet demand without compromising quality. “We’re tightening up our SKU profile to be as consistent as humanly possible,” he added.

Buckeye Relief and the rest of Ohio’s cultivation businesses face an all-important transition that many businesses have confronted in other states. The team is setting priorities, such as a strategic approach to genetic selection, operational efficiency, and consumer education. Those ideas will become more critical to a growing consumer base as Ohio’s market expands.

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Vertical Grow System

How Vertical Farming Helps the Environment: 5 Benefits

Growing food is a necessity, but how we grow it matters. The right approach can mean the difference between resource waste and smart conservation. As sustainable farming takes center stage, indoor cultivation facilities are turning to advanced lighting, climate controls, and technology to boost efficiency while minimizing waste.

All areas of agriculture, including cannabis cultivation, are adopting SOPs, IPM strategies, and fertigation approaches that account for the health of the plants and those who work with them. With vertical farming, cultivators can increase yield while supplying more food or medicine with less space.

Are you interested in learning why vertical farming is essential for the planet? Join the team at Pipp Horticulture as we explore five sustainable advantages.

1. Increased Yield and More Happy Customers

Usable agricultural land is rapidly declining with rising populations and urbanization. However, vertical cannabis facilities require less space, even when housing thousands of plants. Growing upwards rather than outwards allows cultivators to retrofit pre-existing buildings to accommodate increased crop sizes and yields. 

Cultivating in food deserts or places with limited supplies is where urban multitier facilities can reduce transportation miles and storage, reducing their carbon footprint and ensuring customers receive the freshest products.

Moreover, growers can plant their roots nearly anywhere, from untillable deserts to city-based warehouses. This allows creative cultivators who use fully mobile multitier racking to meet yield requirements in smaller, higher-priced spaces.

Our designers at Pipp recognize the necessity of remaining nimble, adapting to building floorplans, and providing solutions on a case-by-case basis. Vertical Grow Racks allow you to produce in rooms with pillars and structural limitations, but you will always have several options to consider. Reach out to Pipp to explore creative solutions for your space that maximize your cultivation output.

2. Water Use Efficiency

Vertical farms are designed with attention to water management, allowing for precise management at various stages of the water life cycle. This accuracy helps decrease water consumption by 95% or more

Indoor cultivation facilities can recycle water from fertigation and dehumidification. While water needs assessment and treatment before reentering the cycle, various filtration technologies make 100% reuse a reality. Additionally, irrigation can be automated, calibrated, and adjusted while the runoff is measured, allowing for the fine-tuning of a media management strategy.

3. Curbs Pesticide & Fertilizer Use

As mentioned briefly above, the nature of indoor farming protects against pests and the elements, meaning chemical use is limited. Automated fertigation systems deliver the precise amount of nutrients needed — at the right time — to maintain plant health and media management metrics. These controls allow cultivators and IPM management teams to create protocols that reduce risk and pesticide/pathogen treatments used to mitigate outbreaks.

Due to the consistent and clean environment, vertical farming systems allow more effective IPM applications and accurate plant management systems. With established preventative measures, cultivation facilities can scale effectively while using less pesticides and fertilizer.

4. Data Collection

So, how does building a sophisticated multitier facility change agriculture? Data. Accurate measurements drive improved room utilization and fertigation/airflow management while lowering production costs per pound of tomatoes or cannabis.Cannabis Grow Facility using Mobile Vertical Grow Racks

Data also underscores production metrics like grams/sf and price per pound, specifically in an indoor cultivation facility. Growers have multiple data-collecting opportunities to achieve the highest return on every kilowatt-hour or resource used.  

For instance, controlling light intensity, adjusting temperature/humidity, and modifying airflow offer significant advantages over traditional farming methods. This level of control yields consistent results and provides avenues for improvement.

Furthermore, data from indoor agriculture has influenced traditional agriculture as the adoption of evolving purpose-built technology increases. Data is such a broad concept, but by focusing on the KPIs that matter to your business and collecting data that has an impact, you can confidently invest in the solutions you need.

5. Quality

Proper lighting, room pressurizations, quality SOPs, and environmental/fertigation controls help maximize cultivar expression in cannabis and bioflavinoid production in basil or prevent bolting in lettuce across tiers. 

Still, indoor vertical farming isn’t about packing as much canopy into a room as possible. Instead, you optimize space and ensure every mechanical system works together seamlessly. 

For example, the spacing between tiers should be carefully calibrated to your lighting setup, as this directly impacts plant performance. By understanding how racking, lighting, HVACD, fertigation, and genetics interact, you can fine-tune each cultivar to achieve its full potential.

One of the best ways to diagnose problems and maintain plant health is through regular inspection for pests, pathogens, and canopy management through defoliation. Pipp creates Mobile Carriages with easy access in mind, so you can easily access, remove, and treat plants when necessary.

This ability to provide consistent customer quality translates to brand awareness, growth, employee pride, increased revenue, and new possibilities. Ultimately, you can reinvest in the facility and your team, encouraging further development.

The Future of Vertical Farming

The vertical farming industry, valued at $5.6 billion in 2024, continues to boom, with projections estimating a value of $41.21 billion by 2032. Sustainability-seeking cannabis growers are catching on to the numerous benefits, transitioning their practices at an annual rate of 18.5%

Pipp Horticulture is here to help cultivators like you adopt eco-friendly practices to help combat climate change and pollution. Better yet, you can significantly boost yield, quality, and revenue in the process. 

From mobile racking systems to grow trays, our team of experts has you covered, allowing for seamless integration into your current (or newly designed) grow facility. Contact us today for a consultation and more information about why Pipp remains the industry-leading indoor vertical farming solutions provider. 

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Ultimate Grow System

5 Common Vertical Farming Challenges & How to Address Them

Vertical farming offers a transformative shift from traditional cultivation methods that can limit business growth and scalability. By utilizing vertical space, growers can significantly increase yield potential, positioning commercial cannabis facilities for higher profit margins and a competitive edge.

However, no cultivation method is perfect. Vertical farming presents minimal challenges, which can be seen as an opportunity. Still, while securing funding, equipment, and a quality team can be difficult, every obstacle has a corresponding solution.

Below are five challenges of vertical farming and how to overcome them:

1. Air Cycling & Airflow Management

Due to the density of plants and racks, ensuring proper airflow, air cycling, and exchanges in vertical setups can be difficult. To maintain environmental setpoints, you must address the capacity of your HVACD system, additional airflow systems, and the location of your supply air and return vents.

Solution

Pipp Horticulture’s VAS 2.0 Airflow Solution mitigates these challenges by providing additional, targeted airflow that optimizes air exchange in multi-tier setups. This system works hand-in-hand with HVAC, ensuring air circulates evenly through all levels, preventing dead zones, and improving overall plant health.

2. Phasing Your Build-Out

Building an entire multi-tier facility from the start without prior experience is risky. Growers often underestimate HVACD, electrical, and COG requirements, leading to inefficiencies and wasted resources. Phasing allows for better planning and adjustments based on accurate data and operational experience.

Solution

Implement a phased approach by starting with a few multi-tier rooms. This way, you can fine-tune SOPs, COGs, and infrastructure needs. Once you’ve dialed in these initial processes, you can confidently scale by applying lessons learned to the rest of your facility. Another option is to start with a single tier and add a second later, but you will need to make HVACD, airflow, and lighting adjustments along with this transition.

3. Defoliation, IPM Application, & Multi-Tier Access

Accessing plants on the second or third tier can be intimidating, especially for defoliation, pest control, and harvesting. Traditional solutions, such as scissor lifts or rolling library ladders, are inefficient and unsafe, limiting one’s ability to scale operations effectively.

Solution

Pipp’s ElevateⓇ Platform Solution offers safe, strong, lightweight access to higher tiers. This easy-to-use decking option simplifies the defoliation and harvesting process, eliminating the need for bulky systems, streamlining production, and promoting employee safety.

4. Planting Density & Genetic Adjustments

Adapting to a multi-tier system may involve adjusting planting density or plant height. Plants need proper space to receive appropriate inputs and the correct tier spacing to accommodate their morphology. Genetics can also dictate how you support the plants, defoliate and move air, and fine-tune your plant layout.

Solution

Choose genetics that perform well in multi-tier environments, modify planting density accordingly, and adjust SOPs for canopy management. Racking should have appropriate spacing between tiers to accommodate airflow by accounting for media size, plant size, lighting intensity goals, and fixture form factor. Additionally, plan for increased plant demand by expanding mother and vegetative operations to meet the needs of a larger flowering canopy.

5. High Capital Investment

Building a vertical cannabis cultivation facility requires a higher upfront investment than traditional single-tier setups. On average, a multi-tier operation costs about 60% more to construct than a single-tier facility due to the need for more equipment. However, the upfront costs are quickly offset by the increased production.

Solution

Talk to experienced multitier cultivators and solutions providers to make a well-vetted plan for your project. View the capital as a long-term investment and take advantage of rebates and efficiencies in equipment selection to reduce the operational costs of your facility.  Although initial costs are higher, the ability to double yield capabilities in the same footprint lowers the construction costs per canopy square foot below single-tier options and provides long-lasting operation efficiency. 

Industry leaders like Pipp Horticulture recognize that adopting a vertical farm system is a significant change for our growers. We offer an extensive range of online instructional videos, webinars, articles, and ebooks to prepare you and your team for this exciting new cultivation experience and help you make the most informed decision regarding your capital investment. 

We even created the Cultivation Elevated podcast for on-the-go listening. With information covering everything from clone propagation to storage, high-quality SOPs are constructed and managed much easier.

Conclusion

Cannabis cultivation is a skill that takes time to master—the same applies to vertical cannabis cultivation. 

You’ll inevitably encounter setbacks as you gain experience, make mistakes, and develop a unique methodology. Nevertheless, the final results are worth the dedication and hard work. Having support throughout the developmental process helps sweeten potential outcomes. For this reason, consider collaborating with Pipp on your next vertical farm project. 

Pipp Horticulture brings decades of industry knowledge from cannabis cultivation. We can guide you through each step of the racking design, layouts, and best use cases. Regardless of facility size, production goals, or industry background, we’ll share our experiences to ensure your team is ready to tackle any challenges head-on. 

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Pipp Horticulture at Sozo

The Importance of SOPs in Your Cannabis Operation

As the cannabis industry quickly expands, cultivators must recognize the importance of Standard Operating Procedures (SOPs). Practical facility-wide guidelines promote consistency to ensure smooth operations. 

Not only are SOPs essential for maintaining the highest quality of your company’s products, but they foster open communication, camaraderie, and risk mitigation. The benefits of those team skill sets will ultimately improve your bottom line. 

At Pipp Horticulture, our cannabis cultivation team has over a century of experience. With thousands of rooms installed, collected customer testimonials, and measured data, we’ve witnessed the impact of good SOPs. We hope to inspire you to refine and refresh fundamental practices to ensure consistent outcomes in the garden. 

The Importance of SOPs in Cannabis

For cannabis cultivators, SOPs are often the heart of operations. Generally, SOPs direct the growing, harvesting, drying, and packaging of products to ensure that every customer receives the same results. Ultimately, this standardization helps with training, scalability, plant health, customer satisfaction, and company culture.  

Here are a few examples of SOPs in the cannabis industry:

Cultivation SOPs

Cultivation-specific SOPs pertain to anything related to direct plant interaction. SOPs are paramount for ensuring proper defoliation, replanting procedures, and integrated pest management. These foundations of fertigation, data collection, and systems management are necessary to prevent common grow room mistakes

Below are common examples of cannabis cultivation SOPs:

  • Fertilizer dilution rates per growth stage
  • Foliar IPM application procedures 
  • Environmental setpoint itinerary for temperature and humidity
  • Defoliation per growth stage 
  • Propagation
  • Taking cuttings from mother plants
  • Measuring media moisture content
  • Grow room sanitizing

SOPs for Vapor Pressure Deficit

But let’s get a little more specific about controlling the vapor pressure deficit and reacting to changes in the room. You need a calibrated emissivity adjustable IR gun set to 0.97 to collect accurate leaf temperature. Then, use that data to adjust the temperature and humidity in the space to achieve your target. Initial data collection must be accurate and consistent because it will directly impact setpoint changes for the room. Cultivation SOPs should include training on how to use the tool, where and how to measure the plant, where to sample in the room, and when to measure data.

With this information, you also have a valuable plant canopy heat map that shows where you could utilize more airflow to eliminate hotspots. Leaf temperature data can also help you adjust your HVAC system to achieve the ideal 78-82F temperature for vitality. In late-stage senescence, this data can drive the efficiency and effectiveness of color-changing cultivars.

Cultivation SOPs mitigate risk, increase plant vitality, and inform the application of mechanical solutions. Accurate and up-to-date information informs SOPs and translates to an efficient facility.

Processing SOPs

Similar to cultivation SOPs, processing policies dictate what happens after harvest, including handling, trimming, curing, packaging, and storing cannabis. These SOPs ensure consistency and safety while minimizing touches and protecting product quality. Ultimately, you honor the bottom line by protecting integrity and providing a consistent customer experience.

Here are some standard cannabis processing post-harvest SOPs:

  • Drying and curing practices for loading the space
  • Daily airflow strategy in curing
  • Transitioning fresh flower from racks to mobile units
  • Handling, sorting, packaging, and labeling final products 
  • Hand trimming / Trim machine operation 

Administrative SOPs

Remember, constructive background work is what drives successful operations. Administrative SOPs concern leadership roles and overall facility management. These consistencies prevent miscommunications, streamline facility management, and facilitate informed decision-making. 

These are essential cannabis administrative SOPs to implement:

  • Employee responsibilities 
  • Waste storage, processing, and removal
  • Safety procedures
  • Emergency procedures (e.g., fire, chemical spills, personal injury, etc.)
  • Leadership hierarchy
  • Continued Compliance
  • Monitoring supply levels (e.g., nutrients, fertilizers, etc.)
  • Supplier communications
  • Decision-making process for resource allocation

The Benefits of Implementing SOPs Now

As state mandates shift, cultivation facilities become more efficient, and the market becomes more competitive. SOPs provide an opportunity to streamline production and are the building blocks of continuous improvement. In short, SOPs are multipurpose handbooks that offer numerous benefits.

1. Consistent Results

The most consequential aspect of a well-developed SOP strategy is consistency. This element is necessary to achieve predictable results and manageable cultivation facilities. Consistency also translates to brand identity, thus directly impacting customer loyalty. Ultimately, SOPs can significantly streamline the entire operation. 

Moreover, SOPs provide the direction necessary to produce top-quality yields, time and time again. Of course, this roadmap will differ across facilities. However, the goal is to optimize plant expression by managing mechanical solutions. Running an efficient facility takes a well-informed, well-trained team versed in executing the proper gameplay.  

To know if your SOP system works, put yourself in your customers’ shoes. According to Michael Williamson, Director of Cultivation at Pipp, “Many people don’t consume their own product on a regular basis, but doing so might be the best form of quality control.”   

2. Bump-Free Operations

Even with established SOPs, cannabis facilities don’t run like well-oiled machines. Equipment breaks, mistakes happen, and the industry is never stagnant. You must be nimble. SOPs allow you to overcome obstacles faster, build a team, and empower others to thrive. 

Dante Metaluno, co-director of cultivation at Redbud Roots, expands on implementing staff roles with distinct responsibilities. He says, “Accountability is the main thing. We took several of our most experienced crew members and made them building managers. This change has gone wonderfully. We’re not just hopping around constantly, putting out these small fires.”

3. Reduced Expenses

You can lower the risk of costly errors remarkably with well-crafted SOPs. Thoroughly trained team members understand where their work stops and ends, helping minimize the urge to get involved in other areas where they need more familiarity. 

Some examples of where clear procedures will save money include:

  • Reduced cloning failure rate 
  • Reduced plant stress
  • Efficiently utilize energy, water, and labor
  • Reduced nutrient costs
  • Prevention of costly employee errors

4. Risk Mitigation

Another perk of a SOP strategy is elevated safety measures. Cultivation SOPs for plant management are critical, but employee safety takes precedence. Clear directives on loading plants onto racks, safely accessing decking, and following IPM protocols can significantly impact workflow, plant health, and team satisfaction.  

In your SOP guidebook, include a comprehensive explanation of correctly using equipment and responding to emergencies. Equip employees with as much information as possible so they feel ready to tackle tasks confidently. Adequate training also prevents legal complications, worker’s compensation, or similar setbacks.

5. Maintaining Compliance

Laws and requirements vary significantly from state to state. SOPs tailored to these specifics ensure your facility remains compliant and legal, no matter what curveballs the government throws your way. Consistency eases any worries about employees making severe blunders, such as using the wrong pesticides, contaminating crops, or labeling products incorrectly.

6. Effective Training Guidelines

SOPs serve as a definitive template for employees to follow. Writing a step-by-step guide with onboarding information, core duties, and operating procedures means staff can seamlessly adapt to their roles–even if they regularly shift between departments.

According to Metaluno, “The best part is that, with the ebb and flow of labor, we can just move people from one building to another if needed. (Training) provides that consistency… We’ve definitely seen more engagement from top to bottom.”

Developing Practical and Adaptive Cannabis Cultivation SOPs

After acquainting yourself with SOPs, you can determine the best course of action for your unique cannabis cultivation business. Use these steps to facilitate positive strides as you establish your brand as a leading provider of outstanding products.

Communicate With All Staff Members

Communication is the key to successful SOP implementation. Keep everyone in the loop by scheduling meetings to discuss procedures and answer questions. Ask employees for their input and address any disagreements or clashing opinions. Most importantly, run through procedures independently to put yourself in their shoes.

Joe Zeller, the second co-director of cultivation at Redbud Roots, later adds, “Every person knows they can come to several of us (with their issues) and we’ll give them attention. I may not be able to solve a problem, but I can try and make a plan… take one step toward making things different.”

Keep a Copy of SOPs in a Central Location

SOPs are only helpful if they’re easily accessible! Place copies throughout the facility, especially department-specific documents. This way, team members can readily reach for these guidelines when they have questions or need immediate assistance. 

Williamson states, “It’s not really about who came up with the idea or who was right. It’s about making the machine better, stronger, and more efficient as a whole.”

Regularly Revisit Established SOPs & Update as Needed

As we already noted, cannabis laws are never stagnant. Because of this constant industry flux, you should routinely re-evaluate your SOPs to ensure operations continue running smoothly and safely. 

You should also update SOPs when expanding, growing new cultivators, or implementing different equipment. For instance, transitioning from a single-tiered facility to a vertical farm will require an entire overhaul of theSOPs. 

As Williamson explains, “SOPs are like an evolving document. As we level up, we update those SOPs… Figure out how to make them more efficient, productive, and profitable.”

Zeller continues, “The strongest quality is observation and communication. (These attributes) ensure we’re going to identify the weak points in our process.”

Conclusion

SOPs are the atlas of an exceptional business. Cultivators who acknowledge the gravity of standardization are better prepared for potential obstacles, helping streamline operations from start to finish. 

Our equipment experts at Pipp Horticulture are happy to offer experienced perspectives on developing SOPs for vertical farming facilities. Navigating multi-tiered systems can seem daunting, but we’ll provide essential information to make the transition as easy as possible. We are interested in hearing more about how Pipp can improve operations. Contact us today for an in-depth consultation, or visit our resource page for additional reading material.

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From Concept to Cultivation: Webinar Q&A Session

In our recent webinar, we discussed navigating the critical start-up phase of your operations—from initial concept and planning to commissioning and baselining. This session gave attendees the knowledge and tools to move smoothly from design to full-scale cultivation. 

They learned how to avoid common mistakes and build a strong foundation for long-term success. At the end of the webinar, we held a Q&A session to address viewer questions. Below are some of the top questions we received and their responses.

 

Q1: What is the minimum space required to start testing the operation of a production facility?

The minimum space required to start testing the operation of a cannabis production facility depends on your goals, scale, and intended market (medical vs. recreational). For testing purposes and early-stage operations, a general guideline is around 500 to 1,000 square feet. Here’s a breakdown of what this size can accommodate:

  • Cultivation Space: A flowering room of around 200-500 sq. ft. can house approximately 30-60 plants, depending on your setup (vertical or horizontal growing) and strain specifics.
  • Vegetative Room: A separate space of 100-200 sq. ft. for plants in the vegetative stage.
  • Support Areas: Areas for storage, drying, trimming, and curing, which could take up an additional 100-300 sq. ft., depending on your operational flow.
  • Laboratory or R&D Space: A small lab or workspace (50-100 sq. ft.) for recording data and adjusting variables can be essential for refining processes.

For more specialized testing operations, additional space may be needed for environmental control and possibly a cloning room or nursery area. Commercial-scale production typically requires larger facilities ranging from 10,000 to 100,000 sq. ft. or more.

 

 

Q2. How high should the walls be when using double-tiered racking systems?

The required height for cannabis production depends on whether you’re moving into an existing building or constructing from scratch. For small-scale operations, two-tier racks with 8-foot tall shelving in rooms with a 10-foot ceiling can be used, but these tight configurations should only be considered by advanced cultivators.

Optimized setups usually feature 12-14-foot tall racks for two-tier operations, with an additional 2-4 feet of headspace above the racking. This extra space accommodates essential equipment like HVAC+D systems, ducting, sprinklers, and other utilities, and serves as a thermal buffer to prevent heat buildup from affecting the plants on the second tier.



Q3: Are there different processes for cultivating different types of marijuana (e.g., Sativa, Hemp, and medical marijuana)?

While Sativa, Indica, Hemp, and medical cannabis share common growing practices, each has specific requirements tailored to cannabinoid profiles, desired effects, and regulatory constraints:

  • Hemp Cultivation: Growers must meet legal THC limits and avoid stressing the plants to prevent THC production. Hemp is often grown in open fields similar to traditional crops.
  • Cannabis Cultivation: Medical and recreational cannabis is usually grown indoors or in greenhouses, where environmental factors such as light cycles, temperature, and humidity can be tightly controlled. For example, shorter light cycles during flowering promote the production of cannabinoid-rich buds.
  • Organic & Sustainable Practices: Many growers prioritize organic cultivation methods, appealing to consumers seeking chemical-free products. This is less of a concern with industrial hemp, treated more like a cash crop.

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Q4: What is the importance of keeping records in cultivation?

Regardless of your cultivation scale, data collection is crucial. The goal is to develop a winning “blueprint” that consistently delivers the desired yield, potency, terpenes, and overall quality. A data-driven blueprint makes it easier to replicate successes and fine-tune processes for continuous improvement.

Q5: What are your thoughts on using solar energy in cultivation?

While we support the idea of using solar energy, several factors have hindered its widespread adoption in cannabis cultivation:

  • High Initial Costs: The upfront investment for solar technology can be substantial.
  • Energy Needs: Cannabis cultivation is energy-intensive, often exceeding what solar panels can provide.
  • Space Limitations: Cultivation may require land that could otherwise be used for growing rather than solar installations.
  • Regulatory Barriers: Permitting processes for solar installations can be complex.
  • Intermittent Energy Supply: Solar energy is variable and may require backup systems, increasing costs.
  • Financing and Incentives: While there are incentives for solar installation, not all cultivators may be aware of or able to access these financial benefits. Additionally, securing financing for solar projects can be challenging.
  • Long ROI: The return on investment (ROI) for solar installations can take several years, which might not align with the financial goals of some cultivators.
  • Grid Dependence: Some cultivators may prefer to remain connected to the electrical grid for more reliable or cheaper energy.

As the industry matures and sustainability becomes a priority, more cultivators may explore solar power as technology advances and costs decrease, coupled with potential changes in regulations and incentives.


Q6: Is Pipp Horticulture willing to set up operations in Bermuda?

Yes, Pipp Horticulture has installations around the world and a team dedicated to global sales and service. We are currently working with groups in Bermuda for non-cannabis controlled environment agriculture (CEA).

Q7: Does Pipp provide RCx services, and what is the cost?

Pipp does not offer RCx services at this time. However, you can reach out to groups like Zartarian Engineering and Catalyst BC for these services. Costs typically vary based on the size of the facility, equipment selected, and scope of work.


Q8: What are the best lights, CO2 levels, and growing mediums for indoor expansion?

The best lights, CO2 levels, and growing mediums depend on your company goals, budget, and grower experience. Our team can help you determine the best solutions for your specific project objectives.

Q9: Where can you find a list of third-party commissioning firms specializing in cannabis CEA?

There is not a single firm that can perform full commissioning, that we are aware of, but you can most likely cover full commissioning between 2-3+ companies that offer specialized services. Companies that our customers have worked with in the past include Zartarian Engineering (zartarianengineering.com) and Catalyst BC (catalyst-bc.com).

Cannabis Business Times (CBT) and Cannabis Industry Journal often publish directories and articles on service providers in the cannabis industry, including those focused on cultivation and CEA. They may feature lists of top consultants or engineering firms with expertise in cannabis. Additionally, the National Cannabis Industry Association (NCIA) offers resources, directories, and member connections, where you can find vetted service providers specializing in cannabis CEA, including commissioning and compliance.

Controlled Environment Agriculture (CEA) organizations like the CEA Alliance or CEA Grow sometimes maintain directories of specialized firms, and many are branching into cannabis as the industry expands.

Industry networking platforms, such as LinkedIn and MJBizDaily’s marketplace, can help you locate experienced commissioning firms by searching for keywords like “commissioning services,” “controlled environment agriculture,” and “cannabis.”

Trade shows and conferences such as MJBizCon, CEA Summit, and other cannabis cultivation expos often have lists of exhibitors and speakers who are consultants or firms in this space. These events frequently publish exhibitor directories, which can be helpful in finding industry-specialized commissioning providers.

Q10: Have you found success with branded merchandise for cultivation facilities?

If you’re referring to branded merchandise like hats, shirts, and other promotional items, then yes, we’ve found success depending on how you define it. While these items may not drive significant revenue, they play a valuable role in brand recognition and public exposure. Additionally, they aren’t subject to Section 280E of the tax code, which disallows deductions for expenses related to businesses involved in federally illegal substances, like cannabis. If cannabis were rescheduled, this would change, but for now, operators must follow Section 280E’s guidelines.

On the other hand, if you’re referring to branded cannabis CPG products, then yes as well. Developing a strong brand with thoughtfully designed packaging, logos, and an aligned marketing strategy is essential for success. Over the past decade, operators have increasingly invested in brand identity, focusing on the details of packaging to represent quality. 

For high-end or connoisseur brands, it’s especially important that product quality matches the caliber of the branding. Markets tend to respond poorly to high-end packaging if the product itself doesn’t deliver a similarly high standard.


Q11: What funding options are available for a micro-cannabis license in DE?

Securing funding through institutional lending can be challenging for micro-cannabis licenses. Many find success by raising funds through friends and family. Consulting with financial advisors experienced in cannabis financing is recommended.

Q12: Is there any chance marijuana will not be rescheduled in December?

While anything is possible, it is difficult to predict the outcome. We recommend staying updated with industry news and developments.

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Contact Pipp Horticulture’s experienced team of indoor cannabis operators and designers to take the first step toward your vertical farming future!

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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

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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.”

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Fresh Grow's veg room

Fresh Grow’s Mobile Racking Strategy Places Clones and Veg at the Center of Operations

Fresh Grow’s Mobile Racking Strategy Places Clones and Veg at the Center of Operations

Optimizing plant movement through the veg room is essential for maintaining an efficient and productive cultivation process. Everything your team does in the veg room will dictate how your plants thrive in flower up through harvest.  

Fresh Grow, a national cannabis cultivation company, implemented Pipp Horticulture’s mobile vertical racking units to make sure  their operations run efficiently. The company operates in Colorado, Delaware, and New Jersey, recently expanding with a 17,000-sq.-ft. facility in Delaware and a 60,000-sq.-ft. facility in New Jersey. 

Steve Spradlin, National Director of Cultivation for Fresh Grow, shares insights into their innovative approaches and the tangible benefits they’ve seen.

So, how do you identify that ideal site for your facility?

As Pipp Cannabis Operations Specialist Anders Peterson said in a recent webinar, it helps to move methodically through a checklist of sorts, covering utilities, structural support, climate considerations, and fire code compliance. Schedule meetings with all your stakeholders to confirm that your checklist aligns with local regulations and business goals.

Let’s get into it…

Veg Room Setup

The veg room sets thefoundation for plants’ growth cycle. While the fertigation room is literally in the center of Fresh Grow’s building, it’s the veg rooms that fan out from there and kickstart the process for plants moving through the facility. 

Proper racking can significantly impact the efficiency of plant movement and overall workflow within a facility. Fresh Grow’s veg room in New Jersey utilizes a three-tier Pipp rack system for clones, mother plants, and all stages of production. 

The team will soon build out a second veg room, both of which will tee plants up for their eventual 10 flower rooms. 

This veg setup optimizes space and workflow, ensuring every square foot is used efficiently.

 

Step-by-Step Movement of Plants

Here’s how it works for Fresh Grow: The veg room runs six racks wide by nine racks deep.

Mother plants are located on the bottom rack at the back of the room. This strategic placement ensures that they are easily accessible for taking cuttings while being somewhat protected from the high-traffic areas at the front of the room. 

Cuttings are taken from these mother plants to produce clones, which are then moved to the front of the room. This cyclical process ensures a steady supply of new plants, which is essential for maintaining production schedules.

Clones are placed on the lowest rack at the front of the veg room for easy access and initial care. This allows for frequent monitoring and adjustments as needed to ensure optimal growth conditions. 

Clones are particularly sensitive to environmental changes, so ensuring stable humidity, temperature, and light conditions at this stage is critical. Pipp’s racking systems allow for precise environmental control with integrated lighting and airflow solutions. It’s a matter of balance, and Spradlin’s seen it all. 

“I’ve seen five-tiered grows, two-tiered grows, and three-tiered grows, but with Pipp’s system, we’re able to maximize our canopy square footage efficiently,” Spradlin said. The key to avoiding microclimates is to keep the air moving across those three tiers in a “cyclonic” pattern. By maintaining consistent airflow, his team can move their plants right on time as they move further into their veg cycle.

Once ready, clones move to the next two tiers of Fresh Grow’s racking system for further growth. 

Each tier corresponds to a specific growth stage, which requires careful monitoring and adjustments to environmental conditions. Plants in the initial veg stage require different environmental conditions than those in the cloning stage. Those veg plants will stick together as they disperse into separate flower rooms. 

“That is where we’ve learned the most about the racks, is in veg,” Spradlin says. “I can tell you that for sure.” Other cultivation teams can use their veg rooms to dial in operational efficiencies that will improve distinct areas of the business, too.

Efficiency at Scale

It would be one thing if Spradlin and his team were setting up only their new facility in this way, but Fresh Grow has prioritized scale when it comes to these on-the-ground efficiencies.

SOPs translate from New Jersey to Delaware and back to Colorado. That’s a critical part of Fresh Grow’s multistate growth strategy. This uniformity extends to their nutrient lines, pruning schedules, and trellising events. By standardizing these procedures, Fresh Grow ensures their operations are efficient and scalable, regardless of location.

As an added bonus, it makes internal team transfers super easy. A Delaware employee recently moved to the Colorado location, and it was a seamless experience, Spradlin says.

On a more granular level, he’s seen the day-to-day benefits of mobile racking all over the facility. Cleaning protocol, for one, has improved markedly. Without proper sanitation SOPs, a cultivation facility is working from a serious disadvantage that may have costly ripple effects throughout production. A clean room is a profitable room, after all, and mobile racks make that part of the job much easier. It’s been a revelation, Spradlin says.

“I’ve worked with static racking forever, and being able to just move a rack to clean under it: Holy cow,” he says. “Instead of getting all your hands and knees in a vacuum to get up under there… That’s one of my favorite parts, is you can move it with one finger and you can clean under them.”

Conclusion

The integration of Pipp Horticulture’s mobile racking systems has revolutionized Fresh Grow’s cultivation process, boosting efficiency and scalability. By optimizing plant movement through the veg room, Fresh Grow ensures each growth stage is meticulously managed and monitored. The result? Greater efficiency throughout the facility. Spradlin says that his entire team can sense the improved workflows.

The strategic placement of mother plants and clones, coupled with precise environmental control, highlights the critical role of a well-structured veg room in maintaining production schedules.

The scalability of those relevant SOPs across multiple states has streamlined operations. Implementing uniform nutrient lines, pruning schedules, and trellising events ensures consistency in cultivation practices, no matter the location. This move boosts operational efficiency and supports their growth strategy as a multistate operator.

Moreover, the practical benefits of mobile racking systems, such as easier cleaning protocols, underscore the operational improvements achieved by Fresh Grow. The ability to move racks effortlessly for thorough cleaning has streamlined maintenance tasks, contributing to a cleaner, more productive growing environment. 

As Spradlin emphasizes, the simplicity of mobile racking has been a game-changer for their cultivation facilities.

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