Retrofitting Indoor Cannabis Facilities with VAS 2.0: Dialing In Your Efficiency, Consistency, and Yield Stability
Airflow management is one of the most overlooked variables in indoor cannabis cultivation, yet it is crucial for plant health, yield consistency, and overall operational efficiency.
Many facilities that initially installed horizontal airflow systems may be experiencing microclimate issues, uneven transpiration rates, and inefficiencies that throw environmental conditions out of balance. VAS 2.0, Vertical Air Solutions’ latest upgrade, is designed to correct these inefficiencies with improved energy efficiency, modular control, and a lighter, easier-to-install system.
VAS 2.0 presents a practical retrofit solution for growers looking to optimize their airflow without completely overhauling their facility. It aligns airflow with plant biology rather than working against it.
Why Retrofit with VAS 2.0 Now?
In many grow operations, airflow was either an afterthought or a CAPEX budget-driven compromise during the initial buildout. While it’s hard to plan for the long haul, in horticulture, it’s a necessary part of the startup process.
The result of this oversight? Facilities that rely on traditional horizontal airflow methods often struggle with inconsistent air distribution. High wind speeds near fans create wind burn while other areas stagnate. Horizontal airflow also leads to poor de-stratification, especially in multi-tiered racking systems where temperature and humidity levels fluctuate between canopy levels.
Inevitably, uneven airflow will increase the risk of pathogens, and the moisture buildup you’ll encounter will encourage powdery mildew and botrytis.
Lastly, inefficient energy use becomes the norm, forcing HVAC and dehumidification systems to compensate for poor air movement.
Not a good way to run a business.
James Cunningham, founder of Vertical Air Solutions, developed the first-of-its-kind In-Rack Airflow System, a groundbreaking technology for vertical farming facilities. VAS version 1.0 was created at James’ cultivation facility, Fog City Farms. With the collaboration and engineering support provided by Pipp Horticulture, VAS 2.0 provides the ability to increase airflow at a lower cost.
James points out that horizontal airflow methods often create pockets of extreme wind force followed by dead zones, putting unnecessary stress on plants and leading to wildly inconsistent conditions across the canopy.
VAS 2.0 corrects this by delivering controlled, uniform air distribution, ensuring every plant receives the same environmental conditions—eliminating hot spots, and uneven humidity swings.
Key Advantages of Retrofitting with VAS 2.0
Airflow Consistency and Microclimate Control
VAS 2.0 is an enclosed airflow system that draws in conditioned air from outside the racking structure and delivers it methodically through each tier.
Unlike horizontal fans, which endlessly recirculate humid air within the same plane, VAS 2.0 stabilizes the grow space by maintaining consistent temperature and humidity across all canopy levels. This results in a controlled environment that eliminates localized stress points and reduces the likelihood of pathogen outbreaks.
Enhanced Energy Efficiency & Lower Operating Costs
One of VAS 2.0’s most significant upgrades is the transition to Electronically Commutated(EC) fans.
These fans consume less energy while delivering higher airflow efficiency, particularly when paired with the new modular 0-10V speed control feature. This feature allows growers to fine-tune airflow rates based on growth stage and real-time conditions.
The improvements go beyond just energy savings:
- Modular control: Unlike VAS 1.0, which had three speed settings, the new system offers precise velocity adjustments to match plant needs.
- Lower overall energy demand: More efficient airflow means HVAC systems aren’t constantly overcorrecting for environmental inconsistencies.
Step 2: HVAC System Optimization
Easier Installation & Retrofit Compatibility
VAS 2.0 was designed specifically with retrofits in mind, meaning it can integrate into existing racking systems—whether the racks are Pipp Horticulture or another racking system. The new VAS 2.0 replaces the metal design of its predecessor with thermoformed and corrugated plastic, making it easier to ship, install, and maneuver.
In many cases, the system can be installed without major facility downtime. Ducts slide into place without the need to remove existing lights. The system also adapts to multiple rack types, making it a straightforward replacement for outdated horizontal fans.
Before installation, growers should ensure electrical circuits are installed at the end of each rack for seamless power access, communicate rack type and spacing details with the Pipp team, and temporarily reposition lighting if necessary to avoid disruptions.
Airflow Misconceptions & The Case for Retrofitting
A common mistake in cannabis cultivation is assuming that more airflow equals better airflow.
Many growers mistakenly believe visible plant movement is a sign of good circulation, but excessive turbulence can actually cause trichome damage and unnecessary stress responses.
As James points out, some of the biggest misconceptions include:
- “More airflow is always better.” Not necessarily. Excessive turbulence can lead to mechanical stress, wind burn, and moisture imbalances.
- “Fans should make plants sway dramatically.” Not true. Consistent, moderate airflow is far more effective than aggressive wind force.
- “Any airflow is good airflow.” Wrong. Uncontrolled air movement creates uneven environmental zones, increasing the risk of mold and temperature fluctuations.
- “I already have HVAC; I don’t need VAS 2.0.” While HVAC systems regulate temperature and humidity, they do not ensure uniform air circulation at the canopy level. Without targeted airflow solutions, plants in different areas of the grow space will experience vastly different conditions, leading to inconsistent growth and higher disease susceptibility.
VAS 2.0 eliminates these inefficiencies by providing a structured, controlled airflow system rather than relying on the inconsistency of traditional horizontal circulation fans.
How VAS 2.0 Improves Bag Appeal & Product Quality
Inconsistent airflow affects more than plant health. A good In-Rack Airflow Solution directly impacts the final product’s visual appeal (think “bag appeal” in the retail environment) and market value.
How airflow is managed in late flowering can determine the trichome integrity, coloration, and density of the final buds.
- Trichome Retention: Excessive wind exposure can degrade trichomes, which house the plant’s cannabinoids and terpenes. A properly calibrated airflow system minimizes trichome loss, ensuring a frostier, more potent final product.
- Color Development: Late-stage temperature and humidity adjustments influence anthocyanin expression, contributing to vibrant purples, reds, and blues in cannabis flowers. VAS 2.0 allows for precise control over these conditions.
- Yield Uniformity: Poor airflow leads to inconsistent nutrient uptake and transpiration, resulting in small, uneven bud development. VAS 2.0 ensures every plant receives uniform environmental conditions, leading to larger, more consistent flower formations.
Growers focused on premium-grade flower, whether for whole flower sales or hash production, a well-managed airflow system is essential to maximizing both aesthetic and chemical quality.
The Bottom Line: Investing in Airflow Pays Off
For growers debating whether upgrading their airflow system is worth the investment, consider a few basic facts…
- The cost of a single failed harvest due to mold or inconsistent conditions often exceeds the entire capital expenditure of a VAS retrofit.
- Inconsistent airflow results in higher HVAC costs, lower yields, and greater risks of regulatory compliance failures.
- VAS 2.0 provides a practical, cost-effective solution for achieving uniform conditions without undergoing a complete facility redesign. As James explains: “I’ve consulted on jobs where growers decided to forego an airflow solution, only to deal with major crop losses and inefficiencies later. If they had installed VAS upfront, they would have avoided those losses entirely.”
Next Steps for Growers Considering a Retrofit
- Conduct a facility audit—Identify airflow weak points, temperature variances, and high-risk microclimates.
- Consult with Pipp Horticulture—Discuss retrofitting options and mounting configurations for your specific racking setup.
- Implement VAS 2.0 gradually—If necessary, roll out installation in phases to minimize disruption.
- Monitor and adjust—Leverage the 0-10V modular control to fine-tune airflow at each growth stage.
For cannabis cultivators looking to improve yield consistency, energy efficiency, and overall plant health, VAS 2.0 presents a high-impact retrofit solution. By eliminating airflow inconsistencies and aligning environmental conditions with plant biology, growers can maximize their production potential—without the need for a total rebuild.
