Greenforges: Underground Farming & Resource Extraction

A New Direction in Vertical Farming: Looking Down to Grow Up

Conventional vertical farms typically focus on maximizing space by building upwards. Companies like Aerofarms, Plenty, and Gotham Greens are pioneering agricultural innovation through tall, warehouse-style facilities. However, GreenForges, a pre-seed startup founded in 2019, is adopting a different approach – looking downwards to establish underground farming operations.

From Rooftops to Subterranean Spaces

CEO and founder Philippe Labrie initially explored the potential of rooftop greenhouses. He soon discovered, however, that the capacity for urban food production using this method was limited, estimated to be only 2 to 5% for cities by 2050. This realization prompted him to investigate the possibility of cultivating crops beneath the surface.

The Challenge of Space in Agriculture

Throughout history, agriculture has been fundamentally constrained by land availability. Early farmers cleared forests to create arable land, a practice that continues today. Expanding food production necessitates acquiring more land. Traditional vertical farming aimed to address this issue by relocating farms to urban areas and stacking crops vertically. Nevertheless, these facilities still require a physical location. GreenForges seeks to utilize previously untapped space – the area beneath our feet.

Pilot Program and Innovative System

Following two years of research and development, GreenForges is preparing to launch its first pilot underground farm system in spring 2022, in collaboration with Zone Agtech, an agricultural technology incubator, located north of Montreal. The system will incorporate established controlled indoor agriculture technologies, including LED lighting, hydroponics, and climate control systems.

Instead of repurposing large warehouses, GreenForges will drill 40-inch-diameter boreholes beneath new buildings, lowering the farming equipment into these shafts. Maintenance and harvesting will be accomplished by mechanically raising the crops to the surface for human intervention.

Energy Efficiency and Environmental Benefits

According to Labrie, relocating vertical farms underground offers numerous advantages, particularly in addressing the significant energy costs associated with controlled environment agriculture. Surface vertical farms expend considerable energy maintaining a stable internal environment due to fluctuating external temperatures.

High energy costs have made vertical farming less economically viable and more environmentally impactful in certain regions compared to traditional agriculture. This is a primary reason why many vertical farms concentrate on leafy greens, as growing other crops is often too energy-intensive to be profitable. However, underground farming could eliminate the need for constant environmental regulation.

Temperature Stabilization and Grid Stability

“Going underground creates a season-agnostic environment,” explains Jamil Madanat, engineering manager at GreenForges. “This is where substantial energy savings will be realized.”

Underground temperatures remain remarkably stable regardless of external conditions. For example, in Malaysia, temperatures stabilize at 20 degrees Celsius at a depth of 10 meters. Similarly, in Canada, the temperature stabilizes at 10 degrees Celsius at 5 meters deep, irrespective of the surface temperature.

“A consistent energy demand, due to the stable underground temperature, improves economic performance,” Madanat adds. “The power grid prefers a steady energy supply rather than large, fluctuating demands.”

Sustainable Practices and Renewable Energy

GreenForges is also optimizing lighting by alternating daylight and nighttime conditions for different crops, ensuring a consistent energy demand. Furthermore, the company is prioritizing locations with access to renewable energy sources, such as solar or hydropower, to minimize its carbon footprint.

“Utilizing fossil fuels to grow food indoors is counterproductive,” Labrie states.

Projected Efficiency and Crop Selection

GreenForges anticipates that its underground system will enhance energy efficiency by 30-40% compared to conventional vertical farms. The company is currently focusing on traditional indoor crops like leafy greens, herbs, and berries. A 100-foot farm is projected to yield approximately 2,400 heads of lettuce monthly, equating to around 14,000 pounds annually. Labrie envisions that increased efficiency will eventually enable the cultivation of more challenging crops, potentially even wheat.

Challenges and Future Outlook

Growing underground presents unique challenges. Designing equipment to fit within a tunnel approximately the size of two truck tires requires innovative hardware solutions. Humidity control also poses a significant obstacle in the subterranean environment.

Unlike leading vertical farm companies, GreenForges does not intend to become a consumer-facing produce brand. Instead, Labrie aims to partner with developers of new high-rise hotels and apartment buildings, offering fresh produce as an amenity for guests or residents and creating a new revenue stream.

“We see significant potential for integration into buildings,” Labrie concludes. “Integrating food production into buildings isn’t straightforward; it often requires sacrificing valuable commercial or residential space. Our solution allows them to monetize their underground areas.”