Startup growing plants without soil or sunlight

According to a U.S. geological survey, 70% of freshwater consumption is used for agriculture. Only half of that can be recycled after use. Growing crops also requires a very large area of land and a great deal of sunlight.

AeroFarms has a solution. Its farming method requires no soil or sunlight and very little water. Everything happens indoors rather than outdoors as in traditional farming, mostly in old warehouses. This also means any location can become fertile ground for cultivation, regardless of climate.

The project was initiated by Ed Harwood, a professor at Cornell University (USA). In 2003, Harwood invented a new system for growing plants in a fabric material he created himself. Beneath the fabric, there is no dirt, and the roots are sprayed with nutrient-rich mist.

The professor patented the idea and used it to create the Aero Farm system. Its name comes from “aeroponics,” a method of growing plants without soil or water. Aero Farm systems use LED lighting for each plant type. The company mainly sold these new growing systems as a side project of Harwood's and made little profit.

In 2011, David Rosenberg, founder of waterproof-concrete company Hycrete, and Marc Oshima, a longtime marketer in the food and restaurant industry, both recognized the inefficiency of traditional agriculture. They saw an opportunity. While searching for potential solutions, they learned about AeroFarms.

Both liked Harwood's system so much that they proposed a deal allowing them to join the founding team. They also suggested a new business model. Rosenberg and Oshima saw a major opportunity in optimizing crop cultivation and sales.

Harwood nodded in agreement. AeroFarms officially had three cofounders. The trio bought several old facilities in New Jersey, including a steel mill, a club and a paintball center, to start the indoor agriculture project.

According to Bloomberg, about 90% of green vegetables consumed in the United States between November and March come from the Southwest. By growing locally year-round, the founders hope the project will provide fresher, cleaner produce at low prices because transportation costs will be minimized. Now, each of the project's farms has vertically stacked trays. There, they grow carrots, potatoes, cucumbers and premium baby vegetables. The products are sold to East Coast food stores including Whole Foods, ShopRite, and Fresh Direct, as well as corporate cafeterias such as Goldman Sachs or The New York Times.

AeroFarms uses LED light to grow crops. Photo: Ellise Verheyen.

AeroFarms collects hundreds of thousands of data points at its facilities to easily adjust LED light levels and control flavor, texture, color and nutritional content. Data also helps it adjust factors such as temperature and humidity to optimize crop yields.

The results exceeded the founding team's expectations. The growing method delivers 130 times the yield per square foot (equivalent to over 30 cm2). An AeroFarm uses 95% less water and 40% less fertilizer than a conventional farm. The method also uses no pesticides at all.

The crops are ready for harvest in 30–45 days. AeroFarms' current retail prices are comparable to those of baby vegetables on the market.

AeroFarms' products brought to market. Photo: Alex Kwok.

“Most farms do not have anyone primarily responsible for technology. We, however, have a dedicated research and development center, plant scientists, microbiologists, mechanical engineers, and electrical engineers. We approach the project with great care and seriousness,” Oshima shared.

However, this solution requires a very large electricity supply, which is costly. AeroFarms' developers acknowledge the drawback and say they are seeking a solution. The company recruited Roger Buelow, former chief technology officer of LED lighting company Energy Focus, to find ways to reduce the system's energy use.

The company has now raised up to USD 100 million from Goldman Sachs and GSR Ventures. AeroFarms currently has 120 employees and 9 farms, including in Saudi Arabia and China. It plans to reach 25 farms within the next 5 years.