View Slides - International Conference on Vertical Farming and

2014 International Conference on Vertical farming and Urban Agriculture
Role of Plant Factory with Artificial Light (PFAL) in
Urban Horticulture and Next Generation Lifestyle
Nottingham University
Jubilee Campus, Exchange Building
September 9, 2014
Toyoki Kozai
Professor Emeritus of Chiba University
Japan Plant Factory Association
kozai@faculty.chiba-u.jp
1
PFAL built at Chiba University, Japan in 2000
Contents
• Plant factory with artificial light (PFAL) in Japan
• Annual productivity of PFAL per unit land area
• Plants feasible for commercial production using
PFAL
• Concepts of CPPS and RUE for PFAL
- Closed plant production system (CPPS)
- Resource Use Efficiency (RUE)
• Changing lifestyle with PFAL in urban areas
• Challenges
PFALs for commercial production in Japan
• As of March 2014, there were 168
PFALs.
• The No. of PFAL has been increasing
since 2009. Probably, ca. 200 by Jan.
2015.
• Roughly, 25% of PFALs is making profit,
50% breakeven, and 25% is loosing
money, as of 2013.
• LEDs are in use at some PFALs recently
3
Production cost and its components in Japan
Building (50%)
1 US$/head(100 g)
Production cost
Depreciation
(30-35%)
10,000-20,000 US$/m2
100％
Facility (50%)
Lighting(70-80%)
Electricity
(20-25%)
Labor (20-25%)
Others (20-25%)
Air Conditioning
(20ｰ30%)
100%
Pumps, Fans, etc. (10%)
Seeds, substrate, fertilizer, delivery,
packing, water, etc.
Relative annual productivity of PFAL
Annual productivity per unit land
area of PFAL is currently roughly 100fold or higher, compared with that of
the field, and has been increasing by
recent technical advancements and
scale-up.
5
Relative annual productivity of PFAL by its
components, compared with those in the open field.
N
o.
Magnification by PFAL compared with the
open fields
1
10-fold by use of 10 tiers
2
2-fold by shortening the culture period by
means of optimal environment control
2-fold by transplanting seedlings one day after
harvest all year round assuring no time loss
3
Component Multiplied
Factor
Factor
10
2
10
20
2-3
40-60
4
1.5-fold by increased planting density
per cultivation area
1.5
60-90
5
1.5-fold per cropping by no damage due to
abnormal weather & outbreak of pest insects
1.3-fold sales price due to improved quality
and less loss of produce after harvest
1.5
90-135
1.3
117175
6
6
The largest PFAL in Japan built in 2006,
producing 23,000 leaf greens daily or 8.3 M/y
Spread Inc. Kyoto, Japan
40 g /contain
80 g/bag
7
PFAL at Chiba University built in 2010.
Floor area of culture room: 338 m2, 10 tiers, 9 rows
Operated by
Mirai Co. Inc.
Leaf lettuce
3,000 heads/day
One M heads/y
2,800 heads/m2/y
Leaf lettuce grown in PFAL at Chiba Univ.
produced by Mirai Co. Ltd. for sale at a supermarket
Romaine lettuce 1.4 Euro/bag (70-80 g)
9
PFAL operated since June 2014 by Mirai Inc. Ltd.
and Mitsui Real Estate Inc., producing 10,000
leafy greens heads daily, near Chiba Univ.
Floor area: 1,400 m2, Number of layers: 11-14
10
PFAL being operated since April 2014 by
E-W Shirakawa Agricultural Co-operative
in Fukushima Prefecture, in cooperation
with Japan Plant Factory Association,
Chiba University and Mirai Inc. Ltd.
11
PFAL with all LEDs, in Miyagi Prefecture, Japan.
Mirai Inc. Ltd, Kajima Corp. and GE Japan
10,000 leafy green heads daily. 14-15 layers
PFAL connected with mushroom factory operated by
‘Japan Dome House’ in Fukushima Pref., Japan
PFAL
Medicinal
Mushroom
Factory
PFAL
Medicinal Muｓｈroom
Factory
キノコ工場内部
13
PFAL exported to Singapore, July 2014
by Panasonic Factory Solution Asia Pacific (PFSAP)
Produce:
Mini red radish, sunny
lettuce, mizuna
(Brassica Rapa L.
Japanese group), etc.
served to a restaurant
Floor area: 248 m2
LED lamps only
http://monoist.atmarkit.co.jp/mn/articles/1408/26/news072.html
PFAL exported to Ulan Bator, Mongolia in
2014 by Mirai Inc. Ltd. ‘-40℃’ in winter.
No heating is required
even at outside temperature
of -40 C, because PFAL
generates heat from lamps
and is thermally well
insulated and airtight.
15
Plants suitable for growing in PFAL
• Short in height (ca. 30 cm or lower)
• Grow fast (harvestable 10-30 days
after transplanting)
• Grow well under relatively low light
intensity and high planting density
• High value if it is fresh, clean, tasty,
nutritious and pesticide-free
• Any kinds of transplants
Leafy vegetables/herbs commonly
produced in PFAL
Leaf lettuce
Frill lettuce Green Mustard
Rocket (Eruca sativa) Sweat Basil
Spinach
Brassica rapa L.
Japonica (mizuna)
Examples of wholesale price per kg in Japan
• leaf lettuce
7 Euro
• basil
20 Euro
• Low potassium leaf lettuce, rocket (Eruca
sativa), watercress, parsley 30 Euro
• Coriander
35 Euro
• Peppermint, spearmint
60 Euro
Root vegetables and medicinal plants being
produced in PFAL very recently
Turnip
Carrot
Radish
Angelica acutiloba Panax ginseng
Leaves, petioles and roots of Wasabi
19
Both shoots with leaves and roots are edible, tasty and nutritious
Processed goods produced from
PFAL-grown plants very recently in
Taiwan (W. Fang, 2014) and Japan
• Paste for baby • Juice
food
• Cosmetics
• Sauce
• Supplements
• Drinks
• Herbal tea
• Powder
• (Herbal medicine)
A basic unit of CPPS for production of transplants
with a floor area of 16 m2 (3.5 by 3.6 m). In 2013,
280 units of CPPS are in use at 120 locations in Japan.
Four layers, 2 rows, holding 96 plug trays
Mitsubishi
Chemicals Inc.
21
PFAL for transplant Production
The largest in Japan consisting of 27 basic units,
with a total floor area of 476 m2 with a production
capacity of over 10 millions/year
Courtesy: Bergearth Co., Ehime, Japan
22
Characteristics of PFAL
• Essential resources for growing plants
• PFAL is quasi- or pseudo- CPPS (Closed
Plant Production System)
• Main components of PFAL
• Resource use efficiency (RUE)
• LUE (light use efficiency) and EUE
(electric energy efficiency) are still low
and need to be improved.
Main components of PFAL
Air conditioners with fans
Thermally insulated &
almost airtight walls
Electric
energy
CO2
supply unit
Light
Nutrient
solution
supply unit
Multi-tiers with lamps & hydroponics
Most components are mass-produced at low costs and are suitable for re-use after their 24
life.
Essential resources for growing green-colored
plants through photosynthesis in PFAL are:
Produce
Essential Resources
Light
Water
CO2
Inorganic fertilizers
Seeds/transplants
Plant
production
system
Heat
(Temperature)
O2
Plants with
Primary & secondary
Metabolites & water
Max. value &
Min. plant residue
Other important resource: Labor
PFAL is called ‘CPPS’, in case that all
substances supplied is fixed/held in plants
with minimum emission of heat energy
Environment
A
Resources
D
CPPS
light, Water, CO2,
fertilizer, seeds,
electricity, labor, etc.
C
B
Plants
Produce
with value
Heat energy
No environmental pollutants including
plant residue, CO2, etc.
PFAL as CPPS is designed & operated to
produce:
• a maximum amount of high quality plants
with minimum yield variation
• using minimum amounts and kinds of
resources, and
• with minimum emission of environmental
pollutants,
• by providing the optimal amount of each
resource at optimal timing,
• for human welfare and global sustainability.
27
Resource Use efficiency (RUE)
Amount of resource fixed/held in produce
RUE =
Amount of resource input
28
Breakdown of RUE
1) Water use efficiency (WUE)
2) CO2 use efficiency (CUE)
3) Light energy use efficiency (LUE)
4) Electric energy use efficiency (EUE)
5) Fertilizer use efficiency (FUE)
6) Seed/transplant use efficiency (SUE)
7) Coefficient of performance of heat
pumps (COP)
29
Water use efficiency (WUE)
Irrigated – Ventilated
Irrigated
Dehumidified by air
conditioners while cooling
2,000 kg
for re-use
2100 – 58
=
= 0.97
2100
Evapotranspired
2,058 kg
Increase in plants and
substrate: 42 kg
Irrigated:
2,100 kg
Ventilated: 58 kg
If dehumidified water is not used, the WUE is 0.02
(=(2100 -58 - 2000)/2100 ⇒ the water needed for irrigation in
the CPPS is 1/48 (=2/97) of that in the greenhouse.
30
Ohyama et al. (2002).
WUE, CUE and LUE are significantly greater
in PFAL than in the greenhouse
Use Efficiency
PFAL
Greenhouse Greenhouse Maximum
ventilators closed
ventilators open
WUE (water) 0.96
N/A
CUE (CO2)
0.4-0.6 N/A
0.88
0.02-0.03 1.00
LUE (light energy) 0.027 0.017> 0.017
-
Value possible
-
1.00
ca. 0.10
0.04
EUE (electricity) 0.007 Ohyama et al. (2002; 2005; 2006); Yokoi ca.
et al. (2005)
LUE and EUE of PFAL are still low
LUE and EUE can be more than
doubled or tripled by improving the
lighting and environmental control
systems.
Methods for improving EUE (1)
• Use LED with a higher % of electriclight energy conversion
• Use the optimal light source with
optimal photoperiod/intensity
• Place the light source close to leaves
• Keep the direction of lighting to leaves
only
• Use light reflectors with good design
33
Methods for improving EUE (2)
• Spacing to keep Leaf Area Index (LAI) at around
3-4
• Keep the light source temperature at optimal to
get a maximum light energy output
• Control the environment factors to maximize
the net photosynthetic rate under a given
lighting condition
• Increase a portion of usable part of plants by
environmental control and cultivation system
• Leveling the daily electricity consumption
34
Also, significant reduction in
production costs by efficient plant
production process management
(PPPM) of PFAL is possible.
Working items of PPPM
Working (operation) items in PPPM
Seeding
1st & 2nd
Transplanting
Harvesting
Trimming
Packing &
packaging
management
Seeds, supports, culture panel
preparation & seeding
Culture panel setting &
transplanting
Harvesting, culture panel removal
& cleaning up
Trimming disordered, yellowed,
and dead leaves
Weighing, packing, labelling,
packaging, pre-cooling & shipping
Managing environments, salinity,
plant growth, plant quality, stocks,
facilities, personnel development
Major Functions of PPPM System
being developed by Plantx Inc., Japan
Major functions
Electricity consumption by components & their costs
Water & CO2 consumptions, costs & use efficiencies
Consumptions & costs of various supplies
Plant environments & the cost for their control
Plant growth, yields and sales figures
Waste production and its processing cost
Photosynthesis, respiration & transpiration rates
Weekly and monthly summary reports
Quality of vegetables and its components
- A big issue in the forthcoming decade Pesticide-free
Quality
Safety
Low CFU
（traceability）
Functions
Delicious
-ness
Long lifetime
No foreign matters
Minerals
Antioxidants （ORAC value）,
Vitamins, Carotenoids
Taste, mouth feeling, color,
texture, shape, freshness
If PFAL is well designed and well
managed,
• Production cost per kg can be
reduced by 20-50%.
• Economic value per kg can be
increased by 10-50%.
• Initial cost can be reduced by
20-40%, even now.
Creating new markets using micro- or miniPFALs for changes in lifestyle
- Ubiquitous PFALs in urban areas •
•
•
•
•
•
•
Home
Restaurant
School
Hospital
Office
Shopping center
Others
2.2 m-PFAL as a furniture purchasable via Internet
Type B
US$ 1,500
http://www.greenfarm.uing.u-tc.co.jp/tri-tower/
as a furniture or a green interior
Products
of U-ing Inc.,
Tokyo
US$ 200
US$ 100
m-PFAL at the entrance of restaurant
Vegetables grown in m-PFAL are served to the customer.
Café Restaurant Agora in Kashiwa
The Plant Environment Designing Program by
Prof. H.Hara, Chiba University
Restaurant ‘Kome-Sta’ at
Mitsui Garden Hotel Kashiwa-no-ha
43
Eight m-PFALs under the service counter of Café
Type B
Panasonic Center Osaka, Café ‘Foodie Foodie’
PFAL adjacent to Chinese cooking restaurant
Entrance of Chinese cooking
restaurant at Grand Front Osaka
PFAL for growing
medicinal herbs
45
m-PFALF has been used as an educational tool for
summer holiday activity by a volunteer group
Kashiwa-no-ha Smart City Museum
The Plant Environment Designing Program by
Prof. H.Hara, Chiba University
46
m-PFALF used as an educational tool for
extracurricular activity at an elementary school
Type B
Tomioka Elementary School in Fukushima
where the big earthquake attacked in
March 11, 2011.
The disaster support project by
Prof. M. Takagaki, Chiba University
47
Integrative understanding of scientific
principles at work through personal
experience with joy, using m-PFAL
• Plant photosynthesis, respiration, transpiration
and growth
• Exchanges of CO2, O2 and H2O in an ecosystem
• Plant-human therapeutic and ecological
relationships
• Differences in nutrition between plant and
humans
• Energy and material balance of the ecosystem
• Importance of ‘life’, ‘growing life’ & ‘quality of life’
PFAL at the lobby of a hospital in Tokyo
Vegetables are supposed to be grown by the
clients and served to the hospitalized clients
49
Photo taken at Sakakibara Memorial hospital on September 8, 2012
m-PFAL as a partition between the desks
Designed by Prof. H．Hara, Chiba University
m-PFAL at café room in the office
Designed by Prof. H．Hara, Chiba University
m-PFAL at a meeting room (left) and
a vending machine in the office
Designed by Prof. H．Hara, Chiba University
PFAL at a shopping center installed
for eye-catch display
At Lalaport Kashiwa-no-ha, Kashiwa City, Chiba.
(Photo credit: Mitsui Estate Co., Mirai Inc. and Sankyo Frontier Inc.)
53
m-PFAL for home use, connected with
Internet for Social Network System (SNS)
Panasonic Inc., Patent pending
m-PFALs connected with Internet
A trial social experiment on mPFALs connected with Internet was
conducted in 2012-2013 at Kashiwa,
Chiba
Household PFAL network for SNA via Internet
Technical
support
R&D
Mirai Co. Ltd.
Chiba University
Ｗebsite
Panasonic Corp.
Mitsui Real Estate Co..
Smart plant factory network
Family A
Family B
Chiba University
large-scale
plant factory
SNS Club
Party
● Seminar
● Meeting
●
Family C
LalaPort Kashiwa-no-ha
shopping center
http://www.miraibatake.ne
3.3 Various ways of using m-PFALS network
Recording cropping
schedule and plant growth
Various ways of
using m-PFALs
Create a new growing
method & recipe
Exchanging information
on recipe & plant growth
3.4 Face-to-face meeting by m-PFAL
users
May 11, 2013, Kashiwa, Chiba, Japan
PFAL Project of Chiba Univ. started in 2011 with 60
private companies. Three PFALs & 3 m-PFALs in this area,
Photo taken in 2011
Hospital,
Community
center
Tsukuba Express
Railway Line
5
My Home
Organic
Farm Garden
Organic
restaurant
Railway Station
Business office,
Hotel, Shops
Rooftop Farm
Shopping Center
My Office
PFAL
59
PFALs
Bee Culture
Garden
Our Campus
Huge amounts of resource inflows and waste
outflows into/from urban areas daily
Resource In-flows
Waste Out-flows
Water
Fossil Fuel
Food
Products
Food
Business
processspace
ing
Living
space
Public
space
Factory Amenity
space space
Materials
Vehicles/Personnel
Heat
CO2
Wastewater
Garbage
wastes
Why not produce fresh foods in urban areas?
In many parts of Russia, leaf vegetables can be grown only
in short summer and most of leaf vegetables are imported
during long winter from southern areas in China?
Frozen
foods
Dry
foods
Fresh
foods
Transporting perishable fresh foods to urban areas
is resource-consuming & environment-polluting
Perishable
Fresh foods
with 90%
water
content
Pollutants
Wastes
Urban
areas
Resource
Why not produce fresh food in urban areas?
Resource In-flows
Water
Fossil Fuel
Food
Waste Out-flows
Food
Business
processspace
ing
Living Fresh foodPublic
production
space
space
system
Products
Factory Amenity
space space
Materials
Vehicles/Personnel
Heat
CO2
Wastewater
Garbage
wastes
By producing fresh vegetables in urban area:
• Resource and its cost for transportation
can be reduced
• Emission of pollutants can be reduced
• Traffic jam can be reduced
• Loss of quality and quantity of fresh foods
can be reduced
• Citizens can enjoy culturing plants and
other living organisms, and
communications in their daily life
The same applies for mushroom, fresh fish, ornamentals,
etc.
Water
Fossil Fuel
Food
Products
Food
Business
processspace
ing
Living
space
Public
space
Factory Amenity
space space
Materials
Vehicles/Personnel
Heat
CO2
Wastewater
Garbage
wastes
Essential resources
for plant growth
Huge amounts of resource inflows and waste
outflows into/from urban areas daily
Resource In-flows
Waste Out-flows
Combinations of PFAL with other eco-systems
PFAL
Open field
Greenhouse
Local
society
Water
processing
Mushroom
Aquaculture
Waste
processing
Home
Solar
energy
Water
Transpiration
Photosynthesis
Light
energy
Electric
energy
Fossil
fuel &
atomic
power
Water,
wind &
biomass
power
CO2
Respiration
Livestock
Fish
Plant
Algae
Residue
Feed, Raw
garbage
Fertilizer
Microorganism
Mushroom
Decomposition
Solid waste
Waste water
Decomposition
Food and other useful substances
Heat energy
Material and energy conversion and recycling in urban agriculture
Conclusion
• PFAL will play an important role in urban
areas to achieve the local production of fresh
foods for local consumption
• Cost performance of PFAL will be improved
considerably within 5-10 years
• Diverse applications of PFAL is expected
• PFAL with combinations of other bio-systems
will reduce the resource consumption and
waste emission greatly
Thank you very much for your kind
attention!
For more details, please refer to the papers below:
1) Kozai, T. 2013. Resource use efficiency of closed plant
production system with artificial light, Proc. Jpn. Acad., Ser. B
89: 447-461. (https://www.jstage.jst.go.jp/browse/pjab)
2) 2) Kozai, T. 2013. Plant Factory in Japan, Chronica
Horticulturae, 53(2): 4-11.
69
Challenges in PFAL
• Life Cycle Assessment (LCA) of APF and its comparison
with other plant production systems
• Developing PFAL simulator consisting of Plant,
Environment and Economic models
• Lighting system & light quality improvement using LEDs
• Flexible, intelligent robotic automation system
• Development of integrative environment control and
total management systems
• Integration of APFL with other bio-production system
and resource recycling systems
• Production of medicinal and other functional plants and
development of agro-medicine industry
70
Challenges in PFAL (Continued)
• Third-party Evaluation of Safety and security of
plants produced in PFAL
• Streamlined cooperation among outdoor
agriculture/facility horticulture/natural
energy/use of IT & ICT/use of plant residue
• Breeding of vegetables suitable for PFAL
• Local employment, creation of job opportunities
for elderly and disabled persons
• Universal design of PFAL suitable for aged,
challenged persons
• Good design of PFAL in all aspects
• Reduction in initial and operation investments
71
Plants which are feasible for
commercial production using PFAL
Rice
Wheat
Staple
foods
Corn
Plantbased Food
Potato, etc.
Functional
foods
High value plants
Vegetables
Herbs PFAL
Medicinal plants, edible flowers
2.9
m-PFALF used as a communication tool
for daily activity at a meeting room
Type B
Meeting room at temporary housing in Miyagi
where the big earthquake attacked in March
Type B
11, 2011.
The disaster support project by
Prof. H. Hara, Chiba University
73
Summary: Resource saving characteristics of CPPS
• WUE and CUE and FUE are fairly high (90%>).
• However, EUE and LUE are roughly 0.25% and
1 %, respectively.
• They can be improved up to 1% and 4%,
respectively, by improving the lighting system,
environments and breeding suitable for PFAL.
• Then, electricity consumption can be reduced
by over 50%.
74
Online estimation of rates of net photosynthesis,
water uptake (or transpiration), and/or dark
respiration of plants
75
Online Estimation of P under CO2 enrichment
based on dynamic CO2 balance
CO2 supply rate Net photosynthetic rate CO2 release rate
S
P
Cin
Plants
R at Cout
kxNxVx(Cin–Cout)
N: No. of air changes
V: Air Volume
k: coefficient
CUE=P/S=(1-R+NxVx(Cin-Cout))/S
If N can be is estimated, P can be estimated by P=S-R
76
Number of operating lamps
1600
No. of operating lamps
1400
0.050
0.040
1200
0.030
1000
800
600
0.020
Net photosynthetic Rate
0.010
400
0.000
200
0
-0.010
10:00 12:00 14:00 16:00 18:00 20:00 22:00 0:00 2:00 4:00 6:00 8:00
Time
Li Ming et al., 201277
Net photosynthetic rate (mol m-2 h-1)
Daily changes in net photosynthetic rate in PFAL
植物の播種から収穫までの植物成長曲線、占有面積
と1日あたり生産性は強く関係する
Fresh weight
100g/head
Harvesting
2nd transplanting
Seeding
0
1st transplanting
2
4
Weeks after seeding
D3：10～15日
6
Summary: Basic characteristics of plant factory
• Resource (material, energy, labor, space and time)
efficient with minimum emission of pollutants and
garbage.
• Stable (as scheduled, year-round, free from bad weather)
production with comfortable working environments for
elderly and handicapped persons.
• High quality (nutritious, tasty, good-looking, hygiene with
long life-time) products in any hazardous environmental
area (hot, cold, dry and humid climate and low- fertility
soil, shaded area)
• However, high initial resource investment and high
electricity consumption -> High light energy use
efficiency (LUE) relative to greenhouse and open fields,
but low LUE compared with maximum LUE theoretically
possible.
Percent energy conversion in plant production
100%
Electric energy
Highest Value
LED: 40%
% Light energy
100%
Average value
Fluorescent lamps:
25%
90%
% Light energy received by leaves 50%
10%
% Chemical energy fixed by plants 2-3 %
90%
3.2%
% Salable part of plants
70-80%
0.2-0.3%
Table-size plant factory displayed at P-Square
in Chiba University, Kashiwa-no-ha Campus
Elementary School in Fukushima where the big
earthquake attacked in March 11, 2011
Tomioka Elementary
School
Photo by
Prof. M. Takagaki
A household plant factory connected
with Internet for SNS by Panasonic Inc.
CO2 use efficiency (CUE)
=
= CO2 Fixed
CO2 supplied
192/221= (221-29)/221=0.87
Fixed by photosynthesis:
Supplied:
221 mol
192 mol
Ventilated: 29 mol
Number of air changes
= 0.01 h-1
In the typical greenhouse with ventilators closed, CUE is 0.4-0.6.
Ohyama et al. (2005)
85
8.0
1.5
6.0
1.0
4.0
0.5
2.0
0.0
0.0
0
1
2
LAI (leaf area index)
LUE (x１0-2)
EUE (x 10-2)
2.0
3
Fig. 3 Electric energy utilization efficiency (EUE) and light
energy utilization efficiency (LUE) as affected by leaf
area index (LAI). LUE is 4 times EUE (h in Eq. (2) is 0.24).