Campo Caribe: Transforming Tropical Farming With High-Tech Innovation
Located in the mountains of Barranquitas, Campo Caribe is officially on its way to providing fresh produce to Puerto Rican families, creating new jobs and reducing the island’s dependence on imports. Following last week’s press conference where Puerto Rico’s Governor Pedro R. Pierluisi announced the expansion of the agricultural project’s state-of-the-art hydroponic greenhouse operation — the largest in the Caribbean – Indoor Ag-Con spoke with Campo Caribe’s Head Grower Jonah Helmer. Read on as he shares the cutting-edge technologies and innovative strategies the team is implementing to overcome tropical weather challenges, optimize growing conditions, and sustainably produce fresh, high-quality lettuce year-round.
Can you share how Campo Caribe will be leveraging its unique location in the central mountains of Puerto Rico to optimize growing conditions and mitigate the challenges posed by the tropical island environment, such as hurricanes and extreme weather fluctuations?
With our location in the central mountains of Puerto Rico, Campo Caribe has climatic advantages, including high levels of sunlight and mostly moderate temperatures due to the higher elevation. However, there are some additional issues we face in our tropical island location, such as risk of hurricanes, periods of excessive sunlight, frequent rain events, periods of low humidity and of excessive humidity, and periods of extreme air and irrigation water temperatures.
To control these variables, Campo Caribe is building one of the most technologically advanced and sustainable lettuce greenhouses in the Caribbean. At 5.5 acres, this is the largest hydroponic greenhouse in the Caribbean and the largest of only 3 greenhouses in the world combining the Cravo retractable roof structure and Hydronov deep water culture growing system. The Cravo retractable roof and shading system allows us to passively cool our greenhouse throughout the day. We can open the roof to maximize our light levels during cloudy periods and close the roof and shade system to reduce peak light intensity. We grow our lettuce in deep water culture, which uses a greater water volume to buffer fluctuations in water and air temperature around the plant. We added a Vifra high pressure fogging system to maintain optimal humidity levels for our plants to help them transpire, photosynthesize, and maximize growth all day long without becoming water stressed under the strong tropical sun.
Our unique combination of location, facility design, growing equipment, and controls systems allows us to overcome these issues and puts us on the cutting edge of the controlled environment agriculture (CEA) industry. This makes our facility more productive, energy efficient, and sustainable than those of our competitors, and makes our products tastier and healthier for our customers. Our greenhouse is built to withstand hurricane force winds up to 165 mph and will allow us to achieve a higher order fulfillment rate for Puerto Rican businesses.
The integration of the Cravo retractable roof structure and Hydronov deep water culture growing system are distinguishing features of Campo Caribe. Can you explain how this combination enhances plant growth and resource efficiency compared to traditional greenhouse setups?
Conventional glass and plastic greenhouses are not designed to operate in tropical climates with high temperatures and humidities all year round. The Cravo greenhouse allows us to optimize the aerial environment around the leaves of the plants in our hot climate while the Hydronov deep water culture system provides deep, cool, and oxygenated reservoirs of recirculating nutrient solution that will support plant growth even with severe fluctuations in temperatures and interruptions in power supply that can occur in Puerto Rico.
The roof and sides of the Cravo greenhouse fully retract allowing us to combine the benefits of outdoor and CEA production systems to enhance plant growth. By maximizing natural sunlight and controlling the environment, Campo Caribe is able to exceed the average yields of lettuce grown in deep water culture without the use of any artificial lighting and with lower chemical inputs.
The retractable roof prevents the excess heat buildup that occurs in conventional greenhouses and ensures that we have uniform growing conditions throughout the 5.5 acre structure. Retractable cooling curtains help regulate the sunlight and air temperatures, while our high-pressure fogging system and horizontal airflow fans optimize the humidity levels around the leaf surface.
Campo Caribe uses minimal electricity since the retractable roofs and cooling curtains consume only 2-3 kw hours of electricity per day per hectare compared to over 1000 kw hours for conventional greenhouses cooled with cooling pads and fans. We are not using any supplemental lighting to grow our lettuce, which saves a significant amount of energy and expense compared to greenhouses in higher latitudes.
Tropical climates provide favorable conditions for foliar and root diseases due to consistently warm temperatures and high humidity and precipitation levels. Hydronov designed our growing system to reduce risk of crop loss from disease and improve productivity. Our growing system features 16 independent production ponds, each fed with ozone sterilized source water to prevent the introduction of water-borne pests and diseases into the ponds. We have precise control systems for the water temperature and oxygen concentration of our growing solution to further reduce disease risk and improve plant health to make our product top in quality and in safety.
The use of rainwater collection and high-pressure fogging systems reflects a commitment to resource efficiency and environmental sustainability. Could you elaborate on how these systems contribute to Campo Caribe’s overall sustainability goals and operational efficiency?
Campo Caribe designed our production systems to improve the sustainability and reliability of produce available in Puerto Rico. By replacing imports with locally grown produce, Campo Caribe will help decrease Puerto Rico’s dependency on imported food, which currently stands at approximately 85%. The majority of lettuce available in Puerto Rico is grown in California or Arizona and shipped by truck and by boat to the island. It is not uncommon for some of this produce to go bad during this long journey and be wasted before it gets to consumers, contributing to higher carbon emissions.
To conserve resources, Campo Caribe utilizes collected rainwater from the roof of the greenhouse as the primary water source for the facility and saves 90% more water than conventional outdoor lettuce farms. By collecting and using our rainwater, Campo Caribe can support its production with less reliance on municipal or well water. This helps us to produce a reliable supply of lettuce for our customers all year round.
The Cravo retractable roof structure significantly reduces the amount of energy used to vent and cool the greenhouse, but high solar radiation levels can cause severe spikes in air temperature and drops in humidity levels. To prevent our plants from getting water stressed, we have installed a Vifra high pressure fogging system to maintain optimal humidity levels and cool down peak air temperatures. Vifra’s high pressure fogging system produces water droplets 1 micron in size that evaporate immediately in the air, increasing humidity without wetting the leaf surface, which reduces risk of foliar disease.
The high pressure fogging system will work in combination with the retractable cooling curtains to reduce peak temperatures making our greenhouse more resistant to extreme temperatures caused by climate change. By maintaining optimal humidity levels during hot summer days, our crop will not become water stressed and instead can take full advantage of the sun’s energy to grow faster and yield more. The high pressure fogging system will only be required for several hours per day when the humidity levels drop below 60% which will reduce the amount of fresh water for cooling by over 95% compared to conventional pad and fan cooled greenhouses.
The Priva Control System will play a key role in maintaining optimal growing conditions. Can you discuss how this system improves operational efficiency and ensures consistent yields – particularly in a high-tech greenhouse environment like Campo Caribe?
Campo Caribe selected a Priva climate control system to monitor and control all climate variables and control the irrigation system in our greenhouse. Priva (based in De Lier, Holland) is a global leader in CEA control systems, developing software, hardware, and services for the horticulture industry worldwide. We collaborated with Priva partner, Borlaug, in designing, developing, manufacturing, shipping, installing, and commissioning our climate control system. Priva integrates with the Cravo greenhouse and production equipment so we can monitor and control the climate conditions in our greenhouse from anywhere with an internet connection via their online platform. We can monitor and control the air temperature, humidity level, light level, CO2 concentration, wind speed, and leaf temperature in the greenhouse. For each independent recirculating pond we can precisely add pH and nutrient adjusted solutions using a Priva Nutrifit system and monitor the pH, EC, water temperature, dissolved oxygen, and Oxidation Reduction Potential (ORP) in real time.
The Priva system notifies growing staff if climate variables are out of range so actions can be taken to resolve problems quickly and to return to optimal conditions. This high level of control and monitoring allows Campo Caribe to optimize the growing conditions at all times to produce high quality lettuce all year round, empowering the farm to hit 95% fulfillment for our customers.
Energy efficiency is a significant focus for Campo Caribe, as demonstrated by your energy management system and facility design. How do these systems contribute to reducing overall energy consumption while still meeting the demands of a large-scale lettuce operation – and what are the expected benefits in terms of cost savings and environmental impact?
To reduce our daily electrical usage, Campo Caribe is utilizing a Deep Sea Electronics generator controller to perform advanced electrical dispatching and integrate with Priva and the major loads of the facility. An easily programable load shed system turns off major electrical loads in the facility to save energy and to prevent overloading our electrical service and back-up generator. We prioritize the dispatching of power to equipment needed to maintain an optimal production climate for our plants including operations of the greenhouse roof and shade curtains, fogging system, and water recirculation pumps. We will only run some equipment at night, such as the Priva Nutrifit, to fill up the production ponds in order to reduce power consumption during the day when we are harvesting and packaging.
Other parts of our operation including the refrigerated warehouse were designed to maximize energy efficiency. Excess insulation in the warehouse and packing room coupled with fast acting roll-up doors will maintain cold food safe temperatures using less energy from the cycling of condensing units.
In case of electrical outages, we have a back-up generator that can support the entire facility. We are continuing our research to determine when our peak power demand occurs, and we are working with Ageto Energy to provide for a variety of power sources in the future. Ageto Energy’s ARC system will ultimately act as the single interface for the disparate energy resources and will optimize to provide the cheapest, cleanest, and most reliable power.
This unique power system and facility design allows us to be more reliable in the face of power outages and storms and provide a more sustainable product with less carbon emissions for our customers.
Learn more about Campo Caribe and keep up with its progress here — www.campocaribe.com
Campo Caribe hosted a press conference on Monday, May 13 where Puerto Rico Governor Pedro R. Pierluisi and other officials participated in the announcement of the company’s expansion plans. Check out some of the press coverage from outlets, including:
Sin Comillas.com, Ey Boricua, WIPR, WAPA
“When people think of dehumidification, they think of mold prevention”, Miller says. “But it’s much more than that. Maintaining an ideal relative humidity range, coupled with a uniform climate (thanks to DryGair’s patented air circulation mechanism), has a major impact on the crop. It creates an active climate that stimulates growth and improves quality.”
Once growers understand that this tool can both improve yields and reduce costs, it’s an easy decision,” he adds.
Every step of our growing process was designed to limit our impact on the planet. For example, we utilize captured rainwater in our soil-less farming, which results in 90% less water usage than field-grown greens. Plus our greenhouse locations are in regions with high natural precipitation and not dependent on groundwater as the west coast growers do. . Our Devens, MA greenhouse gets 45 inches of rain per year alone and we use all of it, whereas Salinas, California sees only 10 inches of rain per year.
We have always approached growing lettuce as a farming company, rather than a tech company. While we are technologists and our technology is cutting-edge, our priority is growing sustainable, local lettuce that most importantly, tastes great. Our lettuce arrives on grocery store shelves within 24 hours of harvesting, spending less time traveling than most other lettuces. This, in addition to our highly automated system and sustainable growing practices, results in fresh, flavorful leafy greens that remain crispy a remarkably long time after purchase. At the end of the day, we’re growing food. People want to buy and eat what tastes good, and our amazing taste is what’s going to continue to be the differentiator for us. We’ve also grown our business in a way that gives us the ability to scale profitably and better service our retailers, which is going to continue to put us in a position to challenge and compete with field-grown brands as we enter new markets. We’ve surpassed field-grown greens in New England and I’m confident we can replicate that success in other markets across the country as we grow.
Our business is about farming, and we consider farming a people-based business that puts the crop first. This mindset enables us to recruit the best team of growers, R&D staff, operations staff, and more to carry out our mission of growing fresh leafy greens for all. The farmer-first mindset also reinforces our commitment to growing a product that tastes great and that people actually want to eat, which ties directly to our mission of bringing fresh, leafy greens for all.
We’ve also expanded our product line to now offer salad kits made with our signature Baby Crispy Green Leaf lettuce, which had an initial launch in the Northeast this fall but will be expanding to our full distribution footprint in January 2024.
As more consumers take an interest in the origin and sustainability of their food, they seek out agricultural companies dedicated to responsible and socially sustainable farming. 
AllWell Greens is that company. Founded in New York by second-generation Taiwanese Americans, AllWell Greens specializes in growing heritage bok choy, Chinese broccoli, and other traditional Asian greens. The founders of AllWell Greens, spurred by their frustration with issues they experienced using traditional farming methods, spent two years researching, developing and testing farming methods in a 200 square foot indoor facility in downtown Manhattan.
IGE-Hydrofarm Commercial Division offers a modular, high-efficiency LED lighting system designed for propagation and vegetative stages, especially for vertical grows. After four separate lighting trials, the AllWell Greens’ founders were thrilled with the results of the PHOTOBIO horticulture lights. Their greens were crisp, flavorful, and disease-free, and they were able to harvest two days faster than in any previous trial! 
The PHOTOBIO lights are a game-changer for AllWell Greens. “We always knew that light was an important factor in growing greens, but I don’t think we anticipated the impact it would have on grow time and ultimately profitability,” explains John Cari, one of the company’s founders. “The PHOTOBIO lighting is so precise that we reduced our grow time by two days, improved our yields and significantly reduced our energy costs.”
Size does matter, and the size of the market for salad and leafy greens in the U.S. and Canada is approximately $15 billion and growing. And it will continue to grow with an estimated CAGR 
The COVID pandemic has shown us that the logistics involved in food transportation are extremely susceptible to disruption; perishable products in particular cannot be stored for long before the quality deteriorates to such an extent that they are no longer fit for sale.
The more stages there are in the food processing and distribution, the higher the chance of some form of contamination.
All this automation not only ensures the minimum possible amount of contamination, but it also reduces labor costs.