Revolutionary 'GigaFarm' Project Poised to Yield 3 Million Kilograms of Food

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In 2022, Dubai revealed the world’s biggest vertical farm at the Al Maktoum International Airport. This 31,000-square-meter indoor facility uses trays stacked in towers to grow plants with minimal water and soil. It produces over one million kilograms of top-quality leafy greens annually.

But the title won't last for long. Over at Food Tech Valley on the other side of the city, a bigger facility is being built. It's called the "GigaFarm," standing at 12 meters high and covering 83,612 square meters.

The GigaFarm project, managed by the UAE-founded company ReFarm, is not only bigger than other vertical farms. According to Oliver Christof, CEO of Christof Global Impact, the company behind ReFarm, it also operates in a unique way.

Food systems are estimated to be responsible for a third of global greenhouse gas emissions, according to the UN. The land-based sector, including agriculture and land use, makes up two-thirds of this, with production contributing 39% of the total, and distribution of produce 29%.

To make farming greener, GigaFarm plans to use a suite of technologies that can transform waste streams — such as food scraps and sewage — into agricultural products like compost, animal feed, clean water, and energy.

By bringing farms closer to consumers and implementing more efficient production methods to reduce fertilizer use, the system aims to decrease the carbon footprint of food production. Christof mentions that they can grow up to three million kilograms of leafy greens, herbs, and vegetable seedlings each year, potentially replacing up to 1% of the UAE's food imports.

The growth towers of IGS can be accessed by an elevator.

Intelligent Growth Solutions (IGS)

“Not just another vertical farm”

GigaFarm utilizes a vertical farming solution provided by IGS, a company based in Scotland established in 2013.

IGS's innovative "growth towers" resemble a multistory car park filled with plants instead of vehicles. These towers create a controlled environment that closely monitors and controls the water and fertilizer levels for optimal plant growth.

In a hydroponics system, plants are grown in trays using a substrate like organic compost or coconut fibers instead of soil. LED light strips beneath each tray simulate sunlight, and sensors, including cameras, monitor plant growth. The towers can automatically adjust light, temperature, humidity, water, and nutrient levels.

The towers, which range from six to 12 meters in height, are modular and easy to scale, according to Andrew Lloyd, CEO of IGS. "Put 200 of them in one place, then you’ve got a GigaFarm."

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Dozens of trays are held by zig-zagging girders, allowing them to be moved between towers. Inside each tower module, thick, insulating foam panels ensure that the climate is carefully controlled.

Lloyd explains, “Once you have the air, humidity, and temperature under control, the amount of replenishment needed is minimal.”

Vertical farming has numerous advantages compared to traditional agriculture. This includes quicker crop growth, a significant reduction in water usage by up to 98%, and the utilization of less space. Furthermore, vertical farms can be constructed in areas where the soil has been depleted and is no longer suitable for traditional farming. Indoor farms are not constrained by seasons or climate, providing further benefits.

However, there are also disadvantages to vertical farming. The initial investment required for the smart technology and infrastructure is substantial. Additionally, the high operational costs, primarily due to electricity expenses from LED lights, have posed challenges for many companies in the industry.

A recent series of well-known financial failures in the industry, such as Fifth Season and AppHarvest declaring bankruptcy last year, show how challenging it is to compete with the low costs of traditional agriculture. In 2023, AeroFarms, a vertical farming company from the US, launched a 65,000-square-foot research and development center in Abu Dhabi, which was the largest of its kind globally. However, shortly after this milestone, the company faced financial difficulties, leading to bankruptcy and reorganization.

To ensure the sustainability of a vertical farm, both economically and environmentally, it is crucial to incorporate waste management and renewable energy, according to Lloyd. This is precisely the approach that ReFarm intends to take.

The growth towers employ hydroponics and LED lights to grow plants indoors.

The growth towers employ hydroponics and LED lights to grow plants indoors.

Intelligent Growth Solutions (IGS)

The farm will utilize energy generated from burning its solid waste and will receive water from insect-based technology. Black soldier fly larvae will consume the food waste and once they reach maturity, they will be transformed into high-protein animal feed. Additionally, water and compost will be produced as by-products. GigaFarm plans to recycle 50,000 metric tons of food scraps each year. According to Christof, the water produced from this process will be sufficient to power the vertical farm completely. The organic compost will also serve as a substrate for the plants grown on the farm.

ReFarm plans to produce animal feed, biofertilizer, and soil enhancer at their facility to sell to farms. Christof states that the biofertilizer can reduce fertilizer application by 50%, while the soil enhancer helps soil or sand absorb water, microorganisms, and fertilizer more effectively. Additionally, the facility will process wastewater to remove ammonia for reuse in fertilizers.

Lloyd suggests that by utilizing the GigaFarm to grow seedlings for the UAE's 38,000 operational farms, ReFarm can address food security more effectively. Many of these farms use hydroponics or high-tech greenhouses, allowing ReFarm to make a significant impact beyond surface-level solutions.

Lloyd emphasizes that this vertical farm is unique and not just like any other. He believes that the recycling model can be implemented in any city or urban area.

According to Lloyd, waste is a common issue wherever humans reside. He explains that by converting waste into value, such as growing food or producing eco-friendly alternatives like biofertilizers, we can make a positive impact. Lloyd stresses the importance of these practices to ensure a sustainable future for our planet.

IGS’s growth towers can be built up to 12 meters high.

Intelligent Growth Solutions (IGS)

Climate-proofing food supplies

Agritech is becoming increasingly important as climate change threatens food security.

The UAE heavily depends on food imports, with over 85% of its food coming from abroad. This reliance makes the country vulnerable to disruptions in the supply chain, as seen during the Covid-19 pandemic and the Ukraine-Russia War, according to Rohit Sharma, a supply chain researcher at the University of Wollongong in Dubai.

In an effort to reduce this vulnerability, the Emirati government is looking to diversify the country's income sources. They are shifting focus from the petrochemical industry towards greener sectors like renewable energy, sustainable transport, and agritech. This shift not only creates new opportunities but also receives government support for innovative ventures such as ReFarm, as highlighted by Sharma.

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The COP28 climate conference in Dubai last year focused on food security. Consumers in the UAE are also becoming more aware of "food miles" and the carbon emissions from long-distance food transportation. Supermarkets like Carrefour in Dubai have even introduced mini hydroponic farms in 2022, allowing customers to pick their own produce in-store.

Interest in vertical farming is not limited to the UAE. Qatar is making significant investments in smart farming, and agritech companies are expanding into Saudi Arabia. Research by Sharma suggests that the value of the sector in the Middle East and Africa is projected to reach $6.22 billion by 2030. This growth is driven by increasing concerns over food security in the region and the continuous growth of urban populations.

Sharma mentions that it will be another ten years before vertical farming becomes popular, and more studies are needed to grow more types of crops.

The GigaFarm project, costing 1.2 billion dirhams ($326.7 million), will start construction later this year and is set to be fully operational by 2026.

Editor's P/S:

The article highlights the innovative GigaFarm project in Dubai, which aims to address food security and sustainability challenges. The farm's unique waste management and renewable energy systems showcase the potential of vertical farming to reduce environmental impact and increase food production. The integration of advanced technologies, such as hydroponics and LED lighting, enables efficient crop growth in a controlled environment. This approach could potentially revolutionize agriculture, particularly in urban areas where traditional farming is not feasible.

The GigaFarm project also highlights the growing importance of agritech in the Middle East and Africa region. As countries face increasing food security concerns due to climate change and population growth, they are looking to vertical farming and other innovative solutions to diversify their food sources and reduce reliance on imports. The projected growth of the agritech sector in the region indicates the potential for vertical farming to become a significant contributor to food security and sustainability in the future.