Retrofitting a cannabis cultivation facility presents significant opportunities for improving operational efficiency, optimizing the growing environment, and achieving substantial financial gains. However, it also involves navigating complex mechanical, electrical, and plumbing (MEP) constraints and structural limitations. To execute a successful retrofit, it is essential to define clear goals and identify the key performance indicators (KPIs) you aim to improve. This article explores various retrofit strategies, from transitioning to multitier cultivation systems to upgrading HVACD controls, and provides a framework for planning and implementing these changes effectively.

Financial Impacts of Retrofitting.

A retrofit can profoundly affect a facility’s bottom line, impacting both capital expenditures (CapEx) and operational expenditures (OpEx). While the initial costs of a retrofit may be high, the long-term savings in energy consumption, labor costs, and improved yields can lead to a favorable return on investment (ROI). For example, upgrading from high-pressure sodium (HPS) lighting to energy-efficient LED lighting can reduce electricity costs by 40-60%, while enhancing light quality and plant growth. Similarly, moving from single-tier to multitier racking systems can maximize canopy space, leading to higher production volumes without expanding the facility’s footprint.

However, to realize these financial benefits, it is crucial to understand the MEP and structural limitations of your facility. Retrofitting without considering these factors can lead to unforeseen expenses, delays, and operational disruptions. Therefore, a comprehensive assessment of your facility’s infrastructure is essential before embarking on any retrofit project.

Key Considerations for a Retrofit:

1. Understanding MEP and Structural Limitations
   Before initiating a retrofit, thoroughly assess the mechanical, electrical, and plumbing (MEP) systems and structural capabilities of the facility. Key areas to evaluate include:
   • Supply/Return Configuration: Understand the airflow dynamics within each room, including supply and return air pathways, to ensure that any changes do not compromise environmental control.
   • Electrical Capacity: Determine if the existing electrical infrastructure can support new equipment, such as LED lights or upgraded HVAC systems, without overloading circuits or requiring substantial rewiring.
   • Drainage and Irrigation Systems: Evaluate the capacity and placement of drainage systems to accommodate new fertigation setups or increased irrigation volumes.
   • Structural Loads: Verify that the facility’s structure can support additional weight from new racking systems, fans, or other equipment.
2. Defining Retrofit Goals and KPIs
   Clearly defining your goals and KPIs is critical to guiding your retrofit strategy. Common objectives include:
   • Increasing Yield: Transitioning to multitier systems or optimizing lighting for higher photosynthetic photon flux density (PPFD) or embracing multitier cultivation to increase total canopy square footage
   • Enhancing Environmental Control: Upgrading HVACD systems or adding airflow to improve plant health and reduce disease risk.
   • Improving Resource Efficiency: Implementing automated fertigation to better manage nutrient delivery and irrigation relative to your crop steering approach.
   • Reducing Operational Costs: Automating processes and optimizing labor to lower production costs per pound. Sometimes this is knowing your genetics, sometimes knowing your people, and other times it’s about knowing your mechanical solutions and how to get the most from them.

3. Find the right solution provider.

When considering HVACD, lighting, fertigation, or racking it’s important to find the right solution for your facility. This often means an interactive and iterative approach with a solution provider that will consider the space itself, the interaction of your mechanical solutions, performance expectations, and your goals. 

Example Retrofit Scenarios

1. Single-Tier Stationary to Single-Tier Fully Mobile
   Converting a single-tier stationary system to a single-tier fully mobile racking system can significantly increase cultivation space by reducing aisle requirements. This approach enhances workflow efficiency, reduces labor costs, and maximizes canopy area.

2. Single-Tier to Multitier Cultivation
Transitioning from a single-tier to a multitier system allows for vertical expansion, which is particularly beneficial in facilities with high ceilings. This retrofit can double or triple your total canopy square footage but requires careful planning to ensure adequate lighting, airflow, and irrigation reach each tier.

3. HPS to LED Lighting
Replacing HPS lights with LEDs can drastically reduce energy consumption, extend the life of ownership, and improve light quality, leading to better plant growth and higher yields. However, it may also necessitate adjustments in HVACD systems due to higher transpiration rates and different environmental setpoints.

Voltgrow

4. Adding inter-canopy lighting

Increased light penetration and more light utilization lead to higher yields often times turning “B” buds or smalls into “A” buds with higher value.

5. Upgrading HVACD Controls and Mechanical Solutions

Enhancing HVACD systems with advanced controls and sensors can provide more precise management of temperature, humidity, and CO2 levels. This upgrade helps optimize the environment for plant growth, reduce pathogen risk, and minimize energy costs. However, when doing this upgrade it is important to understand your electrical availability, ductwork redesign, and new SOPs needed to optimize the system.
Desert-Aire

Growlink

Aroya

6. Automating Fertigation Systems

Automated fertigation allows for precise control over nutrient delivery and irrigation, reducing water usage and optimizing plant health. This upgrade can improve consistency in growth and yield while reducing labor demands.

Rhythmcss

7. Adding Air Filtration in Ductwork

Integrating air filtration systems into ductwork can help reduce the spread of airborne pathogens and contaminants, protecting plant health and ensuring compliance with regulatory standards. Multiple solutions exist for this application like PCO, UVC, or gas phase filtration each with distinct benefits.

Dynamicaqs

Strategic Approaches to Retrofitting

1. Room-by-Room Upgrades
   Implementing retrofits one room at a time allows for phased investments, minimizes operational disruptions, and provides the opportunity to learn and adjust strategies before scaling changes across the entire facility.
2. Data-Driven Decision Making
   Focus on collecting and analyzing data to identify the areas where investments will have the greatest impact. Monitor KPIs such as energy use, yield, resource efficiency, and environmental conditions to inform future decision-making and measure the impact of your investments.
   
3. Realistic expectations – If you do all these things will you increase yield by 1,000%, reduce operating costs by 75%, and eliminate risk entirely…NOPE. But knowing what you need and why you need it in retrofit is about solving a problem and measuring the impact of your investment, not chasing false hopes.

Broader Considerations

When planning a retrofit, consider both internal and external factors that could impact the success of the project:

• Internal Factors: Understand the unique limitations of each room, such as existing racking layouts, drainage, and canopy capacity. Consider the impact of the retrofit on labor requirements, workflow, and storage needs for materials like media, water, and nutrients.
• External Factors: Assess external constraints, such as available electrical supply, permit limitations, and overall production capacity. Consider how retrofitting may affect compliance with local regulations and building codes.

Conclusion

Retrofitting a cannabis cultivation facility can offer significant benefits, from increased efficiency and yield to reduced operational costs. However, it requires a careful, strategic approach that takes into account both the facility’s physical limitations and the specific goals of the operation. By focusing on data-driven decision-making and phased implementation, cultivators can maximize the ROI of their retrofit investments while minimizing risks and disruptions. There are a variety of solutions and advanced technology available to the cannabis community but it is important to why you bought the tool and how to use it if you want to materialize the impact quickly.