Farm.One's underground Tribeca location grows over 100 different varieties of edible flowers, herbs and microgreens at any one time.
By the time you reach for that head of lettuce at the grocery store, it's already probably traveled hundreds of miles and spent almost two weeks sitting in a truck.
"Food is no longer grown for human beings, it's grown for a truck to support a supply chain," says the president of Metropolis Farms in Philadelphia.
But everyone likes fresh produce, so the closer your veggies are grown to your favorite supermarket or restaurant, the better. With the recent outbreak of E.coli contaminating romaine lettuce across the United States, it's especially appealing to know that your produce has been grown nearby in a safe environment. How about a farm right on top of a grocery store in Philadelphia? Or one underground in the heart of Manhattan? Or one inside an iconic restaurant in Australia?
Hyper-local urban farming is providing some consumers with instant access to seriously fresh produce. It's also a way for restaurants and food suppliers to save on costs, eliminating the need for expensive packaging and shipping, experts say. Tour five of the world's coolest vertical farms in pictures below.
NEW YORK
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Farm.One's underground Tribeca location grows over 100 different varieties of edible flowers, herbs and microgreens at any one time.
Farm.One's vision is to build small indoor farms in cities around the country that provide rare herbs and produce to high-end restaurants. Their farm in the heart of Manhattan occupies 1200 square feet in a basement beneath the two-Michelin-starred restaurant Atera, which is conveniently one of their customers. All of the 20 to 25 restaurants they supply to are within a three-mile radius, making delivery possible by subway or bike.
"We have a direct connection with the chefs," says the CEO and founder Robert Laing. "For very perishable produce like herbs and leafy greens, hyper-local vertical farming works really well. It's literally dying the moment you cut it, and this is designed to be fresh."
PHILADELPHIA
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Jack Griffin, president of Metropolis Farms, atop sunflowers grown at his indoor farm.
"Restaurants are important," says Jack Griffin, the president of the indoor vertical Metropolis Farms in Philadelphia. "But not the most important, because they don't feed the majority of people."
Griffin is on a mission to standardize the indoor farming industry so supermarkets and communities around the world can benefit from the technology in a cost-effective and accessible way. Right now, Metropolis Farms supplies to a local grocer, Di Brunos Bros, that is less than two miles from their facility. In the future, they have plans to build a rooftop greenhouse atop a new supermarket in Philadelphia, plus indoor farms in Baltimore, Oklahoma, and as far away as India.
One advantage of their farms, says Griffin, is their proprietary technology. An adaptive lighting system allows them to grow almost any size crop, including tomatoes, cucumbers, peppers, strawberries, and even giant sunflowers.
"It's bigger than just food," he explains. "We are working on growing specialty crops like wine, chocolate, and coffee. All these plants are within reach, and we can cut the cord between supply chains that are difficult to deal with. Can you imagine if you grew Napa wines in Camden, New Jersey?"
BERLIN
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GOOD BANK at lunch: the first vertical farm-to-table restaurant in the world.
GOOD BANK, in Berlin, bills itself as the world's first farm-to-table vertical restaurant. They grow their many of their own vegetables and salads onsite using farming system technology from another German company called INFARM. The latter's co-founder and CEO, Erez Galonska, cites a decline in traditional farming, an increase in urban populations, and the inefficiency of the current food system as motivation for turning to vertical farming to produce food where people actually eat and live.
"INFARM is pioneering on-demand farming services to help cities become self-sufficient in their food production, while eliminating waste and reducing their environmental impact," Galonska says.
MELBOURNE
(Photo credit: Matters Journal)
Geert Hendrix, founder and CEO, looking at the first Farmwall prototype.
Melbourne-based Farmwall leases indoor vertical farms the size of small bookshelves to restaurants and cafes. The farms are designed to be visually appealing, with fish tanks at the bottom supplying nutrient-rich water to the hemp media in which herbs and microgreens grow under LED lights. As part of the subscription model, urban farmers come once a week to check water levels, bring new trays of greens, and maintain the system. So far, two restaurants have signed up -- Top Paddock, in the suburb of Richmond, and Higher Ground, an internationally recognized restaurant in Melbourne.
"It's worth it to the restaurants because they get fresh produce at their fingertips and it has all the benefits of having a garden out back without any of the work," says Serena Lee, Farmwall's co-founder and chief communications officer.
The sky's the limit for future venue possibilities: nursing homes, schools, hotel lobbies, businesses, homes.
"Urban farming is never going to feed the world," Lee acknowledges. "We understand that and we're not saying it will, but when people are able to watch their food grow onsite, it triggers an awareness of local food production. It teaches people about how technology and science can work in coherence with nature to create something super-efficient, sustainable, and beautiful."
LOS ANGELES
(Otium)
Chef Timothy Hollingsworth at the Los Angeles restaurant Otium's rooftop garden.
At the restaurant Otium in Los Angeles, a peaceful rooftop garden sits atop a structure of concrete and steel that overlooks the hustle and bustle of downtown LA. Vegetables and herbs grown on the roof include Red Ribbon Sorrel, fennel fronds, borage blossoms, nasturtium, bush basil, mustard frills, mustard greens, kale, arugula, petit leaf lettuce, and mizuna. Chef Timothy Hollingsworth delights in Otium's ability to grow herbs that local purveyors don't offer, like the wild Middle Eastern Za'atar he uses on grilled steak with onions and sumac.
"I don't think this growing trend [of urban farming] is something that will be limited to a handful of restaurants," says Hollingsworth. "Every business should be concerned with sustainability and strive to protect the environment, so I think we will be seeing more and more gardening efforts throughout the country."
Whether a garden is vertical or horizontal, indoors or outdoors, on a roof or in a basement, tending to one provides not only fresh food, but intangible benefits as well.
"When you put your time and love into something," says Hollingsworth, "it really makes you respect and appreciate the produce from every stage of its life."
Tardigrades can completely dehydrate and later rehydrate themselves, a survival trick that scientists are harnessing to preserve medicines in hot temperatures.
Formulating biologics to withstand drying and hot temperatures has been the holy grail for pharmaceutical researchers for decades. It’s a hard feat to manage. “Biologic pharmaceuticals are highly efficacious, but many are inherently unstable,” says Thomas Boothby, assistant professor of molecular biology at University of Wyoming. Therefore, during storage and shipping, they must be refrigerated at 2 to 8 degrees Celsius (35 to 46 degrees Fahrenheit). Some must be frozen, typically at -20 degrees Celsius, but sometimes as low -90 degrees Celsius as was the case with the Pfizer Covid vaccine.
For Covid, fewer than 73 percent of the global population received even one dose. The need for refrigerated or frozen handling was partially to blame.
The costly cold chain
The logistics network that ensures those temperature requirements are met from production to administration is called the cold chain. This cold chain network is often unreliable or entirely lacking in remote, rural areas in developing nations that have malfunctioning electrical grids. “Almost all routine vaccines require a cold chain,” says Christopher Fox, senior vice president of formulations at the Access to Advanced Health Institute. But when the power goes out, so does refrigeration, putting refrigerated or frozen medical products at risk. Consequently, the mRNA vaccines developed for Covid-19 and other conditions, as well as more traditional vaccines for cholera, tetanus and other diseases, often can’t be delivered to the most remote parts of the world.
To understand the scope of the challenge, consider this: In the U.S., more than 984 million doses of Covid-19 vaccine have been distributed so far. Each one needed refrigeration that, even in the U.S., proved challenging. Now extrapolate to all vaccines and the entire world. For Covid, fewer than 73 percent of the global population received even one dose. The need for refrigerated or frozen handling was partially to blame.
Globally, the cold chain packaging market is valued at over $15 billion and is expected to exceed $60 billion by 2033.
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Freeze-drying, also called lyophilization, which is common for many vaccines, isn’t always an option. Many freeze-dried vaccines still need refrigeration, and even medicines approved for storage at ambient temperatures break down in the heat of sub-Saharan Africa. “Even in a freeze-dried state, biologics often will undergo partial rehydration and dehydration, which can be extremely damaging,” Boothby explains.
The cold chain is also very expensive to maintain. The global pharmaceutical cold chain packaging market is valued at more than $15 billion, and is expected to exceed $60 billion by 2033, according to a report by Future Market Insights. This cost is only expected to grow. According to the consulting company Accenture, the number of medicines that require the cold chain are expected to grow by 48 percent, compared to only 21 percent for non-cold-chain therapies.
Tardigrades to the rescue
Tardigrades are only about a millimeter long – with four legs and claws, and they lumber around like bears, thus their nickname – but could provide a big solution. “Tardigrades are unique in the animal kingdom, in that they’re able to survive a vast array of environmental insults,” says Boothby, the Wyoming professor. “They can be dried out, frozen, heated past the boiling point of water and irradiated at levels that are thousands of times more than you or I could survive.” So, his team is gradually unlocking tardigrades’ survival secrets and applying them to biologic pharmaceuticals to make them withstand both extreme heat and desiccation without losing efficacy.
Boothby’s team is focusing on blood clotting factor VIII, which, as the name implies, causes blood to clot. Currently, Boothby is concentrating on the so-called cytoplasmic abundant heat soluble (CAHS) protein family, which is found only in tardigrades, protecting them when they dry out. “We showed we can desiccate a biologic (blood clotting factor VIII, a key clotting component) in the presence of tardigrade proteins,” he says—without losing any of its effectiveness.
The researchers mixed the tardigrade protein with the blood clotting factor and then dried and rehydrated that substance six times without damaging the latter. This suggests that biologics protected with tardigrade proteins can withstand real-world fluctuations in humidity.
Furthermore, Boothby’s team found that when the blood clotting factor was dried and stabilized with tardigrade proteins, it retained its efficacy at temperatures as high as 95 degrees Celsius. That’s over 200 degrees Fahrenheit, much hotter than the 58 degrees Celsius that the World Meteorological Organization lists as the hottest recorded air temperature on earth. In contrast, without the protein, the blood clotting factor degraded significantly. The team published their findings in the journal Nature in March.
Although tardigrades rarely live more than 2.5 years, they have survived in a desiccated state for up to two decades, according to Animal Diversity Web. This suggests that tardigrades’ CAHS protein can protect biologic pharmaceuticals nearly indefinitely without refrigeration or freezing, which makes it significantly easier to deliver them in locations where refrigeration is unreliable or doesn’t exist.
The tricks of the tardigrades
Besides the CAHS proteins, tardigrades rely on a type of sugar called trehalose and some other protectants. So, rather than drying up, their cells solidify into rigid, glass-like structures. As that happens, viscosity between cells increases, thereby slowing their biological functions so much that they all but stop.
Now Boothby is combining CAHS D, one of the proteins in the CAHS family, with trehalose. He found that CAHS D and trehalose each protected proteins through repeated drying and rehydrating cycles. They also work synergistically, which means that together they might stabilize biologics under a variety of dry storage conditions.
“We’re finding the protective effect is not just additive but actually is synergistic,” he says. “We’re keen to see if something like that also holds true with different protein combinations.” If so, combinations could possibly protect against a variety of conditions.
Commercialization outlook
Before any stabilization technology for biologics can be commercialized, it first must be approved by the appropriate regulators. In the U.S., that’s the U.S. Food and Drug Administration. Developing a new formulation would require clinical testing and vast numbers of participants. So existing vaccines and biologics likely won’t be re-formulated for dry storage. “Many were developed decades ago,” says Fox. “They‘re not going to be reformulated into thermo-stable vaccines overnight,” if ever, he predicts.
Extending stability outside the cold chain, even for a few days, can have profound health, environmental and economic benefits.
Instead, this technology is most likely to be used for the new products and formulations that are just being created. New and improved vaccines will be the first to benefit. Good candidates include the plethora of mRNA vaccines, as well as biologic pharmaceuticals for neglected diseases that affect parts of the world where reliable cold chain is difficult to maintain, Boothby says. Some examples include new, more effective vaccines for malaria and for pathogenic Escherichia coli, which causes diarrhea.
Tallying up the benefits
Extending stability outside the cold chain, even for a few days, can have profound health, environmental and economic benefits. For instance, MenAfriVac, a meningitis vaccine (without tardigrade proteins) developed for sub-Saharan Africa, can be stored at up to 40 degrees Celsius for four days before administration. “If you have a few days where you don’t need to maintain the cold chain, it’s easier to transport vaccines to remote areas,” Fox says, where refrigeration does not exist or is not reliable.
Better health is an obvious benefit. MenAfriVac reduced suspected meningitis cases by 57 percent in the overall population and more than 99 percent among vaccinated individuals.
Lower healthcare costs are another benefit. One study done in Togo found that the cold chain-related costs increased the per dose vaccine price up to 11-fold. The ability to ship the vaccines using the usual cold chain, but transporting them at ambient temperatures for the final few days cut the cost in half.
There are environmental benefits, too, such as reducing fuel consumption and greenhouse gas emissions. Cold chain transports consume 20 percent more fuel than non-cold chain shipping, due to refrigeration equipment, according to the International Trade Administration.
A study by researchers at Johns Hopkins University compared the greenhouse gas emissions of the new, oral Vaxart COVID-19 vaccine (which doesn’t require refrigeration) with four intramuscular vaccines (which require refrigeration or freezing). While the Vaxart vaccine is still in clinical trials, the study found that “up to 82.25 million kilograms of CO2 could be averted by using oral vaccines in the U.S. alone.” That is akin to taking 17,700 vehicles out of service for one year.
Although tardigrades’ protective proteins won’t be a component of biologic pharmaceutics for several years, scientists are proving that this approach is viable. They are hopeful that a day will come when vaccines and biologics can be delivered anywhere in the world without needing refrigerators or freezers en route.