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Bruce Carman on engineering modular micro-environments for urban food production

“You can keep adding capsules to your overall operation as finances permit”

Controlled Environment Farms (CEF) is introducing a structural rethink to indoor agriculture. Rather than retrofitting entire buildings to grow one crop under one set of conditions, the company's approach centers on a modular, patent-pending innovation: the growing capsule. Each capsule functions as a sealed micro-environment embedded within a larger controlled environment agriculture (CEA) structure. This two-layered system enables precision control at the crop level while maintaining operational flexibility across the facility.

© Bruce Carman

"The basic capsule is an independent structure, typically 102 feet long, 20 feet wide, and between 10 and 16 feet tall," explains Bruce Carman, founder of CEF. "The CEA structure houses a neutral, macro-environment that can fluctuate, while the capsule contains a very specific micro-environment customized for the crops cultivated within. This feature enables the facility to grow a wide range of crops and be a more complete localized food source."

Flood and drain, engineered for efficiency
CEF's growing capsules combine vertically positioned horizontal piping with a deep-water trough at the base. This configuration supports a hybrid aquaponic system, where nutrient-rich water is delivered using gravity wherever possible. "Our experience has suggested that this is the best method of providing nutrients to the plants while minimizing operational costs," says Carman.
"Gravity-based flow makes the system less dependent on pumps and reduces complexity."

Each capsule operates as its own unit, with nutrients monitored and adjusted in real time to match the specific requirements of the crops inside. "The nutrient water flow system is engineered to be monitored at various points for macro- and micronutrient concentrations. This allows us to adjust the concentration of a specific nutrient in real time for the specific crop or crops being cultivated," he adds.

© Bruce Carman

Why capsules?

Unlike traditional continuous grow rooms, growing capsules offer isolation and control. That makes multi-crop production feasible under one roof. "There are several advantages to having independent capsules," says Carman. "A facility can cultivate many different crops. The control of pests and diseases, should they enter the macro-environment, is much easier when an outbreak can be contained in the micro-environment of a capsule."

"Additionally, crop selection can be retrofitted quickly to meet market and seasonal demands. Economically, you can keep adding capsules to your overall operation as finances permit, rather than having to find funding for an entire continuous grow room."

Real-time control and flexible design
Environmental control does not stop at nutrients. Sensors embedded throughout each capsule track airflow and CO₂ levels continuously. Data is sent back to a central system that can intervene as needed. "Air circulation and CO₂ are managed through sensors within the air handling system and the capsule," Carman explains. "All readings are sent to a central location that can activate adjustments to meet the specific need."

While these environments are highly controlled, they are not fully sealed. Air exits the capsule through one-way vertical wall curtains, maintaining directional airflow and sanitary conditions. The materials used throughout the system are food-grade and designed for easy cleaning. Capsules can support either mono-cropping or mixed crops, provided environmental needs are compatible. "The design is very modular, flexible, and can be completely scaled up or down depending on building size," Carman says. "The concept is more valuable when used in multi-level buildings. The best use is in multi-level, new construction as seen in the four-capsule wide by four-capsule high model."

Intellectual property status
CEF is currently in the process of securing intellectual property protection for the growing capsule system. While full details are pending legal confirmation, Carman says the intent is to ensure that the system remains defensible and adaptable as it moves toward implementation in new and existing buildings.

For more information:
Controlled Environmental Farming
Bruce Carman
+1 (218) 370 2005
conenvfarm@gmail.com